Shape optimization of three-dimensional stamped and solid automotive components

The shape optimization of realistic, 3-D automotive components is discussed. The integration of the major parts of the total process: modeling, mesh generation, finite element and sensitivity analysis, and optimization are stressed. Stamped components and solid components are treated separately. For stamped parts a highly automated capability was developed. The problem description is based upon a parameterized boundary design element concept for the definition of the geometry. Automatic triangulation and adaptive mesh refinement are used to provide an automated analysis capability which requires only boundary data and takes into account sensitivity of the solution accuracy to boundary shape. For solid components a general extension of the 2-D boundary design element concept has not been achieved. In this case, the parameterized surface shape is provided using a generic modeling concept based upon isoparametric mapping patches which also serves as the mesh generator. Emphasis is placed upon the coupling of optimization with a commercially available finite element program. To do this it is necessary to modularize the program architecture and obtain shape design sensitivities using the material derivative approach so that only boundary solution data is needed

Workshop on the Integration of Finite Element Modeling with Geometric Modeling

The workshop on the Integration of Finite Element Modeling with Geometric Modeling was held on 12 May 1987. It was held to discuss the geometric modeling requirements of the finite element modeling process and to better understand the technical aspects of the integration of these two areas. The 11 papers are presented except for one for which only the abstract is given

Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed

3D Capacitance Extraction With the Method of Moments

In this thesis, the Method of Moments has been applied to calculate capacitance between two arbitrary 3D metal conductors or a capacitance matrix for a 3D multi-conductor system. Capacitance extraction has found extensive use for systems involving sets of long par- allel transmission lines in multi-dielectric environment as well as integrated circuit package including three-dimensional conductors located on parallel planes. This paper starts by reviewing fundamental aspects of transient electro-magnetics followed by the governing dif- ferential and integral equations to motivate the application of numerical methods as Method of Moments(MoM), Finite Element Method(FEM), etc. Among these numerical tools, the surface-based integral-equation methodology - MoM is ideally suited to address the prob- lem. It leads to a well-conditioned system with reduced size, as compared to volumetric methods. In this dissertation, the MoM Surface Integral Equation (SIE)-based modeling approach is developed to realize electrostatic capacitance extraction for 3D geometry. MAT- LAB is employed to validate its e?ciency and e?ectiveness along with design of a friendly GUI. As a base example, a parallel-plate capacitor is considered. We evaluate the accu- racy of the method by comparison with FEM simulations as well as the corresponding quasi-analytical solution. We apply this method to the parallel-plate square capacitor and demonstrate how far could the undergraduate result 0C = A ? =d\u27 be from reality. For the completion of the solver, the same method is applied to the calculation of line capacitance for two- and multi-conductor 2D transmission lines

Animating physical phenomena with embedded surface meshes

Accurate computational representations of highly deformable surfaces are indispensable in the fields of computer animation, medical simulation, computer vision, digital modeling, and computational physics. The focus of this dissertation is on the animation of physics-based phenomena with highly detailed deformable surfaces represented by triangle meshes. We first present results from an algorithm that generates continuum mechanics animations with intricate surface features. This method combines a finite element method with a tetrahedral mesh generator and a high resolution surface mesh, and it is orders of magnitude more efficient than previous approaches. Next, we present an efficient solution for the challenging problem of computing topological changes in detailed dynamic surface meshes. We then introduce a new physics-inspired surface tracking algorithm that is capable of preserving arbitrarily thin features and reproducing realistic fine-scale topological changes like Rayleigh-Plateau instabilities. This physics-inspired surface tracking technique also opens the door for a unique coupling between surficial finite element methods and volumetric finite difference methods, in order to simulate liquid surface tension phenomena more efficiently than any previous method. Due to its dramatic increase in computational resolution and efficiency, this method yielded the first computer simulations of a fully developed crown splash with droplet pinch off.Ph.D.Committee Chair: Turk, Greg; Committee Member: Essa, Irfan; Committee Member: Liu, Karen; Committee Member: Mucha, Peter J.; Committee Member: Rossignac, Jare

Integrated modeling and analysis methodologies for architecture-level vehicle design.

