Algebraic level sets for CAD/CAE integration and moving boundary problems

Boundary representation (B-rep) of CAD models obtained from solid modeling kernels are commonly used in design, and analysis applications outside the CAD systems. Boolean operations between interacting B-rep CAD models as well as analysis of such multi-body systems are fundamental operations on B-rep geometries in CAD/CAE applications. However, the boundary representation of B-rep solids is, in general, not a suitable representation for analysis operations which lead to CAD/CAE integration challenges due to the need for conversion from B-rep to volumetric approximations. The major challenges include intermediate mesh generation step, capturing CAD features and associated behavior exactly and recurring point containment queries for point classification as inside/outside the solid. Thus, an ideal analysis technique for CAD/CAE integration that can enable direct analysis operations on B-rep CAD models while overcoming the associated challenges is desirable. ^ Further, numerical surface intersection operations are typically necessary for boolean operations on B-rep geometries during the CAD and CAE phases. However, for non-linear geometries, surface intersection operations are non-trivial and face the challenge of simultaneously satisfying the three goals of accuracy, efficiency and robustness. In the class of problems involving multi-body interactions, often an implicit knowledge of the boolean operation is sufficient and explicit intersection computation may not be needed. Such implicit boolean operations can be performed by point containment queries on B-rep CAD models. However, for complex non-linear B-rep geometries, the point containment queries may involve numerical iterative point projection operations which are expensive. Thus, there is a need for inexpensive, non-iterative techniques to enable such implicit boolean operations on B-rep geometries. ^ Moreover, in analysis problems with evolving boundaries (ormoving boundary problems), interfaces or cracks, blending functions are used to enrich the underlying domain with the known behavior on the enriching entity. The blending functions are typically dependent on the distance from the evolving boundaries. For boundaries defined by free form curves or surfaces, the distance fields have to be constructed numerically. This may require either a polytope approximation to the boundary and/or an iterative solution to determine the exact distance to the boundary. ^ In this work a purely algebraic, and computationally efficient technique is described for constructing signed distance measures from Non-Uniform Rational B-Splines (NURBS) boundaries that retain the geometric exactness of the boundaries while eliminating the need for iterative and non-robust distance calculation. The proposed technique exploits the NURBS geometry and algebraic tools of implicitization. Such a signed distance measure, also referred to as the Algebraic Level Sets, gives a volumetric representation of the B-rep geometry constructed by purely non-iterative algebraic operations on the geometry. This in turn enables both the implicit boolean operations and analysis operations on B-rep geometries in CAD/CAE applications. Algebraic level sets ensure exactness of geometry while eliminating iterative numerical computations. Further, a geometry-based analysis technique that relies on hierarchical partition of unity field compositions (HPFC) theory and its extension to enriched field modeling is presented. The proposed technique enables direct analysis of complex physical problems without meshing, thus, integrating CAD and CAE. The developed techniques are demonstrated by constructing algebraic level sets for complex geometries, geometry-based analysis of B-rep CAD models and a variety of fracture examples culminating in the analysis of steady state heat conduction in a solid with arbitrary shaped three-dimensional cracks. ^ The proposed techniques are lastly applied to investigate the risk of fracture in the ultra low-k (ULK) dies due to copper (Cu) wirebonding process. Maximum damage induced in the interlayer dielectric (ILD) stack during the process steps is proposed as an indicator of the reliability risk. Numerical techniques based on enriched isogeometric approximations are adopted to model damage in the ULK stacks using a cohesive damage description. A damage analysis procedure is proposed to conduct damage accumulation studies during Cu wirebonding process. Analysis is carried out to identify weak interfaces and potential sites for crack nucleation as well as damage nucleation patterns. Further, the critical process condition is identified by analyzing the damage induced during the impact and ultrasonic excitation stages. Also, representative ILD stack designs with varying Cu percentage are compared for risk of fracture

Doctor of Philosophy

dissertationWhile boundary representations, such as nonuniform rational B-spline (NURBS) surfaces, have traditionally well served the needs of the modeling community, they have not seen widespread adoption among the wider engineering discipline. There is a common perception that NURBS are slow to evaluate and complex to implement. Whereas computer-aided design commonly deals with surfaces, the engineering community must deal with materials that have thickness. Traditional visualization techniques have avoided NURBS, and there has been little cross-talk between the rich spline approximation community and the larger engineering field. Recently there has been a strong desire to marry the modeling and analysis phases of the iterative design cycle, be it in car design, turbulent flow simulation around an airfoil, or lighting design. Research has demonstrated that employing a single representation throughout the cycle has key advantages. Furthermore, novel manufacturing techniques employing heterogeneous materials require the introduction of volumetric modeling representations. There is little question that fields such as scientific visualization and mechanical engineering could benefit from the powerful approximation properties of splines. In this dissertation, we remove several hurdles to the application of NURBS to problems in engineering and demonstrate how their unique properties can be leveraged to solve problems of interest

Doctor of Philosophy

dissertationVolumetric parameterization is an emerging field in computer graphics, where volumetric representations that have a semi-regular tensor-product structure are desired in applications such as three-dimensional (3D) texture mapping and physically-based simulation. At the same time, volumetric parameterization is also needed in the Isogeometric Analysis (IA) paradigm, which uses the same parametric space for representing geometry, simulation attributes and solutions. One of the main advantages of the IA framework is that the user gets feedback directly as attributes of the NURBS model representation, which can represent geometry exactly, avoiding both the need to generate a finite element mesh and the need to reverse engineer the simulation results from the finite element mesh back into the model. Research in this area has largely been concerned with issues of the quality of the analysis and simulation results assuming the existence of a high quality volumetric NURBS model that is appropriate for simulation. However, there are currently no generally applicable approaches to generating such a model or visualizing the higher order smooth isosurfaces of the simulation attributes, either as a part of current Computer Aided Design or Reverse Engineering systems and methodologies. Furthermore, even though the mesh generation pipeline is circumvented in the concept of IA, the quality of the model still significantly influences the analysis result. This work presents a pipeline to create, analyze and visualize NURBS geometries. Based on the concept of analysis-aware modeling, this work focusses in particular on methodologies to decompose a volumetric domain into simpler pieces based on appropriate midstructures by respecting other relevant interior material attributes. The domain is decomposed such that a tensor-product style parameterization can be established on the subvolumes, where the parameterization matches along subvolume boundaries. The volumetric parameterization is optimized using gradient-based nonlinear optimization algorithms and datafitting methods are introduced to fit trivariate B-splines to the parameterized subvolumes with guaranteed order of accuracy. Then, a visualization method is proposed allowing to directly inspect isosurfaces of attributes, such as the results of analysis, embedded in the NURBS geometry. Finally, the various methodologies proposed in this work are demonstrated on complex representations arising in practice and research