2
INSIGHTS 10 2007 Dassault Systèmes Realistic Simulation Magazine
Distributed Memory Parallel Enables Faster Turnaround
adidas Builds Better Running Shoe
It’s All in the
Solder Joints at Delphi
Glass Service Improve BV Optimizes Bottle Forming
OCT_INS_Y07_VOL 02 OCT_INS_Y07_VOL
owners. Copyright Dassault Systèmes, 2007. Systèmes, Dassault Copyright owners.
may be trademarks or service marks of their respective respective their of marks service or trademarks be may
subsidiaries. Other company, product, and service names names service and product, company, Other subsidiaries.
or registered trademarks of Dassault Systèmes or its its or Systèmes Dassault of trademarks registered or
The 3DS logo, SIMULIA, and Abaqus are trademarks trademarks are Abaqus and SIMULIA, logo, 3DS The
Sabelli Todd
Graphic Designer: Graphic
• Webinars New Release of Abaqus for CATIA V5 CATIA for Abaqus of Release New
Tim Robinson (adidas), Jon Wiening Jon (adidas), Robinson Tim
Product Update Product 8
Call for Papers for Call Corp.), (Dana Ramkumar, Rohit
• Conference Users’ Abaqus 2008 Group, Parker The Mercer, Colin
Alaska), of (U. Lee Jonah Dr.
•
Abaqus Regional Users’ Meetings Users’ Regional Abaqus
in Gas Field Projects Field Gas in Heers, Brad Dunbar, Matt
Donovan, Karen SpA), Tyre
JP Kenny Pioneers FEA Software Use Use Software FEA Pioneers Kenny JP Events 18
(Delphi), Massimo Donatellis (Pirelli (Pirelli Donatellis Massimo (Delphi),
Customer Spotlight Customer 6 David Cadge, Dr. Mahesh K. Chengalva Chengalva K. Mahesh Dr. Cadge, David
Dermot O’Brien & Paul Jukes (JPK), (JPK), Jukes Paul & O’Brien Dermot
Cluster Deployment Cluster
Harun Bayraktar, Vladimir Belsky, Belsky, Vladimir Bayraktar, Harun
• Intel Creates Program to Simplify Simplify to Program Creates Intel Sports Equipment Designers Equipment Sports Contributors:
• Realistic Simulation—A Winning Edge for for Edge Winning Simulation—A Realistic
AVL EXCITE EXCITE AVL
Lisa Miller Lisa
Vibration Analysis with Abaqus and and Abaqus with Analysis Vibration
Forming Analysis Analysis Forming
Editor: Associate
• and Noise Powertrain Enhanced • Automatic Meshing Improves Glass Glass Improves Meshing Automatic
Webb Tim
Alliances Updates Alliances 17
Gets Ready for the Street the for Ready Gets Editor:
• KTM Sportmotorcycle’s RC8 Superbike Superbike RC8 Sportmotorcycle’s KTM
www.simulia.com
• Pan-Mass Challenge Pan-Mass New SIMULIA Academic Website Academic SIMULIA New
• the Tackles SIMULIA Team
Model Tire-Snow Interaction Interaction Tire-Snow Model
Fax. +1 401 276 4408 276 401 +1 Fax.
• • Industry Press Coverage Press Industry Researchers Alaska of University
4400 276 401 +1 Tel.
Providence, RI 02909-2499 RI Providence, In The News The In 4 Academic Update Academic 16
Street Valley 166
Rising Sun MiIls Sun Rising
Dassault Systèmes Simulia Corp. Simulia Systèmes Dassault
Product Development Development Product High Tech Industry Tech High
INSIGHTS INSIGHTS is published by published is
President, Vice Mercer, Colin Realistic Simulation Strategy for the the for Strategy Simulation Realistic
Executive Letter Executive 3 Electronics Strategy Electronics 13
In Each Issue Each In
Shoe from Inside Out Inside from Shoe Time Turnaround Faster
adidas Builds Better Running Running Better Builds adidas Enables Parallel Memory Distributed It’s All in the Solder Joints at Delphi at Joints Solder the in All It’s
9 Customer Case Study Case Customer 14 Update Solution Cover Story Cover 10 Inside This Issue This Inside
10 14 9
INSIGHTS
October/November 2007 October/November Contents Executive Message
Ensuring Our Focus on Advanced Technology and Quality Two years ago, when Abaqus Inc. was acquired by Dassault Systèmes (DS), the SIMULIA Product Development organization was tasked with bringing realistic simulation to the world of Product Lifecycle Management (PLM). The past 24 months have been both exciting and challenging, and I am very proud to be part of a development organization so eager and passionate about delivering high-quality, technically strong products with high value to the end user.
I say exciting because the acquisition presented many opportunities. We merged two complementary groups of developers in the simulation domain: the Abaqus developers, who have experience predominantly focused on products for advanced mechanics users, and the CATIA Analysis developers, who have experience in developing analysis products mainly aimed at design engineers. The newest version of Abaqus for CATIA V5 exemplifies the progress being made by these teams to integrate advanced FEA technology in the design environment of CATIA (see page 8). Colin Mercer Our new organization has also faced challenges as we have transitioned from our origins, with varied histories Vice President, and cultures, to become a first-class brand within a much larger company. Since 1990, when I first started in the Product Development, SIMULIA development of Abaqus software, I have been involved in many transformations. The expansion of our product line to include Abaqus/Explicit and Abaqus/CAE was in many ways the most difficult, since it required developers to move from an entrepreneurial mindset with a focus on one product to a more structured environment with an emphasis on process.
By going through this transformation, we have made significant progress in maturing our processes while continuing to develop innovative simulation technology, including major performance improvements in Abaqus Version 6.7 (see page 9). Our progress is best illustrated by the significant increase in the number of product releases in production. We are now managing an order of magnitude more releases per year, including the Abaqus general and extended functionality releases, various Beta test programs, Abaqus for CATIA V5, as well as products for CAD associativity and multiphysics, among others.
Another aspect of being part of a larger company is that our Product Development organization is now geographically located in three countries. Nearly all development is split between the US and France, with a relatively small group in India, which includes a team focused on Quality Assurance. While this geographic distribution has presented communication challenges, the diversity, creativity, and depth of experience within this talented group of people is key to our ongoing success.
Advanced Mechanics development continues to be centered at SIMULIA HQ in Providence, Rhode Island. We continue to grow our staff in this domain by hiring engineers with the strongest mechanics skills from throughout the world. With my roots in computational mechanics, I strongly believe that the majority of this group needs to be co-located so that the interaction between the team members can foster technical innovation.
The broad spectrum of mechanics capabilities in our products—coupled with advances taking place in computational mechanics research, enhancement requests from customers and our perennial efforts to improve usability, performance, and quality—means we must make careful decisions and keep everyone focused on developing and delivering new and enhanced capabilities. We are confident that we have created a strong development organization that can execute on maturing our advanced technology, while being nimble enough to evolve and create new and valuable simulation products.
As we announced at the 2007 Abaqus Users’ Conference, we will soon release our new Simulation Lifecycle Management (SLM) solution. This new product line demonstrates how we are leveraging the extensive resources, technology, and PLM experience within the Dassault Systemes R&D organization. I encourage you to attend your Regional User Meetings and the 2008 AUC to learn more about our new products and initiatives. I look forward to continuing to work with the SIMULIA Product Development team to deliver many more exciting products and enhanced capabilities over the coming years.
