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@inproceedings{faucris.110542784,
abstract = {Today’s product development process is picking up the pace. To avoid
performing complex and expensive testing including all iterations of the
product development with a real prototype, various FE-simulations
(finite element) for the functional validation of the desired characteristics
are made. The discretization of a developed component and the use of
the simulation conditions, like taking different non-linearities (i.e.
material behavior, contact situations, large deflections etc.) into
account, is a tremendous effort and is necessary to get precise and
significant results.
In general, every constructed component shows differences to its ideal
geometry of the designed CAD-model (Computer Aided Design), i.e.
due to deformations in the production process. Depending on the
manufacturing process, random deviations and the component size,
these differences can vary. In cutting processes the value is relatively
small, but using forming (i.e. deep-drawing or bending) and casting
techniques (i.e. die casting or injection molding) process-related effects
like spring back and shrinkage or warpage occur and can trigger bigger
deformations. Despite knowing the effects of deformations, due to the
production process mentioned above, the product developer always
uses the non-deformed design model of a CAD-system for the FEsimulation
of a component. It seems rather doubtful that further
refinement of simulation methods makes sense, if the real
manufactured geometry of the component is not considered for in the
simulation.
For an efficient exploit of the potential of simulation methods, an
approach has been developed which offers a geometry model for
simulation based on the existing CAD-model but with integrated
production deviations as soon as a first prototype is at hand. Thus, a
functional validation of the real geometry can easily be performed.
The approach in this article is to detect the occurring deformations of a
near-series produced prototype with a high-resolution optical measuring
instrument and to use that data for simulation purposes. The whole
reverse engineering (RE) process including data preparation, complex
surface reconstruction and furthermore a complete new simulation
preprocessing is omitted due to lack of capacity. Therefore, the
detected data (either point cloud or polygonal model) is used directly for
the creation of an adapted FE mesh.
The presented method describes an opportunity to automatically adapt
existing FE-meshes, generated with the non-deformed CAD-model, to
the deviated geometry caused by production. Thereby 3d surface scans
and relevant algorithms are used. Therefore, the surface nodes are
extracted from an ANSYS input file. A measurement of the deviation to
the scanned model at each node position (point cloud or polygonal
model) takes place by using a comparison point within the software
PolyWorks. Afterwards a preload-step is defined, in which the deviation
of every surface node is applied as a displacement. The mesh
emerging from this preload-step with its new nodes coordinates is the
basis for further simulations with real geometry. Herewith, a completely
new input file with the new mesh and the identical content of the initial
input file based on the ideal CAD-model (considering material definition,
forces, boundary conditions etc.) is created. As a result, an FE-model
with real geometry is available and can be used directly for a simulation
without spending a lot of time on additional preprocessing. The
advantage can be seen in the omission of a complex creation of a new
model for simulating the real manufactured geometry. Comparative
analysis between ideal and real geometry is simple, when using this
approach in the product development process.},
author = {Katona, Sebastian and Sprügel, Tobias and Koch, Michael and Wartzack, Sandro},
booktitle = {Summary of Proceedings},
date = {2015-06-21/2015-06-24},
faupublication = {yes},
isbn = {978-1-910643-24-2},
keywords = {FEA (finite element analysis), preprocessing, simulation, 3D surface detection, RE (reverse engineering)},
note = {UnivIS-Import:2015-10-26:Pub.2015.tech.FT.FT-KLMEFK.adapti},
pages = {-},
peerreviewed = {Yes},
title = {{Adapting} {FE}-{Meshes} to real, {3D} surface detected geometry data to improve {FE}-simulation results},
url = {https://www.mfk.uni-erlangen.de?file=pubmfk{\_}563780b5b6f6d},
venue = {San Diego, Kalifornien},
year = {2015}
}
@article{faucris.107268084,
