FEA Comparison in ARAMIS and ARGUS

Optical Metrology 2009
FEA Comparison in
ARAMIS and ARGUS
Harald Friebe
May 25th 2009

Introduction
Former Workflow
— FEA computation and measurement
are different in:
—Coordinate Systems
—Result presentation
— Colored Images
— Section Plots
— FLDs
Forming process
Page 2 FEA Comparison in ARAMIS and ARGUS
Harald Friebe
2-Frame 2-Frame Setup / Frame 1 Setup / Frame 2
— Example: Forming of Suspension Arm
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:
— Colored Images
— Section Plots
— FLDs
— For a visual comparison of full field data
—Same visualizations must be chosen
—Same legends must be used
Harald Friebe
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
Harald Friebe
Section definition (LS-DYNA)
Section definition (ARGUS)

Introduction
Former Workflow
are different in:
— Colored Images
— Section Plots
— FLDs
—Same diagrams must be defined
Harald Friebe
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
Harald Friebe
FEA-Data-Export ARGUS-Data-Export

Introduction
Former Workflow
— Summary
—No automatism
— Time consuming
—Only comparison of
— Local areas (Sections and images)
— Rough values (color images)
Harald Friebe

Introduction
FEA Comparison Module in ARAMIS/ARGUS
— 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, …)
Simulation
Measurement
Harald Friebe
Major true strain deviation

Workflow
Import
— 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
Consider: measurement results are
surface 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)
Harald Friebe

Workflow
Alignment
— For comparison Measurement and FEA must have the same coordinate system
— Transformation
Measurement coordinate system FEA coordinate system
Harald Friebe
Without alignment
by
—Manual Transformation Functions
— 321-Transformation
— Translation, Rotation
—Best fit alignment
— Pre-orientation
— Best fit by selected areas
After pre-orientation
After best fit by complete surface

Workflow
Geometry deviation
— Calculation of distances between Measurement surface and FEA surface
—Quality control of alignment
Good alignment
— Quality control of simulation boundary conditions like
—Depth of drawing
—Shape of Die
— Quality control of simulation results
—Geometry
—Spring back
—Wrinkling
Harald Friebe
Small Surface deviation

Workflow
Mapping
— 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
Harald Friebe
Measurement: red points
FEA: gird

Workflow
Deviation calculation
— Calculation of deviations for all points, e.g.:
Major Strain deviation = Major (measurement point) – Major (mapped point)
Measurement
Mapped Simulation
Harald Friebe
Major strain deviation

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
Harald Friebe

Application Example
Suspension Arm
— Optimization of FEA
—Adjustment of
clamping simulation
(blank holder movement)
Harald Friebe
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 with spring-back in FEA
Harald Friebe
Surface deviation without 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
Harald Friebe

Application Example
Trunk Lid
Major true strain FEA
Harald Friebe

Application Example
Trunk Lid
Major true strain deviation
Harald Friebe

Application Example
Trunk Lid
— Local details
Major true strain measurement Major true strain FEA Major true strain deviation
Simulation mesh
Harald Friebe
Boundary FEA
Boundary measurement

Application Example
Trunk Lid
— Local wrinkles
Surface measurement Surface FEA
Harald Friebe
Simulation mesh Surface deviation

Application Example
Trunk Lid
— Local detail: Missing seam in FEA
Simulation mesh
Surface measurement
Surface FEA
Seam
No Seam
Major true strain measurement Major true strain FEA Major true strain deviation
Harald Friebe

Summary
— 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)
Harald Friebe

Thank you for your
attention
info@gom.com
www.gom.com

FEA Comparison in ARAMIS and ARGUS

More Related Content

FEA Comparison in ARAMIS and ARGUS