Colin Mercer
www.simulia.com INSIGHTS October/November 2007 In The News
Industry Press Coverage
R&D Product Design & Development June 2007, pp. 20–21 July 2007, pp. 38–39 Modeling Earthquakes with Realistic Simulation Software Foretelling Failure More accurate prediction of earthquakes and tsunamis using FEA is Delphi Electronics research engineer Dr. Mahesh Chengalva (see the goal of University of Alabama geophysicist Tim Masterlark in INSIGHTS cover story and on pp. 10–12) and his group use Abaqus this feature article illustrated with 3-D models of tectonic plates and a to predict the reliability of solder joints in automobile circuit boards. deformed ocean floor, created using Abaqus software. The researcher Months of testing time can be saved by using FEA models to simulate uses data collected from the December 2004 Sumatra-Andaman thermal cycling. Delphi’s web-based expert system, D-Cube, puts quake and tsunami to simulate the complexity of deformation of the Abaqus FEA power in the hands of design engineers all over the Earth’s surface. world, day or night.
Design News Aerospace Engineering July 2007, p. 54 August 2007, p. 18 Dassault Takes Life Cycle Approach to Simulation SIMULIA Shaping Future of Simulation Dassault Systèmes’ new Simulation Lifecycle Management (SLM) Recent announcements about Abaqus Version 6.7, the new strategy mirrors its life cycle approach to product development, multiphysics platform, and the strategic initiative to deliver according to contributing software/hardware editor Beth Stackpole in simulation lifecycle management (SLM) caught the attention this review of SLM capabilities. The new product portfolio melds the of assistant editor Matt Monaghan, who wrote about all these SIMULIA simulation environment with Dassault’s V5 SOA for PLM, developments in the “Computers in Engineering” section of the helping companies integrate simulation earlier and more effectively magazine. Greg Brown, Product Management, SIMULIA, and into their core product development processes. Marc Schrank, Director of Crashworthiness and Occupant Safety, SIMULIA, were both quoted in the in-depth article.
For More Information To read the full stories highlighted here, please visit To share your case study, send an e-mail with a brief description of www.simulia.com/news/media_coverage your application to [email protected]. Team SIMULIA Tackles the Pan-Mass Challenge On August 5, 2007, a group of 19 bike riders from SIMULIA have raised more than $102 million for cancer research and treatment. headquarters volunteered to ride 47 miles across parts of Team SIMULIA members were John Ballem, Scott Berkey, Greg Massachusetts in the 28th annual Pan-Mass Challenge (PMC). This Brown, Janet Buckley, Pierre Burgers, David Cadge, Charles Chopin, was the premiere year for members of Team SIMULIA, who rode to John Doll, Jon Foster, Glenda Jeffrey, John Mangili, Mike Mathers, raise money for the Dana-Farber Cancer Institute. Paul Montour, Steven Morse, Peter Nannucci, Matt Rees, Ken Short, Lisa Stein, and Michael Wood. Now one of the largest fundraisers in the United States, the PMC began in 1980 and has evolved to include a cast of thousands who At the time of this article, the team has surpassed its goal of $25,000 with a significant amount being coming from individual contributions by SIMULIA personnel. The team would like to recognize their corporate sponsors, UVEX, Fuel Belt, CADNEXUS, and Providence Bicycle, who donated directly and through in-kind gifts such as cycling gear, hydration systems, discounts, and moral support.
For More Information Visit www.simulia.com/news
INSIGHTS October/November 2007 www.simulia.com In The News
KTM Sportmotorcycle’s RC8 Automatic Meshing Improves Superbike Gets Ready for Glass Forming Analysis Glass Service Improve BV, a provider of advanced solutions for the Street glass manufacturing, is utilizing SIMULIA professional services and To help meet their customers’ performance expectations for their Abaqus Unified FEA to accelerate and optimize the development new street bike, KTM Sportmotorcycle AG, Europe’s second largest process of non-round glass bottle forming. motorcycle manufacturer, is using Abaqus Unified FEA to evaluate their product’s performance and reliability. In collaboration with Glass Service Improve, SIMULIA has developed an automated remeshing technique to simulate a “For the launch of our new Superbike RC8, which will be available multistage manufacturing process involving viscous materials that to the market in the spring of 2008, we are using Abaqus software are subjected to high temperatures, large geometry deformation, to evaluate thermal behavior, noise and vibration, structural and complex contact. The innovative process allows designers to performance of assemblies, and stress-based fatigue,” stated D.I. accurately evaluate the optimum blow mold process in a virtual Gunther Hager, R&D Teamleader Engine Structural Analysis, KTM environment. Sportmotorcycle AG. “This integrated simulation process gives us a better understanding of the physical behavior of our products during “Customer partnerships, innovative methods development, and the design phase.” advanced simulation technology are core values for SIMULIA,” stated Ken Short, Vice President, SIMULIA Strategy and Marketing. “During a services engagement, our engineering teams work to gain a thorough understanding of our clients’ requirements and processes in order to develop a solution that helps get new products to market reliably and efficiently.”
The new method and the underlying Abaqus FEA technology are central to Glass Service Improve’s Galileo-Plus product, which enables designers to reliably simulate the glass forming KTM is using Abaqus Unified FEA software for all applications process during the design phase. While the in engine and chassis development to analyze the stiffness and methodology has been developed to fulfill the flexibility of vehicle frames and engine systems, including gaskets, needs of simulating boutique glass forming, like pistons, and headblocks. They also use AVL EXCITE, which perfume bottles, it may apply to other forming leverages Abaqus technology to study crankshaft dynamics that and industrial applications. influence noise and vibration. Realistic Simulation—A Winning Edge for Sports Equipment Designers According to an article in the September 2007 issue of Science Daily, shoe will behave on different the Sports Technology Research Group (STRG) from Loughborough surfaces when subject to varying University, UK, uses Abaqus Unified FEA to predict the complex stressors. This technology real-world behavior of products on and off the playing field. not only saves manufacturers Designers of sports equipment are already taking advantage of this time and money, it also allows information to enhance their designs and accelerate time-to-market. designers to focus on specific user needs, enhance safety Dr. Andy Harland, STRG leader, explains, “Our computer models and durability, and encourage can provide invaluable technical input to the sports equipment increased participation in sports. design process. For example, by enabling the real-world behavior of This specially designed kicking different design options to be simulated with extreme accuracy, they robot is used to test the computer can reduce the need to manufacture expensive prototypes and cut the models’ accuracy. Image courtesy of Engineering and Physical Sciences time required to get improved equipment from the drawing-board to Research Council. the shops.”
