Methodology for automatic recovering of 3D partitions from unstitched faces of non-manifold CAD models

Data exchanges between different software are currently used in industry to speed up the preparation of digital prototypes for Finite Element Analysis (FEA). Unfortunately, due to data loss, the yield of the transfer of manifold models rarely reaches 1. In the case of non-manifold models, the transfer results are even less satisfactory. This is particularly true for partitioned 3D models: during the data transfer based on the well-known exchange formats, all 3D partitions are generally lost. Partitions are mainly used for preparing mesh models required for advanced FEA: mapped meshing, material separation, definition of specific boundary conditions, etc. This paper sets up a methodology to automatically recover 3D partitions from exported non-manifold CAD models in order to increase the yield of the data exchange. Our fully automatic approach is based on three steps. First, starting from a set of potentially disconnected faces, the CAD model is stitched. Then, the shells used to create the 3D partitions are recovered using an iterative propagation strategy which starts from the so-called manifold vertices. Finally, using the identified closed shells, the 3D partitions can be reconstructed. The proposed methodology has been validated on academic as well as industrial examples.This work has been carried out under a research contract between the Research and Development Direction of the EDF Group and the Arts et Métiers ParisTech Aix-en-Provence

Merging enriched Finite Element triangle meshes for fast prototyping of alternate solutions in the context of industrial maintenance

A new approach to the merging of Finite Element (FE) triangle meshes is proposed. Not only it takes into account the geometric aspects, but it also considers the way the semantic information possibly associated to the groups of entities (nodes, faces) can be maintained. Such high level modification capabilities are of major importance in all the engineering activities requiring fast modifications of meshes without going back to the CAD model. This is especially true in the context of industrial maintenance where the engineers often have to solve critical problems in very short time. Indeed, in this case, the product is already designed, the CAD models are not necessarily available and the FE models might be tuned. Thus, the product behaviour has to be studied and improved during its exploitation while prototyping directly several alternate solutions. Such a framework also finds interest in the preliminary design phases where alternative solutions have to be simulated. The algorithm first removes the intersecting faces in an n-ring neighbourhood so that the filling of the created holes produces triangles whose sizes smoothly evolve according to the possibly heterogeneous sizes of the surrounding triagles. The holefilling algorithm is driven by an aspect ratio factor which ensures that the produced triangulation fits well the FE requirements. It is also constrained by the boundaries of the groups of entities gathering together the simulation semantic. The filled areas are then deformed to blend smoothly with the surroundings meshes

Merging enriched Finite Element triangle meshes for fast prototyping of alternate solutions in the context of industrial maintenance

A new approach to the merging of Finite Element (FE) triangle meshes is proposed. Not only it takes into account the geometric aspects, but it also considers the way the semantic information possibly associated to the groups of entities (nodes, faces) can be maintained. Such high level modification capabilities are of major importance in all the engineering activities requiring fast modifications of meshes without going back to the CAD model. This is especially true in the context of industrial maintenance where the engineers often have to solve critical problems in very short time. Indeed, in this case, the product is already designed, the CAD models are not necessarily available and the FE models might be tuned. Thus, the product behaviour has to be studied and improved during its exploitation while prototyping directly several alternate solutions. Such a framework also finds interest in the preliminary design phases where alternative solutions have to be simulated. The algorithm first removes the intersecting faces in an n-ring neighbourhood so that the filling of the created holes produces triangles whose sizes smoothly evolve according to the possibly heterogeneous sizes of the surrounding triagles. The holefilling algorithm is driven by an aspect ratio factor which ensures that the produced triangulation fits well the FE requirements. It is also constrained by the boundaries of the groups of entities gathering together the simulation semantic. The filled areas are then deformed to blend smoothly with the surroundings meshes

