The Development of the Use of Expert Testimony

The steadily increasing performance of modern computer systems is having a large influence on simulation technologies. It enables increasingly detailed simulations of larger and more comprehensive simulation models. Increasingly large amounts of numerical data are produced by these simulations. This thesis presents several contributions in the field of mechanical system simulation and visualisation. The work described in the thesis is of practical relevance and results have been tested and implemented in tools that are used daily in the industry i.e., the BEAST (BEAring Simulation Tool) tool box. BEAST is a multibody system (MBS) simulation software with special focus on detailed contact calculations. Our work is primarily focusing on these types of systems. focusing on these types of systems. Research in the field of simulation modelling typically focuses on one or several specific topics around the modelling and simulation work process. The work presented here is novel in the sense that it provides a complete analysis and tool chain for the whole work process for simulation modelling and analysis of multibody systems with detailed contact models. The focus is on detecting and dealing with possible problems and bottlenecks in the work process, with respect to multibody systems with detailed contact models. The following primary research questions have been formulated: How to utilise object-oriented techniques for modelling of multibody systems with special reference tocontact modelling? How to integrate visualisation with the modelling and simulation process of multibody systems withdetailed contacts. How to reuse and combine existing simulation models to simulate large mechanical systems consistingof several sub-systems by means of co-simulation modelling? Unique in this work is the focus on detailed contact models. Most modelling approaches for multibody systems focus on modelling of bodies and boundary conditions of such bodies, e.g., springs, dampers, and possibly simple contacts. Here an object oriented modelling approach for multibody simulation and modelling is presented that, in comparison to common approaches, puts emphasis on integrated contact modelling and visualisation. The visualisation techniques are commonly used to verify the system model visually and to analyse simulation results. Data visualisation covers a broad spectrum within research and development. The focus is often on detailed solutions covering a fraction of the whole visualisation process. The novel visualisation aspect of the work presented here is that it presents techniques covering the entire visualisation process integrated with modeling and simulation. This includes a novel data structure for efficient storage and visualisation of multidimensional transient surface related data from detailed contact calculations. Different mechanical system simulation models typically focus on different parts (sub-systems) of a system. To fully understand a complete mechanical system it is often necessary to investigate several or all parts simultaneously. One solution for a more complete system analysis is to couple different simulation models into one coherent simulation. Part of this work is concerned with such co-simulation modelling. Co-simulation modelling typically focuses on data handling, connection modelling, and numerical stability. This work puts all emphasis on ease of use, i.e., making mechanical system co-simulation modelling applicable for a larger group of people. A novel meta-model based approach for mechanical system co-simulation modelling is presented. The meta-modelling process has been defined and tools and techniques been created to fully support the complete process. A component integrator and modelling environment are presented that support automated interface detection, interface alignment with automated three-dimensional coordinate translations, and three dimensional visual co-simulation modelling. The integrated simulator is based on a general framework for mechanical system co-simulations that guarantees numerical stability

Structured Linearization of Discrete Mechanical Systems for Analysis and Optimal Control

Variational integrators are well-suited for simulation of mechanical systems because they preserve mechanical quantities about a system such as momentum, or its change if external forcing is involved, and holonomic constraints. While they are not energy-preserving they do exhibit long-time stable energy behavior. However, variational integrators often simulate mechanical system dynamics by solving an implicit difference equation at each time step, one that is moreover expressed purely in terms of configurations at different time steps. This paper formulates the first- and second-order linearizations of a variational integrator in a manner that is amenable to control analysis and synthesis, creating a bridge between existing analysis and optimal control tools for discrete dynamic systems and variational integrators for mechanical systems in generalized coordinates with forcing and holonomic constraints. The forced pendulum is used to illustrate the technique. A second example solves the discrete LQR problem to find a locally stabilizing controller for a 40 DOF system with 6 constraints.Comment: 13 page

Structured Linearization of Discrete Mechanical Systems for Analysis and Optimal Control