His group takes advantage of easily customized Abaqus algorithms For More Information http://www.sciencedaily.com/releases/2007/09/070913081035.htm to complete complex analyses, such as how a soccer ball or running www.simulia.com INSIGHTS October/November 2007 Customer Spotlight
J P Kenny Pioneers Software Use in Gas Field Projects
management a key design issue. Pipeline n response to increasing Pipeline Design Challenges I In a recent gas project approximately wall thickness, corrosion inhibitors, and demand for oil and gas, 150 miles off the western coast of Australia, claddings all impact costs; and FEA is energy exploration companies J P Kenny applied state-of-the-art helping in the selection of alternative are tackling challenging, deep Abaqus FEA technology to evaluate the materials. “The deepwater location of part of the gas field presents clear challenges for sea projects that have been design performance and route mapping for a large system of subsea pipelines. Many the design and installation of large diameter commercially and technically critical issues affect subsea pipeline design pipeline,” said O’Brien. “The pipeline impossible until now. including the great length of the pipeline, requirements include about 260km of large Advances in FEA software and the depth of the sea bed at up to 1350m, the gas delivery line and some 520km of small diameter pipe connecting the well heads, growing industry knowledge high temperature of the gas at up to 130°, and relatively high pressure at 360barg. manifolds, and other equipment.” have been instrumental to the Other issues being considered in the design success of these new projects. According to Pipeline Business Leader Dermot O’Brien, the mix of high of the pipeline are the effects of the local Companies such as J P Kenny pressure and high temperature also make marine environment (which features steep are leveraging the latest pipeline material selection and corrosion escarpments at the continental shelf), technology to evaluate their the annual cyclone season, large tidal movements, and strong currents, which designs and achieve long-term impact the seabed and the pipeline itself. project sustainability. Effective Force (lay tension, A number of design criteria and equations pressure, temp) Non-Linear fall outside the current design codes, so End Axial Spring to specialized engineering assessments are model pipe Scarp crossing super span model simplified from continuity being applied. Pipe Nodes Abaqus integration of Fledermaus 3D view. Evaluating Subsea Loading J P Kenny is pioneering the use of Abaqus PIPE31 Abaqus FEA to evaluate conceptual designs, pipe elements Submerged perform Front End Engineering Design Weight Seabed Nodes (FEED) studies, and conduct detailed design Effective Force Pipe-seabed interaction (lay tension, modeled using studies of the pipeline. Abaqus nonlinear Abaqus‘Contact Pair’ option pressure, temp) and contact capabilities are readily applied to a deep water environment, coupling the 1km long model analysis of water and seabed movements Non-Linear End 1m element length Axial Spring to and pressures with high temperature, high model pipe continuity pressure gas products.
INSIGHTS October/November 2007 www.simulia.com Customer Spotlight
Image of the preferred pipe lay path dropping from 200m water depth to 800m at about 130km off the coast of Western Australia.
It is estimated that the combined pipeline has the structural integrity to cross Meeting Future Demands characteristics of high pressure/high the escarpment. In addition to the usual lay J P Kenny, involved in more than half temperature gas flow and natural seabed tension, pressure, temperature, submerged of all subsea projects around the world, behavior could cause a 7m expansion of pressure, and axial spring tensions to be is addressing challenging engineering the main line. The forces associated with calculated, there were additional elements problems on several cutting-edge projects. this expansion include lateral displacement defining the local geo-hazards, including Paul Jukes, Advanced Engineering Manager cycles of the pipe on the seabed of up to mudflows on the scarp face. J P Kenny for J P Kenny, suggests that key success 10m. Abaqus is helping engineers develop found that crossing the escarpment at the factors in developing a viable engineering and test designs to withstand the pipeline optimum point will reduce the pipe lay for solution for these projects are employing dynamics and the forces operating at the the project by up to 40km—a significant engineers with a high level of experience, continental shelf crossing. cost saving. encouraging creative problem solving, and leveraging advanced numerical tools. For example, detailed lateral buckling Finite element analysis is being done It is the combination of these factors analyses are being done to assess forces, for a complete range of conditions, that is enabling J P Kenny to gain a moments, and strains across the full range of including empty pipelines, those with deeper understanding of subsea pipeline behaviors, including ratchetting due to start operating contents, and those containing performance. up and shut down cycles, the cumulative flushing media. The sensitivity cases effect that pressure and temperature being considered are different pipe outer Reference: Innovative Pipeline and Subsea Engineering Experience by Dr. Paul Jukes, Ph.D., CEng FIMarEST, fluctuations have on the highly stressed apex diameters, wall thicknesses, addition of J P Kenny. Presented at the International Conference on of the buckle, and the investigation of the concrete coating, and residual lay tension. Subsea Technologies, SubSeaTech’ 2007, June 2007, potential for pipeline creep or walking. Results from the span analysis reveal the St. Petersburg, Russia. bending moment distribution, longitudinal In addition to helping the pipe lay team strain profile and spanning pipeline profile understand the loads on the pipeline due to For More Information along the route, and modal shapes and pressure and seabed contact, Abaqus is being www.jpkenny.com or frequencies. used to confirm the location where the pipe www.simulia.com/solutions/power.html line should span the sea floor escarpment “To make the subsea infrastructure more at the continental shelf, which drops from secure, we have used Abaqus FEA software 200m to 800m water depth. The pipe lay to plan for major event scenarios, including team successfully integrated the Fledermaus the impact of cyclones on pipe line interactive 3-D visualization system from dynamics,” explained O’Brien. “Abaqus has IVS 3D with the Abaqus FEA tool to reduced simulation times, and improved the accurately map the escarpment. At the scarp efficiency and accuracy of pipeline design crossing there is a potential pipeline span and route mapping since the team switched of 200 to 300m, so it is crucial that the from our former FEA tool.”
www.simulia.com INSIGHTS October/November 2007 Product Update
New Release of Abaqus for CATIA Supports Design Analysis Collaboration To meet customer demands for tighter integration and more advanced analysis features, Abaqus for CATIA V5 Version 2.5 offers a new level of ease-of- use and integration with CATIA, further enabling design engineers and expert analysts to access Abaqus technology and CATIA’s Knowledgware tools enable companies to capture design collaborate by using the same FEA models knowledge inside the model and to and methods. With this product your manage complex design relationships. In this steering knuckle model a design CATIA V5 models and your Abaqus models table manages the data for a number become synchronized, making the software of design variables and mandatory load cases. a scalable solution for evaluating design performance.
“Abaqus for CATIA V5 allows our design Tight integration with CATIA V5 is one Abaqus for CATIA V5 helps us to engineers to immediately evaluate how new of the most important usability features of “ minimize the number of software concepts and design changes affect product Abaqus for CATIA V5 Version 2.5. The interfaces that we use during performance,” states Michael Thienel, new release takes full advantage of CATIA the development of our exhaust MANN+HUMMEL GMBH. “This approach Knowledgeware, publications, and sensors, turbocharger,” states Markus not only accelerates our development further enabling the development of analysis Staedeli, ABB Turbo Systems Ltd. time, but also improves knowledge of our templates, performance of interactive design design’s physical behavior, giving us greater loops, and leveraging of knowledge capture “This approach allows us to work confidence in our product quality during the within Abaqus for CATIA V5 models. seamlessly with the same geometry development stage.” Specifically, support for publications model throughout our virtual enables the easy replacement of assembly development process and gain Delivering Enhanced Features components while automatically updating significant efficiencies. This latest release continues our strategy the FEA model. Support for sensors ” of providing robust analysis solutions to allows users to obtain specific locations in Deploying Integrated Workflows the extended enterprise. A wizard-based the model and to use the results to drive Design engineers skilled in using approach greatly simplifies the way users parameters in Knowledgeware formulas. CATIA V5 have access to a wide array define and manage contact interactions. of Abaqus simulation capabilities, while The latest version also provides support When the user hits ‘Run,’ all likely contact Abaqus experts can readily access CATIA for 64-bit and 32-bit architecture. To take pairs in the model are automatically V5 models for their analysis work. detected. There are also several options advantage of the 64-bit architecture, you available to help verify, merge, edit, and must use Abaqus for CATIA V5 Version 2.5 Abaqus for CATIA V5 Version 2.5 is a delete these detected pairs. This approach in conjunction with a 64-bit installation of valuable tool for deploying customer- makes setup easier and reduces the CATIA V5. specific workflows across the engineering likelihood of overlooking parts that may enterprise. It enables advanced simulation be in contact. capabilities to be used routinely by design engineers to accelerate and improve product development.
In models such as this airplane fuselage panel (left) and this personal electronic device (right), For More Information the Find Interactions Wizard automatically detects pairs of surfaces (indicated in red and green) Request the Abaqus for CATIA V5 2.5 that will likely come into contact during the analysis. Setup time is greatly reduced for models webinar replay at www.simulia.com/webinars with a large number of contact pairs.
