May 2012 / deskeng.

com

Optimize Designs
for Analysis P. 42

COMSOL Review P. 30

SPECIA
SECTIONL:
Test
Measureamndent
TECHNOLOGY FOR DESIGN ENGINEERING

Composites
Take Off
Simulation helps
engineers reach
new heights. P. 26

TESTING HEV POWERTRAINS P. 16

RE-USING CAD MODELS P. 37
PRINT & SCAN VIA THE CLOUD P. 40

de0512_Cover_NoAddressLabel.indd 1 4/16/12 4:07 PM

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 Degrees of Freedom by Steve Robbins

Uncompromising
Composites
I
have owned the same fiberglass sailboat, a Southern Cross build stealth contour surfaces
31, for more than 25 years. It was built in 1983 out of and in consumer aircraft to
glass fiber and polyester resin with an Airex foam core. add strength. The new Boeing 787, for example, is made of ap-
The challenge of building with composites, even 30 years proximately 60% composite materials.
ago, was to build the boat to be as light as possible without The uses of these materials in current designs has been fa-
comprising its structural integrity. Without the simulation and cilitated by the increased availability of the right materials for
mechanical testing tools we have today, my sailboat, designed the right jobs, and a decreased overall cost of the materials.
to be used for offshore cruising, was overbuilt for toughness But the key factor to using composites is being able to test the
and stability. It weighs a lot. designs in a cost effective and accurate manner.
You really don’t want your sailboat hull oil canning 300
miles offshore in the middle of the Atlantic Ocean in 12-ft. Simulate and Test
seas. But weight doesn’t matter in a boat like it does in an Being able to simulate the lifecycle of a design using composite
aircraft or even a car. Whether in an automobile, spacecraft, material will save companies time and money, and they will be
able to build better products. Although simulation is getting a
lot of attention, mechanical testing will not diminish in this area.
Composites will continue to Have you noticed how composite test equipment looks a lot like
torture machines from the Inquisition? That’s because they are
make their mark in designs that designed to torture composite materials until they break!
will change the way we live. Composite simulation and mechanical testing has come a
long way from the day my sailboat was launched. In 1983, boat
builders didn’t know the durability and strength of the mate-
or the cellphone in your pocket, composite materials need to rials they were using. Polyester resin was relatively new and
perform to the specified requirements of particular products. vacuum bagging the laminate was almost unheard of, so they
Fatigue, puncture, delamination, and tensile strength are key just added a few more inches of material to stress areas, like
factors in using the right composite. compression posts and hull-to-deck joints. The foam core in
my boat added tremendous strength. It was cutting edge. Most
A Lighter, Stronger Future builders were using solid fiberglass layups.
Today, there are many tools to help design composite parts But today, using the appropriate software and test equip-
and structures. They fall into two areas: simulation tools used ment, designers can build aerodynamic, lightweight vessels,
during the design phase and mechanical testing tools that are vehicles and aircraft — from composite tractor-trailer trucks
used during the prototyping phase. Composite simulation has that will double their mileage to larger planes that use less
become a hot topic in the design engineering world as more fuel. I haven’t flown in a 787 yet, but when I do, I will look out
engineers are using it to great advantage. Composite materials the window at the composite wing and remember the night
are a great, lightweight way to improve stiffness and strength. I spent offshore sailing from Bimini to Lake Worth, FL, in
In recent issues of DE, we have covered applications where 25-knot winds from the northeast, directly opposite the di-
lightweight structures are very important. In aerospace and auto- rection of the Gulf Stream. Crashing into 12-ft. waves, I was
motive, for instance, fuel efficiencies improve greatly as weight is comforted by the strength of Ananda’s hull, and I will marvel
jettisoned. As materials and manufacturing processes continue to at the engineering accomplishments made possible with the
improve, composites will continue to make their mark in designs composites we now experience in our lives. DE
that will change the way we live. In the future, one of the greatest
advantages to using composites, aside from its inherent strength Steve Robbins is the CEO of Level 5 Communications and
and reduced weight, is the ability to easily manufacture them into executive editor of DE. Send comments about this subject to
complex shapes. This ability has been used in military aircraft to [email protected].

2 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_DOF.indd 2 4/15/12 10:12 AM

NationalInstruments.indd 1 4/15/12 10:10 AM
 March 2011 May 2012 VOLUME 16/ISSUE 7
VOLUME 17/ISSUE 9

SIMULATE
28 Simulating Composites
From helicopter design to fiber placement to
hole-drilling, software tools play a critical role
for optimum composite use.
By Pamela J. waterman

30 Quantum Leap
COMSOL Version 4.2a expands its multiphysics offering.
By Vince Adams

32 Direct Modelers as FEA Pre-Processors, Part 2

Direct modeling and CAD-integrated FEA propels design optimization.
By Kenneth Wong

42 Opting for Optimization, Part 1

Find out how this powerful concept can rev up your analysis tools.
By Pamela J. Waterman

PROTOTYPE
34 Comparing Additive and Subtractive Processes
Cost, volume, geometry and tolerancing are differentiators in what
technology to choose for mold making.
By Susan Smith

COVER STORY DESIGN

37 Designs Live On and On
Composites Blast Off From collaboration and rendering to technical manuals, your design
can live on through neutral file formats.
By Kenneth Wong

26
Mark Clarkson reports on the
simulation software technologies ENGINEERING COMPUTING
that have allowed composite
materials to advance in 40 Print & Scan via the Cloud
aerospace design. Understanding Manufacturers respond to an increasingly mobile engineering workforce.
composites’ many failure modes By Jamie J. Gooch
requires modern, accurate
analytical tools. Previously,
FOCUS: TEST & MEASUREMENT
manufacturers’ only option was 16 Developing a Powertrain Test Bench
to invest in expensive physical Dynacar combines digital and physical simulation to model pow-
testing. Now testing is being used ertrains for hybrid electric vehicles.
By Adrian Martín
to confirm simulations.
18 Moving into Intelligent Engineering
The Center for Advanced Engineering Environments assists researchers,
industry and government partners with product creation and testing.
By Debbie Sniderman
ON THE COVER: SpaceX’s Dragon spacecraft launches atop
a Falcon 9 rocket. Image courtesy of Space Exploration
Technologies Corp./Chris Thompson.
22 Data Logger Product Roundup
Check out some of the latest tools for logging engineering data.

4 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_TOC.indd 4 4/16/12 11:38 AM

 SECURITY: RFIDs are used in a multitude of applications such
as tracking or identifying consumer products and their
packaging. The reader antenna generates an electromagnetic
field that energizes a chip (IC-circuit) inside the tag.

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©2012 COMSOL. COMSOL, COMSOL Multiphysics and LiveLink are either registered trademarks or trademarks of COMSOL AB. AutoCAD and Inventor are registered trademarks of Autodesk, Inc., in the USA and other countries. LiveLink for AutoCAD and LiveLink for Inventor
are not affiliated with, endorsed by, sponsored by, or supported by Autodesk, Inc., and/or its affiliates and/or subsidiaries. MATLAB is a registered trademark of The Mathworks, Inc. Pro/ENGINEER and Creo are trademarks or registered trademarks of Parametric Technology Corporation
or its subsidiaries in the U.S. and in other countries. SolidWorks is a registered trademark of Dassault Systèmes SolidWorks Corp. CATIA is a registered trademark of Dassault Systémes. SpaceClaim is a registered trademark of SpaceClaim Corporation.

Comsol.indd 1 4/15/12 10:08 AM

 May 2012 VOLUME 17/ISSUE 9

DEPARTMENTS 45 Spotlight
Directing your search to the companies
that have what you need.
2 Degrees of Freedom EDITORIAL
Uncompromising composites. 46 Editor’s Picks Steve Robbins | Executive Editor
Jamie J. Gooch | Managing Editor
By Steve Robbins Products that have grabbed the Kenneth Wong | Senior Editor
editors’ attention. Anthony J. Lockwood | Editor at Large
7 Engineering on the Edge By Anthony J. Lockwood
Heather Pittinger | Copy Editor

IBM’s Optochip, Intel’s connected cars, CONTRIBUTING EDITORS

Brian Albright, Mark Clarkson, David S. Cohn, Barbara
robotic bees, a space elevator and a 47 Fast Apps Goode, Mike Hudspeth, John Newman, Susan Smith,
superadhesive. Engineering case studies. Peter Varhol, Pamela J. Waterman

10 Kenneth Wong's 47 Advertising Index

PUBLISHER
Thomas Conlon
Virtual Desktop ADVERTISING SALES
Autodesk PLM 360 goes live, an HTC 2012 48 Cool Tool 603-563-1631 • Fax 603-563-8192
preview, Intel unveils the Xeon E5-2600, BOXX Technologies’ renderPRO. Erich Herbert | Sales Executive (x263)
and a wrap up of SmartGeometry 2012. Jeanne DuVal | Account Manager (x274)

ART & PRODUCTION

14 Rapid Ready Tech Darlene Sweeney | Director (x257)
Stylish prosthetics, 3D printing in GE’s
A LEVEL 5 COMMUNICATIONS PUBLICATION
Garage, nanometer layers, Shapeways and Steve Robbins | Chief Executive Officer
Materialise plan to expand, and more. Thomas Conlon | President

ADVERTISING, BUSINESS, & EDITORIAL OFFICES

15 What’s New Desktop Engineering ® magazine
Level 5 Communications, Inc.
Improve efficiency and reduce costs with 1283D Main St., PO Box 1039 • Dublin, NH 03444
process simulation. 603-563-1631 • Fax 603-563-8192
E-mail: [email protected]
By Jim Romeo www.deskeng.com

SUBSCRIBER CUSTOMER SERVICE

deskeng.com
Desktop Engineering ® magazine
PO Box 677 • Northbrook, IL 60065-0677
847-559-7581 • Fax 847-564-9453
E-mail: [email protected]

NEW
RAPID READY TECH BLOG Desktop Engineering® (ISSN 1085-0422) is published
Read all about making digital designs physical monthly by Level 5 Communications, Inc., 1283D Main
Street, P.O. Box 1039, Dublin, NH 03444, 603-563-1631.
@ rapidreadytech.com. Periodicals postage paid at Dublin, NH, and at additional
mailing offices. Desktop Engineering® is distributed free
ENGINEERING ON THE EDGE BLOG to qualified U.S. subscribers.
See the future of engineering technology @ engineeringontheedge.com. SUBSCRIPTION RATES: for non-qualified; U.S. $108
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countries $195 one year.
VIRTUAL DESKTOP BLOG LIST RENTALS: For information on list rentals, contact
Read Kenneth Wong @ deskeng.com/virtual_desktop for Statlistics, Danbury, CT: 203-778-8700.
a closer look at lifecycle components via articles, podcasts and video reports. POSTMASTER: Send all address changes to Desktop
Engineering, P.O. Box 677, Northbrook, IL 60065-0677.
NEWSLETTER REGISTRATION Address all editorial correspondence to the Editor, Desktop
Newslink; Editor’s Pick of the Week; Check It Out; Virtual Desktop; Focus on Engineering. Opinions expressed by the authors are not
necessarily those of Desktop Engineering. Unaccepted
Analysis and Simulation; Focus on Engineering IT & Computing; Focus manuscripts will be returned if accompanied by a
on MCAD; and Focus on Rapid Technologies. self-addressed envelope with sufficient first-class postage.
Not responsible for lost manuscripts or photos.

