Product Performance Evaluation with CAD/CAE

1 Introduction to e-Design......Page 1
Questions and Exercises......Page 2
The e-Design Paradigm......Page 6
Parameterized CAD Product Model......Page 8
Analysis Models......Page 9
Motion Simulation Models......Page 11
Motion Analysis......Page 12
Product Reliability Evaluations......Page 13
Product Virtual Manufacturing......Page 14
Design Decision Making......Page 16
Design Problem Formulation......Page 17
Design Sensitivity Analysis......Page 18
Parametric Study......Page 19
Design Trade-Off Analysis......Page 20
What-If Study......Page 21
Rapid Prototyping......Page 22
CNC Machining......Page 24
System-Level Design......Page 26
Component-Level Design......Page 27
Design Trade-Off......Page 29
Example: High-Mobility Multipurpose Wheeled Vehicle......Page 30
Outline placeholder......Page 0
Hierarchical Product Model......Page 31
Preliminary Design......Page 32
Detail Design......Page 34
Design Trade-Off......Page 35
Summary......Page 38
References......Page 39
Sources......Page 40
2 Structural Analysis......Page 42
Introduction to Pro/MECHANICA Structure......Page 428
Analytical Methods......Page 45
Strength of Materials......Page 46
Energy Method......Page 48
Linear Elasticity......Page 51
Types of Analyses......Page 481
Uncertainties, Variations, and Safety Factors......Page 57
Finite Element Methods......Page 58
A Simple Example......Page 59
Finite Element Formulation......Page 64
p-Version FEA......Page 71
S2.3.3 Defining and Running the Simulation......Page 406
Using Finite Element Method......Page 79
5.4 Reliability Analysis Methods......Page 81
Idealization and Simplification......Page 82
Mesh Generation and Refinement......Page 86
The Thin-Walled Tank Example......Page 87
Define Boundary Conditions, Load, and Solve......Page 500
Mesh Improvement......Page 91
The Reliability Index Approach......Page 313
CAD Model Translations......Page 94
Mesh the Model......Page 455
Results Checking......Page 98
Strategy for Complex Problems......Page 101
General-Purpose Codes......Page 102
Specialized Codes......Page 103
Case Study......Page 104
Cantilever Beam......Page 107
Thin-Walled Tube......Page 109
Summary......Page 110
References......Page 115
Sources......Page 116
Appendix: The Default in.-lbm-sec Unit System......Page 117
3 Motion Analysis......Page 119
Questions and Exercises......Page 121
Analytical Methods......Page 125
Particle Motion......Page 126
Rigid-Body Motion......Page 135
Multibody Kinematic Analysis......Page 139
Multibody Dynamic Analysis......Page 143
Thin-Walled Tank......Page 501
Kinematic Analysis......Page 148
Kinematic Joints......Page 155
Multibody Dynamic Analysis......Page 159
Motion Simulation......Page 162
Ground Parts (or Ground Bodies)......Page 163
Constraints......Page 164
Degrees of Freedom......Page 166
4.6.2 Peak-Valley Editing......Page 168
4.6.4 Blocks to Failure......Page 250
Results Visualization......Page 169
General-Purpose Codes......Page 170
Specialized Codes......Page 171
Formula SAE Racecar......Page 172
4.8.2 Case Study: Engine Connecting Rod......Page 183
Driving Simulators......Page 189
Recreational Waterslides......Page 192
Sliding Block......Page 196
Single-Piston Engine......Page 198
Summary......Page 200
Sources......Page 201
4 -\rFatigue and Fracture Analysis......Page 203
Questions and Exercises......Page 205
P2.2.1 Pro/ENGINEER Parts and Assembly......Page 364
4.3.1 The S-N Diagram......Page 211
4.3.2 Nonfully Reversed Cyclic Loads......Page 214
4.3.3 In-Phase Bending and Torsion......Page 217
4.3.4 Complex Multiaxial Stress......Page 218
5.3.2 Random Variables and Distribution Functions......Page 220
4.4 The Strain-Based Approach......Page 221
4.4.1 The Manson–Coffin Equation......Page 222
4.4.2 Multiaxial Analysis......Page 227
4.5 Fracture Mechanics......Page 228
4.5.1 Basic Approaches......Page 229
4.5.2 Linear Elastic Fracture Mechanics......Page 231
4.5.3 Mixed Mode......Page 233
4.5.4 Quasistatic Crack Growth......Page 236
4.5.5 The Extended Finite Element Method......Page 237
4.6 Dynamic Stress Calculation and Cumulative Damage......Page 242
4.6.1 Dynamic Stress Calculations......Page 243
4.6.3 Rain-Flow Counting......Page 248
5.7 Case Study......Page 251
4.7.2 Non-FEA-Based Crack Propagation......Page 252
4.8.1 Case Study: Tracked Vehicle Roadarm......Page 254
4.8.3 Tutorial Example: Crankshaft......Page 265
4.9 Summary......Page 267
References......Page 269
Sources......Page 270
5 -\rReliability Analysis......Page 272
Questions and Exercises......Page 274
S2.2 Sliding Block......Page 401