INSIGHTS October/November 2007 www.simulia.com Solution Update
Accelerating Nonlinear Analysis Using Abaqus/Standard on Compute Clusters For companies relying on finite element analysis to support research and product development, the availability of faster and cheaper hardware has created the opportunity to solve larger more detailed models. For nonlinear implicit finite element analysis, turnaround time is largely determined by the performance of the equation solver. Furthermore, the solver’s relative contribution to analysis time typically increases as the problem size increases, making enhancements to solver performance even more crucial. Powertrain model. Courtesy of Dana Corp. At SIMULIA we have invested significant The results in Figure 1 show that the scaling time can also be achieved which justify resources into developing a high- of the powertrain model is much better than parallel execution, particularly when performance, scalable distributed memory the smaller tire model. The speed-up of taking into account token hours cost. As parallel (DMP) direct sparse solver. almost 11 for the powertrain analysis on we work to improve the scalability of Abaqus Version 6.6 marked the first release 64 cores means that this analysis, which Abaqus/Standard, we are also pushing in which users could run Abaqus/Standard takes 60 hours (2.5 days) on a single the boundary on the size of the models on compute clusters while enjoying the compute node using 4 cores, can be that can be solved. Recently, we have run robustness and accuracy of a direct sparse completed in less than 6 hours on 64 cores. in-house models with over 25 million
solver. In Abaqus Version 6.7 the solver 16 degrees of freedom, and we are looking has been enhanced to include expanded 14 Powertrain at scalability on up to 512 cores using feature coverage, reduced memory usage, Tire-Total 12 Tire-Footprint Abaqus/Standard. and improved performance and scalability. 10 Tire-SST Ideal For those customers with large and The improved scalability is particularly 8
Speed Up medium size models, we encourage you to noticeable in large models with over a 6 leverage the documentation, training, and million degrees of freedom. 4
2 support resources available to you to take
Benchmark Models 0 advantage of DMP on compute clusters. 0 8 16 24 32 40 48 56 64 The solver performance improvements During software development, we work Total Number of Cores closely with our customers to benchmark can increase productivity significantly. Figure 1 Speed-up results for the analyses in real-life industrial applications. This article comparison to ideal (linear) speed-up. Speed-up Powertrain Tire demonstrates the benefits of running Abaqus is the ratio of the analysis wall clock times on 4 cores and N cores (N=4, 8, 16, 32, 64). Footprint Steady- on a compute cluster using a powertrain state model (courtesy of Dana Corp.) and a In addition to completing the analysis much transport tire model (courtesy of Pirelli Tyre S.p.A). faster, a simple analysis token utilization Elements 1.25M 350K 350K calculation shows software costs for the Nodes 3.28M 448K 448K Both are nonlinear analyses, which include Equations (dofs) 9.63M 796K 796K contact and nonlinear material behavior. powertrain model are 67% lower for the run FLOPS per iteration 3.62E+13 2.69E+12 4.68E+12 on 64 cores. For the tire model, running on Steps 10 3 2 The scalability of Abaqus/Standard was 32 cores is 46% cheaper than running on Iterations 65 51 38 measured by calculating the speed-up for 4 cores. Pertinent Model and Analysis Information jobs run on up to 16 compute nodes (64 cores) with respect to jobs run on 1 node SIMULIA Authors: Harun Bayraktar, Developer, Summary Implicit Analysis/Solvers; Matt Dunbar, Manager, (4 cores). All jobs were run on a Hewlett- These benchmark models clearly Platform Specialists; Vladimir Belsky, Director, Solver Technology. Packard XC3000BL Linux cluster with two demonstrate the cost-effectiveness of Intel 3.0GHz Core2 Duo processors on each running large nonlinear simulations in Special thanks to: Rohit Ramkumar, Dana Corp., and Massimo Donatellis, Pirelli Tyre S.p.A. node. The powertrain model was run using Abaqus/Standard on compute clusters. The Abaqus Version 6.7-1 and the tire model was scalability of Abaqus/Standard is capable For More Information run using a prerelease of Abaqus Version of reducing analysis time from days to Request a replay of the DMP Webinar at 6.7-EF (required for DMP execution of the hours for large models. For medium size www.simulia.com/webinars steady-state transport procedure). models, significant reductions in turnaround www.simulia.com INSIGHTS October/November 2007 Cover Story
It’s All in the Solder Joints By Karen Donovan
Lately it’s hard not to notice that automobiles have morphed into There can be as many as 2,000 solder joints in a high-volume powertrain controller board such as this. circuit boards on wheels. “In terms of cost, there is more electronic generation of automotive electronics. As Electronics now control every content in vehicles today than even steel,” one of the largest automotive systems important system in the says Dr. Mahesh Chengalva, Staff Research suppliers in the United States, Delphi runs Engineer at Delphi. “The performance 170 manufacturing facilities in more than average passenger vehicle, requirements are challenging, and these 30 countries. On a typical day, the Kokomo from entertainment and systems are expected to last ten years or facility alone produces over a million IC navigation to chassis and more. It’s a severe vibration and thermal packages. environment, especially for underhood steering, brakes, security, In electronics design and manufacture, electronics.” and powertrain. A dazzling package reliability is sacrosanct. The menagerie of electronic Chengalva is part of the Hardware Analysis reliability of electronics systems in automotive components populates and Simulation group at Delphi Electronics applications hinges on the reliability of every & Safety, a division of Delphi Corporation solder joint on every circuit board. A major automotive printed circuit that is headquartered in Kokomo, Indiana. factor in solder joint reliability is thermal board assemblies. His group provides analysis services to cycling. “The single largest driver of failure squadrons of Delphi design engineers in electronics systems in the field is the at work all over the world on the next repeated temperature cycling that the product
View of a typical leaded IC package assembled Cross-sections of leaded IC packages before and after extensive thermal cycling, showing copper leads onto a high-density on-engine automotive soldered to the contact pad on the circuit board. Delphi gathers data on the thermal cycling failure of solder controller board. The electrical connections are joints via extensive physical testing, which provides raw data for comparing and validating simulation results. made by leads projecting from the package body that are soldered onto the circuit board.
10 INSIGHTS October/November 2007 www.simulia.com Cover Story
View of a ball grid array (BGA). Sample contour plot of FEA results These versatile components often in Abaqus, showing equivalent form the brains of an electronics creep strain for a ball grid array package. For example, the CPU of under thermal load. Thermal a powertrain controller is often a expansion mismatch between the BGA. The electrical connections with BGA package and the circuit board the board are made through solder causes differential movement balls. Predicting the thermal cycling between the top and bottom reliability of each one of these surfaces of the solder balls with solder balls is important because every temperature cycle, eventually a single failure can cause vehicle leading to fatigue failures. malfunction.