DE MOBILE BETA Each separate contribution to this issue, and the

issue as a collective work, is copyright © 2012 Level 5
Check out our mobile app for Android and iOS by visiting Communications, Inc. All rights reserved. Copying for
wbxapp.com/de-mobile on your mobile device, or scan the other than personal or internal reference use without the
QR code to the right. permission of Level 5 Communications, Inc. is prohibited.
Requests for permission should be addressed in writing
to Desktop Engineering Permissions, 1283D Main Street,
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de0512_TOC.indd 6 4/16/12 11:45 AM

 Future Focus Engineering on the Edge
IBM’s Holey The product development center in
Karlsruhe, Germany, will concentrate on
process is called the Monolithic Bee
(Mobee), and includes a carbon-fiber
Optochip creating products and technologies for airframe and titanium wings. Designers
Breaks infotainment and telematics. The facility
includes a secured car park, wireless and
had to hand-draw CAD files for each of
the 18 layers cut during laser milling.
the Terabit GPS development and testing facilities, MORE ➜ engineeringontheedge.
and what the company describes as
Barrier a “world-class engineering computer
com/?p=1288
IBM Labs’ Holey Optochip is a parallel infrastructure.”
optical transceiver that has managed to
MORE ➜ engineeringontheedge. Carbon Nanotubes Could
break 1 terabit (1 trillion bits) per second.
For some perspective, that would allow
com/?p=1325 Make Space Elevator
users to download 500 HD movies in a Potential space tourists may be able to
second, or the entirety of the Library of Making ditch their tickets for one of the various
spacecraft now under development, and
Congress in about an hour.
Scientists have been working on a Pop-up instead simply queue up for a ride on a
way to create photonic chipsets that Robotic space elevator. Tokyo-based engineering
firm Obayashi Corp. has proposed building
allow for low-cost, mass production. IBM
researchers created the Holey Optochip Bees just such a massive elevator for space
by manufacturing a silicon CMOS chip The Harvard Microrobotics Lab has come travel, with a potential launch date of 2050.
with 48 holes in it, to allow light to reach up with a manufacturing process that A 60,000-mile-long cable would be
the back of the chip. The result allows 24 uses CAD models and laser milling to anchored to the ground here on Earth;
receiver and 24 transmitter channels to economically produce small-scale flying the other end would be a counterweight.
operate on a compact frame. robots, and that could enable industrial- The elevator (capable of carrying 30
The prototype proves that a shift in scale microbot production. passengers) would ascend at 125
high-speed communications is possible Sheets of carbon fiber, titanium, mph, taking about a week to reach the
in the near future. Photonic chips could plastic and other materials are laser-cut terminal station approximately 22,400
allow companies to leverage the power of and sandwiched together to create tiny miles up in geosynchronous orbit.
cloud computing at speeds fast enough to robots. The robots are then pressed into Key to the project would be carbon
make working with remote collaborators a 3D shape using pop-up folding and nanotubes—stronger and lighter than steel—
as easy as sending an e-mail. locking in a process the researchers have that could be used to build the cabling.
MORE ➜ engineeringontheedge. compared to origami or a pop-up book. MORE ➜ engineeringontheedge.
The initial microbot created via the com/?p=1269
com/?p=1368

Intel Invests in Gecko Feet Inspire Superadhesive

‘Connected Cars’
The world’s largest chipmaker wants to
G eckos are good at two things: selling insurance, and
using their tiny feet to apply enough adhesive force to
carry nearly 18 times their own body weight up a wall. What
help bring the Internet to your car. Intel could design engineers do with a dry adhesive device that
is investing $100 million into connected could hold that much weight, and be easily removed without
car technology via its new Intel Capital leaving any residue? Some polymer scientists and biologists
Connected Car Investment Fund, which at the University of Massachusetts Amherst wanted to know,
will help bankroll development of and have come up with their own adhesive, called Geckskin,
technologies like in-vehicle infotainment that mimics the lizard’s fancy footwork.
systems, mobile connectivity systems and The UMass Amherst group created an adhesive with a soft pad woven into a stiff
advanced driver assistance systems. fabric. Geckskin, which comes in an index-card-sized sheet, can hold up to 700 lbs. on
Intel also announced it would create a a smooth wall (like the TV in the picture above). Using the same types of high-capacity
new Automotive Innovation and Product reversibility and dry adhesion as gecko feet, it can easily attach and detach heavy objects
Development Center, expand the Intel on flat or slanted surfaces—even glass. The Geckskin can be released with little effort and
Labs Interaction and Experience Research re-used, and leaves no residue.
(IXR) division’s focus on automotive, and MORE ➜ engineeringontheedge.com/?p=1217
create an academic outreach program.

➜ For daily coverage on the future of engineering technology, visit EngineeringOnTheEdge.com

deskeng.com /// May 2012 DESKTOP ENGINEERING 7

de0512_Edge_Albright.indd 7 4/15/12 10:36 AM

 Mega-Performance Designed
to Meet Your Demands.

Groundbreaking technologies built into the latest Intel® Xeon® processor-based

workstations unleash mega-performance capabilities so you can take full
advantage of your most intensive design applications.

• High bandwidth and low latency accelerates data availability to the

processing cores.

• I/O traffic streams 30% faster, saving power and reducing latency.1

• Core frequencies respond faster during peak workloads.2

1
Intel measurements of average time for an I/O device read to local system memory under idle conditions. Improvement compares Intel® Xeon® processor E5-2600 product family (230 ns) vs. Intel® Xeon® processor
5500 series (340 ns). Baseline Configuration: Green City system with two Intel® Xeon processor E5520 (2.26GHz, 4C), 12GB memory @ 1333, C-States Disabled, Turbo Disabled, SMT Disabled, Rubicon* PCIe* 2.0
x8. New Configuration: Meridian system with two Intel Xeon processor E5-2665 (C0 stepping, 2.4GHz, 8C), 32GB memory @1600 MHz, C-States Enabled, Turbo Enabled. The measurements were taken with
a LeCroy* PCIe* protocol analyzer using Intel internal Rubicon (PCIe* 2.0) and Florin (PCIe* 3.0) test cards running under Windows* 2008 R2 w/SP1.
2
Requires a system with Intel® Turbo Boost Technology capability. Intel Turbo Boost Technology 2.0 is the next generation of Turbo Boost Technology and is only available on select Intel® processors. Consult your PC
manufacturer. Performance varies depending on hardware, software, and system configuration. For more information, visit http://www.intel.com/go/turbo.

Intel_Spread_pg1.indd 1 4/15/12 10:08 AM

 Match Your Professional Demands To
The Perfect Workstation Configuration
What Workstation Use of
2D or 3D Basic or Advanced Frequent
Best Meets My Basic 3D Advanced
HQ Rendering
(Ray/Raster)
Design Needs? CAD 3D CAD
and Simulation

2D Basic Occasional

Which Intel® Xeon® Processor Intel® Xeon® Processor Two (2) Intel® Xeon®
Processor? E3-1200 Family E5-1600 Family Processors E5-2600 Family

How Much MODEL SIZE: Medium MODEL SIZE: Large MODEL SIZE:
Memory? SMALL (100s of MEDIUM (1,000s of LARGE (10s of 1,000s
components) to components) to of components) to
Data rates to/from CPUs MEDIUM (1,000s LARGE (10s of 1,000s X-LARGE (<100s of
increase as either faster of components) of components) 1,000s of components)
memories are used or
more memory channels
are available.
SMALL MEDIUM LARGE X-LARGE
6-8 GB of Memory 8-12 GB of Memory 12-24 GB of Memory <24 GB of Memory

Which Graphics Advanced Advanced And Ultra Extremely

Basic 2D and
Device? 3D or Advanced Lighting Lighting and Large Models
Extremely Large
Lighting
Data Models

Basic 2D and 3D Advanced

Model and Lighting Lighting

NVIDIA Quadro* NVIDIA Quadro*

(Only available on Intel® Intel® HD
2000/AMD FireGL* 4000/AMD FireGL*
Xeon® Processor 12x5 family) Graphics P4000
V5600 or Above V7600 or Above

Which Storage Opening and Opening Consider Using an SSD

Device? Closing Many and Closing to Increase Data Access
Applications Multiple Large and User Productivity
per Day Data Sets

No No
Purchase Hard
Disk Drive

Today nothing is holding you back from creating your most amazing ideas.
intel.com/go/workstation

Copyright © 2012 Intel Corporation. All rights reserved. Intel, the Intel logo, Xeon, and Xeon inside
are trademarks of Intel Corporation in the U.S. and other countries. Printed in USA.

