Abstract:
Numerically-simulated physical behaviors of workpiece sheet metal during a metal forming process having a predefined load path is obtained based on received FEA mesh model and mesh adjustment criteria as follows: initializing current simulation time; determining current simulation period from current simulation time and next mesh adjustment time; using characteristic length to establish a 3-D mesh refinement zone that contains a space encompassing a corresponding section of the predefined load path for the current simulation period; updating the FEA mesh model by refining those finite elements located within the 3-D mesh refinement zone to a desired level and by coarsening certain finite elements outside of the zone according to mesh coarsening criterion; conducting corresponding portion of the time-marching simulation using the updated FEA mesh model for current simulation period until current simulation time reaches next mesh adjustment time; and repeating until current simulation time passes the total simulation time period.
Abstract:
Numerical simulation method includes receiving a manufacturing process configuration specification for moving various types of arbitrarily-shaped objects from an egress area onto a lower surface with desired mass flow rate in a predefined time period; creating a FEA model representing the lower surface; creating respective bonded discrete element models (BDEMs) representing the various types of the objects, each BDEM containing discrete elements connected by connection bonds; generating a list of BDEMs each with randomly-chosen types and orientation, such that total mass of the list of BDEMs exceeds a target total mass; and obtaining numerically-simulated physical behaviors of the objects in a time-marching simulation. At each solution cycle of the simulation, placing respective objects into randomly-selected ‘open’ sub-regions by activating next relevant portion of the BDEMs based on the mass flow rate and time-step size; releasing activated BDEMs from the egress area onto the lower surface.
Abstract:
Systems and methods of designing geometry of a tool set in a numerical simulation of sheet metal forming operations including springback compensation are disclosed. Computerized die face model representing an initial geometry of a tool set is generated for forming a sheet metal work-piece to a part's desired geometry. Numerically-simulated deep drawing operation, optional trimming operation and a springback effect are conducted to obtained a trial geometry of the part. A deviation between the trial geometry and the desired geometry is obtained. When the deviation is outside of tolerance, computerized die face model is regenerated according to a modified geometry of the tool set that includes an estimated amount of springback compensation derived from the deviation due to springback together with a node adjustment scheme for ensuring model conformity along the boundary line. Final modified geometry of the tool set is iteratively obtained.
Abstract:
Characteristics of a blast source and a FEA model representing a surrounding fluid domain are defined. One layer of new border nodes and elements are created outside of the fluid domain's original outer boundary formed by the original border elements. Each new border element/node is associated with one of the original border elements/nodes as corresponding master element/node. At each time step of a time-marching simulation of an underwater explosion, simulated fluid behaviors are computed for all but the new border elements. The computed fluid behaviors of each original border element are saved into a corresponding lookup table configured to store the computed fluid behaviors for a predefined number of time steps in a first-in-first-out manner. Simulated fluid behaviors of each new border element are determined by interpolating, with the calculated blast wave propagation time from the master element, the stored fluid behaviors in the corresponding master element's lookup table.
Abstract:
Systems and methods for refining ALE elements in a time-marching simulation are disclosed. A FEA model representing a physical domain is defined and used in a time-marching simulation that simulates physical phenomena of the physical domain. Certain ones of the ALE elements are refined upon detecting a user-defined triggering condition. Each of said certain ones of the ALE elements is refined into a number of child elements. When an ALE element contains more than one material, volume fractions representing respective materials are calculated in each of the child elements right after each refinement. At each advection phase, each donor maps its flux to one or more receptors. When a donor maps its flux to multiple receptors, each receptor calculates its own share of the flux from the donor. When the donor contains more than one material, each receptor must account for such situation.
Abstract:
Systems and methods for numerically simulating muscle's movements along bones and around joints are disclosed. A computerized model containing a plurality of truss elements along with one or more rollers is used. The truss elements are configured for modeling a muscle strand while each roller is configured for a joint. Each truss element includes two end nodes and is configured or associated with a muscle bio-mechanical property model. Each roller is fixed at the location of a corresponding joint. To simulate the muscle strand movements around the joint, each pair of truss elements straddling a roller is adjusted dynamically in a time-marching simulation (e.g., computer simulation of an impact event of an automobile and one or more occupants). Adjustments are performed at each solution cycle of the time-marching simulation. Adjustments include two types—“slipping” and “swapping”.
Abstract:
Methods and systems of determining a trim line in deep draw manufacturing of a sheet metal part are disclosed. A computerized model of a sheet metal part and the addendum surface geometry are defined. At least one flange portion in the computerized model is identified. Perform a numerical simulation of unfolding of the flange towards the addendum surface by applying a first set of numerical loads to each pair of adjacent finite elements. The first set of numerical loads is configured for flattening out the pair of finite elements with a bending moment determined using relative orientations of the pair finite elements and material properties of the part. A second set of numerical loads is applied to close any remaining gap between the unfolded flange and the addendum thereafter. The outer edge of the flange portions in their final unfolded configuration is designated as a trim line.
Abstract:
Systems and methods for numerically simulating inflation of an airbag configured with more than one connected flexible-boundary volumes (i.e., primary and secondary pouches) are disclosed. A finite element analysis model of such airbag is defined in the airbag's folded configuration. Numerical simulation of inflating the primary pouch is based on corpuscular particle theory by interacting simulated corpuscular or gas particles with one another and with the shell elements representing the primary pouch. The simulated corpuscular particles are created by flow characteristics generated by an explosive blast. Numerical simulation of inflating the secondary pouch is based on control volume theory by converting kinetic energy of those of the simulated corpuscular particles having flowed through the interconnected opening from the primary to the secondary pouch to a uniform pressure. The uniform pressure is then applied onto the shell elements representing the secondary pouch.
Abstract:
Systems and methods of numerically simulating physical phenomena of firing an electromagnetic rail-gun using a coupled FEM-BEM procedure are disclosed. Electromagnetic rail-gun includes a pair of parallel rails and a projectile located therebetween. Rails and projectile are represented by a FEM model, while the ambient air surrounding the rail-gun is represented by a BEM mesh for simulating the electromagnetic fields. The BEM mesh is generated from the FEM model as a surface encasing the projectile and rails. A sliding contact interface between each of the rails and the projectile causes the BEM faces in contact to be removed and thus resulting into a hole/gap in the BEM mesh. The hole/gap is patched up with new triangular BEM faces without adding new nodes in accordance with a predefined set of rules, such that the resulting BEM mesh is suitable for carrying out the coupled FEM-BEM procedure.
Abstract:
A system, method and software product to simulate guided cable contacts is disclosed. The guided cable contact includes a slave node and an associated beam. A normal vector is established between the slave node's projection point and the slave node. Each of the slave node and two end nodes of the beam has three translational degrees-of-freedom. A spring is placed between the slave node's projection point and the slave node. The spring constant is assigned such that the spring is substantially stiffer than that of the beam. The guided cable contact stiffness matrix is then calculated using the spring constant, the normal vector, the length of the beam, and the distance between the first end node of the beam and the projection point. According to one aspect, the guided cable contact may be used for modeling human spinal column.