undergoes,” says Chengalva. “Eventually, properties of solder and has developed is fundamental to the company’s strategy of in this harsh thermal environment, a solder validated material models for use with incorporating simulation upfront in design. joint will develop a crack, and we want to be Abaqus. “Unlike steel or copper or ordinary To illustrate, Chengalva describes a scenario able to predict when that will happen.” plastic, solder is extremely complicated,” where a Delphi design engineer in Singapore says Chengalva. “Its behavior is time needs to select a suitable ball grid array Considering that the daily production of dependent, temperature dependent, and package from a number of suppliers. “The solder joints at Delphi is about one billion, stress dependent. This behavior cannot be designer knows what he wants for package the task of predicting thermal cycling simulated accurately without very in-depth reliability,” he says, “but he needs a way to reliability for all the electronic packages nonlinear analysis tools.” evaluate each supplier’s product and pick under design calls for very special tools. the best one. All he has to do is open the Chengalva’s simulation group has tackled Along with the material model, Chengalva’s thermal tools section in D-Cube, click on the the challenge from two sides. For analysis group has developed a library of prebuilt ball grid array icon, fill out an online form power, they rely on the advanced nonlinear thermal-cycling reliability models for many with input parameters, and hit submit.” solution capabilities of Abaqus simulation families of electronics devices. These range software from SIMULIA, the Dassault from single components such as capacitors Input parameters vary with the type of Systèmes brand for realistic simulation. To and resistors to full packages such as ball package. Detailed dimensions of the speed analysis throughput, they offer Delphi grid arrays, flip chip assemblies, and a package assembly, and material properties design engineers direct access to the Abaqus variety of surface-mount leaded ICs. To such as the coefficient of thermal expansion solver by means of a turnkey web-based validate the FEA models for each electronic for each part in the assembly, are commonly expert system called D-Cube. package, the team simulates a set of thermal required input. Once the designer submits cycling tests and compares the results of the data, the input parameters go to Simulating Solder Joints simulations with the results of tests. “All our Chengalva’s group for scheduling. The next To study solder joint performance and FEA models have been carefully correlated step, FEA modeling, has been automated ensure field reliability, Delphi subjects its with test data,” he says, “so our design to cut preprocessing time from several electronics products to a battery of thermal engineers can be confident that simulations days for complicated assemblies to about cycling tests that replicate automotive give accurate predictions of package an hour at the most. In the case of this ball operating environments. Some tests require reliability.” grid aray, a prebuilt parametric modeler as many as a thousand or more thermal would automatically create a model for the cycles, where a package is repeatedly The D-Cube Doorway package the designer has specified. Regions heated and cooled between two temperature In fact, getting accurate simulation results of interest in the package geometry are extremes, until solder joint failure occurs. for thermal reliability has never been easier automatically identified for greater mesh For underhood applications, these extremes for Delphi design engineers. They have refinement. can range from −40˚C to 125˚C. Thermal- Abaqus FEA power at their fingertips any Finally, the input file goes to the Abaqus cycling tests are time consuming (a 3,000- time of the day or night, anywhere in the solver. Complex three-dimensional cycle test would take four months), so the world, thanks to the D-Cube web-based simulations might take three or four days of ability to simulate reliability testing gives expert system. Up and running on the continuous run time. “Once the simulation Delphi a significant advantage in faster time Web since May 2000, the company-wide is complete,” says Chengalva, “the design to market. site offers a collection of over 200 design engineer receives a reliability value. Perhaps optimization tools, materials resources, self- Creating a valid FEA model for predicting this particular package, from this particular taught tutorials, and notes on engineering thermal cycling reliability starts with supplier, for this particular thermal-cycling lessons learned. characterization of material properties. profile will last 3,400 cycles. That number Delphi has amassed a substantial amount The brainchild of Chengalva and Scott is what the designer needs. We can also of laboratory creep test data on the material Baxter, a former Delphi colleague, D-Cube compute a value for relative life prediction, (Story continued on page 12) www.simulia.com INSIGHTS October/November 2007 11 Cover Story
Screen views of Delphi’s D-Cube web-based expert system. At left is a menu of tools for performing thermal cycling reliability analysis with Abaqus. At right are parameter input fields for analyzing the thermal cycling reliability of a ball grid array. A prebuilt parametric modeler automatically utilizes the designer’s input to create an analysis model for the simulation.
which helps the designer compare one The FEA process automation that D-Cube solution. You might remember that the next package with another. Relative life offers design engineers is an efficient way to time one of those rolling circuit boards predictions are particularly useful when assess electronic packages, especially when passes you on the highway safely at 80 mph. input data are incomplete.” numerous competing design configurations
are being considered. “In electronics, parts It is interesting to note that D-Cube helps Mahesh K. Chengalva is may look identical, but their reliability can tie together the far-flung global centers of a veteran Abaqus user vary significantly, based on the mechanical Delphi analysis into a single integrated and owner of 11 patents structure or on the materials used,” says unit. In the example mentioned above, and trade secrets. He Chengalva. “For a leaded IC that is used on although the request originated in Singapore, has worked for Delphi a FR4 substrate, if you change the material it would be processed in Kokomo (USA), for 12 years, and was of the lead from copper to Alloy 42, you with the actual FEA modeling and execution inducted into the Delphi Hall of Fame could have almost a tenfold decrease in conducted in either Krakow (Poland) or in May 2006. He is currently technical solder joint reliability. If not selected Bangalore (India). manager of their mechanical analysis carefully, additions such as conformal coats, laboratory in their Electronics and Safety which are applied to some circuit board division. At Delphi, Mahesh conducts assemblies to prevent moisture damage, can reliability simulations for electronics interact mechanically with components to systems, manages the company’s web- degrade reliability. For design engineers, based engineering expert system, provides information about reliability as related consulting services to internal customers, to these multiple parameters is powerful and interfaces with overseas technical because it enables tradeoff decisions very centers. In his spare time, he is also a early in the design cycle.” founding member of a robot racing team Simulating thermal-cycling reliability using headed for the semi-finals of the DARPA Abaqus FEA saves Delphi an enormous Grand Challenge this October. amount of time and cost and opens doors to design innovation. With D-Cube, design engineers can quickly use Abaqus to explore For More Information different configurations for automotive Visit www.delphi.com electronics packages and select the optimal or www.simulia.com/solutions
Close-up view of an audio system board showing chip components, some as small as 2 mm in length. Since these components lack leads or other compliant structures, the entire thermal mismatch between component and board is borne by the solder joints.
