fea comparison in aramis and argus

Optical Metrology 2009

FEA Comparison in

ARAMIS and ARGUS

Harald Friebe

May 25th 2009

FEA Comparison in ARAMIS and ARGUSHarald Friebe

2-Frame Setup / Frame 22-Frame Setup / Frame 1

3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3

Introduction

Former Workflow

� FEA computation and measurement

are different in:

�Coordinate Systems

�Result presentation

� Colored Images

� Section Plots

� FLDs

� Example: Forming of Suspension Arm

Forming process




� FEA computation and measurement

are different in:



� Colored Images

� Section Plots

� FLDs

� For a visual comparison of full field data

�Same visualizations must be chosen

�Same legends must be used

Simulation result (LS-DYNA)

Measurement result (ARGUS)

Introduction

Former Workflow




� FEA Computation and Field Measurement

are different in:



� Colored Images

� Section Plots

� FLDs




� For comparison of section data

�Same 3D sections must be generated

Section definition (LS-DYNA)

Section definition (ARGUS)

Introduction

Former Workflow





are different in:



� Colored Images

� Section Plots

� FLDs






�Same diagrams must be defined

Simulation result (LS-DYNA)

Measurement result (ARGUS)

Introduction

Former Workflow





are different in:



� Colored Images

� Section Plots

� FLDs






�Same diagrams must be defined

� Export of section Data

�Third party software can used for comparison

�Manual alignment of x-Axis

ARGUS-Data-ExportFEA-Data-Export

Introduction

Former Workflow




� Summary

�No automatism

�Time consuming

�Only comparison of

� Local areas (Sections and images)

� Rough values (color images)

Introduction

Former Workflow




� Import of FEA results in ARAMIS/ARGUS in V6.2

� Alignment of measurement coordinate system to FEA

� Calculation of full field deviation for

�Geometry

�Strain values (Major, Minor, …)

Introduction

FEA Comparison Module in ARAMIS/ARGUS

Major true strain deviation

Simulation

Measurement




� Import of FEA results in ARAMIS/ARGUS

�Formats:

� ABAQUS (ABAQUS input)

� LS-DYNA (DYNAIN)

� PAM-STAMP (M01)

� AutoForm (AF)

� ASCII (equivalent to DYNAIN)

�Datatypes

� Shell elements, considering:

� Layers (upper or/and lower)

� Normals (for accurate mapping)

� Imported Values

� Node coordinates (geometry)

� Elements (connection between nodes)

� Result values

� Nodal results (LS-DYNA, ASCII)

� Element results

� 2D surface strain tensor (ABAQUS, PAM-STAMP)

� Scalar (AutoForm)

Workflow

Import

Consider: measurement results are surface values




� For comparison Measurement and FEA must have the same coordinate system

� Transformation

Measurement coordinate system FEA coordinate system

by

�Manual Transformation Functions

� 321-Transformation

� Translation, Rotation

�Best fit alignment

� Pre-orientation

� Best fit by selected areas

Workflow

Alignment

After pre-orientation

After best fit by complete surface

Without alignment




� Calculation of distances between Measurement surface and FEA surface

�Quality control of alignment

Workflow

Geometry deviation

Good alignment

� Quality control of simulation boundary conditions like

�Depth of drawing

�Shape of Die

� Quality control of simulation results

�Geometry

�Spring back

�Wrinkling

Small Surface deviation




� Measurement Points and FEA nodes have

always different positions

�Measurement: red points

� FEA: gird

� Mapping:

�Projection of measurement points to

FEA mesh = mapped points

� Interpolation of FEA result values for

mapped points

� Integration of FEA results to

measurement result structure

Workflow

Mapping

Measurement: red points

FEA: gird




� Calculation of deviations for all points, e.g.:

Major Strain deviation = Major (measurement point) – Major (mapped point)

Workflow

Deviation calculation

Major strain deviation

Mapped Simulation

Measurement




FEA Comparison Result

Results in ARAMIS/ARGUS

� Available result values for all points after comparison:

�Coordinates

�3D Displacements of measurement, FEA and deviation

�Strains (Major, Minor, Mises, …)

� All result evaluation functions of ARAMIS/ARGUS are available:

� Postprocessing

� Filter

� Interpolation

� Statistics

�Elements

� Full field data

� Sections

� Pointmarker

� Presentation

� 3D Window

� Diagrams

� Reports

�Export




Application Example

Suspension Arm

� Optimization of FEA

�Adjustment of

clamping simulation

(blank holder movement)

Major true strain deviation of first simulation step

Major true strain deviation after FEA optimization




Application Example

Suspension Arm

� Optimization of FEA

�Without spring-back simulation

�With spring-back simulation

Surface deviation without spring-back in FEA

Surface deviation with spring-back in FEA




Application Example

Trunk Lid

� ARGUS XL measurement

�Unformed point distance: 1mm

�Amount of measurement point: 1.300.000

�Points made by Laser

Major true strain measurement




Application Example

Trunk Lid





Major true strain FEA




Application Example

Trunk Lid





Major true strain deviation




Application Example

Trunk Lid

� Local details

Simulation mesh

Major true strain deviationMajor true strain FEAMajor true strain measurement

Boundary FEABoundary measurement




Application Example

Trunk Lid

� Local wrinkles

Simulation mesh Surface deviation

Surface FEASurface measurement




Major true strain deviationMajor true strain FEAMajor true strain measurement

Application Example

Trunk Lid

� Local detail: Missing seam in FEA

Simulation mesh

Surface measurement

Surface FEA

Seam

No Seam




� FEA-comparison modul

� Is part of ARAMIS and ARGUS in V6.2 (summer 2009)

�Available for Linux and Windows

� Full field comparison for ARAMIS/ARGUS

�Comfortable alignment and mapping

�Determination of full field deviations for

� Geometry

� Displacements

� Strains (Major, Minor, …)

� Easy and comfortable

� FEA verification

�Result evaluation

�Reporting

� Comparison from measurement to measurement (ARAMIS/ARGUS)

Summary

Thank you for your

attention

[email protected]

www.gom.com

fea comparison in aramis and argus

Software

fea comparison

comparison of section

visual comparison

fea calculat

workflow fea computation

field datasame visualizations

import of fea results

coordinate systems