FEA ANALYSIS AND AUTOMATED DESIGN OPTIMIZATION USING SIMULIA ABAQUS AND ...

55 Pages·2010·2.87 MB·English

FEA ANALYSIS AND AUTOMATED DESIGN OPTIMIZATION USING SIMULIA
ABAQUS AND ISIGHT
Rajashekar Reddy Kallem
B.Tech. Jawaharlal Nehru Technological University, India, 2008

PROJECT

Submitted in partial satisfaction of
the requirements for the degree of

MASTER OF SCIENCE
in
MECHANICAL ENGINEERING
at
CALIFORNIA STATE UNIVERSITY, SACRAMENTO

FALL
2010
FEA ANALYSIS AND AUTOMATED DESIGN OPTIMIZATION USING SIMULIA
ABAQUS AND ISIGHT
A Project

by

Rajashekar Reddy Kallem

Approved by:

________________________________, Committee Chair
Yong S.Suh,Ph.D.

_________________________
Date

ii
Student: Rajashekar Reddy Kallem

I certify that these students have met the requirements for format contained in the
University format manual, and that this project is suitable for shelving in the Library and credit is
to be awarded for the project.

________________________, Graduate Coordinator _____________________
Kenneth Sprott,Ph.D. Date

Department of Mechanical Engineering

iii
Abstract
of
FEA ANALYSIS AND AUTOMATED DESIGN OPTIMIZATION USING SIMULIA
ABAQUS AND ISIGHT

by
Rajashekar Reddy Kallem
Depending upon the size every structure or product which is designed for applying some loads
using various parameters like lengths, widths area etc.. Need to be tested for reliability ,maximum
performance and its capacity to sustain loads. For finding these factors we use different
techniques in the field of mechanical engineering . Every product which undergoes stresses after
its manufacturing must be checked for its structural analysis depending upon its dimensions. For
this operation design tools play a major role. I have chosen a cantilever beam as a better example
for structural analysis and abaqus as my tool.Abaqus is one of the tools which is new to learn and
had a good scope of CAE modeling and structural analysis. •On the other side optimization is an
major concern depending upon the cost of manufacturing ,performances, size etc. All these
factors has to be maximized or minimized depending upon their effectiveness. Aero plane wing is
one of those structures which I found as a good example to go with. Isight is a new optimization
tool used for this operation using wing span, wing area , fuse diameter and fuse length as input
parameters and surface area , LOD an wet area as output variables.

________________________________, Committee Chair
Yong S.Suh,Ph.D.

______________________
Date

iv
ACKNOWLEDGMENTS

I owe a great many thanks to a great many people who helped and
Supported me during this project.
Thanks to professor,YOUNG SUH the Guide of this project for guiding and correcting various
documents of mine with attention and care. He has taken pain to go through the project and make
necessary correction as and when needed.
I express my thanks to the president of CALIFORNIA STATE UNIVERSITY, for extending his
support.
My heartfelt thanks to Dr KENNETH SPROTT, GRADUATE CO-ORDINATOR,
DEPARTMENT OF MECHANICAL ENGINEERING, CALIFORNIA STATE UNIVERSIT,
SACRAMENTO.
I would also thank my Institution and my faculty members without whom this project would have
been a distant reality. I also extend my heartfelt thanks to my family and well wishers.

v
TABLE OF CONTENTS
Page
Acknowledgements .................................................................................................................... v
List of Figures ........................................................................................................................ viii
Chapter
1. INTRODUCTION .... .......................................................................................... ................. 1
1.1 About ISIGHT ..................................................................................................................... 1
1.2 Different Components used in ISIGHT ............................................................................... 1
1.3 Types of DOE Techniques ................................................................................................... 3
2.OPTIMIZATION OF AEROPLANE WING ......................................................................... 7
2.1 Objective ......................................................................................................................... 7
2.2 Terminology ......................................................................................................................... 7
2.3 Design Procedure ............................................................................................................... 11
2.4 Noise Factor. ..................................................................................................................... 33
3. FEA ANALYSIS OF A CANTILERVER BEAMUSING ABAQUS ................................ 34
3.1 Inroduction ........................................................................................................................ 34
vi
3.2Importance of Structural Analysis ...................................................................................... 34
3.3Definitions ......................................................................................................................... 35
4. FEA ANALYSIS OF BEAM .............................................................................................. 36
5. CONCLUSION ................................................................................................................... 45
Bibliography ........................................................................................................................... 46