12 INSIGHTS October/November 2007 www.simulia.com Electronics Strategy
Realistic Simulation Strategy for the High Tech Industry The competitive high tech industry requires other electronics customers to capture expert- innovative new products to be brought to generated workflows of advanced simulation, David Cadge market extremely quickly. In addition to time which are then packaged, automated, and Senior Solutions Engineer, pressures, manufacturers face the challenge of deployed to design engineers. Electronics, SIMULIA squeezing more capabilities into smaller, yet SIMULIA is known for the development and David Cadge has worked design-conscious packages. The industry is deployment of innovative simulation methods. with SIMULIA since 1995 also faced with regulatory compliance issues The direct cyclic solution method is a unique in various capacities within such as the elimination of lead-based solder, capability in Abaqus to automatically calculate our customer service and marketing teams. which has been in use since the beginning of the stabilized, steady-state response of a David initially worked at our SIMULIA UK the electronics revolution. structure to cyclic loading, thus increasing office and then transferred to our Providence, SIMULIA has actively engaged with a solution accuracy and reducing solution time RI, headquarters in 2003, where he is now number of high-tech customers to gain a compared to traditional methods. In a recent responsible for developing and promoting our deeper understanding of their processes and IMECE paper, engineers at Intel described strategy for simulation within the high tech simulation requirements. As a result, we seek how they applied the direct cyclic solution industry. He has traveled extensively, visiting to deliver more simulation functionality within method for thermal fatigue analysis of our high tech customers around the world to easier-to-deploy environments. For example, electronic packages. understand their workflows and requirements we are making functionality like fracture while promoting our current capabilities and We continue to make advances in our state- modeling and advanced time- and temperature- best practices for this industry. Information of-the-art material modeling capabilities dependent material models more accessible to gathered during these visits will help by including special models for analyzing designers though automated model creation, us provide enhancements for advanced lead-free solder. Integrated and coupled enhanced material libraries, and integrated technology, usability, and productivity so that multiphysics capabilities support robust multiphysics capabilities. simulation can become an integral part of coupled-field analyses of thermal, electrical, electronics design practices. mechanical (both static and dynamic), and moisture-sensitivity load regimes. We have industry-leading capabilities for progressive For More Information fracture-failure modeling and nonlinear Abaqus Extensions contact, and our recent Abaqus releases PCB modeler have also delivered best-in-class solver www.simulia.com/extensions performance, allowing larger and more Abaqus Users’ Conference 2007 Paper realistic models to be solved in much less time. Temperature Cycling Analysis of As a result of our focused high tech strategy, Lead-Free Solder Joints in Electronic Packaging by Shan Li, Zhenyu Huang, our products and services are gaining Screen capture of a PCB modeler in Abaqus Jianfeng Wang, Intel Technology momentum and growing rapidly within this Development Ltd., Shanghai, China and Electronics-Focused Capabilities industry. To support the market, we plan to Shaowu Gao, SIMULIA China. Our Unified FEA strategy leverages existing host a series of half-day electronics seminars www.simulia.com/solutions/high_tech Abaqus strengths to allow a single model in select locations to enable customers to Technology Brief definition and user environment to be interact directly with our technical staff Creep Analysis of Lead-Free Solders used for multiple simulation types such as and gain first-hand knowledge of our latest Undergoing Thermal Loading package reliability, thermal fatigue, moisture technology. In addition, we have developed www.simulia.com/tech_briefs sensitivity, shock, and drop. This approach a Technology Brief and Electronics Webinar; Webinar is being applied by several cell phone both are available for download from the Validate Electronics Packaging manufacturers to leverage their Abaqus models SIMULIA website. If you have specific Performance with Realistic Simulation to simulate bending, thermal load, drop, and requirements for high tech and electronics www.simulia.com/webinars acoustics. packaging simulation, please contact your local office. We look forward to working The Delphi article on page 10 of this issue with you to provide the most robust high tech provides an excellent example of the types industry solutions on the market. of custom interfaces that are able to be created with Abaqus/CAE. These interfaces enable efficient and automated modeling for electronics applications such as ball grid arrays. Similar approaches have been taken by www.simulia.com INSIGHTS October/November 2007 13 Customer Case Study
Quick! Build a Better Running Shoe from the Inside Out
adidas achieved significant design cycle reduction for their ForMotion™ line of running shoes by coupling surface-based computer aided design (CAD) with Abaqus finite element analysis software. A unique sliding plate technology in the heel of the
shoe absorbs shock in three dimensions. Wear testing of the heel unit, using a bespoke test device, reproduces the motion and impact of an actual runner using the shoes.
Check out a store display of running shoes line of running shoes, adidas has achieved buildings) located in the heel of the shoe. and you may conclude that it’s all about significant design cycle reduction by Stiffness is provided to the system by way style, color, and fashion. In fact, people in coupling their surface-based computer aided of a thin polymer seal, and sometimes also the sports equipment industry admit that design (CAD) tool with FEA software polymer springs and washers, depending on over half of all athletic shoes are bought (Abaqus/Explicit and Abaqus/CAE) the model. solely for their looks. from SIMULIA. “Instead of just absorbing the shock in But those people who actually run in their “If you were going to retool and test a whole a vertical axis, the sliding plates adjust shoes—recreationally or professionally— new shoe it could take six to eight weeks,” to shock in three dimensions—vertical, will be pleased to hear that the designers says adidas Mechanical Engineer Tim horizontal, and rotational,” Robinson and engineers at adidas are paying attention Robinson. “But when you run simulations it says. “Car banking systems also use a to more than flashy exteriors. They know only takes a few days. In terms of speeding similar technology. There’s a lot of cross- that shin splints, a twisted knee, or one bad up the entire development process, the FEA fertilization within engineering these days.” turn of the ankle can ruin any runner’s day. software has proved invaluable.” The heel unit benefits the runner in a number Using materials science, biomechanics, and Robinson is part of the adidas innovation of important ways. For one, decoupling the finite element analysis (FEA) software, they team made up of designers, engineers, heel with sliding plates slows down “sole are building motion-responsive, stress- and biomechanists working together from angle velocity,” the speed at which your reducing technologies—similar to ones two locations: adidas’ birthplace outside toes slap the ground after your heel makes found in earthquake-resistant buildings and Nuremberg, Germany, and Portland, Oregon, contact—when it happens too fast you can car stability systems—right into the heels of U.S.A. Declaring 2007 to be the Year of end up with the common runner’s complaint their running shoes. Running, adidas is releasing some details called shin splints. The shoes still look good, of course. But the (but not all—the sports shoe industry is as The plates can also rotate to counteract best parts of the sneaker are now definitely secretive about R&D as anyone else) about pronation, the amount your foot rolls those you can’t see. how they create their high-tech products. inwards with each step (most people pronate Simulation Software is Key Unique Sliding Plate Technology to some degree). Too much pronation is Historically, new athletic shoe models have A key element in the creation of the one of the biggest causes of knee injury in been based on a retooling of existing ones, ForMotion™ line of running shoes is a unit running. The spherical plates automatically necessitating time-consuming rounds of comprised of a pair of sliding polyamide correct for this, with the rotational motion real-world prototype testing and redesign. plates with a spherical bearing (similar “give” protecting the knee. Overstraining But in creating their new ForMotion™ to those earthquake protection systems in in the opposite direction is prevented by displacement limiters.
14 INSIGHTS October/November 2007 www.simulia.com Customer Case Study
A B And finally, the unit automatically adjusts to each individual foot strike (how turned out your feet are when you run). Women tend to land straighter than men, notes Robinson. “Men can land at up to 30˚ away from a straight forward line. We’ve been able to engineer the heel unit to perform the same no matter which angle you land on
the shoe.” External side view strain contour plots generated with Abaqus/CAE show the results of a biomechanical loading of the heel unit. View A shows the undeformed state, and B is the deformed state. In the first round Turning the Concept into Reality of virtual prototypes, this information warns the engineers about areas that could be prone to excessive strain and lets them modify the design accordingly. Forces from the FEA outcome compared to mechanical With the concept in hand, the next step for tests from bespoke equipment show a very high degree of correlation. the innovation team is ensuring that the heel A B unit works as intended in an actual running shoe and can also be functionally graded to different shoe sizes.