Intel_Spread_pg2.indd 1 4/15/12 10:09 AM

 Virtual Desktop by Kenneth Wong

Autodesk PLM 360 Goes Live

A
utodeskPLM360.com is live
The site is not a just a product
homepage to tell you how
to get the compamy’s new
product lifecycle management (PLM)
software; the site is the software.
Coming to the market nearly a decade
behind, Autodesk is undeniably a Johnny-
come-lately. But its offering, delivered
in the software-as-a-service (SaaS) style,
has one serious advantage over those
from its rivals: For the first three users,
Autodesk PLM 360 is completely free.
You may add additional users at $25 to
$75 per user per month, through annual
Autodesk PLM 360 launched with more than 140 apps, each designed to
subscription agreements. This is PLM at
address a business operation. Where appropriate, the web-based interface
Walmart pricing—something few others
offers viewing and markup (based on Autodesk Design Review) tools.
would or could attempt.
Introducing the product in a web-
cast, Brenda Discher, Autodesk’s vice • design review; tions, Oracle and PTC. But the variety
president of marketing, emphasized • bill of materials; and more. and comprehensiveness of apps avail-
that Autodesk PLM 360 is “insanely As with other SaaS solutions, Au- able through Autodesk makes Autodesk
configurable.” She added, “We think todesk PLM 360 is expected to be always PLM 360 a serious contender in the SaaS
our pricing underscores our belief that on, accessible from “anywhere, from PLM segment. Other PLM vendors like
customers and companies of all sizes any device,” according to Steve Bodnar, Dassault Systèmes and Siemens PLM
should have access to PLM.” Autodesk’s vice president of PLM and Software offer some cloud-hosted data-
“The only technical skill you need is product data management (PDM). At management functions and mobile apps,
to use a browser,” quipped Buzz Kross, press time, the Apple App Store offers a but their reliance on the cloud is only
Autodesk’s senior vice president of manu- slew of Autodesk apps, but no app specific partial. Autodesk PLM 360 requires full
facturing. Autodesk PLM 360’s interface to Autodesk PLM 360 is listed yet. commitment to the cloud, which comes
allows you to map out business processes Autodesk continues to offer Au- with benefits as well as risks.
using drag-and-drop schematics, and cus- todesk Vault as a PDM solution, to be Autodesk PLM 360’s aggressive pricing
tomize the type of reports to view. How- installed and maintained on-premise poses a threat to smaller vendors with simi-
ever, those with a knack for programming at client sites, behind firewalls. By lar web-hosted functions. With its cloud-
may incorporate Java scripts. contrast, Autodesk PLM 360 is aimed hosted DWG display technology Auto-
Subscriptions are offered at two at small, medium and large enterprises CAD WS in the background, Autodesk
levels: Participant ($25 per month) and looking for a PLM system with low PLM 360 offers browser-based viewing
Professional ($75 per month). Partici- overhead and low cost. and markup that few others can rival.
pants have only limited workflow access “Customers do not need Vault to “Autodesk PLM 360 is 1/20th of the
and communication functions. Profes- work with PLM 360,” clarified Bodnar. costs of the traditional PLM systems.
sional subscription gives you full access. “More than half of our beta customers The cost benefits users get is pretty
At launch time, subscribers can access do not use Vault.” phenomenal,” hailed Kross at a recent
about 140 apps to accomplish different According to Kross, some of the media summit in San Francisco.
tasks. The initial lineup includes apps for: beta testers are small firms with em- Autodesk CEO Carl Bass once
• program and project management; ployee numbers in single digits. mocked PLM as “a solution in search
• requirements management; of a problem.” Now, Autodesk has of-
• task management; Market Impact ficially unleashed a PLM solution that
• costing; Cloud-hosted PLM is also available from could become a problem for many of
• change order; several vendors, including Arena Solu- its competitors.

10 DESKTOP ENGINEERING May 2012 /// deskeng.com

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 Altair Gets Ready for HTC 2012
An astronaut, a designer and an analyst walk into a hotel ...

I
t’s not a joke. It’s a scenario that that focuses on using high-performance nan, taking note of the focus of Altair
will come to pass in the Marriott computing (HPC) to solve engineer- and HTC. “There’s a lot of players,
at the Renaissance Center in De- ing and simulation problems. Since its a lot of change as well. Technology is
troit. That’s the site of Altair En- launch five years ago, the conference has changing rapidly. People are taking
gineering’s HyperWorks Technology grown to include events in Japan, India, up the technology … Last year, we
Conference (HTC) 2012, scheduled China and Europe, among other loca- showed our conceptual design product
for May 15-17. The astronaut is T.K. tions. Most of them are free to attend [Solidthinking] on stage, and how it
Mattingly, the retired astronaut who (attendees have to cover their travel and integrates with simulation tools.”
once flew on the Apollo 16, STS-4 and accommodation expenses). The conference is expected to de-
STS-51-C missions. The designer is Altair landed an astronaut as a liver sessions on computational fluid
Luca Pignacca, chief designer at Dal- speaker this year because of the work the dynamics, scripting, optimization,
lara Automobili. The analyst is Marc company has been doing with NASA to crash-worthiness analysis, advanced
Halpern, vice president of research, develop a crew-landing module, explains mid-surface processing, noise, vibration
Gartner. They’re all keynote speakers Altair’s chief marketing officer, Jeff Bren- and harshness, vehicle durability test-
who have signed on to appear at HTC nan. (Editor’s note: For more on aerospace ing, and composites materials. Hands-
2012. They will join Altair’s Chairman design and simulation, see this month’s cover on training will be punctuated with
and CEO Jim Scapa on stage. story on page 26.) networking events. To register, visit
Hosted by the HyperWorks divi- “The computer-aided engineering AltairHTC.com/na/HTC12Registra-
sion of Altair, HTC is a series of events industry is very dynamic,” says Bren- tionForm.aspx.

Engineering Success...

Simulation Software for a New Frontier in Engineering Innovation.

Follow us online.
For more information: [email protected]
www.cd-adapco.com/aerospace

deskeng.com /// May 2012 DESKTOP ENGINEERING 11

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 Virtual Desktop by Kenneth Wong

Intel Xeon E5-2600,

a Better Traffic Cop for the Cloud

I
n early March, as commuters
in the West Coast begrudg-
ingly joined the morning’s
rush hour traffic, Intel un-
veiled what could be the solution
to heavy traffic in the cloud. Diane
Bryant, the newly appointed vice
president and general manager of
Intel’s Datacenter and Connected
Systems Group, took the stage at
San Francisco’s Contemporary Jew-
ish Museum to launch the Intel
Xeon E5-2600 family, described by
Intel as “the heart of a flexible, ef-
ficient data center.”
“The growth in cloud com-
puting and connected devices is
transforming the way businesses
benefit from IT products and ser-
vices,” said Bryant. “For businesses
to capitalize on these innovations, Diane Bryant, vice president and general manager of Intel’s Datacenter and
the industry must address un- Connected Systems Group, ushered in the Xeon E5-2600 family, which is
precedented demand for efficient, designed to tackle cloud traffic.
secure and high-performing data
center infrastructure. The Intel The new processors are ex- dation have led to strong growth
Xeon processor E5-2600 product pected to increase performance in 10 Gigabit Ethernet deploy-
family is designed to address these “by up to 80% compared to the ments, with adapter port ship-
challenges by offering unparalleled, previous-generation Intel Xeon ments exceeding 1 million units
balanced performance across com- processor 5600 series,” according in each quarter of 2011,” Intel
pute, storage and network, while to Intel. The new processors come reports.
reducing operating costs.” with Advanced Vector Extension The integrated controllers in
One of the biggest changes that (AVX) instruction set. Xeon E5 family, according to the
comes with the new processors “These instructions double the company, represent Intel’s “com-
is its input/output (I/O) delivery. number of floating point opera- mitment to driving 10 Gigabit
Xeon E5-2600 uses Intel Ethernet tions per clock,” said Bryant. Ethernet to the mainstream by re-
controllers and adapters to route The increased I/O throughput and ducing implementation costs.”
I/O traffic directly to the processor processing power, Intel theorizes, will Intel plans to offer the E5-2600
cache. This, the company claims, make E5 processors ideal for those with 17 different parts, which
results in “reducing trips to system seeking to deploy cloud computing range in price from $198 to $2,050
memory [and] reducing power con- and virtualization solutions. in quantities of 1,000.
sumption and I/O latency.” Xeon Additionally, three single-
E5-2600 will support PCI-Express 10 Gigabit Going Mainstream socket Intel Xeon processor E5-
3.0, which promises to “triple the “Increasing bandwidth demands 1600 parts will be offered for
movement of data into and out of driven by server virtualization and workstations that range in price
the processor,” according to Intel. data and storage network consoli- from $284 to $1,080.

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 Bentley Wraps Up sg2012

S
martGeometry 2012 (sg2012), fiber-enforced polymer
the annual conference hosted behaviors.
by Bentley Systems, came to a The clusters’ work-
close on March 24, following flow and progress are
a series of workshops and a public sym- guided by leaders. But,
posium in Troy, NY, home of the Rens- as sg veteran Shane Burger (Grimshaw Systems and other technology suppli-
selaer Polytechnic Institute (RPI). Architects, NY) pointed out, “It’s not a stu- ers. The event usually takes place on the
Between March 19 and 23, several dent-teacher relationship; it’s a champion premises of an academic institution.
working groups—known as “clusters” who came up with the idea, and collabora- The strength of sg conferences comes
in sg lingo—set up temporary head- tors who made it happen.” from the participants’ commitment to
quarters inside the RPI’s Experimental Often, sg participants use a mix of pro- produce, usually in time for the Sympo-
Media and Performing Arts Center. gramming, electrical components, para- sium, a scale model or a physical prototype
With a blend of academic research- metric modeling software (such as Bentley representing the solution they are pro-
ers and professionals in each cluster, Systems’ GenerativeComponents and posing. This tradition forces clusters to
they set out to explore the year’s theme Rhino plug-in Grasshopper), handmade collaboratively troubleshoot, use creative
of “Material Intensities: Simulation, prototypes and 3D-printed prototypes methods, and work in a multi-disciplinary
Energy and Environment” by combin- to test their ideas. On the last day of the environment. DE
ing theory, practice and prototypes. event, participants present their experience
The clusters investigated, among to a wider audience at a symposium. Kenneth Wong is DE’s Senior Editor.
other things, bio-responsive building Annual sg conferences are sponsored Read his Virtual Desktop blog at deskeng.
envelopes, acoustic environments and and supported by Bentley Systems, 3D com/virtual_desktop.