In order to satisfy customer expectations, a ground vehicle must be designed to meet a broad range of performance requirements. A satisfactory vehicle design process implements a set of requirements reflecting necessary, but perhaps not sufficient conditions for assuring success in a highly competitive market. An optimal architecture-level vehicle design configuration is one of the most important of these requirements. A basic layout that is efficient and flexible permits significant reductions in the time needed to complete the product development cycle, with commensurate reductions in cost. Unfortunately, architecture-level design is the most abstract phase of the design process. The high-level concepts that characterize these designs do not lend themselves to traditional analyses normally used to characterize, assess, and optimize designs later in the development cycle. This research addresses the need for architecture-level design abstractions that can be used to support ground vehicle development. The work begins with a rigorous description of hierarchical function-based abstractions representing not the physical configuration of the elements of a vehicle, but their function within the design space. The hierarchical nature of the abstractions lends itself to object orientation - convenient for software implementation purposes - as well as description of components, assemblies, feature groupings based on non-structural interactions, and eventually, full vehicles. Unlike the traditional early-design abstractions, the completeness of our function-based hierarchical abstractions, including their interactions, allows their use as a starting point for the derivation of analysis models. The scope of the research in this dissertation includes development of meshing algorithms for abstract structural models, a rigid-body analysis engine, and a fatigue analysis module. It is expected that the results obtained in this study will move systematic design and analysis to the earliest phases of the vehicle development process, leading to more highly optimized architectures, and eventually, better ground vehicles. This work shows that architecture level abstractions in many cases are better suited for life cycle support than geometric CAD models. Finally, substituting modeling, simulation, and optimization for intuition and guesswork will do much to mitigate the risk inherent in large projects by minimizing the possibility of incorporating irrevocably compromised architecture elements into a vehicle design that no amount of detail-level reengineering can undo

Automatic mesh generation

The objective of this thesis project is a study of Pre-Processors and development of an Automatic Mesh Generator for Finite Element Analysis. The Mesh Generator developed in this thesis project can create triangular finite elements from the geometric database of Macintosh Applications. The user is required to give the density parameter to the program for mesh generation. The research is limited to Mesh Generators of planar surfaces. Delauny Triangulation method maximizes the minimum angles of a triangle. Watson\u27s Delauny Triangulation method can mesh only the \u27convex hull\u27 of a set of nodes. This algorithm has been modified to create triangular elements in convex and non-convex surfaces. The surfaces can have holes also. A node generation algorithm to place nodes on and inside a geometry has been developed in this thesis project. The mesh generation is very efficient and flexible. Geometric modeling methods have been studied to understand and integrate the Geometric Modeler with the Finite Element Mesh Generator. Expert Systems can be integrated with Finite Element Analysis. This will make Finite Element Method fully automatic. In this thesis project, Expert Systems in Finite Element Analysis are reviewed. Proposals are made for future approach for the integration of the two fields

Multi-angle valve seat machining: experimental analysis and numerical modelling

Modern automotive manufacturers operate in highly competitive markets, heavily influenced by Government regulation and ever more environmentally conscious consumers. Modern high-temperature, high-pressure engines that use high hardness multi-angle valve seats are an attractive environmental option, but one that manufacturers find requires more advanced materials and tighter geometric tolerances to maintain engine performance.Tool manufacturers meet these increasingly tougher demands by using, higher hardness cutting materials such as polycrystalline cubic boron nitride (pcBN), that on paper, promise to wear at a lower rate, require less coolant and deliver tighter tolerances than their carbide counterparts.The low brittle fracture toughness of pcBN makes tools that use it vulnerable to minute chipping. A review of literature for this work pointed to no clear answer to this problem, although suggestions range from manufacturing defects, dynamic and flexibility problems with the production line machinery and fixtures, and radial imbalances in the cutting loads.This work set about experimentally investigating those potential explanations, coming to the conclusion that the high radial imbalance of the cutting loads is responsible for pcBN cutting insert failure during multi-angle valve seat machining, and that by simply relocating the cutting inserts around the multi angle cutting tool, the imbalance can be reduced, thus extending the life of the cutting inserts.It is not always easy to predict the imbalance due to the multiple flexibilities in the system, and simulating such a system in 3D with all its associated cutting phenomena such as friction, thermal expansion, chip flow and shearing, would call upon extraordinary computational power and extremely precise experimental inputs to reduce cumulative error.This thesis proves that such a 3D simulation can be made, that runs in exceptionally short durations compared to traditional methods, by making a number of simplifications.MSC Marc was used to host the simulation, with a parametric script written in Python responsible for generating the model geometry and cutter layout. A Fortran program was developed that is called upon by Marc to calculate the required cutting load outputs and generate new workpiece meshes as material is removed.</div

Fabricate

Bringing together pioneers in design and making within architecture, construction, engineering, manufacturing, materials technology and computation, Fabricate is a triennial international conference, now in its third year (ICD, University of Stuttgart, April 2017). Each year it produces a supporting publication, to date the only one of its kind specialising in Digital Fabrication. The 2017 edition features 32 illustrated articles on built projects and works in progress from academia and practice, including contributions from leading practices such as Foster + Partners, Zaha Hadid Architects, Arup, and Ron Arad, and from world-renowned institutions including ICD Stuttgart, Harvard, Yale, MIT, Princeton University, The Bartlett School of Architecture (UCL) and the Architectural Association