Surfaced-based CAD modeling is the starting point at adidas, due to the design freedom it allows when dealing with the very organic geometry of objects like shoes. From the CAD models, 3D meshes are Internal cut view strain contour plot generated with Abaqus/CAE showing biomechanical loading of the created and imported into Abaqus/CAE. heel unit. View A shows the undeformed state, and B is the deformed state. This function in Abaqus/CAE “We create the modeling interface and software allows engineers to cut sections through virtual shoes. This is extremely useful when analyzing the movement of internal components and making any necessary design changes. then use it to apply boundary conditions and material properties to the mesh, and Since human feet—and bodies—come At this point there are rarely any surprises, tie everything together defining contact, in many different sizes, an important Robinson notes. “Since we’ve already used friction, connectors, and other factors,” says part of FEA modeling at this stage is the FEA to run simulations that are comparable Robinson. “Then we solve it using functional grading of the shoes. “From our to movements of our test devices, we are Abaqus/Explicit.” biomechanics results we have data about the very confident that when we get the first correlation between shoe size and average Material characteristics come from custom sample shoes back they will be very close to weight,” Robinson points out. “The radius libraries adidas creates based on their highly what we predicted them to be.” above the ankle joint will change with a proprietary materials. Biomechanics data, larger size. We use this relationship to Wear testing is done using another the basis of the boundary conditions, are functionally grade the shape of the plates, bespoke device, Performance Evaluation equally confidential; they are generated in- employing FEA to predict the optimum Test Equipment (PETE). This uses the house using a Vicon motion-capture system stiffness of the heel unit required for each previously obtained Vicon biometric input of tiny markers placed at strategic points on shoe size.” The shoes also come in four to reproduce the motion and impact of an a human runner, which are then tracked with variations for control, cushion, trail, and actual runner wearing the shoes. Testing infrared cameras as the person moves. competition. runs up to 100,000 cycles, comparable to 1000 km of running. Seeing Inside the Virtual Shoe Testing, Testing For postprocessing, Abaqus/CAE is used All that running will now take less of a toll When prototypes are ready for testing in the again. The engineers look for areas of on legs, thanks to adidas’ ForMotion line of real world, a bespoke adidas test device is strain and/or friction by applying simulated shoes. So with shins and knees now better put to use. Located just a few meters from horizontal and vertical displacement forces. protected, can hips be far behind? “That’s the workstations running FEA software, it “At this stage of development it’s definitely a question for our biomechanists,” says is used to measure the “horizontal stiffness” very useful to be able to ‘see’ inside the Robinson. “Engineering shoes to work of the ForMotion™ shoes. The shoe is held actual shoe, and even cut through the with hips might be next. We are continually at an angle of 30˚—the “male” foot strike modeling for a closer look, especially when making improvements using Abaqus angle—and a quasistatic displacement is we’re dealing with a complex unit including software to advance the science of shoe applied to the heel. This non-destructive test plates, seal, springs and washers,” Robinson design.” is also used later for quality control testing notes. “It greatly helps communication of shoes taken directly from the factory line. with our designers about any changes we For More Information recommend.” www.adidas.com or www.simulia.com/solutions adidas, the adidas logo, ADIPRENE, and the 3-Stripe trade mark are registered trademarks of the adidas Group, used with permission. FORMOTION and geoFIT are trademarks of the adidas Group, used with permission. www.simulia.com INSIGHTS October/November 2007 15 Academic Update
University of Alaska Researchers Model Tire-Snow Interaction for Improved Safety Studying vehicle and tire behavior in arctic Contact between the side surface of Contact between the side tire and snow due to rotation of tire surface of tire and snow due (zone 3, negative stress) to downward motion of tire conditions creates a challenging simulation (zone 1, positive stress) environment. Researchers encounter highly nonlinear conditions in sinkable terrain with low friction surfaces and uneven or Contact between the side surface of tire and snow uncertain ground, which cause complex, due to rotation and lateral Contact between the motion of tire (zone 4, bottom of tire and varying pressure, friction, stress, and contact positive stress) snow due to lateral motion of tire (zone 2, distribution. Tire-snow interaction has transition from positive to negative) been studied for decades at the U.S. Army
Cold Regions Research and Engineering Contact shear stress (CSHEAR2) for FZ= 6,240N, α=8, and i =0.407 Laboratory. Extensive modeling, simulation, x and tests have been conducted for a variety resistance, drawbar pull, snow sinkage, tire and snow sinkage depend significantly of vehicles. However, the studies reviewed deflection, contact pressure, and contact on the longitudinal slip, slip angle, and did not consider the effects of controlled shear stresses were obtained under combined vertical load. It was also concluded that longitudinal slip, lateral slip, or wheel slip conditions as well as the wheel states. vehicle-snow interaction modeling methods load. In addition, the traction and motion and results are similar to those for vehicle- Since the deflection of a tire on snow is resistance were not separated from the sand interfaces, allowing this research to smaller than on the rigid ground, the tire reaction force at the hub of the wheel. be shared by those modeling off-road tire can be considered as rigid; however, the Consequently, the off-terrain wheel states behavior under desert conditions. deflection can influence the actual value of were not identified. In addition, contact longitudinal slip. Due to the fact that the full Dr. Jonah H. Lee is Professor and Chair of stresses were not studied as a function of range of longitudinal slip was prescribed in Mechanical Engineering at the University wheel state. the simulations, the off-terrain wheel states of Alaska Fairbanks (UAF), Alaska, U.S.A. Professors Jonah Lee and Qing Liu of the were identified, which served as an indicator He received his Ph.D. in Engineering Vehicle Terrain Interaction Group (VTIG) to categorize the interfacial forces and Mechanics from Iowa State University in at the University of Alaska Fairbanks are contact stresses. Trends of the distribution of 1983. His recent research interests are in building on previous research by using contact pressure as a function of wheel state the area of vehicle-snow interaction and Abaqus to evaluate three-dimensional finite and vertical load were established. Multiple structure-property relationships of random element simulations of pneumatic tire-snow zones of the distribution of shear stresses heterogeneous materials. interaction. Such analyses enable them to at the contact patch were identified and gain insight into contact mechanisms and analyzed as a function of wheel state. obtain associated interfacial stresses and The simulations indicated that the length For More Information forces, sinkage of snow, and deflection of contact patch increases slightly with Visit Dr. Lee’s webpage at of the tire as a function of vertical load www.faculty.uaf.edu/ffjhl/. vertical load and that the interfacial forces under combined slip conditions where the longitudinal and lateral slips are explicitly controlled. NEW! SIMULIA Academic Website tread belt rebar carcass Learn more about what researchers, students, and teachers are
sidewall accomplishing with the Abaqus Unified FEA product suite. Our academic website features compelling state-of- rebar bead the-art Abaqus research applications as well as examples of innovative student projects that span many industries such Finite element tire model as consumer goods, crashworthiness, The pneumatic tire was modeled using high tech, and life sciences. Purchase For More Information elastic, viscoelastic, and hyperelastic Abaqus Student Edition online or find Visit www.simulia.com/academics material models; the snow was modeled out how you may use our Academic and using the modified Drucker-Prager cap Research Editions at your university. plasticity model. The traction, motion
16 INSIGHTS October/November 2007 www.simulia.com Alliances