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 Rapid Ready Tech Making Digital Designs Physical

GE Garages Offer
3D Printing Brings
Hands-on 3D Printing
Style to Prosthetics
A s part of its GE Works campaign, GE has
rolled out a program it calls GE Garages.
Begun in March in Austin, TX, at South by
Southwest (SXSW), the program allows the
public a chance to interact with MakerBot’s
Replicator 3D printer, a CNC mill, laser cutter, MIG welder, injection molder, cold
saw and an ironworker (all under expert supervision, naturally).
GE hopes to drum up interest in manufacturing by exposing the public to a
number of different high-tech procedures. The GE Garage was designed by Sub
Rosa, and is part of a collaborative effort that involves the community-teaching
marketplace Skillshare, manufacturing developers TechShop, Quirky, Inventables
and Make. A number of the companies involved will also have staff on hand to
discuss manufacturing.
Bespoke Innovations has taken aesthetic The GE Garage moved from Austin to Houston and San Francisco. Later this
philosophy to heart with the creation of summer or early fall, the it will take up permanent residency in Houston and Cincinnati.
what it calls prosthetic fairings. In this MORE ➜ RapidReadyTech.com/?p=787
case, a fairing is a covering for a prosthetic
leg that is designed to emulate the shape
of the human body. University Develops Mcor to Showcase Matrix
Bespoke uses a 3D scanner to capture
the shape of a client’s leg. The company Two-Photon Lithography 300 at RAPID 2012
then uses CAD software to adjust and Vienna University has created a 3D Mcor Technologies is a 3D printer
reverse the image, creating a duplicate printer using what it calls “two-photon manufacturer that uses standard paper as
virtual leg. For bilateral amputees, lithography.” The process is able to build its material of choice.
Bespoke looks for volunteers with similar objects with nanometer-thick layers, using The machine designed by Mcor lays
features as the customer and creates a mirrors to produce a narrow-focus laser down paper one sheet at a time, where
scan to be “donated” to the cause. that builds layers of liquid resin. it’s cut before being attached to the next
Scan complete, the client chooses the Researchers gave the process its sheet by a water-based adhesive. The end
materials used to construct the fairing. name because the resin must be able to result of the process is an object built by
Available materials include leather, ballistic absorb a minimum of two photons in order layers the same way as other 3D printers.
nylon fabric and chrome plating. The to set. This particular process also allows MORE ➜ RapidReadyTech.com/?p=861
company also allows for designs to be layers to be built without having to cure to
included on the fairing, creating patterns topmost layer, which speeds up the build.
Researchers are working on developing
Expanding Operations
or approximating tattoos. All the available Shapeways, a Dutch 3D printing services
options allow a customer to create biocompatible resins for medical
marketplace, has recently expanded
something that goes beyond functional— applications. Potential applications include
operations to Queens, NY. The company
instead, becoming a personal statement. using the process to create scaffolds for
intends to use the new facilities to reduce
Once the design has been finalized, living cells to latch onto.
costs and shipping times for customers.
Bespoke sends the file to 3D Systems MORE ➜ RapidReadyTech.com/?p=811 Among the tech to be deployed at the
to be printed. The result is a fairing that production facility is a ZPrinter 650 full-
weighs an average of 6.6 oz. (depending color 3D printer.
on materials used) and costs between Belgium-based Materialise is opening
$4,000 and $6,000. Bespoke hopes a new additive manufacturing (AM)
to work with prosthetists and insurance Automation and Control System center to
companies to help defray the cost. It is help better manage its flow of products.
also developing whole leg replacements The center will have an interactive
that integrate the art of fairings with a focus and complete integration with the
prosthetic limb into a single whole. company’s Magics AM software.
MORE ➜ RapidReadyTech.com/?p=680 MORE ➜ RapidReadyTech.com/?p=895

➜ For more coverage of rapid technologies, visit RapidReadyTech.com

14 DESKTOP ENGINEERING May 2012 /// deskeng.com

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 SIMUL8 Software What’s New

Improve Efficiency and Reduce

Costs with Process Simulation
BY JIM ROMEO

Engineering design is ordinarily an effort experimenting with some clever main-

Frances Sneddon
that depends on a larger system or pro- tenance rules using SIMUL8. This is
cess. That system or process may be a something they wouldn’t have otherwise
manufacturing line, supply chain or some been able to do without stopping the line, FS: We have a pretty aggressive devel-
flow where variables are many and unde- changing the entire layout of the factory, opment schedule, which means we
termined—and the engineered design of and testing out new schedules over a few release a new version of our main
a product, equipment or complex process months. SIMUL8 gave them the freedom product, SIMUL8, each year. This
depends on what those variables are. to experiment with new layouts, the abil- allows us to incorporate user feed-
This is where simulation software ity to see the impact in years to come, back over the year to improve existing
comes in. When simulation and modeling and the confidence that they would see features and introduce exciting new
are applied to a process or system, risk results in a matter of hours. ideas from our team. The people who
and probability of failure can be known use the product are those who are
and controlled, and a design engineer or DE: Does SIMUL8 develop its closest to it, so input from users and
other process owner can be more expedi- products with a niche industry in our in-house consultants—who deliver
ent in his or her design. mind, or are products developed to serve various external projects—is key to
Based in Glasgow, Scotland, SIMUL8 a functional requirement enhancing the user experience. We
Corp. offers simulation solutions for across multiple industries? also ask our users to nominate fea-
many different applications and settings, FS: SIMUL8 can be applied to any tures they’d like to see included in the
from the shop floor of an auto manufac- industry; however, custom-built prod- next release, and this has resulted in
turing facility to a major healthcare facil- ucts have been created using SIMUL8 some great features over the years.
ity. Desktop Engineering recently spoke as a base to address a specific need
with Frances Sneddon, chief technology within that industry. DE: How much training is required for
officer of the firm, which was founded The design of airport security can be users to be able to use your products
in 1994: pretty crucial to the smooth running of to build simulation models and bring
any airport, and we’re currently work- about results?
DE: Can you tell us a little bit more about ing with the team at London’s Gatwick FS: Our aim is for the user to start
SIMUL8 and the applications Airport—the busiest single-runway airport using the product straight away, and
it offers? in the world—to improve the passenger to start seeing results as quickly
FS: SIMUL8 is business process simula- experience there. as possible—so, within the first few
tion software. With SIMUL8, you can cre- By using SIMUL8 to create a visual hours! Of course, simulations can be
ate a visual representation of your busi- representation of the security process, as complex as you need them to be,
ness to allow you to experiment with new the team can experiment with key factors but we believe that the best simula-
ideas to improve efficiency and reduce like new layouts for waiting lines, number tions are built quickly, produce results
costs—all in a risk-free environment. of X-ray machines, and makeup of staff at and develop over time. We have
Think of it like a bird’s eye view of your peak times to see what setup will reduce numerous support resources to help
business or process. bottlenecks for passengers. users get started on our website at
Take, for example, the new $1 million This ability to quickly experiment SIMUL8.com. DE
oven the guys on the shop floor say you’ll with ideas has led to exciting new initia-
need to meet demand next year. With tives like “family-friendly” lanes that Jim Romeo is based in Chesapeake, VA.
SIMUL8, you can see whether the invest- separate business travelers from those Contact him via [email protected].
ment is justified, or if there are ways you heading on vacation—and that keeps
can do things a little differently with your everybody happy!
current setup to meet the demand. DE: In developing new products and INFO ➜ SIMUL8: SIMUL8.com
General Motors increased throughput revising existing products, how does For more information on this topic,
on one of its assembly lines by 5%, by SIMUL8 incorporate user feedback? visit deskeng.com.

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 Focus on: Test & Measurement /// Test Bench

Developing a
Powertrain Test Bench
Dynacar combines digital and physical simulation to
model powertrains for hybrid electric vehicles.
BY ADRIAN MARTÍN

N
early 2 million hybrid electric vehicles (HEVs) have
been sold in the U.S. since 1999, according to the U.S.
Department of Energy. And with soaring gasoline prices
and stringent governmental regulations mandating better vehicle
fuel efficiency and reduced vehicle emissions, interest in HEVs
grows daily. Many characteristics of HEVs—energy efficiency,
vehicle performance, distance traveled and total cost, for exam-
ple—depend on the vehicle’s powertrain system design and its
control strategy.
A team of engineers at Robotiker-Tecnalia in Spain, one of
the largest research institutes in Europe, developed Dynacar,
a parametrized model that can simulate HEV powertrains, as
well as powertrains for electric and conventional fossil-fuel
vehicles. Dynacar simulates longitudinal and lateral vehicle Here, a model front panel features code programmed
dynamics—as well as the powertrain system components in in LabVIEW software. Users can configure the model
real time, for testing in model-in-the-loop (MIL), hardware- according to the needs of the test carried out.
in-the-loop (HIL) and dynamometer test applications.
One key component of the model is that it integrates digital modeling and simulation in the conceptual and preliminary
simulations with physical simulations of powertrain components. design stages of its HEV to analyze the behavior of all com-
This combination enables HuIL (human-in-the-loop) testing, ponents integrated in the powertrain.
which provides an advanced virtual driving simulator for com- After defining the general powertrain architecture, Robo-
plete vehicle simulation over a test bench. By using HuIL simula- tiker-Tecnalia conducted model-based studies to implement
tion, the team was able to develop analyses of driver requirements control and optimization strategies to manage the different
and the dynamic response of an entire HEV. energy sources. They also considered the differences in the dy-
The Robotiker-Tecnalia team used NI LabVIEW as the devel- namic responses of the components in an electrical powertrain
opment environment for the vehicle model. They used NI Veri- from those in conventional powertrains. Because the electrical
Stand real-time testing software for model integration, stimulus powertrain provides greater motor speed, they developed a new
generation, and data logging, and the INERTIA add-on for NI drive control strategy to give HEV motorists equal or increased
VeriStand, created by Wineman Technology, to implement multi- vehicle drivability, comfort and safety.
mode control of a dynamometer-based test cell. Additionally, the They considered both longitudinal and lateral vehicle dy-
team used NI’s PXI hardware, and a range of vehicle bus commu- namic responses with the powertrain components and dynamic
nication cards, and data acquisition (DA) interfaces. effects, as well as tire data and the modeling approach of road-
to-tire contact. The model target was to calculate the vehicle
HEV Full Dynamic Model speed and position, in addition to such dynamic variables as force,
HEVs have electrical components—such as energy stor- torque, slip angle, lateral acceleration and vertical axis load.
age systems (batteries or supercapacitors), electric machines, These variables are part of the differential equations that define
power inverters and control systems—that are key factors in the vehicle dynamic response, such as roll stiffness, weight transfer
the electrical powertrain design phase. Because these compo- and vehicle model, according to such inputs as acceleration and
nents can be complex, the team used high-fidelity tools for brake pedal position, steering and wheel position, as well as tire,

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 geometry, roll center, inertia, weight and powertrain parameters. To
solve the differential equations, the team used an integration solver
based on the Runge-Kutta method in NI LabVIEW.