Semantic-preserving mesh direct drilling

Advances in modeling of discrete models have allowed the development of approaches for direct mesh modeling and modification. These tools mainly focus on modeling the visual appearance of the shape which is a key criterion for animation or surgical simulation. Most of the time, the resulting mesh quality as well as the semantics preservation capabilities are not considered as key features. These are the limits we overcome in this paper to enable fast and efficient mesh modifications when carrying out numerical simulations of product behaviors using the Finite Element (FE) analysis. In our approach, the modifications involve the resolution of an optimization problem where the constraints come from the shapes of the operating tools and the FE groups (sets of mesh entities) used to support the semantic information (e.g. boundary conditions, materials) contained in the FE mesh model and required for FE simulation. The overall mesh quality, a key point for accurate FE analysis, is guaranteed while minimizing an objective function based on a mechanical model of bar networks which smoothes the repositioning of nodes. Principle of the devised mesh operators is exemplified through the description of a 2D/3D mesh drilling operator. The proposed mesh modification operators are useful in the context of fast maintenance studies and help engineers to assess alternative design solutions aimed at improving the physical behavior of industrial machinery

Direct modification of semanticaly-enriched finite element meshes

International audienceBehaviour analysis loop is largely performed on virtual product model before its physical manufacturing. The last avoids high expenses in terms of money and time spent on intermediate manufacturing. It is gainful from the reality to the virtuality but the process could be further optimized especially during the product behaviour optimization phase. This process involves repetition of four main processing steps: CAD design and modification, mesh creation, Finite Element (FE) model generation with the association of physical and geometric data, FE Analysis. The product behaviour analysis loop is performed on the rst design solution as well as on the numerous successive product optimization loops. Each design solution evaluation necessitates the same time as required for the first product design that is particularly crucial in the context of maintenance. In this paper we propose a new framework for CAD-less product optimisation through FE analysis which reduces the model preparation activities traditionally required for FE model creation. More concretely, the idea is to directly operate on the rstly created FE mesh, enriched with physical/geometric semantics, to perform the product modi cations required to achieve its optimised version. In order to accomplish the proposed CAD-less FE analysis framework, modification operators acting on both the mesh geometry and the associated semantics need to be devised. In this paper we discuss the underlying concepts and present possible components for the development of such operators. A high-level operator speci cation is proposed according to a modular structure that allows an easy realisation of di erent mesh modification operators. Here, two instances of this high-level operator are described: the planar cracking and the drilling. The realised prototypes validated on industrial FE models show clearly the feasibility of this approach

Direct Modification of Semantically-Enriched Finite Element Meshes

Behaviour analysis loop is largely performed on virtual product model before its physical manufacturing. The last avoids high expenses in terms of money and time spent on intermediate manufacturing. It is gainful from the reality to the virtuality but the process could be further optimized especially during the product behaviour optimization phase. This process involves repetition of four main processing steps: CAD design and modification, mesh creation, Finite Element (FE) model generation with the association of physical and geometric data, FE Analysis. The product behaviour analysis loop is performed on the first design solution as well as on the numerous successive product optimization loops. Each design solution evaluation necessitates the same time as required for the first product design that is particularly crucial in the context of maintenance. In this paper we propose a new framework for CAD-less product optimisation through FE analysis which reduces the model preparation activities traditionally required for FE model creation. More concretely, the idea is to directly operate on the firstly created FE mesh, enriched with physical/geometric semantics, to perform the product modications required to achieve its optimised version. In order to accomplish the proposed CAD-less FE analysis framework, modification operators acting on both the mesh geometry and the associated semantics need to be devised. In this paper we discuss the underlying concepts and present possible components for the development of such operators. A high-level operator specification is proposed according to a modular structure that allows an easy realisation of different mesh modication operators. Here, two instances of this high-level operator are described: the planar cracking and the drilling. The realised prototypes validated on industrial FE models show clearly the feasibility of this approach