abstract = {Simulation driven product development is state of the art to insure that the desired characteristics in use behave as requested without performing a time-consuming testing using expensive prototypes. To achieve the aim of realistic and confidential results within this product simulations, a tremendous afford (i.e. when taking different non-linearities into account, like material behavior, contact situations, large deflections etc.) is necessary. Conflicting to this, the ideal CAD-model is always used for the analysis, despite knowing the effect, that every manufactured component shows differences to its ideal geometry. Within this paper an approach of a knowledge-based process to integrate real geometry data into product simulations is given. Furthermore, different methods for preparation of the simulation models are represented.},
author = {Katona, Sebastian and Koch, Michael and Wartzack, Sandro},
doi = {10.1016/j.procir.2016.04.176},
faupublication = {yes},
journal = {Procedia CIRP},
keywords = {Computer aided design (CAD); deformation; finite element method (FEM); geometry; knowledge-based system; process; simulation; strucural analysis},
pages = {813-818},
peerreviewed = {No},
title = {{An} {Approach} of a {Knowledge}-based {Process} to {Integrate} {Real} {Geometry} {Models} in {Product} {Simulations}},
year = {2016}
}
@article{faucris.106329564,
abstract = {Laminating carbon-fiber-reinforced plastic (CFRP) traditionally uses rigid moulds. This process means that customising CFRP components is expensive since the costs of each rigid mould are allocated fully to only one associated CFRP. Therefore, using form-flexible moulds is beneficial, because it would eliminate the conventional restriction that each CFRP geometry needs one single rigid mould. The costs of one flexible mould would be allocated to all produced CFRP components. Thus, the more CFRP laminated on this single form-flexible mould, the less the CFRP is affected by mould costs. Creating form-flexible moulds by using pin-type tooling results in a discrete pin accumulation. To achieve the required continuous laminating surface, an interpolation layer is placed on the pins. However, compared to conventional CFRP moulds, normally made by CNC-milling, pin-type tooling complicates accuracy achievement. This is due to the fact that the elastic, silicone-like interpolation layer as well as several tolerances or inaccuracies within the mould mechanics, as an assembly, accumulate into the range of millimeters. Instead of using more accurate pin-type moulds, which is associated with increasing costs, this paper introduces an approach to integrate 3D surface detection methods into the process of form-flexible moulding of spatially curved CFRP using pin-type tools, which maintains costs and increases accuracy. The developed control loop compensates deviations dynamically and results in accuracies in the same range as parts produced using CNC-milled rigid moulds.},
author = {Lušić, Mario and Katona, Sebastian and Hornfeck, Rüdiger},
doi = {10.1016/j.procir.2016.08.028},
faupublication = {no},
journal = {Procedia CIRP},
keywords = {Quality Assurance; Form Flexible Moulding; Pin-Type Tooling; CFRP; 3D Surface Detection},
pages = {158-163},
peerreviewed = {No},
title = {{Compensating} {Deviations} {During} {Flexible} {Pin}-type {Moulding} of {Spatially} {Curved} {CFRP} by {Using} {3D}-{Surface} {Detection}},
year = {2016}
}
@inproceedings{faucris.106352884,
abstract = {Due to increasing product- and process-requirements and shorter development periods the usage of numerical simulations has become an essential part of the product development process. This has led to expose simulation to not only the CAE experts but also to less experienced users such as designers. However, such users typically do not have the expertise to perform simulations from the ground up and need appropriate help systems.
Therefore, the aim of the Bavarian Research Cooperation FORPRO² for “Efficient Product and Process Development by Knowledge based Simulation” is to increase the efficiency of virtual product and process development. This is achieved by creating a simulation environment that allows corresponding users to automatically benefit from expert practices and knowledge. As a result, non-expert users can produce reliable results for virtually optimizing design parameters. This will allow shifting work load from the simulation engineer to the designer. As a consequence, the simulation process will become more agile and quick without compromising on quality of the simulation and the final product.
