rbf update of cae models on actual manufactured shapes

RBF update of CAE models on actual manufactured shapesProf. Marco Evangelos Biancolini – University of Rome “Tor Vergata”

Outline

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Robust design concepts

Update of CAE model of manufactured part

Standard methods RBF methods RIBES wing example

Robust design concepts

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The actual manufactured shapes represent the nominal geometry within a prescribed tolerance

The effect on performances can be predicted in advance (mesh morphing and RS method are typically adopted)

The effect on performances can be evaluated after manufacturing (an update of CAE models is required!)

The same concepts can be applied to parts that passed QA (i.e. deviations within prescribed tolerances) as well to off-design parts (for instance repaired ones)

CAE update workflow Main advantages

No need to generate a new CAD No need to generate a new mesh Cloud of acquired points can be

directly filtered using RBF An STL can be used as input Fast process that keeps the same

mesh Main disadvantages

RBF filtering technique has to be mastered

Computational intensive

Main advantages Accurate geometry quality

control Updated CAD available

Main disadvantages Highly skilled CAD user required CAD reconstruction is a long and

complex process Remesh required Comparison with baseline CAE

mesh requires interpolationFeb 2017

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RBF Morph

RBF based CAD based

CAE based

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Acquired geometry available as: a cloud of points (usually automatic

triangulation and filtering available) regular points scanned on 3d-curves (curve

fitting) New surfs can be built as:

automatic multipatch parametric surfaces

Once the new CAD is built the CAE model has to be regenerated (new mesh and set-up)

RBF based

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Acquired geometry available as: a cloud of points (usually automatic triangulation

and filtering available) regular points scanned on 3d-curves (curve fitting)

Direct surface mesh update: Experimental points are projected onto the original

CAD A field moving points from original to acquired

position results The field is filtered using RBF regression (rbf4noisy)

RBF based

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CAD acquired surf update: Direct projection on CAD entities in RBF Morph

ACT for Workbench STL projection on meshes in RBF Morph SA/Fluent

Add On FEA mesh update:

Updated surfaces are controlled RBF set-up for mesh morphing completed using

RBF Morph A quick comparison between original and actual

geo can be conducted on the same FEA model

RIBES EU Project Radial basis functions at fluid Interface Boundaries to Envelope

flow results for advanced Structural analysis JTI-CS-2013-GRA-01-052

Feb 2017

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RBF Morph

RIBES test article

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WT test article built as an aeronautical wing box. Manufacturing fidelity is tricky, especially at the leading edge because of the thickness of the skin.

RIBES test article

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The shape of the manufactured part has been recorded using a contact profilometer at 8 cross sections of the airfoil, some noise is observed in the experimental data.

RIBES test article

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A new CAD has been manually defined by fitting the 8 curves (filtering out the noise) and connecting them in the span direction.

RIBES test article

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (ACT Extension for WB) interact with the BREP (multiple surfaces, virtual topology can be considered)

Projection works with a single face projection

RIBES test article

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (ACT Extension for WB) interact with the BREP (multiple surfaces, virtual topology can be considered)

Projection works with a single face projection

RIBES test article

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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The update of the volume mesh can be achieved using the new CAD.

RBF Morph (Stand Alone and Fluent Add On ) comes with a projection tool based on the implicit surface

The airfoil has been split in 3 surfaces (double wall issues at trailing edge)

RIBES test article

Feb 2017RBF Morph

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A direct method which consists in RBF filtering the acquired points (rbf4noisy) can be used

Experimental points are projected onto the baseline CAD to create a field

The field is filtered according to the retained spatial wavelength

RIBES test article

Feb 2017RBF Morph

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A direct method which consists in RBF filtering the acquired points (rbf4noisy) can be used

Experimental points are projected onto the baseline CAD to create a field

The field is filtered according to the retained spatial wavelength

RIBES test article

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A direct method which consists in RBF filtering the acquired points (rbf4noisy) can be used

Experimental points are projected onto the baseline CAD to create a field

The field is filtered according to the retained spatial wavelength

Geometries comparison

RBF Morph

CAD

CAD RBF Morph

CL 0.3132 0.3135CD 145.9 dc 144.8 dc

Aerodynamic solutionsCAD

RBF Morph

Pressure

Related topics

Feb 2017RBF Morph

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RBF4ARTIST a system that allows to use an haptic device to directly insert individual control points https://youtu.be/74yjd7ZWcNk

RBF4METRO a system for compensation of metrological data (correction field defined using CAE)

Robust design using mesh morphing to define a shape parametric CAE model

Local update of a large dead mesh using local CAD (original and target) and RBF

Conclusions

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RBF technology can simplify and shorten the update of the CAE model onto the actual measured shape

Powerful RBF noise filtering tools available Final Update of the CAE model using mesh morphing To learn more about RBF technology of RBF Morph

consider a visit of our web site www.rbf-morph.com.

biancolini@ing.uniroma2.it

Many thanks for your kind attention!

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