FE Stress Transfer Iterative Equilibrium for Shape Accuracy
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Solution Overview
Problem
Conventional methods for transferring stress states in finite element simulations lead to undesired shape alterations due to incompatible meshes and differing mesh densities, element types, and material models, causing inaccuracies in simulation chains for complex 3-D shaped components like motor vehicle parts.
Innovation Solution
A method involving iterative equilibrium calculations in a new FE mesh geometry, where the stress tensor is transferred and adjusted until the shape alteration meets a tolerance criterion, ensuring that stress components causing undesired effects are minimized, thereby maintaining stress equivalence across the simulation chain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stress state is transferred from one FE mesh to another incompatible FE mesh, then simulation chain can proceed with different modelings, but undesired shape alterations occur
Solution Approach 1:
The patent implements an iterative feedback mechanism where the transferred stress state is applied to the new FE mesh, shape alterations are detected, and the stress state is corrected based on the detected alterations. This closed-loop feedback process continues until shape accuracy requirements are met, enabling stress transfer between incompatible meshes while maintaining precision.
Solution Approach 2:
The patent modifies the stress state parameters iteratively by detecting shape alterations and adjusting the stress components accordingly. The stress tensor components are changed in response to detected shape deviations, transforming the stress state parameters to compensate for mesh incompatibility effects and maintain shape accuracy.
2Manufacturing precision
If iterative equilibrium calculations are performed to correct shape alterations, then shape accuracy is maintained, but computational time increases
Solution Approach 1:
The patent applies partial correction by focusing iterative calculations only on the stress components that cause shape alterations, rather than recalculating the entire stress state. This selective partial action maintains shape accuracy while reducing the computational burden compared to full iterative recalibration.
3Manufacturing precision
If stress components causing undesired effects are decreased through iteration, then shape fidelity is improved, but stress transfer complexity increases
Solution Approach 1:
The patent extracts and isolates only the problematic stress components that cause undesired shape alterations, rather than dealing with the complete stress tensor. By identifying and separately correcting only the offending stress components through the detection-correction loop, the method simplifies the overall transfer process while maintaining accuracy.
Data Source
AI summary
The invention relates to a method for transferring a stress state of an FE simulation result to a new FE mesh geometry of a simulated construction system, such as a component for motor vehicles that has a 3-D shape, in a simulation chain of production operations, comprising: a) providing a first data set, which describes the FE simulation result with a stress state of the FE simulation of the construction system or component of a first production operation, b) creating the new FE mesh geometry of the simulated construction system or component, which new FE mesh geometry is associated with a second production operation, c) transferring the stress state of the provided first data set to the new FE mesh geometry of the construction system or component, d) performing an equilibrium calculation by using the stress tensor in the FE mesh geometry, wherein deformation of the construction system or component results, which deformation differs from the deformation in the FE mesh by a shape alteration u>tolerance value ε, e) iteratively repeating the equilibrium calculation as a cyclic equilibrium iteration in the new FE mesh geometry (in the new target FE mesh) of the construction system or component, wherein, in each cycle, a new stress state is applied to the FE mesh geometry of the construction system or component and stress components that lead to undesired shape alterations are decreased until a displacement/termination criterion of shape alteration u<tolerance value ε is achieved, and f) displaying the fulfilled condition of u<ε.