Numerical methods in testing product characteristics ... - PoMaCoM

UNIVERZITET U ZENICI Mašinski fakultet

PART I: Numerical methods in testing product characteristics (Virtual prototyping)

Aleksandar Karač MFZE, room 1111 Tel: 449 120, ext. 140 Email: [email protected]

TESTING PRODUCT CHARACTERISTICS


Numerical methods in testing product characteristics

Traditional approach in product development

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Virtual Prototyping (VP) approach in product development

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Virtual prototyping o

simulation-based-design

o

iterative design refinement of a designed product using a computer-based functional physical simulation (CAD/CAE)

o

CAD – Computer Aided Design

o

CAE – Computer Aided Engineering

o

CAM – Computer Aided Manufacturing

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VP - benefits

o

Decreasing slow and expensive hardware’s cycles produce-test-modify

o

Increasing quality

o

Vast application usage: automotive, aero, metal, electro industry, …

o

Treating the system as a whole

o

Covering wider area of analyses: ergonomics, noise, safety tolerances, …

o

Decreases number of actual prototypes for the same functionality

BUT ….

o

Cannot overcome the need for a physical model (prototype)

o

Give the best results with physical prototype

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CAD – computer aided design

o

2D drafting

o

3D modelling – contemporary approach

o

Global team work

o

Geometrical modelling: primitives, Boolean operations, lines, arcs, …

o

Parametric modelling

o

Feature-based parametric modelling

o

Interactive freeform surfacing

o

Reversed engineering (3D scanning of physical models)

o

Digital sketching

o

Applications for 3D model formations from sketch

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CAD – computer aided design

o

3D to 2D views

o

3D components can be easily assembled into complex virtual models

o

The major benefit: reusability

o

Different CAD formats

o

Model calculations (mass, centre of gravity, moment of inertia)

o

Visualisation (rendering, semi-transparency, perspectives, hidden lines, …)

o

Programming codes for model control and establishing relations between parts

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CAE – computer aided engineering

• Simulations based on numerical methods (DM, FEM, FVM, BEM, MM, PM, MoC, … )

• Stress and strain analysis • Computational fluid dynamics (CFD) • Kinematics analysis • Analysis and sintesis of mechanisms • Production process simulations (casting, forging, … ) • Tolerance analysis

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• Product or process optimisation • Variable parameters • Calculations for different parametric variants • Optimal solution from iterative process, and model correction

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CAM – computer aided manufacturing

• CAD model is used for (semi-)automatic generation of CNC program for machining centres • Metal, wood industry, rapid prototyping, art, …

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Visualisation

• VP visualisation • 3D model manipulation • Virtual Reality

• Balić S., Numerička analiza procesa strujanja i naponskog stanja centrifugalnih pumpi u sistemima za hlađenje automobilskih motora, PhD, 2002

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• Simulations based on numerical methods (DM, FEM, FVM, BEM, MM, PM, MoC, … )

Basic steps of numerical simulation of an engineering problem

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CAE – computer aided engineering • Concept of continuum • Continuity, homogeneity and isotropy • Fundamental laws of continuum mechanics and other concepts 1.Mass conservation 2.Reynold’s theorem 3.Conservation of linear momentum (1st Euler’s law, 2nd Newton’s law) 4.Conservation of angular momentum 5.Energy conservation law (1st law of thermodynamics) 6.Law of entropy production (2nd law of thermodynamics) 7.Equations for large deformations, … • Constitutive relationships and equation of state 1. Hooke’s law of elasticity, 2. Pascal’s law of hydrostatic pressure, 3. Newton’s law of viscosity, 4. Fourier’s law of heat conduction. A. Karač

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CAE – computer aided engineering • Mathematical model

φ- transported property (displacement u, velocity v or temperature T) Bφ and Gφ are given in Table qφS contains parts of the mass or heat flux vector or the stress tensor, which are not included in Γφ grad φ q φS contains the volumetric source terms.

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CAE – computer aided engineering • Finite Volume discretisation

Main concepts and ideas of numerical analysis

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CAE – computer aided engineering • Finite Volume discretisation Time and space discretisation

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CAE – computer aided engineering • Finite Volume discretisation Equation discretisation

Aφ ⋅ φ = bφ Initial and boundary conditions

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ITT test – asphalt, UCD, 2007

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CAE - examples of application Fluid flow through hydrulic components*

razvodni ventil sa klipom

* Hodžić N., Numerička analiza strujanja ulja kroz razvodne elemente hidrauličnih sistema, PhD, 2005 http://www.unze.ba/doktorati/index.htm

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CAE - examples of application

Fluid flow through hydrulic components

z = 1 mm

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z = 0,8 mm

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z = 1 mm

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z = 0,8 mm

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1

2

naizmjenično nepovratni ventil

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Nepovratni ventil

naizmjenično nepovratni ventil

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CAE - examples of application design optimisation of centrifugal pumps*

• Balić S., Numerička analiza procesa strujanja i naponskog stanja centrifugalnih pumpi u sistemima za hlađenje automobilskih motora, PhD, 2002

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design optimisation of centrifugal pumps

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CAE - examples of application Mataln M, Particle filtration processes in deformable media

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Particle filtration processes in deformable media

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CAE - examples of application Ledri M, Poian M, Russo R, Aerodynamic analysis of Sails

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Aerodynamic analysis of Sails

• Free surface flows • Aerodynamic study of hull appendices • Aerodynamic analysis of sails

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CAE - examples of application Gallinger T et al, FSI on Light-weight structures

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FSI on Light-weight structures

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CAE - examples of application Page M and Beaudoin M, Turbomachinery Turbomachinery Applications Applications

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Turbomachinery Turbomachinery Applications Applications

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CAE - examples of application Bos F, van Oudheusden B, Bijl B, Three-dimensional numerical simulations of flapping wings at low Reynolds numbers

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3D numerical simulations of flapping wings at low Reynolds numbers

http://fluid.mech.kogakuin.ac.jp/~iida/mav/dragonfly.html

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Similarity theory (basics) • the study of physical phenomena based on the concept of physical similarity • testing performed on similar (usually smaller) model Cauchy’s similarity law Term

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Original

Model

Dimension

Ratio

λ

λ

-

Length

lo

lm

M

Force

Fo

Fm

N

Young’s modulus

Eo

Em

Pa

Strain

εo

εm

-

Stress

σo

σm

Pa

Area

Ao

Am

m2

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Basic assumptions • linear elasticity • same stresses in the corresponding regions of the original and its model

lm λ= 0 l

length:

Am

area:

A

l

Vm

volume:

V

o

= λ2 = λ3

stresses:

σ =E 0

o

∆l 0

l

0

σ =E m

m

∆l m

lm

σ m E m ∆l m l o 1 m o λ = = = = ⋅ ⋅ =1 E E 1 l o o m σ λ E ∆l l A. Karač

Lušija Z., Istraživanje mogućnosti primjene modelske sličnosti na razvoju konstrukcije visokotlačnih cilindara velikih gabarita, MSc, 2004. 53/53

UNIVERZITET U ZENICI Mašinski fakultet

PART II: Testing polymeric materials and products

Aleksandar Karač MFZE, room 1111 Tel: 449 120, ext. 140 Email: [email protected]


Numerical methods in testing product characteristics ... - PoMaCoM

Numerical methods in testing product characteristics ... - PoMaCoM

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