Integration of Computer Aided Design and Finite Element

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Pittsburgh PA 15213 3890,Integration of Computer Aided. Design and Finite Element,Analysis Tools in a Small. Manufacturing Enterprise,CMU SEI 2003 TR 015,ESC TR 2003 015. Joseph P Elm,John E Robert,Technology Insertion Demonstration and Evaluation. TIDE Program,Unlimited distribution subject to the copyright.
This report was prepared for the,SEI Joint Program Office. HQ ESC DIB,5 Eglin Street,Hanscom AFB MA 01731 2116. The ideas and findings in this report should not be construed as an official DoD position It is published in the. interest of scientific and technical information exchange. FOR THE COMMANDER,Christos Scondras,Chief of Programs XPK. This work is sponsored by the U S Department of Defense The Software Engineering Institute is a. federally funded research and development center sponsored by the U S Department of Defense. Copyright 2003 by Carnegie Mellon University,NO WARRANTY. THIS CARNEGIE MELLON UNIVERSITY AND SOFTWARE ENGINEERING INSTITUTE MATERIAL IS. FURNISHED ON AN AS IS BASIS CARNEGIE MELLON UNIVERSITY MAKES NO WARRANTIES. OF ANY KIND EITHER EXPRESSED OR IMPLIED AS TO ANY MATTER INCLUDING BUT NOT. LIMITED TO WARRANTY OF FITNESS FOR PURPOSE OR MERCHANTABILITY EXCLUSIVITY OR. RESULTS OBTAINED FROM USE OF THE MATERIAL CARNEGIE MELLON UNIVERSITY DOES. NOT MAKE ANY WARRANTY OF ANY KIND WITH RESPECT TO FREEDOM FROM PATENT. TRADEMARK OR COPYRIGHT INFRINGEMENT, Use of any trademarks in this report is not intended in any way to infringe on the rights of the trademark holder.
Internal use Permission to reproduce this document and to prepare derivative works from this document for internal use is. granted provided the copyright and No Warranty statements are included with all reproductions and derivative works. External use Requests for permission to reproduce this document or prepare derivative works of this document for external. and commercial use should be addressed to the SEI Licensing Agent. This work was created in the performance of Federal Government Contract Number F19628 00 C 0003 with Carnegie Mel. lon University for the operation of the Software Engineering Institute a federally funded research and development center. The Government of the United States has a royalty free government purpose license to use duplicate or disclose the work. in whole or in part and in any manner and to have or permit others to do so for government purposes pursuant to the copy. right license under the clause at 252 227 7013, For information about purchasing paper copies of SEI reports please visit the publications portion of our Web site. http www sei cmu edu publications pubweb html,Table of Contents. Executive Summary ix,Abstract xi,1 Introduction 1, 1 1 Small Manufacturing Enterprises and Technology Adoption 1. 1 2 TIDE Program 1,1 3 This Report 2,2 Background 3. 2 1 Engineering Tools and Technology 3,2 1 1 Computer Aided Design CAD Functions 3.
2 1 2 Finite Element Analysis FEA Functions 3,2 2 SME Environment 4. 2 2 1 SME Design Environment and Processes 5,2 2 2 SME Engineering Tool History 7. 3 SME Goals and Strategies 9,3 1 Project Selection 12. 4 Case Studies 15,4 1 Case Study 1 Introduction of 3D CAD 15. 4 1 1 The Project 15,4 1 2 Conceptual Design 15,4 1 3 Introduction of 3D CAD 16.
4 1 4 Product Design with an Integrated Product Model 17. 4 1 5 Initial FEA 21,4 1 6 Adapting to CAD and FEA 23. 4 1 7 Back to FEA 24,4 1 8 Manufacturing 24,4 1 9 Test and Delivery 25. 4 2 Case Study 2 In House FEA 26,4 2 1 The Project 26. 4 2 2 Introduction of In House FEA 28,4 2 3 Conceptual Design and Analysis 29. CMU SEI 2003 TR 015 i,4 2 4 Preliminary Design 31,4 2 5 Final Design 32.
4 2 6 Manufacturing Test and Delivery 33,5 Lessons Learned 35. 5 1 Design Process Lessons 35,5 1 1 FEA for Design Optimization 35. 5 1 2 Model Generation Using CAD 36,5 2 3D CAD Lessons 36. 5 2 1 Integrated Model 36,5 2 2 Large Assembly Management 37. 5 2 3 Structure Model to Suit FEA Needs 37,5 2 4 Training 38.
5 3 FEA Lessons 38,5 3 1 Interoperability with 3D CAD 38. 5 3 2 Meshing 39,5 3 3 Gluing 41,5 3 4 Ease of Use 42. 5 3 5 Training and Consulting Support 42,6 Summary 45. Acronyms 47,References Bibliography 49,ii CMU SEI 2003 TR 015. List of Figures,Figure 1 FEA Mesh Process 4,Figure 2 Design and Production Process 6.