The goal of the simulation environment is to provide the necessary situational simulation knowledge as a function of decisive factors such as the phase in the development process, the manufacturing processes employed, and the company's individual circumstances. Considering such a wide range of factors, results in several challenges in the development of the simulation framework. Some of the challenges are associated with (manual or automatic) extraction processes of simulation knowledge from existing sources and the publication of the knowledge to the end user in an adequate manner.
The presentation will demonstrate the implementation of the central knowledge environment within the framework of a commercial SPDM system. Special emphasize will be laid on presenting an automatic acquisition of simulation knowledge from validated simulation reports by means of KDD-processes (Knowledge Discovery in Databases). The overall approach is demonstrated by considering the use case of performing a numerical FE simulation with real life geometry (including deviations caused by the manufacturing process) instead of ideal geometry from the CAD system (see image below for a the conceptual workflow for this use case).},
author = {Kestel, Philipp and Sprügel, Tobias and Katona, Sebastian and Lehnhäuser, Thomas and Wartzack, Sandro},
booktitle = {NAFEMS European Conference: Simulation Process and Data Management},
faupublication = {yes},
peerreviewed = {unknown},
title = {{Concept} and implementation of a central knowledge framework for simulation knowledge},
url = {https://www.mfk.uni-erlangen.de?file=pubmfk{\_}574db07979a41},
venue = {München},
year = {2015}
}
@inproceedings{faucris.121284064,
abstract = {In general, every component shows differences to its ideal geometry of the
designed CAD-model, i.e. due to deformations in the production process. Despite
knowing the effects of deformations, the product developer always uses the ideal,
non-deformed design model of the CAD-system for FE-simulations of a component.
It seems rather doubtful that further refinement of simulation methods (e.g. using
different non-linearities) makes sense, if the real manufactured geometry of the
component is not considered for in the simulation process. Therefore, this paper
describes an approach to use hybrid geometry models for simulations, which are
mostly built of the parametric CAD-model, but areas with large deviations are
substituted with surface reconstructed scan-inserts based on 3d surface scanned
data, reconstructed to NURBS-patches. This procedure allows a more precise
simulation as it considers deviations by minimizing the amount of data and the
time for model preparation.},
author = {Katona, Sebastian and Koch, Michael and Wartzack, Sandro},
booktitle = {Proceedings of the 20th International Conference on Engineering Design (ICED2015)},
date = {2015-07-27/2015-07-30},
faupublication = {yes},
keywords = {CAD, Product modelling, models, Simulation, Reverse Engineering},
peerreviewed = {Yes},
title = {{Generating} hybrid geometry models for more precise simulations by combining parametric {CAD}-models with 3d surface detected geometry inserts},
venue = {Mailand, Italien},
year = {2015}
}
@article{faucris.119754404,
abstract = {Due to springback, deviations compared to the designed ideal modal occur during pipe bending processes. With quality control gauges no quantitative statements can be made regarding the process stability. The components are either good or bad and no production trends can be determined. This leads to high scrap rates and in addition, the real performance of the produced components may differ from the target behaviour of the initially designed CAD model. As addressed within this contribution, with integrating optical 3D measuring systems into the bending process, the actual state can be detected continuously. This enables to give feedback to the bending device for automatically readjust of bending parameters and thus prevent producing defective components. Moreover, the digitalisation of the actual contour allows a parametric correction of the designed CAD model, whereby the functional behaviour can be closer to reality within simulation models.},
author = {Katona, Sebastian and Lušić, Mario and Koch, Michael and Wartzack, Sandro},
doi = {10.1016/j.procir.2016.04.163},
faupublication = {yes},
journal = {Procedia CIRP},
keywords = {In-process measurement; bending; springback; computer aided design (CAD); simulation; real function design behaviour},