Variational integrators are well-suited for simulation of mechanical systems because they preserve mechanical quantities about a system such as momentum, or its change if external forcing is involved, and holonomic constraints. While they are not energy-preserving they do exhibit long-time stable energy behavior. However, variational integrators often simulate mechanical system dynamics by solving an implicit difference equation at each time step, one that is moreover expressed purely in terms of configurations at different time steps. This paper formulates the first- and second-order linearizations of a variational integrator in a manner that is amenable to control analysis and synthesis, creating a bridge between existing analysis and optimal control tools for discrete dynamic systems and variational integrators for mechanical systems in generalized coordinates with forcing and holonomic constraints. The forced pendulum is used to illustrate the technique. A second example solves the discrete LQR problem to find a locally stabilizing controller for a 40 DOF system with 6 constraints.Comment: 13 page

Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: Integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations

How “International” Should a Third Conflicts Restatement Be in Tort and Contract?

The main goal of this work is to gain knowledge of how and to what extent state-of-the-artsimulation tools can be used in a conceptual development phase for vehicle dynamics control atVolvo Car Corporation (VCC).The first part of the thesis deals with an evaluation of vehicle dynamics simulation tools and theiruses. The three simulation tools selected for the study, namely Mechanical Simulation CarSim 8.2.1,IPG CarMaker 4.0.5, and VI-Grade CarRealTime V14, are briefly described and discussed. In order toevaluate and compare these tools with respect to application for vehicle dynamics control, a criterialist is developed covering aspects such as tool requirements and intended usage. Based on thecriteria list and certain identified drawbacks, a ranking of the tools is made possible. Furthermore,the process of developing vehicle models for the different tools is discussed in detail, along with theprocedure of validating the vehicle models.In the second part, the concept of Collision Avoidance Driver Assistance (CADA) function isintroduced and possible approaches for developing CADA functions are discussed in brief. It isimportant to note that the CADA functions in this work are based on cornering the vehicle i.e.maneuvering around the threat, rather than solely reducing vehicle speed. A number ofimplementations of the functions are developed in Simulink. A frequency analysis of a simplifiedlinear vehicle model is performed to investigate the influence of steering, differential braking, andtheir combination on the resultant lateral displacement of the vehicle during an evasive maneuver.The developed CADA functions are then simulated using the vehicle simulation tools. Two specificmetrics - Lateral Displacement gain and DeltaX - are formulated to evaluate the effectiveness of theCADA functions. Based on these metrics, the assistance obtained due to the functions for a specificevasive maneuver is compared.From the evaluation process of the three tools, two were considered suitable for the purpose ofsimulating collision avoidance functions. The evaluation of the CADA functions demonstrates thatcombined assistive steering with differential braking provides considerable assistance in order toavoid collisions. The simulation results also present interesting trends which provide a usefuldirection regarding the conditions for intervention by such collision avoidance functions during anevasive maneuver. The use of simulation tools makes it possible to observe these trends and utilizethem in the development process of the functions

Fully automatic worst-case execution time analysis for MATLAB/Simulink models

“This material is presented to ensure timely dissemination of scholarly and technical work. Copyright and all rights therein are retained by authors or by other copyright holders. All persons copying this information are expected to adhere to the terms and constraints invoked by each author's copyright. In most cases, these works may not be reposted without the explicit permission of the copyright holder." “Copyright IEEE. Personal use of this material is permitted. However, permission to reprint/republish this material for advertising or promotional purposes or for creating new collective works for resale or redistribution to servers or lists, or to reuse any copyrighted component of this work in other works must be obtained from the IEEE.”In today's technical world (e.g., in the automotive industry), more and more purely mechanical components get replaced by electro-mechanical ones. Thus the size and complexity of embedded systems steadily increases. To cope with this development, comfortable software engineering tools are being developed that allow a more functionality-oriented development of applications. The paper demonstrates how worst-case execution time (WCET) analysis is integrated into such a high-level application design and simulation tool MATLAB/Simulink-thus providing a higher-level interface to WCET analysis. The MATLAB/Simulink extensions compute and display worst-case timing data for all blocks of a MATLAB/Simulink simulation, which gives the developer of an application valuable feedback about the correct timing of the application being developed. The solution facilitates a fully-automated WCET analysis, i.e., in contrast to existing approaches the programmer does not have to provide path information