Architecture of the Integrated HEV Test Bench

The team replaced the powertrain electric component dy-
namic submodels with a PXI platform populated with real
electronic components. They ran two motors with a physi-
cal coupling: one working as a load and the other as a trac-
tion drive. The load drive and traction drive torque reference
commands were calculated using the Dynacar vehicle dynamic
model. Drive response feedback signals were sent back to the
Dynacar model through the NI PXI platform. This data was
used in the vehicle dynamic response calculation.
The PXI platform integrates multiple I/O options. These in-
This HEV test bench architecture layout shows
clude data acquisition with the NI PXI-6229 module, as well as
virtual models of the Dynacar dynamic model and
communication and data interfaces required by a variety of ap-
real hardware.
plications with the NI PXI-8464 two-port, transceiver-selectable
CAN interface. The team also developed additional communica-
tion and DA interfaces using the NI PXI-7833R multifunction
intelligent DA module and the LabVIEW FPGA module.
SCANeR II, a driving simulation software system from
OKTAL, completed the test bench architecture. SCANeR
conducts driving cycle simulations using a human driver over
virtual scenarios with a HuIL approach. To connect SCANeR
with the Dynacar dynamic model, the team leveraged an ap-
plication programming interface (API) for LabVIEW, based in
.NET provided by OKTAL. They implemented the connec-
tion with the SCANeR II modules through an Ethernet cable.
This approach allowed the developers to play with different
parameters while a human drove the components under inter-
est. Similar to a sound jury with noise, vibration and harshness
(NVH) research, the driver can identify the user features that
The Dynacar engine selection configuration utility. please or repel—and the developers can make better decisions
that balance safety and efficiency with human subjectivity.
The Robotiker-Tecnalia engineers will continue to use an
integrated test bench architecture with real components. The re-
searchers hope that detailed analysis of powertrain configurations
will further improve the implementation of advanced control and
optimization strategies for energy and power management, as
well as electric traction advanced control solutions. DE

Adrian Martín and his teammates, Iñaki Iglesias, Angel Goti,

Jose Luis Calvo and Juanjo Valera, work for Robotiker-Tecnalia.

INFO ➜ Inertia: WinemanTech.com

➜ National Instruments: NI.com
➜ OKTAL: SCANeRsimulation.com
➜ Robotiker-Tecnalia: Tecnalia.com/en
➜ Real-time Test and Hybrid Car Demo: NI.com/niweek/
The Dynacar wheel selection configuration utility. keynote_videos.htm

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 Focus On: Test & Measurement /// Profile

Moving into
“Intelligent Engineering”
The Center for Advanced Engineering Environments
assists researchers, industry and government partners
with product creation and testing.
BY DEBBIE SNIDERMAN

T
he Center for Advanced Engi-
neering Environments (CAEE)
at Old Dominion University in
Hampton, VA, serves as a pathfinder
and a focal point for research activi-
ties pertaining to advanced learning
environments—and collaborative, dis-
tributed knowledge discovery and ex-
ploitation. It identifies the direction of
aeronautical and space research, and
demonstrates and transfers results to
engineers and researchers.
CAEE’s advanced visualization
equipment ranges from autostereo-
scopic displays that allow users to view
3D images without headgear or glasses,
to an EON TouchLight display that
uses gestures and multimodal interac-
tions. It also includes an EON IPres- Virtual reality tools and new methods of interfacing enable groups of people
ence tele-immersion facility, EON to interact with a model simultaneously in an immersive classroom setting.
Icatcher 3D stereo projector, and a
multi-user, touch- and gesture-activated “As the trends of distributed col- knowledge discovery so product plan-
tabletop display that is debris-tolerant. laboration, large-scale integration of ners and developers can visualize, as-
Technologies that link virtual and computing resources, enterprise tools, semble, test and optimize products and
physical worlds are used to create im- facilities and processes continue, a fun- production processes very quickly.
mersive, interactive 3D virtual worlds damental paradigm shift will occur in
with augmented reality to get the most the virtual product creation,” he adds. Assisting NASA
out of visual simulations. When used ef- “Future high-tech systems will be com- Virtual structural test facilities and wind
fectively, says Ahmed Noor, Ph.D., the plex systems-of-systems, developed tunnels are just two examples of the type
center’s director and professor of Mod- through just-in-time collaborations of of virtual facilities the center uses for elab-
eling, Simulation and Visualization En- globally distributed teams, linked seam- orate structural, material and aerodynamic
gineering at Old Dominion University, lessly by an infrastructure of networked testing. Simulations of NASA Langley’s
they can automate several activities and devices, tools, facilities and processes.” Subsonic and Full-scale Wind Tunnels
significantly enhance an engineer’s or With this as motivation, Noor says were built to help NASA understand how
user’s productivity, creativity and innova- researchers at the center are trying to simulations could help quickly converge
tion. They also allow collaboration with a build an intelligent, adaptive, cyber- on optimal component and system de-
wide range of people. physical ecosystem that has intelligent signs. They wanted to validate the simu-

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de0512_Focus_CAEE_Sniderman.indd 18 4/15/12 3:36 PM

 DAQFlex
Program
in any OS

Avatars are available to answer a wide variety of questions about the model, Small footprint driver
the simulation, or procedures, to help users complete virtual testing.
ideal for OEM’s
•
lations and understand what they could The Role of Immersive Displays
obtain from physical tests that could not NASA found that traditional training For use with
easily be obtained from the simulations. methods—using courses, lectures and Windows®, Linux®, Mac®,
By using simulations of these wind slides—were not exciting for younger Android™, and more
tunnels and major structural test facili- audiences, and some older audiences felt •
ties in the virtual world, users can ob- intimidated when new technologies were
Supported MCC DAQ
tain procedural and operational train- introduced. To solve this problem, CAEE
ing—and complete intelligent design proposed using the most advanced tech- hardware from
of experiments to run in the facilities.
The simulations also help them un-
derstand response quantities that can
nologies available that will engage the
younger audiences, along with very sim-
ple interfaces for the older audiences, and
$ 99
be measured during testing, the types demonstrated the concept using a num- For more information
of materials and sensors required, and ber of simulations and design systems. on DAQFlex, visit:
their placement on test articles before The interface of the center’s Touch- mccdaq.com/DAQFlex
arriving at the facility. After complet- Light display was designed to be very sim-
ing pre-test work, virtual tests can be ple to interact with, using hand gestures, To read our white paper
run as often as required to understand voice commands or a smart mobile device. on tablet-based DAQ
the response before going to the phys- There is no user manual to read. Standing
ical test facility, where testing time is in front of the display containing simula-
and download sample
expensive. tion models, the system will list possible code for Android OS, visit:
CAEE also completed a simula- interactions. Users can ask “what are the mccdaq.com/Android
tion of a large structural test facility for models you have now in the system” to
NASA: the Combined Loads Testing display a list of models. Commands such
System (COLTS). The COLTS simula- as “show me this model” or “what com-
tion allowed a user to run a virtual test, mands can I use with this model” are un-
then adjust the experiment, the bound- derstood, and users can change command
ary conditions, or change the test article words to those they are more comfortable
material itself and re-run the test. Vir- with, including foreign words.
tual testing with facility simulations is The center has also developed tech-
less expensive than performing multiple nology that adds intelligence to simu-
Contact us
iterations of physical experiments, ac- lation and design systems, providing 1.80 0.234.4232
cording to Noor. Once the simulation intelligent virtual assistants as advisers.
©2012 Measurement Computing Corporation
system is built, virtual tests are available Not only can these intelligent agents 10 Commerce Way, Norton, MA 02766
at the relatively low cost of labor. perform mundane tasks such as auto- [email protected]

deskeng.com /// May 2012 DESKTOP ENGINEERING 19

de0512_Focus_CAEE_Sniderman.indd 19 4/15/12 10:28 AM

 Focus On: Test & Measurement /// Profile
interfaces that include gestures, and fa-
cial expression recognition are used to
facilitate the natural interaction of the
user with the simulation system. One
prototype notices when users look puz-
zled, and offers assistance. Noor says the
avatar “feels” when the user needs help.
He says he believes that more simula-
tion systems should include these types
of avatars: “They can significantly en-
hance productivity and engage the user.”

Digital Simulation
The center has developed tools such as this TouchLight Display for interacting
Complements Physical Testing
Digital and visual simulation tools are being
with models and simulations, using brain and gestural commands.
used to accelerate the development of pow-
mating model generation, they can also a manual for operational instructions. erful systems, far beyond automatic model
lead a user through solving a problem, Prototypes were developed more than generation and self-designing components.
or help a technician running the test fa- five years ago, long before the invention “We are moving from what we call the
cility during a physical test. of Siri used with the iPhone 4S. Information Age to another era, the Intel-
Eventually, facility technicians or The CAEE has developed intelligent ligence Era, which is essentially the result of
users will be able to use handheld de- avatars—“cognitive” agents that use advances in artificial intelligence going way
vices to ask a virtual agent for assistance novel interaction technologies. Brain- beyond expert systems of the past, to arti-
during any point of the testing, such as based interfaces that combine brain ficial general intelligence trying to mimic
retrieving a specification or querying signals to register thoughts, multimodal cognitive characteristics of humans in our

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DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_Focus_CAEE_Sniderman.indd 20 4/15/12 3:36 PM

 systems,” Noor says. “In the Intelligence
Era, the convergence of facilities, technol-
ogies and devices will have an impact on
every engineering field and activity.”
He points out that it is important to Data Analysis and Graphing Software
have a virtual representation of the entire
value chain—the ability to go through
Powerful. Flexible. Easy to Use.
the entire process, from concept and

‘‘leadingOverallstatusOriginPro
product development through operation
preserves its
during the expected lifetime of a product.
as the most functional
“The simulation should also include
upgrade or disposal in a way that will not and comprehensive data analysis and
adversely affect the environment,” Noor graphing software on the market.
continues. “We should capture and reuse Although other software programs
the multi-disciplinary knowledge of the are available, few are as easy to use,
organization that is developing the sys- accessible, and high-end when it comes
tem, and consider how to effectively to performing rigorous data analysis or
apply this knowledge to other products.”
Digital factories of the future will be
able to create much bigger components
producing publication-quality graphs.
Keith J. Stevenson ’’
Journal of American Chemical Society, March 2011
than the 3D printers of today, he adds:
“We will add intelligence to those sys-
tems, so they can automatically select
the production process and test it in a ‘‘ In a nutshell, Origin, the base version, and
OriginPro, with extended functionality, provide
virtual world, like Second Life.” point-and-click control over every
But Noor stresses that this doesn’t element of a plot. Additionally,
replace physical testing. users can create multiple types

0
“Physical testing will be reduced, of richly formatted plots, perform
and it will be done in much more in- data analysis and then embed
telligent ways than are done today,” he both graphs and results into
concludes. “Simulations will be used to dynamically updated report
intelligently design the experiments,
templates for efficient re-use
and we should think about the simula-
tion and physical testing as two compo-
nents of an integrated system that looks
of effort.
’’
Vince Adams
for ‘predictive engineering’ to obtain Desktop Engineering, July 2011
more knowledge than we are today, by
thinking more intelligently about the Compatible with Windows 7. ®

role that each could play.” DE Native 64-bit version available.