Improving Powertrain Noise & Vibration Analysis Designing low noise engines is a challenge Total due to the contrary demands of using Surface Integral lightweight materials while increasing the Level power and performance of vehicles. To 5dB meet these challenges, AVL and SIMULIA 500 Figure 1: Result evaluation are leveraging significant advances in and determination of critical Frequency [Hz] speeds and frequencies substructure (“superelement”) capabilities Level [dB] based on structure borne noise results (inline of Abaqus with AVL EXCITE to provide Engine Selection Area compelling new functionality for powertrain 3000 Speed [rpm] 4-cylinder engine) noise and vibration analysis. Integrated Analysis Workflow powertrain engineers to obtain all motion A typical engine simulation model A noise and vibration analysis begins quantities and structural vibrations for the consists of various parts (bodies) such as a with the generation of FE models for entire FE model (Figure 1). crankshaft, connecting rods, and an engine engine components such as the crankshaft, This process provides the necessary cylinder block, coupled with nonlinear connecting rod, and power unit. The first integration of simulation methodologies to contact (joints) such as journal bearings. analysis step is a natural frequency analysis automate data transfer, improve workflow The mass/moment of inertia and elasticity of of all parts using Abaqus as a model check efficiencies, and gain improvements in these bodies are included by using Abaqus. and to investigate dynamic behavior. A simulation fidelity. In addition, leveraging This method enables engineers to calculate combined static and dynamic condensation the latest improvements, Abaqus/AMS the dynamic behavior of powertrains, of the FE models in Abaqus provides engineers are able to significantly shorten including the influence of hydrodynamic reduced mass and stiffness matrices for project turnaround times and reduce costs in contact under realistic running engine the following nonlinear forced vibration reaching performance targets. conditions. By conducting a transient engine calculation with AVL EXCITE. run-up simulation, the dynamic behavior in AVL EXCITE performs an internal For More Information the full range of engine speed and loading recovery of the results from Abaqus using www.avl.com or condition may be investigated. www.simulia.com/solutions a transformation matrix. This enables
Intel Creates Program to Simplify Cluster Deployment According to IDC, a global provider of The Intel® program technology provides a market information for the information standardized and replicable way to build technology markets, compute clusters clusters and run “off-the-shelf” high- captured more than 50% of technical server performance applications. It includes a revenue in 2006. However, IDC is projecting specification that sets minimum standards a slow down in growth that they attribute to for software and hardware components. the increased complexity in deploying and A central component of the platform managing compute clusters. certification process is the Intel® Cluster The Intel® Cluster Ready program addresses Checker. This tool checks the cluster describe any software dependencies beyond this industry concern by establishing a hardware and software components to those required by the Intel® Cluster Ready reference architecture for Intel-based ensure that the cluster was built according Specification; this ensures the smooth systems. Hardware vendors can use this to the specification and that the cluster is installation and proper execution of architecture to certify their configurations, operational before an ISV code is loaded. It registered ISV applications on any certified and ISVs, such as SIMULIA, can use it to also provides a fault isolation tool for early cluster. SIMULIA engineers have tested and test and register their applications. The chief detection of cluster problems which helps registered both Version 6.7-1 and Version goal of this program is to ensure fundamental improve productivity and reduce support 6.7-2 of Abaqus/Standard and Abaqus/ hardware/software integration, so that end costs. Explicit to run on clusters certified as users can focus on getting their job done, Intel® Cluster Ready. To register their software applications knowing that Intel® Cluster Ready ISV as Intel® Cluster Ready, ISVs must test applications will run on their cluster that has their applications on certified platforms been certified as Intel® Cluster Ready. with realistic workloads. Of particular For More Information importance to end-users, the ISV must www.intel.com/go/cluster/ www.simulia.com INSIGHTS October/November 2007 17 Events
2007 Abaqus Regional Users’ Meetings and Update Seminars Our regional offices and representatives are in the midst of hosting the 2007 Regional Users’ Meetings (RUMs). The twenty-six RUMS held around the world provide a local forum to learn about innovative analysis methods and how our customers are applying Abaqus FEA technology within their industry or academic institution. More than 2,000 attendees will learn first-hand about the latest enhancements to Abaqus and the overall SIMULIA strategy. The meetings also offer our customers the opportunity to provide input on future software enhancements, network with other users, and China RUM share experiences and new ideas.
While most RUMs are held September through November, Abaqus users in China, Korea, and South Africa gathered in June and July. Our China RUM, held in Guilin, was the gathering place for more than 160 attendees. Of the 84 papers that were published in the proceedings, eight received awards, and four were presented China RUM: Mingwei Chen, KC Jen, Korea RUM Scott Berky, Barry Bai at the conference. Abaqus experts from our regional offices The Korea RUM was held in Daejon, with and our headquarters will be on-hand to more than 150 Abaqus users in atendance. provide specific product and technology Among the papers presented, LG Chemistry information and answer your questions. provided insight into creep behavior of plastics, As an additional educational opportunity, Schaeffler Korea Corporation discussed contact several of the regions are including another stress analysis of seal mechanism of a bearing, seminar either before or after the user and Kumho Tire reviewed the simulation of the meeting. driving performance for a vehicle tire. To learn more about the Regional Users’ As this issue goes to press, RUMs in Erie, Meeting in your area, contact your local Central, Scandinavia, and Deutschland will office or visit the events page on the Erie RUM have just concluded. We trust that you were SIMULIA website. able to take advantage of the meeting in your area. For those of you in regions that still For More Information have upcoming meetings on the calendar, www.simulia.com/events/rums we encourage you to take part in these conveniently located and valuable events.
Americas Europe / South Africa Asia Pacific Date Location Date Location Date Location October 1–2 Córdoba, Argentina October 9 Prague, Czech Republic October 24 Bangalore, India October 17 Houston, TX November 5–6 Bilbao, Spain October 29–30 Malaysia October 22–24 Las Vegas, NV November 8–9 Istanbul, Turkey October 31 Tokyo, Japan November 5–6 Toronto, Ontario November 12–13 Salzburg, Austria November 2 Osaka, Japan November 7–8 Plymouth, MI November 13–15 Daventry, United Kingdom November 14–15 Providence, RI November 15–16 Poznan, Poland November 15–16 Leuven, Belgium November 21–23 Turin, Italy November 26 Herzelia, Israel
18 INSIGHTS October/November 2007 www.simulia.com Events
2008 Abaqus Users’ Conference May 19–22, 2008 Newport Marriott - Newport, Rhode Island The 2008 AUC will mark the 30th Submit Your Abstract anniversary of the commercialization of Abstracts for conference papers are now Call for Papers Abaqus FEA software. Released for the first being accepted. Prospective authors are November 8, 2007: time in 1978, Abaqus FEA software has invited to submit abstracts of 250 words or Final date for Abstracts and undergone significant development over the less. Suggested topics can be found online at Permission Forms years, making it the world’s technology- the 2008 AUC website. Paper acceptance will January 17, 2008: leading simulation software. be based on the review of the abstract and Draft Manuscript Due Our customers’ tradition of sharing draft manuscript by SIMULIA management information about their industrial and technical professionals. Please take time February 21, 2008: applications is one of the reasons that we to submit your abstract today. Final Manuscript and have been able to grow and advance this Registration for Conference Due important technology. Benefits of Presenting • Enhance your professional credentials by being published in the Conference Proceedings. • Receive $100 off your registration fee to the conference and $100 off an Advanced Seminar. • Gain recognition as an expert by the simulation community • Establish beneficial industry contacts
For More Information www.simulia.com/auc2008
Webinars SIMULIA provides free informational webinars to help you get the most from our products and solutions. Attend upcoming live webinars or request a replay of a recorded webinar and view it at your convenience.
Upcoming Live Webinars Introducing Simulation Lifecycle Management from SIMULIA • December 4: 4:00–5:00 p.m. EST • December 6: 9:00–10:00 a.m. EST
Webinars On-Demand Request a replay of a recorded Webinar and view it at your convenience. • Realistic Simulation for Offshore Exploration Applications • Realistic Simulation with SIMULIA Multiphysics Solutions Abaqus Version 6.7 for Unified FEA • Improving Powertrain Noise & Vibration Analysis
For More Information www.simulia.com/webinars
www.simulia.com INSIGHTS October/November 2007 19 SIMULIA Helps Get Me There.
Simulation for the Real World Aircraft manufacturers are using advanced composites to create the next generation of quieter, more comfortable airliners. Our customers use SIMULIA solutions to understand the behavior and improve the application of composite materials for aerostructures. We partner with our customers to invent new methods and deploy realistic simulation technology, which helps them drive innovation and make flights more relaxing.
SIMULIA is the Dassault Systèmes Brand for Realistic Simulation. We provide the Abaqus product suite for Unified Finite Element Analysis, multiphysics solutions for insight into challenging engineering problems, and an open www.3ds.com PLM platform for managing simulation data, processes, and intellectual property.
Learn more at: www.simulia.com/ae07
The 3DS logo, SIMULIA, and Abaqus are trademarks or registered trademarks of Dassault Systèmes or its subsidiaries. Other company, product, and service names may be trademarks or service marks of their respective owners. Copyright Dassault Systèmes, 2007.