Comparison between computed and measured fibre orientation in injection moulded parts

International audienceShort fibre reinforced thermoplastic materials play an important role in automotive industries due to their excellent processing behaviour, reasonable good mechanical performance, high design freedom and cheap prices. Although the thermo-mechanical requirements for the materials used increase the development cycles decrease. Numerical simulation, FEA, analysis can be a strong assistant when judging designs and reducing cost and time consuming experimental tests. The mechanical properties for short fibre reinforced thermoplastics are mainly dominated by fibre orientation which results from injection moulding process. Several commercial tools offering 3D flow simulation are on the market, each of them with strengths and weaknesses and a lot of opportunities for future application in part design. In cooperation with Ecole Nationale Superieure des Mines de Paris a study was carried out in order to compare two different injection moulding simulation tools (MOLDFLOW MPI® and REM-3D®) with experimental data concerning fibre orientation prediction. The study contains investigations on the accuracy and sources of measurement errors on the well-established surface ellipse method on polished surfaces and gives an overview on the state-of-the art in this field. On the other hand simulation results compared with measurements on a sample geometry taken at different locations indicate that the accuracy of the simulation needs some improvement, too. Areas of fairly good agreement and those of significant differences are discussed. The importance of accurate fibre orientation on subsequent thermo-mechanical analysis is stressed out by comparing experimental data with simulated deformation behaviour. As a conclusion, alternatives both for experimental setup and algorithms used for the numerical prediction of fibre orientation so far based on the well-known Folgar-Tucker model are proposed. The limitations of this model for real parts will be discussed for this purpose

A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines

Ultraprecision machines with small footprints or micro-machines are highly desirable for micro-manufacturing high-precision micro-mechanical components. However, the development of the machines is still at the nascent stage by working on an individual machine basis and hence lacks generic scientific approach and design guidelines. Using computer models to predict the dynamic performance of ultraprecision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machines. Furthermore, the machine dynamic performance depends not only upon the mechanical structure and components but also the control system and electronic drives. This paper proposed a holistic integrated dynamic design and modelling approach, which supports analysis and optimization of the overall machine dynamic performance at the early design stage. Based on the proposed approach the modelling and simulation process on a novel 5-axis bench-top ultraprecision micro-milling machine tool – UltraMill – is presented. The modelling and simulation cover the dynamics of the machine structure, moving components, control system and the machining process, and are used to predict the overall machine performance of two typical configurations. Preliminary machining trials have been carried out and provided the evidence of the approach being helpful to assure the machine performing right at the first setup

Computational determination of macroscopic mechanical and thermal material properties for different morphological variants of cast iron

The sensitivity of macroscopic mechanical and thermal properties of grey cast iron is computationally investigated for a variety of graphite morphologies over a wide temperature range. In order to represent common graphite morphologies according to EN ISO 945-1, a synthetic approach is used to algorithmically generate simulation domains. The developed mechanical and thermal model is applied in a large simulation study. The study includes statistical volume elements of the graphite morphology classes GJL-150 and IA2 to IA5, with 10, 11 and 12 v.−% of graphite precipitations, respectively, for a temperature range from 20 to 750 °C. Homogenised macroscopic quantities, such as the Young’s moduli, Poisson’s ratios, yield strengths and thermal conductivities, are predicted for different morphology classes by applying simulation and data analysis tools of the research data infrastructure Kadi4Mat. This is the first work to determine the mechanical and thermal properties of the morphology classes defined in EN ISO 945-

μ\mu2mech: a Software Package Combining Microstructure Modeling and Mechanical Property Prediction

We have developed a graphical user interface (GUI) based package $\mu$2mech to perform phase-field simulation for predicting microstructure evolution. The package can take inputs from ab initio calculations and CALPHAD (Calculation of Phase Diagrams) tools for quantitative microstructure prediction. The package also provides a seamless connection to transfer output from the mesoscale phase field method to the microscale finite element analysis for mechanical property prediction. Such a multiscale simulation package can facilitate microstructure-property correlation, one of the cornerstones in accelerated materials development within the integrated computational materials engineering (ICME) framework