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11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
2
Introduction: About AAM
World Headquarters
Technical Center
North America
South America
Europe
Asia
Key Facts
• $2.93 Billion USD Sales (2012)
• 33 Locations in 13 Countries
• 11,000 Associates
• 20 Manufacturing Facilities
• 11 Business, Technical and
Engineering Centers
• 2 Joint Venture Operations
NX and LMS Test.Lab Integration at AAM Company Background
NX CAE
Symposium
2013
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
Front Axle
Rear Beam Axle
Driveshafts
AAM’s products
Passenger Car & Crossover Vehicle
Commercial Vehicle
Light Truck and SUV
Multi-piece Propeller shaft
Power Transfer Unit
Rear Drive Module w/ Torque
Transfer Device
eAAM electric AWD
Front Axle (Independent & Steerable)
Front & Rear Propeller shafts
Transfer Case
Rear Beam Axle
55.8%
16.8%
6.3%
8.0%
11.5%
1.6%
Rear Axle Systems
(Includes Rear Drive Modules)
Front
Axles
Metal
Formed Products
Propeller
Shafts
Other
Chassis Components
3
NX and LMS Test.Lab Integration at AAM Company Background
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
4
AAM’s Customers
Driveshafts
Light Truck / SUV
Front AxlesRear Axles
Transfer Cases
Passenger Car / Crossover
Independent Rear
Drive Axles (IRDAs)
Torque Transfer
Devices (TTDs)
Multi-Piece Driveshafts
Independent Front
Drive Axles (IFDAs)
Transmission
Differentials
Power Transfer Units (PTUs)
Bus Axles (Rear Engine)
Rear Axles
Commercial Vehicle
Front Axles
Tandem
Metal Formed Products
Transmission Components
Axle / Output ShaftsDifferential Gears
Ring / Pinion Gears
NX and LMS Test.Lab Integration at AAM Company Background
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
5
Typical Automotive Driveline System NVH Problems • Gear Whine
• Driveshaft critical speed
• Engine torque fluctuation
• Gear Rattle
• Shudder / Moan / Chatter
• Clunk
NX and LMS Test.Lab Integration at AAM NVH Background
AAM NVH CAE Responsibilities 1. Early upfront analysis and optimization to minimize
NVH risks
2. Model correlation and physical validation during product development
1. Product behavior with different boundary conditions (Dyno vs Vehicle etc.)
2. Model methodology and database improvement
3. Problem troubleshooting and identification
3. Assist with Production and Field NVH Issues
• NVH CAE Team resides in NVH Product Engineering Department
• Test, Project Management, CAE
• Driveline 1st order (imbalance and pitch line run-out)
• Driveline 2nd order (Cardan joint kinematics)
• Propshaft instability
• Chain noise
• Wheel imbalance
• Engine idle shake
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM AAM Software History
• LMS Test.Lab
• No CAE functionality
• Very easy user interface
• Entire group has learned how to use the software effectively
• Used by CAE for Function Math and Plotting
6
NX CAE
Symposium
2013
Timeline
1990s 2000 2001 2002 … 2010 2011 2012 2013
LMS Cada-X
Test
C
AE
I-DEAS
LMS Test.Lab
I-DEAS Siemens NX 8.5
Windows 7 Upgrade
Siemens LMS Acquisition
• LMS Cada-X
• No CAE functionality
• Few individuals could use the software efficiently
• I-DEAS
• Thoroughly integrated Test and CAE functionality
• Entire group used the software efficiently through use of scripts
I-DEAS
• Siemens NX
• Mature CAE Environment
• Easy transition from I-DEAS
• Entire CAE group is very capable within the software
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
7
NX CAE
Symposium
2013 CAE Analysis Process
• Generating correlated CAE results involves a fairly standard iterative loop consisting of :
1. Model Construction
2. Model Solution
3. Calculating Responses
4. Comparison/Correlation to Test Data
5. Design Studies
• As with any iterative process, several repetitive software functions are used as each iteration requires a new calculation of results
• This is further complicated by the need to use Test.Lab for function math and powerful plotting tools
• NX 8.5 Journaling has saved significant effort as repetitive functions within NX can be replayed automatically
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
800100 200 300 400 500 600 700150 250 350 450 550 650 750
Hz
100.0
100e-6
1.0e-3
10e-3
0.1
1.0
10.0
300e-6
3.0e-3
30e-3
0.3
3.0
30.0
Log (
...)