Semantic-preserving mesh direct drilling

Advances in modeling of discrete models have allowed the development of approaches for direct mesh modeling and modification. These tools mainly focus on modeling the visual appearance of the shape which is a key criterion for animation or surgical simulation. Most of the time, the resulting mesh quality as well as the semantics preservation capabilities are not considered as key features. These are the limits we overcome in this paper to enable fast and efficient mesh modifications when carrying out numerical simulations of product behaviors using the Finite Element (FE) analysis. In our approach, the modifications involve the resolution of an optimization problem where the constraints come from the shapes of the operating tools and the FE groups (sets of mesh entities) used to support the semantic information (e.g. boundary conditions, materials) contained in the FE mesh model and required for FE simulation. The overall mesh quality, a key point for accurate FE analysis, is guaranteed while minimizing an objective function based on a mechanical model of bar networks which smoothes the repositioning of nodes. Principle of the devised mesh operators is exemplified through the description of a 2D/3D mesh drilling operator. The proposed mesh modification operators are useful in the context of fast maintenance studies and help engineers to assess alternative design solutions aimed at improving the physical behavior of industrial machinery

Méthodologie de simulation d'assemblage/ désassemblage de composants flexibles : Application à la simulation de pièces de type « poutres flexibles » dans un environnement de réalité virtuelle

Il est important, pour la développement rapide et à moindre coût d'un produit, de considérer différentes contraintes liées à la conception, l'assemblage/ désassemblage (A/D), l'usinage, l'ergonomie, etc. L'utilisation des outils comme les systèmes de réalité virtuelle (RV) donne une nouvelle dimension en terme de développement efficace du produit. Cette thèse propose d'appliquer les technologies de RV à l'étude/ optimisation des systèmes mécaniques complexes et, en particulier, à la simulation d'A/D de composants flexibles. Afin de tenir compte d'un comportement complexe de ces pièces, une telle simulation est basée sur leur modélisation mécanique. Le modèle non-linéaire de poutres flexibles est utilisé, adapté à des spécificités de la RV, étudié et intégré dans un démonstrateur de simulation. Une telle modélisation permet de générer des informations réalistes (efforts, déformations, trajectoires d'A/D,...) et de les utiliser dans l'étude/ évaluation adéquate et rapide des opérations d'A/D en se basant sur la méthodologie proposée. Cette méthodologie tient compte des spécificités dues à la simulation mécanique temps réel, à la caractérisation des propriétés du matériau, aux interfaces de RV, aux problèmes des modèles CAO. Ainsi, les problèmes de stabilité numérique et de recherche rapide de solutions adéquates, la validation expérimentale, les contraintes d'interfaçage en RV, la caractérisation d'A/D à travers des expérimentations physiques et numériques, etc. sont considérés dans ce mémoire. De nombreux tests et exemples montrent l'intérêt de la démarche proposée vis-à-vis des besoins industriels

DIRECT MERGING OF TRIANGLE MESHES PRESERVING SIMULATION SEMANTICS FOR FAST MODIFICATION OF NUMERICAL MODELS

Nowadays, most of the numerical product behavior analyses are carried out following four steps: Computer Aided Design (CAD) modeling, mesh definition, Finite Element (FE) simulation and results analysis. This process can be completed by optimization loops. In the context of current maintenance and lifecycle problems, the product is already designed, and its behavior has to be studied and improved during its exploitation. For the maintenance of the EDF power plants, it is critical to identify the problem source and to provide the adopted solution in a short time. In this paper, we propose a method to enable the direct modification of 2D FE models for fast and accurate FE simulation. This approach enables to avoid both multiple iterative updatings of the CAD model and the remeshing problems of complex shapes while reusing the exiting meshes together with the semantic data useful for FE simulation. Starting from existing triangle meshes to be merged, the algorithm removes the intersected faces and fills in the created holes while ensuring that the semantics initially associated to the meshes is preserved. The holes filling algorithm is driven by an aspect ratio factor which ensures that the produced triangulation fits well the FE requirements

Proposal of a methodology for assembly/disassembly simulation of deformable parts in a virtual reality environment

International audienc