Learn more at www.OriginLab.com
Debbie Sniderman is an engineer,
writer and consultant in manufacturing
and R&D. Contact her at VIVLLC.com.

INFO ➜ CAEE: aee.odu.edu

➜ Visualization Technologies at CAEE: OriginLab Corporation
aee.odu.edu/facilities_visualization.php One Roundhouse Plaza
Northampton, MA 01060 USA
➜ “Emerging CAE technologies and
their role in Future Ambient Intelligence
USA: (800) 969-7720
Environments”: SpringerLink.com/
FAX: (413) 585-0126
content/b03n746w81521654
EMAIL: [email protected]
➜ EON Reality Inc.: EONreality.com WEB: www.originlab.com

deskeng.com /// May 2012 DESKTOP ENGINEERING 21

de0512_Focus_CAEE_Sniderman.indd 21 4/15/12 10:29 AM

 Focus on: Test & Measurement /// Data Logging Products

1NINewReleases Two
Mobile Apps
National Instruments (ni.com)
1 2

has announced NI LabVIEW

software- and NI hardware-
compatible mobile apps for
iPhone, iPad and Android
devices. Data Dashboard for
LabVIEW and Data Dashboard
Mobile for LabVIEW allow
users to remotely view PC or
embedded measurements
from LabVIEW on mobile
devices using a combina-
Free Data Logging
Software Available
MicroDAQ.com, an online
2Data Logger
Has Built in GPS
Kistler (kistler.com) has
GPS has an update rate
of 100 Hz with GPS signal
output via CANBus. With
tion of charts, gauges, text provider of data loggers released the Corrsys- quick vehicle mounting
indicators and LEDs. The and data acquisition Datron model CDS-GPS, capabilities, the device
NI cDAQ-9191 Data Display products, has announced a high-performance data provides high-accuracy
directly connects wireless NI the newest version of the logger with a built-in global measurements of absolute
CompactDAQ hardware to iOS Lascar data logging soft- positioning system (GPS) speed, traveled distance,
and Android devices using ware, EL-WIN-USB. It is for longitudinal vehicle latitudinal and longitudinal
new technology featured on compatible with all Lascar dynamics testing applica- position, height, time and
NI Labs. Users can configure, loggers purchased in the tions. Offering compatibility date, and system status
visualize and save measure- last five years and will work with other sensors within information, such as the
ments without a PC or teth- on PCs running Windows 7, Kistler’s Corrsys-Datron number of satellites, signal
ered display. XP, and Vista. product range, model CDS- quality, and other factors.

Composite Design with

Quickness and Ease
• Material library with over • Advanced failure criteria
70 fibers, resins and lamina including Hashin, Puck & MCT
• Multitude of analysis modules • Easy to use
• Export, plot & print functions • Extensive user documentation

TRY IT FOR FREE! firehole.com/deskeng

THE COMPOSITE ENGINEER’S TOOLBOX FIREHOLE COMPOSITES

22 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_Focus_Data_Log.indd 22 4/15/12 10:37 AM

 3
fer, enabling large bursts of recorders, plug-in card data
data up to 20bits at 100MHz acquisition equipment, and
to be sampled, according to the VXI/PXI systems. System
company. A USB 2.0 connec- builders can create test solu-
tion is used to stream collected tions with a combination of
data to the PC, enabling more channel count, cost per chan-
data storage. It features a data nel, and system performance.
filtering capability, storing only The input modules provide
relevant data. the flexibility to vary the chan-
nel count from 20 to 200
Log Event Data
Omega (omega.com) has
released a series of event
3LOG Storm Has 8MB
Memory Buffer
Saelig (saelig.com) has intro-
Model 2701 DMM,
Data Acquisition,
Datalogging System
(2-pole), apply a stimulus to
the device under test, route
signals, control system com-
data loggers. The OM-CP- duced Byte Paradigm’s LOG Keithley Instruments’ ponents, and make precision
EVENT101A interfaces to Storm, a high-speed digital (keithley.com) Integra Series measurements with up to 14
other devices with TTL pulse or data logger for troubleshoot- systems (2700, 2701, 2750) functions. Digital I/O capabili-
contact closure output. They ing digital system buses. It is a combine measurement, ties can be used for triggering,
feature a 10-year battery, 4Hz hardware/software combina- switching, and control in a handshaking with other auto-
reading rate, a multiple start/ tion that can collect high-speed single, integrated enclosure mation equipment, and alarm
stop function, and an ultra-high- digital bus activity for periods of for either rack-mounted or limit outputs. Scan rates of up
speed download capability, hours or even days, and extract benchtop applications. These to 500 channels/second (up
according to Omega. Options specific functional events of test platforms offer alterna- to 3500 readings/second on
include memory wrap and interest. LOG Storm contains tives to separate DMMs and a single channel) will increase
password protection. an 8MB sample memory buf- switch systems, dataloggers/ test productivity. DE

High Temperatures?
New technology offers wide range of high temperature durability simulations

Thermo-Mechanical Fatigue in
nCode DesignLife enables you to:

 Perform efficient high-temperature analysis

using simple FE thermal and linear stress analysis

 Incorporate advanced elasto-viscoplastic FE

simulations as necessary

 Easily derive material parameters based on

industry-standard iso-thermal fatigue tests
and creep-rupture tests nCode DesignLife 8 employs new
technology for high temperature
durability simulations

See other new technologies for short-fibre

composites and adhesive bonds at
www.hbm.com/ncodewebinars

www.hbm.com/ncode | [email protected]

deskeng.com /// May 2012 DESKTOP ENGINEERING 23

de0512_Focus_Data_Log.indd 23 4/15/12 10:40 AM

 Collaboration & Interoperability Congress /// Sponsored Report

T
he 3D Collaboration & Interoperability Congress (CIC), • 3D based Process Plans on 787, Leveraging Model Based
May 21-23 in Denver, is dedicated to fostering and im- Definition for Manufacturing, Max Jensen, Senior Developer,
proving collaboration and interoperability in product ME Systems Development, Boeing
design, development and manufacturing. The ninth annual • Driving High Volume and High Quality in a Huge, Globally
Congress is the only vendor- and product-neutral event in the Inter-Connected Automotive Supply Chain, Rahim Alsaffar,
world addressing collaboration and interoperability in manufac- Lead Engineering Specialist, Johnson Controls Automotive Group
turing and business communications. The international event • How PMI and Data Modeling Standards Affect Successful
has grown into an essential forum to network, learn and strate- Implementation of 3D MBD and MBE, Bryan Fischer, Presi-
gize with thought leaders from automotive, aerospace and many dent, Advanced Dimensional Management
other manufacturing industries, as well as with representatives • Manufacturing & PLM in 2020, Stephen Bodnar, VP Manufac-
from government and defense. turing Solutions, Autodesk, Inc.
• How 3D is Helping with the Recovery at Fukushima, Sakiko
The 2012 CIC program features these informative presenta- Seki, Business Development Manager, Smartscape, Inc., Japan
tions, and many more (visit www.3dcic.com for the full agenda): • Leveraging the Rise of the Social Consumer for New Prod-
• Lessons Learned in over 40 years in Aerospace and De- uct Innovation, Rob Fisher, Director of Marketing, Madison
fense, Rockwell Collins; Director, Advanced Manufacturing Electric Products
Technology (Retired) • Incorporating Equipment Information into New Facility
• Leveraging Virtual Engineering Environments to Drive Mar- Construction and Retrofits, Jason Hosch, Senior Industrial
gin Improvement AND Product Development Flexibility, Tom Engineer, Intel
Curtis, VP of United Rotocraft, A Division of Air Methods • Data Distribution on the 787, Bringing Model Based Defini-
• Aerospace and Defense: Global Interoperability Across the tion to the World, David Briggs, Associate Technical Fellow -787
Supply Network for Life, Howard Mason, Corporate Informa- Engineering Information Delivery, The Boeing Company
tion Standards Manager, BAE Systems • Design, Development, and Testing of an Open Standards-
• Democratizing 3D: Leveraging Product Data Assets Beyond Based Simulation Data Management and Archival System,
Design Engineering, Lars Peder Hansen, Senior Systems Con- Keith Hunten, Senior Staff Aerospace Engineer, Lockheed Martin
sultant - CAD/PLM, Grundfos Group, Denmark Aeronautics Company

Automated Geometry Simplification

in a Multi-CAD PLM Environment
A
large general machinery company ducing the size of a model. Another major
wanted to develop an automated challenge is to create simplified representa- tually access the data. The only effective
process to generate simplified 3D tions without compromising the information solution is geometry that does not contain
CAD models from existing master models business partners need to accomplish their confidential details. The automatic pro-
and manage the results in their PLM appli- tasks. CT Core Technologies is introducing cess produces models which lack internal
cation. The current manual process was time Automated Geometry Simplification using data sets. In detailed models, such as en-
consuming with inconsistent results. It was 3D Evolution for Multi-CAD PLM applica- gines, gearboxes or powertrains, a massive
difficult to keep in sync the master models tions. The module is based on the 3D_Evo- reduction of the file size will be achieved
with the simplified models due to concur- lution software. With the press of a button through 3D Evolution scripts.
rent modifications. In addition, the company the Geometry Simplification (GS) module Simplifying assemblies involves fill-
wanted to protect their Intellectual Property enables the automatic simplification of 3D ing holes before GS with the removal of
(IP) by removing the internal components, models, creating a bounding geometry while internal and external objects. Simplifying
thus creating the envelop and reducing the reducing model size and complexity. the bodies can be automated by keeping re-
size of the model by 65%. 3D models reveal details and design moved details in ‘no-show.’ Setup configu-
To gain a competitive advantage in a features about a new product before it ration allows making the choice to remove
global environment, companies must be reaches production. This sensitive data is holes or bosses, saving time to remove the
able to safeguard IP contained in their 3D exposed in the model history and assembly. smallest of detailst. Automatic simplifica-
CAD models, while retaining the ability to Because the data is sent to many different tion creates an outer shape bounding ge-
share data through process automation. A end-users for layout, mock-up, and engi- ometry, which exceeds even the most strin-
persistent challenge in sharing data is re- neering, it is difficult to control who even- gent quality standards.