m/s
2
NX and LMS Test.Lab Integration at AAM
• Predictive Analysis is conducted in NX Advanced Simulation Module
• Models are solved using standard Sol 103 (Normal Modes)
• Response Simulation (FRF Calculator) is used to generate functions
• Iterative correlation activities occur often requiring the use of both Test.Lab and NX for analysis currently
• Test.Lab Functionality allows for more complex operations
• NX does not currently read Test.Lab data
• Test.Lab does read NX data
• Test.Lab has Advanced Function Math Tools
• Test.Lab plotting is very advanced
8
NX CAE
Symposium
2013
Pinion Nose Vertical Response
Test CAE
Front Axle Model in NX
Test and CAE Data displayed in Test.Lab
CAE Analysis Process
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
0.0100
100.00
0.1000
1.000
10.00
100 1000 200 400 600 800Frequnecy (Hz)
NX and LMS Test.Lab Integration at AAM
9
NX CAE
Symposium
2013
Pinion Nose Vertical Response
Test CAE
Rear Drive Module Model in NX
Test and CAE Data displayed in Test.Lab
CAE Analysis Process
• While the process could be conducted within NX, efficiency is improved dramatically when post processing is carried out within Test.Lab for the following reasons:
• Advanced function math, data manipulation and calculation “scripting” capability
• Very advanced plotting capabilities that enhance ability to review data
• Convenient comparison of Test data and model data (overlays)
• For reporting purposes, calculated results are displayed in LMS Test.Lab
• NX data is in .afu format and is automatically saved externally
• LMS created a plugin for AAM that allows Test.Lab to read AFUs directly for comparison to Test data
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
10
NX CAE
Symposium
2013 CAE Analysis Process - Correlation
Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.)
NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components
Solve
NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions
Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness
Yes Acceptable Correlation?
Report
No
Strain Energy Table
NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs)
NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.)
NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization
NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary)
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
11
NX CAE
Symposium
2013 CAE Analysis Process – Design Studies
Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.)
NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components
Solve
NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions
Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness
Yes Acceptable Correlation?
Report
No
Strain Energy Table
NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs)
NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.)
NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization
NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary)
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
12
NX CAE
Symposium
2013 CAE Analysis Process
Rear Axle Single Piece Propshaft Example
Mode #8
Mode #9
• The Strain Energy Tabulation allows the primary contributor to each mode to be clearly identified so that appropriate modifications to the mesh can be easily made to achieve the desired dynamic changes
• The table shows clearly that Modes #7 and #8 are Propshaft Bending Modes
• The Prop 2D (Tube modeled as shells) group contains more than 90% of the Strain Energy
• Mode #9 is Propshaft/Transmission Interface Torsion as the Prop 2D and Prop Joint Groups are the highest contributors
• Animation of the mode in conjunction with the Strain Energy table clearly identifies the controlling components in each mode
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
13
NX CAE
Symposium
2013 CAE Analysis Process
• A great improvement to the NX user experience has been the addition of the Journaling Tool
• Works like Macros in Microsoft products
• Can Record and Playback actions as needed
• Very useful for repetitive actions
Journal used to Calculate and Display Frequency Response Functions
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
14
NX CAE
Symposium
2013 CAE Analysis Process
• The calculated functions are easily read into Test.Lab by browsing to the files from the Navigator
• Functions are stored locally as .AFU files
• LMS created an AFU reader plugin to easily access the data
NX AFU files plotted within Test.Lab
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
15
NX CAE
Symposium
2013 CAE Analysis Process
• The functions are added to the Data Calculator and a previously used Formula Set is loaded
• For each iteration the FRFs and the necessary calculations are the same
Functions are easily loaded for calculation
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
16
NX CAE
Symposium
2013 CAE Analysis Process
• The newly calculated Acceleration data is then displayed easily within Test.Lab
• The use of tabs in Test.Lab lets the user easily switch between the current plot window and a previously created plot
Previous Plot
Calculated CAE Surface Acceleration
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM
17
NX CAE
Symposium
2013 CAE Analysis Process
• The plots within LMS can then be copied to the MS Office suite and manipulated as the user sees fit
• Plot editing from within PowerPoint includes:
• X and Y-Axis modification
• Addition of cursors
• Curve Color and Line Thickness editing
• Statistical calculations (Max, Mean, RMS, etc)
• And much more…
• CAE data is easily overlaid with Test Data for correlation
6000.000.00 1000 2000 3000 4000 5000500 1500 2500 3500 4500
Hz
1000.00
1.00
10
100
2
3
5
7
20
30
50
70
200
300
500
Log
m/s
2
1580.49
451.92
F FRF 60Y:+X/3000:+X 0 /
F FRF 61Y:+X/3000:+X 0 /
F FRF 62Y:+X/3000:+X 0 /
F FRF 63Y:+X/3000:+X 0 /
11/5/2013
NX CAE
Symposium
2013
NX and LMS Test.Lab Integration at AAM
18
Summary
• The NVH CAE team at AAM has been using NX for almost 18 months
• The transition from IDEAS was smooth as old IDEAS models were easily imported into NX
• NX provides a very powerful environment for analysis
• The primary shortcomings on NX are with Function Math and Data Plotting
• Test.Lab serves very well as a supplement to complete the required analyses