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Building Models with 3DScanned Geometry usingAbaqus ScriptingA Case Study on Disc SpringsZentrum für Konstruktionswerkstoffe (MPA-IfW)Max Benedikt Geilen M. Sc.Dr.-Ing. Marcus KleinProf. Dr.-Ing. Matthias Oechsner
� in MPaPn𝜎𝑎𝑚𝑝 in MPa𝑃𝑊𝑎𝑙𝑘𝑒𝑟 in MPa21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 2
Software architectureif name ‘ main ‘Spring inpevaluatedelVisualization.odb21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 3.bat.csv
Self.build modelgoing through Abaqus CAE modulesmethods may be replaced;order of method calls mustalways remain the same21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 4
Data acquisitionscanning: GOM ATOSsmoothing: GOM Inspectbeforeedge Iedge IIafteredge Iedge II21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 5
Data preprocessingalignment by translation and rotationyyxxzzcriterion 1: heightcriterion 2: surface areayy yx21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 6x
Self.build in module partmanual workflow: Abaqus Toolboxautomated workflow: Import from *.inp21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 7
Self.build in module meshC3D4C3D10 lowest computationalcost- too stiff, bad meshconvergence- high computationalcost no dealbreakingdrawbackC3D10M literatures choice- anecdotical evidence:doesn‘t converge withbad element geometryautomated workflow: „convert tri to tet“part.generateMesh(elemShape TET)*Element pictures: Abaqus documentation21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 8
Self.build in module assemblypositioning springs by translation21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 9
Self.build in module interactionslinear elements C3D4quadratic elements C3D10125100755025015129630RAM in GB10general contactsurface to surface7,5force in kNforce in kN10computing time inhrs52,50computing time inhrsRAM in GBgeneral contactsurface to surface7,552,5000,25s / h00,50,7500,25s / h00,521.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 100,75
Self.build in module interactionsgeneral contactsurface to surface pair𝜇D 𝜇Deiloop: all combinations of partsdefinecontactproperties fasteasy toimplementsame frictioncoefficienteverywheremaster/slave logiccreatemastersurfacecreateslavenode setsurface is possible, implementationmore complicated21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 11
Self.build in module jobstandard solutionwith modified outputwhyhowcoordinates we need coordinates requestableby CAE/Scripting21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 12
Self.evaluate walkermaths – computing Walker damage in every integration point ���𝑛 � 𝜎𝐼,𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 (𝑟)𝜎𝐼𝐼,𝑚𝑎𝑥/𝑚𝑖𝑛 �𝑛 𝜎𝐼𝐼,𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 (𝑟)𝜎𝐼,𝑚𝑒𝑎𝑛 0,5 𝜎𝐼,𝑚𝑎𝑥 𝜎𝐼,𝑚𝑖𝑛𝜎𝐼𝐼,𝑚𝑒𝑎𝑛 0,5 (𝜎𝐼𝐼,𝑚𝑎𝑥 𝜎𝐼𝐼,𝑚𝑖𝑛 )𝜎𝐼,𝑎𝑚𝑝 0,5 𝜎𝐼,𝑚𝑎𝑥 𝜎𝐼,𝑚𝑖𝑛𝜎𝐼𝐼,𝑎𝑚𝑝 0,5 𝜎𝐼𝐼,𝑚𝑎𝑥 �𝑛 𝜎𝑠𝑖𝑔𝑛 𝜎𝑀𝑖𝑠𝑒𝑠 (𝜎𝐼,𝑚𝑒𝑎𝑛 , 𝜎𝐼𝐼,𝑚𝑒𝑎𝑛 )𝜎𝑎𝑚𝑝 𝜎𝑀𝑖𝑠𝑒𝑠 (𝜎𝐼,𝑎𝑚𝑝 , 𝜎𝐼𝐼,𝑎𝑚𝑝 )𝜎𝑚𝑎𝑥 max(𝜎𝑚𝑒𝑎𝑛 𝜎𝑎𝑚𝑝 , 0)1 𝛾𝛾𝑃𝑊𝑎𝑙𝑘𝑒𝑟 𝜎𝑚𝑎𝑥 𝜎𝑎𝑚𝑝21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 13
Self.evaluate walkerfrom scalarField to human-readable graphtrianglestrianglessurface areasfaces of all finiteelementsfinite element facesat part surfacesurface areas oftrianglesscalarFieldWalker damagesdata pairsWalker damage atintegration pointsnear finite elementfaces at part surfacesurface area; meanWalker damagefatigue parametersSurface areasmaximum walkerdamage ignoringsingularitieslist of surface areaswhere damageexceeds increments21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 14
Walker postprocessing1251007550250computing time inhrsRAM in GBsurface triangles /2,500545543541Walker damage inMPa21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 15
Walker postprocessing545260255543250245240541Walker damage inMPa23523090% loaded surfacein mm² 0.921.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 16
Generalisabilityabc Abstract assemblyClass Spring stackabstract methodsnon-abstract methodspromise that in childclasses there will be amethod fullfilling adefined odsfulfillmentofpromisecurrently about65% of codebaseAbaqusScriptingnon-abstract methodsactual implementationcan be used in all childclassesdefine the architecturefulfill general utdatanew class ofassemblys21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 17
Automated testingUnittest.TestCase (functional testing)Inputregression oldversionAre they(almost) equal?newversionspecific tests: mesh quality / convergence versatilemany true negativesmany false positivesexpensive to createexpensive to maintainexpensive to performerror handlingcheaper implementation and maintenancecan test randomlycan only test initand solve as unit cheap implementation- only for error handling21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 18
Summary𝜎𝐼,𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 in MPaPn𝜎𝑎𝑚𝑝 in MPa𝑃𝑊𝑎𝑙𝑘𝑒𝑟 in MPa21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 19
FundingThis contribution was created as part of the research project AVIF A 309“Bewertung des Einflusses realer Bauteilgeometrien auf die Beanspruchbarkeit vonTellerfedern anhand numerischer Simulation”. This project is funded by StiftungStahlanwendungsforschung, which is part of the Association for the Promotion ofScience and Humanities in Germany. The Association’s mission is the promotion ofresearch into the manufacturing and utilization of steel in Germany. The researchproposal was audited by a panel of experts from the Research Association of theWorking Group of the Iron- and Metal-processing Industries (AVIF), which iscomposed of specialists from the steelworking industry and academia. The projectis accompanied by a working group from the VDFI (Association of the GermanSpring Industry).21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 20
Thank you for your attention!Max Benedikt Geilen M. Sc.Dr.-Ing. Marcus .tu-darmstadt.de06151 16-2586706151 16-2531321.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 21
21.11.2019 MPA-IfW Darmstadt M. B. Geilen et al. Abaqus Scripting and 3D-Scans 3DEXPERIENCE Conference Folie 17 Abaqus Scripting abstract assembly user interaction spring stack input data Generalisability abc Abstract_assembly abstract methods non-abstract methods Class Spring_stack non-abstract methods promise that in child classes .