vii
LIST OF FIGURES
Figure Page
1. Figure 2.2-1 Aero plane Wing ........................................................................................ 7
2. Figure 2.3-1 Main Work Bench of Isight ...................................................................... 11
3. Figure 2.3-2 Assigning Input Parameters ....................................................... ............... 12
4. Figure 2.3-3 Defining Simcode Component .................................................. ............... 13
5. Figure 2.3-4 Running Defined Parameters .................................................... .............. 14
6. Figure 2.3-5 Converting Parameters to Real Numbers .................................. ............... 15
7. Figure 2.3-6 After Simulation ....................................................................... ............... 16
8. Figure 2.3-7 Entering Input and Output Parameters ...................................... ............... 17
9. Figure 2.3-8 Defining DOE Component ....................................................... ............... 18
10. Figure 2.3-9 Selecting Latin Hypercube Technique ....................................... ............... 19
11. Figure 2.3-10 Defining Input Parameters in DOE ............................................ ............... 20
12. Figure 2.3-11 Design Matrix ............................................................................. ............... 21
13. Figure 2.3-12 Before Assigning Task ............................................................... ............... 22
14. Figure 2.3-13 Selecting NLPQL Technique ..................................................... ............... 23
15. Figure 2.3-14 Entering Input Values................................................................. ............... 24
viii
16. Figure 2.3-15 Entering Output Values .............................................................. ............... 25
17. Figure 2.3-16 Setting Maximization for Surface Area...................................... ............... 26
18. Figure 2.3-17 Loop Formation Before Running Optimization ......................... ............... 27
19. Figure 2.3-18 Final Optimization Set ............................................................... ............... 28
20. Figure 2.3-19 Graphical Representation of Surface Area Fluctuation .............. ............... 29
21. Figure 2.3-20 Graphical Representation of all the Parameters ......................... ............... 30
22. Figure 2.3-21 Iterations Formed During Optimization ..................................... ............... 31
23. Figure 2.3-22 Graphs Between Input and Output Parameters .......................... ............... 32
24. Figure 4-1 2D View of Cantilever Beam .................................................... ............... 36
25. Figure 4-2 3D View and Assigning Parameters ......................................... ............... 37
26. Figure 4-3 After Assigning Parameters ...................................................... ............... 38
27. Figure 4-4 Fixing one Side of Beam .......................................................... ............... 39
28. Figure 4-5 Applying Load .......................................................................... ............... 40
29. Figure 4-6 After Meshing ........................................................................... ............... 41
30. Figure 4-7 After Seeding ............................................................................ ............... 42
31. Figure 4-8 Before Adaptive Meshing ......................................................... ............... 43
32. Figure 4-9 Final Result ............................................................................... ............... 44
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1

Chapter 1
INTRODUCTION
1.1.About ISIGHT
• Isight provides a suite of visual and flexible tools to set up and manage computer software
required to execute simulation based design process, including commercial CAD/CAE software,
internally developed programs, and excel worksheet.
•The rapid integration of these applications and Isight’s ability to automate their execution greatly
accelerates the evaluation of product design alternatives.
•It uses advanced techniques like optimization, design of six sigma approximations and DOE.
•Design trade-offs and the relation ships between parameters and results are easily understood
and assessed, leading to the best possible design decisions.
•It enables design organizations to reduce design cycle time and manufacturing cost, and
significantly improves product performance, quality, and reliability.
1.2.Different Components used in ISIGHT
Abaqus: Exchange data with and execute Abaqus solvers or Abaqus/CAE
Approximation: Construct an approximation to use in place of some other code/process
Calculator: used for calculating the formulae
COM: Interacts with Microsoft COM Objects
Database: Exchange data with Databases