24 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_CIC_Advertorial.indd 24 4/15/12 10:06 AM

 The 3D PDF Consortium
A
cross many industries, 3D data is available to them a platform on which
becoming a key part of the data as- they can innovate their processes and
sets on which an organization op- develop highly effective, impactful
erates. In discrete manufacturing, process ways to represent 3D information. For
manufacturing, geospatial applications, instance, in discrete manufacturing,
and health care, more and more 3D data you can now include a full fidelity 3D
is generated each day, and increasingly or- representation of a manufactured part as attributes, product manufacturing infor-
ganizations need to find ways to leverage or assembly, along with the metadata acces- mation, and instructions; and the ability to
that data to improve their business pro- sible in a PLM or ERP system. Using capa- allow anyone, anywhere to consume that
cesses and financial performance. One of bilities such as templates and forms within information in their day-to-day duties.
the most significant barriers in developing a PDF file, you can create documents that The 3D PDF Consortium is a new com-
tools and processes which can provide the support extremely accurate and complete munity of software developers, system inte-
benefits being sought, is how to standard- representations that allow you to automate grators and end user companies that focus
ize on the representation of that informa- processes such as request for quote (RFQ) on driving adoption of 3D PDF-based tools
tion, and the other forms of data that so and request for proposal (RFP), or create and solutions through demonstration, infor-
often must accompany the 3D asset, in a dynamic documents which are deliverable mation, and evangelism, on the premise that
form that is easily consumed and fits with as shop floor work instructions, assembly a dynamic community ensures world class
the procedures and processes that the or- instructions, training manuals, or main- tools and solutions continue to remain avail-
ganization depends on. tenance and repair procedures. In almost able in the marketplace. We have elected to
With the addition of the ability to rep- any industry, what is needed to make this sponsor the 3D Collaboration and Interop-
resent 3D data within PDF files, and the ac- effective are two key elements: a way to erability Congress as our premier event in
companying support of that representation combine in a relational fashion 3D data 2012, given the relevance of the conference
as an ISO standard, companies now have with structured and unstructured text such focus to our mission.

Theorem Solutions
O
ur products and solutions are all only forms a part of our business.
driven by market demand so listen- As technology and data exchange needs
ing to the needs and views of users have advanced, and the complexity of data
and experts in the fields of collaboration and has increased, we have developed and built
interoperability is one of the main objectives upon our core skills and expertise based on
for Theorem as a silver sponsor at the 2012 the needs and feedback of our users. This
3D CIC event. enables us to provide solutions that reduce
We have always found the event very costs for engineering and manufactur- and PLM to PLM can be tailored to meet
useful as it allows us to meet users and de- ing departments when collaborating with any requirement. Resulting formats are not
cision makers in a relaxed business environ- business partners. an issue as we partner with all major vendors.
ment. The event’s presentations and work- Our large-scale automated solutions for We concentrate on the “Process.” Automa-
shops enable us to hear views and identify CAD and PLM data migration and long- tion, data validation & checking, with de-
trends, as well as to meet with technical spe- term data archiving projects save time and tailed audit trails can all be included in one
cialists from a broad spectrum of industries money by streamlining and eliminating the efficient process underpinned by the Theo-
and design disciplines. labour intensive tasks involved in migrating rem Process Management suite of technolo-
3D CIC provides us with the opportu- large volumes of data. gies, which can also be used to manage non-
nity to refine current products to meet users’ The advanced technical solutions and in- Theorem products.
short-term needs, but also to plan for the depth expertise that we bring to every proj- Providing effective engineering ser-
next generation of requirements. ect enables companies to seamlessly carry vices is about implementing the right mix
Over the past 20+ years we have been forward CAD and PLM data into the latest of people, technology, data, processes and
very successful in the CAD data translation generation systems. infrastructure.
marketplace with our CADverter products Our solutions and services for: CAD to We welcome the views and opinions of users
and continue to be so; however, today this CAD, CAD to Visualization, CAD to PLM and look forward to meeting you at the event.

deskeng.com /// May 2012 DESKTOP ENGINEERING 25

de0512_CIC_Advertorial.indd 25 4/15/12 10:07 AM

 Simulate/// Composites

Composites Blast Off

Everywhere you look in aerospace,
you’ll find composites.
BY MARK CLARKSON

A
TK Aerospace Systems builds composite space struc-
tures, including solid rocket boosters for the shut-
tle, rocket motor cases and nozzles. Its commercial
launch vehicle, Liberty, is expected to launch next year.
When it comes to building for space, designs are cut to
the bone, asserts Nathan Christensen, ATK’s senior man-
ager, engineering tools and analysis.
“In space vehicles,” he says, “you have very low margins
of safety. They’re designed right down to the gnat’s eyeball.
An unmanned vehicle might have a safety margin of 1.2. A
manned vehicle might still only have a 1.5 margin, whereas
with an aircraft you’re looking at margins of 4 or 5.”
On top of that, Christensen says, the space industry is a lot
more risk-averse than it used to be: “A lot of that has to do with
our ability to do simulation. Using tools that we didn’t have 20 Fabricators at ATK in Iuka, MS, laying up plies of
or 30 years ago, we’re able to test dozens of different designs [in composite material to create the inner honeycomb
the computer] before any of them take physical form.” sandwich skin of the NASA crew module. The plies are
Although those designs seem relatively straightforward— being laid up with the assistance of a laser projection
cylinders, cones, etc.—there’s a bit more to them than that. system, which is driven by VISTAGY’s FiberSIM software.
Consider the nozzle of a solid rocket motor, for example.
“The throat is composite,” says Christensen. “It’s de- also out-of-plane failures that involve delamination. The tradi-
signed to erode while the rocket fires. The thrust changes tional fracture mechanics become much more complicated: You
with the throat diameter.” don’t have one crack, you have thousands of cracks, micro-cracks,
You can’t “de-couple” the fluid and finite element (FE) separation voids and so forth. These require very sophisticated
simulations; each affects the other. Modeling this interaction simulations. You can’t do [the math] on the back of an envelope.”
takes sophisticated tools, which companies like ATK used to
develop in-house. “But now,” says Christensen, “you’re seeing The Parable of the Ironbridge
commercial tools—like ANSYS multiphysics and Nastran How did engineers build composite structures without these
multiphysics—that do that kind of coupled analysis, coupling simulations? Jerad Stack, CEO of Firehole Composites,
structure, thermal and fluid flow. It’s cost-effective to use Laramie, WY, shares an illuminating story: “There’s a place
commercial software when we can. We don’t have to invest in England called Ironbridge, where humankind built the
the resources in software development that we once did.” first iron bridge. We didn’t really know what we were doing.
The commercial availability of these tools is key to the All we knew then was wood, so we used wood engineering.”
proliferation of composites in aerospace, because composites The cast iron bridge was built using a modified form of car-
are hard to understand. pentry. It worked. The bridge is still standing 230 years later.
But what’s significant is that the bridge was over-designed,
The Many Modes of Failure using perhaps twice the necessary iron.
“Composites are unique,” says Stanford Professor Emeritus “When composites were new, we were taking tools that
Stephen Tsai, “in that you have structural behaviors that have we’d been using for decades with metals, and trying to use
no counterpart in homogeneous material.” them for composites, Stack says. “But composite materi-
It’s much easier to characterize a flaw in a homogenous mate- als are different,” he continues. “They’re not metals. The
rial, according to Tsai. “For composites, you not only have in- mechanics behind them are different than aluminum or
plane failures—matrix failure, fiber failure, interfacial failure—but steel. The fundamental difference is that there are two

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 materials there. Our belief is you have to treat it like two
materials, so we have composite-specific tools like our
Helius:MCT.”