Figure 3 Proposed Design 16,Figure 4 Finished Product for Case Study 1 26. Figure 5 Modified Design and Production Process 28. Figure 6 Conceptual Design from Study Contract 31,Figure 7 Final Design for Project 2 34. Figure 8 Glue Function 41,CMU SEI 2003 TR 015 iii,iv CMU SEI 2003 TR 015. List of Tables,Table 1 Mesh tradeoff example 40,CMU SEI 2003 TR 015 v. vi CMU SEI 2003 TR 015,Acknowledgements, The authors wish to thank Congressman Mike Doyle D 14 PA who was instrumental in.
establishing the TIDE program and Carco Electronics Mallet Technology and Kingsway. Engineering for their support and assistance in this research. CMU SEI 2003 TR 015 vii,viii CMU SEI 2003 TR 015,Executive Summary. A small manufacturing enterprise SME providing custom designed precision electro. mechanical equipment to the aerospace industry was faced with increasing competition in a. stable market Maintaining market share required this SME to provide faster deliveries lower. prices and enhanced product performance This SME initiated a program to adopt advanced. computer aided design CAD and computer aided engineering CAE tools to improve their. design and engineering capability and achieve these business goals. This paper presents two case studies focusing on this SME s efforts to integrate three. dimensional 3D CAD and finite element analysis FEA into the design and engineering. process In doing this the SME obtained additional benefits by revising the overall design. process to include more analytical efforts at the early stages of the product design thereby. evolving from an analysis for validation to an analysis for optimization operational. model The insertion of the analysis effort into the design process is facilitated by the ability. of advanced CAD tools to produce 3D representations of the product design and by the abil. ity of the FEA tool to accept product design information from the CAD tool. During the first case study the SME transitioned from a familiar two dimensional 2D CAD. tool to a new 3D CAD tool When using the 2D CAD tool the SME created detailed design. drawings for each component of the product Interfaces between these components were veri. fied manually With the 3D CAD tool the SME created a single integrated model of all com. ponents and individual component production drawings were derived from this integrated. model The integrated model provided automated verification of component interfaces ena. bling the SME to identify and correct design errors e g mismatched mating dimensions. mismatched bolt holes during the design phase rather than after the components were manu. The SME addressed several challenges encountered during the creation and use of the inte. grated model Due to the complexity of the product the integrated model became quite large. as the design progressed creating difficulties in loading updating and storing the model The. SME developed a number of strategies to manage the size of the model These strategies re. sulted in specific procedures defining effective ways to synthesize organize and utilize de. sign data within the CAD tool, During the second case study the SME acquired in house FEA capability to replace efforts. that had previously been outsourced The starting point of FEA is the creation of a 3D model. CMU SEI 2003 TR 015 ix, of the product to be analyzed The availability of a 3D model from the CAD tool offered the. opportunity for the SME to transfer this model to the FEA tool Although the FEA and CAD. tools shared several common interface standards the transfer of a 3D model from the CAD to. the FEA tool was not without difficulty In general the CAD model contains considerably. more detail than is required by the FEA tool Attempting to analyze the detailed CAD model. overtaxed the FEA tool and yielded no results The SME developed strategies to improve. model transfer from CAD to FEA These strategies resulted in procedures defining preferred. methods of synthesizing and organizing the model These methods enabled the SME to de. velop CAD models that were highly compatible with the FEA tool They also enabled the. SME to easily and temporarily remove detail from the CAD model that was unneeded in the. The integration of 3D CAD and FEA affected not only the technology in place at this SME. but also design and engineering processes While there were increases in the amount of engi. neering effort these increases were more than offset by reduced engineering rework and de. creases in manufacturing effort achieved from improvements in the quality of the design Ad. ditional benefits were also seen in the quality of sales proposals. x CMU SEI 2003 TR 015, Small manufacturing enterprises face a number of challenges when integrating computer. aided design CAD tools and computer aided engineering CAE tools into their design. processes One of the most significant challenges is interoperability across the wide range of. commercial CAD and CAE tools Although many of these tools support industry data stan. dards and claim to be interoperable the connection between them is not seamless. This report summarizes two case studies of tool integration activities at one small manufac. turer The first study examines the enhancement of the product development process resulting. from replacement of a two dimensional CAD system with a three dimensional CAD system. The second examines the creation of an in house capability to perform finite element analysis. FEA replacing analysis that had previously been outsourced. As a result of these experiences the manufacturer learned that improved productivity and. superior designs could be obtained by integrating analysis into the design process at the ear. lier stages of conceptual and preliminary design The manufacturer also learned that the de. sign process and some design techniques had to change for the company to use the CAD and. Integration of Computer Aided Design and Finite Element Analysis Tools in a Small Manufacturing Enterprise CMU SEI 2003 TR 015 ESC TR 2003 015 Joseph P Elm John E Robert June 2003 Technology Insertion Demonstration and Evaluation TIDE Program Unlimited distribution subject to the copyright

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