pages = {808-812},
peerreviewed = {Yes},
title = {{Integrating} optical {3D} measurement techniques in pipe bending: a model-based approach minimising waste by deriving real functional design behaviour},
year = {2016}
}
@inproceedings{faucris.121264704,
abstract = {Simulation driven product development is state of the art to insure that the desired characteristics in use behave as requested without performing a time-consuming testing using expensive prototypes. To achieve the aim of realistic and confidential results within this product simulations, a tremendous afford (i.e. when taking different non-linearities into account, like material behavior, contact situations, large deflections etc.) is necessary. Conflicting to this, the ideal CAD-model is always used for the analysis, despite knowing the effect, that every manufactured component shows differences to its ideal geometry. Within this
paper an approach of a knowledge-based process to integrate real geometry data into product simulations is given. Furthermore, different methods for preparation of the simulation models are represented.},
author = {Katona, Sebastian and Koch, Michael and Wartzack, Sandro},
booktitle = {Proceedings of the 14th International Design Conference DESIGN 2016},
date = {2016-05-16/2016-05-19},
editor = {Marjanovic D, Storga M, Pavkovic N, Bojcetic N, Skec S},
faupublication = {yes},
keywords = {CAx, computer aided design (CAD), product development, structural analysis, knowledge based engineering},
pages = {689-696},
peerreviewed = {Yes},
title = {{Integrating} real geometry models into product simulations: an approach of knowledge-based process},
venue = {Cavtat, Dubrovnik},
year = {2016}
}
@inproceedings{faucris.107182064,
abstract = {An efficient use of Finite Element Analyses requires an early application in the product development process. Furthermore, extensive specialist knowledge is a crucial prerequisite to perform reliable and meaningful simulations. However, due to the strongly expanding field of application, Finite Element Analyses are increasingly performed by less experienced simulation users.
Against this background, the objective of the Bavarian Research Association FORPRO² is to enhance virtual product and process development through strategically planned and operationally supported simulations. For this purpose the required expert knowledge is compiled in a structured and suitable manner and provided targeted through a central knowledge base.
ANSYS Engineering Knowledge Manager (EKM) offers high potential to handle and context-sensitively apply the wide range of necessary simulation knowledge in versatile fields of application. This knowledge ranges from modeling rules for recurring components in product and process simulations depending on the development stages and tasks through to analytical equations for checking the plausibility of simulation results. In this presentation a concept for the implementation of a context-sentive knowledge-base in EKM for simulation knowledge will be presented.},
author = {Kestel, Philipp and Sprügel, Tobias and Katona, Sebastian and Wartzack, Sandro},
booktitle = {ANSYS Conference & 33th CADFEM Users' Meeting},
faupublication = {yes},
note = {UnivIS-Import:2015-10-26:Pub.2015.tech.FT.FT-KLMEFK.konzep},
pages = {-},
peerreviewed = {unknown},
title = {{Konzept} zur {Umsetzung} einer zentralen {Wissensbasis} für {Simulationswissen} in {ANSYS} {Engineering} {Knowledge} {Manager}},
url = {https://www.mfk.uni-erlangen.de?file=pubmfk{\_}56386f94e7d59},
venue = {Bremen},
year = {2015}
}
@inproceedings{faucris.119730864,
author = {Katona, Sebastian and Koch, Michael and Wartzack, Sandro},
booktitle = {16. Bayreuther 3D-Konstrukteurstag},
date = {2014-09-17/2014-09-17},
editor = {Rieg F, Hackenschmidt R},
faupublication = {yes},
isbn = {978-3-00-046550-5},
keywords = {Reverse Engineering},
peerreviewed = {No},
title = {{Reverse} {Engineering} - {Prozess}, {Technologien} und {Anwendungsfälle}},
venue = {Bayreuth},
year = {2014}
}
@article{faucris.121260744,