5.2.1 Deterministic Design versus Probabilistic Prediction......Page 276
5.2.2 Probabilistic Design......Page 282
5.2.3 Short Summary......Page 285
Thin-Walled Tank......Page 448
S2.1.5 Viewing Results......Page 399
Random Variables......Page 289
Distribution Functions......Page 290
Joint Probability Density Function......Page 291
Normal Distribution......Page 296
Lognormal Distribution......Page 297
Extreme Value Distributions......Page 299
5.4.1 The Limit State Function......Page 300
5.4.2 Monte Carlo Simulation......Page 301
5.4.3 The First-Order Reliability Method......Page 305
FORM......Page 306
The Performance Measure Approach......Page 317
5.4.4 The Second-Order Reliability Method......Page 320
5.4.5 Transformation of Random Variables......Page 322
Correlated Random Variables of Normal Distribution......Page 323
Independent Random Variables of Non-Normal Distribution......Page 326
Correlated Random Variables of Non-Normal Distribution......Page 329
5.4.6 Importance Sampling......Page 331
5.4.7 The Response Surface Method......Page 335
5.4.8 Short Summary......Page 337
5.5.1 Series System......Page 338
5.5.2 Parallel System......Page 340
5.5.3 FORM Approximation for a Series System......Page 342
5.6 General-Purpose Reliability Analysis Tools......Page 345
5.8 Summary......Page 350
References......Page 353
Sources......Page 354
Project P2 Motion Analysis Using Pro/ENGINEER Mechanism Design......Page 355
P2.1 Introduction to Pro/ENGINEER Mechanism Design......Page 356
P2.1.1 Overall Process......Page 357
P2.1.2 User Interface......Page 358
P2.1.4 Motion Simulation......Page 360
P2.1.5 Viewing Results......Page 361
P2.1.6 Examples......Page 362
P2.2.2 Motion Model......Page 365
P2.3 Using Pro/ENGINEER Mechanism Design for the Sliding Block......Page 366
P2.3.1 Defining Gravity......Page 367
P2.3.2 Defining Initial Position......Page 368
P2.3.3 Defining and Running the Simulation......Page 370
P2.3.4 Saving and Reviewing Results......Page 371
P2.3.5 Results Verification......Page 373
P2.4 Single-Piston Engine......Page 375
P2.4.2 Motion Model......Page 376
P2.5 Using Pro/ENGINEER Mechanism Design for the Single-Piston Engine......Page 378
P2.5.2 Defining and Running the Simulation......Page 383
P2.5.4 Results Verification......Page 385
Exercises......Page 390
Project S2 Motion Analysis Using SolidWorks® Motion......Page 392
S2.1.1 Overall Process......Page 393
S2.1.2 User Interface......Page 394
S2.1.3 Defining Motion Entities......Page 398
Open Pro/ENGINEER Part......Page 434
S2.2.2 Motion Model......Page 403
S2.3 Using SolidWorks Motion for the Sliding Block......Page 405
Run Analysis......Page 487
S2.3.5 Results Verification......Page 412
S2.4 Single-Piston Engine......Page 413
S2.4.1 SolidWorks Parts and Assembly......Page 414
S2.5 Using SolidWorks Motion for the Single-Piston Engine......Page 415
Enter Pro/MECHANICA Structure......Page 450
S2.5.2 Displaying Simulation Results......Page 418
S2.5.3 Results Verification......Page 419
Exercises......Page 424
Project P3 Structural FEA and Fatigue Analysis Using Pro/MECHANICA Structure......Page 427
Overall Process......Page 429
User Interface......Page 430
Viewing Results......Page 433
Preprocessing: Creating Finite Element Model......Page 437
Define and Run Analysis......Page 443
Display of Analysis Results......Page 447
Model Idealization: Define Mid-surfaces......Page 452
Enter SolidWorks Simulation......Page 504
Define Displacement Constraints......Page 454
Analysis......Page 457
Display Results......Page 459
Convergence Study......Page 462
Fatigue Analysis......Page 464
The Crankshaft Example......Page 466
Create Fatigue Analysis Model......Page 467
Display Results......Page 471
Exercises......Page 473
Project S3 Structural FEA and Fatigue Analysis Using SolidWorks Simulation......Page 475
Introduction to SolidWorks Simulation......Page 476
User Interface......Page 477
Defining FEA Entities......Page 480
Simple Cantilever Beam......Page 482
Enter SolidWorks Simulation......Page 484
Create Finite Element Model......Page 485
Display Results......Page 488
Convert Solid Model to Beam......Page 499
The Thin-Walled Tank Example......Page 502
Model Idealization: Define Shell Surfaces......Page 505
Create Finite Element Model......Page 507
Run Analysis and Display Results......Page 511
Mesh Refinement......Page 513
Fatigue Analysis......Page 516
The Crankshaft Example......Page 517
Create Fatigue Analysis Model......Page 518
Display Results......Page 522
Exercises......Page 524
D......Page 527
F......Page 528
H......Page 530
M......Page 531
P......Page 533
S......Page 534
V......Page 536
X......Page 537