abstract = {Within today’s product development process, various FE-simulations (finite element) for the functional validation of the desired characteristics are made to avoid expensive testing with real components. Those simulations are performed with great effort for discretization, use of simulations conditions, like taking different non-linearities (i.e., material behavior, etc.) into account, to create meaningful results. Despite knowing the effects of deformations occurring during the production processes, always the non-deformed design model of a CAD-system (computer aided design) is used for the FE-simulations. It seems rather doubtful that further refinement of simulation methods makes sense, if the real manufactured geometry of the component is not considered for in the simulation. For an efficient exploit of the potential of simulation methods, an approach has been developed which offers a geometry model for simulation based on the existing CAD-model but with integrated production deviations as soon as a first prototype is at hand by adapting the FE-mesh to the real, 3D surface detected geometry.},
author = {Katona, Sebastian and Sprügel, Tobias and Koch, Michael and Wartzack, Sandro},
doi = {10.17265/2159-5275/2015.07.001},
faupublication = {yes},
journal = {Journal of Mechanics Engineering and Automation},
keywords = {FEA (finite element analysis), preprocessing, simulation, 3D surface detection, RE (reverse engineering)},
pages = {387-394},
peerreviewed = {Yes},
title = {{Structural} {Mechanics} {Analysis} {Using} an {FE}-{Mesh} {Adaption} to {Real}, {3D} {Surface} {Detected} {Geometry} {Data}},
volume = {5},
year = {2015}
}
@inproceedings{faucris.110984324,
abstract = {The structural optimization as a tool of the virtual product development process (PDP) provides broad possibilities to scoop leightweight design and improvement potentialities when developing new products. To promote the further dissemination of structural optimization, the focus of the developments lies on a process-ready structural optimization, which does not only aim at design, safeguarding and later alteration through process restrictions , but at a straightforward generation of a process- and production-ready part by using computer-aided optimization tools. This efficient approach in product development helps to reduce iterations in the PDP, but also brings along the need for a validation of the newly created procedure because manufacturing processes like forming often cause deviations in the physical part which were not regarded in the dimensioning of the desired part. Hence the established simulation of the desired component design (based on 3D CAD data) should be supplemented with a simulation of the physical part geometry (based on the 3D scan of a prototype). The overvalue of the current development is a efficiency increase of the product development process through a reduction of iteration loops and effective generation of process-, production- and utilization-ready part designs with the aid of structural optimization tools and a knowledge database, illustrated exemplarily by the forming process. The finite element (FE) analysis of the desired geometry is joined by a validation of the adapted product development process by geometry analysis and FE-simulation of the physical geometry provided by a 3D scanner. Consequently, the deviations made by the manufacturing process can be analyzed for their relevance for the part's performance and the design can be safeguarded.},
address = {Hamburg},
author = {Hautsch, Stefan and Katona, Sebastian and Sprügel, Tobias and Koch, Michael and Rieg, Frank and Wartzack, Sandro},
booktitle = {Design for X. Beiträge zum 26. DfX-Symposium},
date = {2015-10-07/2015-10-08},
editor = {Krause, D.; Paetzold, K.; Wartzack, S.},
faupublication = {yes},
isbn = {978-3-941492-93-6},
keywords = {validation; finite element analysis; structural optimization; 3D scan},
pages = {182-192},
peerreviewed = {Yes},
publisher = {TuTech Verlag},
title = {{Validierung} von prozessgerecht strukturoptimierten {Bauteilentwürfen} mittels integrierter {FEM}-{Realgeometrieanalyse}},
url = {https://www.mfk.uni-erlangen.de?file=pubmfk{\_}56385b1b58ac1},
venue = {Herrsching},
year = {2015}
}
@inproceedings{faucris.111029864,
address = {Dresden},
author = {Katona, Sebastian and Kestel, Philipp and Koch, Michael and Wartzack, Sandro},
booktitle = {Entwerfen Entwickeln Erleben – Beiträge zu virtuellen Produktentwicklung und Konstruktionstechnik},
editor = {Stelzer, R.},
faupublication = {yes},
peerreviewed = {Yes},
publisher = {TUDPress},
title = {{Vom} {Ideal}- zum {Realmodell}: {Bauteile} mit {Fertigungsabweichungen} durch automatische {FE}-{Netzadaption} simulieren},
url = {https://www.mfk.uni-erlangen.de?file=pubmfk{\_}56386fd1e4a10},
venue = {Dresden},
year = {2014}
}