Embracing Anisotropy
Carbon fiber composites, for example, comprise the carbon fibers
themselves and the resin, or matrix, that glues them together.
The fibers are usually parallel and unidirectional. As a result,
these composites are anisotropic (or orthotropic) materials; they
exhibit very different material properties in different directions.
They are, generally speaking, strong in the direction of the fibers,
and weak in the directions perpendicular to the fibers.
To those used to working with isotropic materials such as LEFT: Buckling analysis results and magnified deformation
metal, the logical response was to stack the composite in lay- of a filament-wound composite solid rocket motor case
ers, or plies, with fibers oriented in different directions. The sitting in the rotator chock system. RIGHT: 3D FEA model
resulting laminate is reasonably strong in every direction, but of graphite epoxy filament-wound composite rocket motor
it somewhat misses composites’ potential. case sitting on rotator chock belt system. The rotator
chock belt system uses a chain and rubber pads (discretely
“Many people feel more comfortable and confident with a
modeled) for ground-handling operations to prevent
more uniform composite,” says Dr. Kim Parnell, principal and
composite fiber damage. Image Courtesy of ATK Aerospace
founder of Parnell Engineering & Consulting, Sunnyvale, CA.
Systems; Engineer: M. Gonzalez; Software: NX, Abaqus.
Still, he points out, its effective modulus (a measure of stiffness)
is “much less than the strong modulus in the fiber direction. Its structure can sustain and how it changes over time. Once
effective strength is much less.” something starts to fail, how much load can it still sustain?
By controlling fiber orientation, you can direct a structure’s “NASTRAN and a few other [applications] do this, but I
strength where it’s needed. You’re not just designing a part with see it becoming pretty big in the next few years,” he continues.
the desired properties; you’re designing a material with those
properties. You’re exploiting, rather than fighting, the anisotropy. When You Assume …
Composite material properties are also highly dependent Not every component needs to be analyzed down to the indi-
on the manufacturing and layup processes. Different manu- vidual fibers. Your analysis can assume a homogenous material
facturers using the same “recipe” can produce significantly and still produce useful results.
different materials. But there’s opportunity hidden here as “The more assumptions you make, the easier it is to do
well. Composites are customizable. You can create different, the analysis,” says Kyle Indermuehle, director, aerospace and
finely tuned materials. All of those options can be hard to defense industry, for SIMULIA at Dassault Systèmes. “What
sort through, but automation can help. assumptions do you think you can get away with?”
“The real differentiator for us is in the optimization,” says Take a spacecraft designed to re-enter the atmosphere, he
Bob Yancey, executive director, global aerospace, for Altair. “If offers as an example. The thermal loads will be tremendous.
you know the general shape of the structure, and the loading and “If you’re designing an aircraft,” says Indermuehle, “you
boundary conditions, you can set up an optimization problem [in could decouple the problem. The thermal loads won’t affect
Altair’s OptiStruct]. How should those ply angles be distributed the structure much. For spacecraft, the interaction between
in the laminate? How many do I need of each ply angle? Where thermal and structure are coupled very, very tightly. If you
should my laminate be thicker? Where can it be thinner? try to decouple them, you’re going to get the wrong answer.”
“It’ll come back with a proposed design, which is a great
conversation piece to get manufacturing, design, stresses and
operations all in the same room, talking,” he adds. INFO ➜ ANSYS: ANSYS.com
➜ Altair Engineering: Altair.com
Progressive Failure
Unlike metals, composites fail progressively. Cracks or de-
➜ ATK Aerospace Systems: ATK.com
laminations in one area redistribute stresses to adjoining ➜ Firehole Composites: Firehole.com
areas, which fail in turn. ➜ MSC Software Corp.: MSCsoftware.com
“I see progressive failure analysis as the next level of composite ➜ Parnell Consulting & Engineering: Parnell-Eng.com
analysis,” says NEi Application Engineer Allan Hsu. “It’s a
type of lifecycle analysis where you’re concerned about not ➜ SIMULIA: SIMULIA.com
just how damage happens, but also how much damage the ➜ VISTAGY: VISTAGY.com

deskeng.com /// May 2012 DESKTOP ENGINEERING 27

de0512_AreospaceComposites_Clarkson.indd 27 4/15/12 10:52 AM

 Simulate /// Composites

Simulating
...Continued from page 27

That answer may only be off by about

Composites
15%, but if you’re running on the
razor-thin safety margins of the space
industry, can you afford it?
The fewer assumptions you make,
the more difficult it is to set up and
interpret a simulation. You have to
By PAMELA J. WAtErMAn
define different layers, materials and
fiber orientation angles. On the back
end, you’ll be studying many more part count by 93. It
contour plots. still has a metallic
Indermuehle estimates that about torque box, but the
70% of an engineer’s time would be skins and bars are
spent building the model; about 20% composites. Sec-
is spent running the model; and about ond, the 256-in.-
10% is spent understanding the results. long main rotor
“Philosophically, we’d much rather blade will now
the engineer spend 70% of the time be all compos-
absorbing the results and about 10% ite, with a glass/
of the time developing the model,” he epoxy hybrid spar
adds. “The technology to solve the laminate structure
problem is there today—the usability and a Nomex fiber core.
is still a challenge, and one we take And third, designers have

W
very seriously.” achieved a 4-lb. weight re-
hat hap- duction on the aft avionics
Simulation is Now King pens when you drill a pass-through doors, whose con-
Understanding composites’ many hole in a multi-layer com- current part-count reduction also makes
failure modes requires modern, ac- posite? Is there damage that will cause them easier to manufacture.
curate analytical tools. Previously, trouble when that structure is in use?
manufacturers’ only option was to And how precisely can you layer it in Software Solutions
invest in expensive physical testing the first place? These are just some of With so many operational benefits dictat-
and testing was king. the issues addressed at the 2012 SME ing the expanded use of composites, it was
“But that’s not the case anymore,” Composites Manufacturing conference not surprising that several presentations
says ATK’s Christensen, “Now, your that took place in Mesa, AZ, in March. addressed relevant software simulation
test is just a confirmation of your Attendees heard about the increasingly tools for both design and production.
simulation, and the test had bet- important role that composites play in the Bill Hasenjaeger is the product mar-
ter confirm what your simulations design and manufacture of manned ve- keting manager for CGtech, developers
showed or you’ve got a lot of ex- hicles, wind-turbine blades and a host of of VERICUT software that simulates
plaining to do. Our customers—the applications in-between, plus new ways of computer numerically controlled (CNC)
U.S. Department of Defense, the Air dealing with them—many involving simu- machining to detect errors, potential colli-
Force, the Navy, NASA—are very lation for design and manufacturing. sions or areas of inefficiency. His company
demanding that way.” DE For example, the new Boeing AH-64D has used this experience to create VERI-
Apache Block III combat helicopter uses CUT Composite Simulation (VCS), a
Contributing Editor Mark Clarkson is an increased horsepower engine whose package that reads CAD models and NC
DE’s expert in visualization, computer successful operation depends on rede- programs, and simulates the sequence of
animation, and graphics. His newest signing a number of subsystems, with im- NC programs on a virtual machine.
book is Photoshop Elements by Ex- provements that incorporate composites. Hasenjaeger talked about the need
ample. Visit him on the web at Mark- First, the new composite horizontal for process simulation software to verify
Clarkson.com or send e-mail about this stabilizer saves 15.8 lbs. over the same the accuracy of automated fiber-place-
article to [email protected]. design in metal, and also reduces the ment (AFP) programs. In the real world

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de0512_CompositeConference_Waterman.indd 28 4/16/12 12:10 PM

 of manufacturing, one or more bands of
material are laid at the rate of 2,000 in.
per minute. He emphasized, “On curved
surfaces, you will have gaps and overlaps,”
as the tape unrolls and is laid in position
over a tool’s surface. Therefore, verifying
FE Modeling and analysis of twist
the layout process and performing a de-
drilling forces using Third Wave
sign-for-manufacturing analysis are both
Systems AdvantEdge FEM software.
critical tasks addressed by VCS software.
The simulation shows microstructure
Dr. Shuji Usui, lead developer and com-
damage when drilling a hole through
putational mechanics engineer at Third
(previous page) aluminum and a
Wave Systems, tackled another very rel-
multi-layer composite (above). The
evant question: What happens to the mi-
composite delaminates and shreds.
crostructure of a composite material when
Images courtesy Third Wave Systems.
holes are drilled into it?
Third Wave Systems markets predic- -45°, etc. So far, the -45° orientation seems
tive, physics-based material modeling to result in the most internal damage. Usui
software used by companies to improve is comparing the simulated results with
machining processes and is currently in- laboratory experiments on an aluminum
volved in early-stage R&D efforts related block and a graphite/epoxy composite.
to composites modeling. The company’s Future simulations will include the effects
AdvantEdge FEM software is a CAE so- of the drill wearing down and cutting at an
lution traditionally targeted to the optimi- oblique angle.
zation of metal cutting, enabling users to John Schibler, chief engineer and IPT
analyze machining processes in 2D and 3D lead, Attack Helicopter Programs, for The
environments. Users are typically looking Boeing Co., gave the keynote presentation
to improve part quality, increase material about the Apache Helicopter program and
removal rates, and extend tool life. its use of composites. He wrapped up his
Usui has now applied finite element talk by noting a major wish-list item: room-
(FE) modeling to predict the damage temperature-curing composites. It would
caused when twist-drilling holes into com- reduce the costs associated with autoclave
posites. He modeled a Constant Virtual curing, and allow the use of embedded-
Drill Bit with CATIA and NX software, electronics sensors (which currently can’t
then ran the model through AdvantEdge handle autoclave heat).
FEM on both composite and aluminum For more conference information,
materials for comparison. see SME.org/composites and consider
Cutting energy for metal includes plas- joining the SME Plastics, Composites
tic work (heat) plus friction, while cutting and Coatings (PCC) technical commu-
energy for composites must account for nity (SME.org/pcc). DE
surface energy (transverse cracks) plus fric-
tion. Usui employed an unstructured mesh Contributing Editor Pamela Waterman,
to solve the isotropic (metal) problem, and DE’s simulation expert, is an electrical en-
a structured mesh to handle the brittle gineer and freelance technical writer based
behavior of the orthotropic (composite) in Arizona. You can send her e-mail to de-
problem, modeling each ply individually. [email protected].
AdvantEdge FEM was able to simulate a
punch-shear test similar to the entry of a
twist drill-bit, generating detailed anima- INFO ➜ Dassault Systèmes: 3ds.com
tion graphics of layer delamination and
fiber-shard splitting as the drill advanced.
➜ CGTech: CGtech.com
Current Third Wave Systems work ➜ Siemens PLM Software: plm.
involves simulating various lay-up designs automation.siemens.com
where layers are 90° to each other, 45°, ➜ Third Wave Systems: ThirdWaveSys.com

deskeng.com /// May 2012 DESKTOP ENGINEERING 29

de0512_CompositeConference_Waterman.indd 29 4/16/12 10:37 AM

 Simulate /// Multiphysics

Quantum Leap FIGURE 1: This model uses the

COMSOL Version 4.2a new charged particle tracing
expands its multiphysics offering. user interface to compute the
trajectories of electrons in a
BY VINCE ADAMS spatially varying magnetic field.

I
“ t is our mission to stay ahead of the with the new Particle Tracing Module. no extra cost. Because the purpose of Live-
curve,” says Bjorn Sjodin, vice presi- As implemented, this is a secondary or Link is to provide native CAD support with
dent of product management for bi-directional calculation on top of field persistent boundary conditions and proper-
COMSOL Inc., Burlington, MA. Its mul- and vector data that can compute particle ties, one might ask what value there is in
tiphysics application, COMSOL, reflects position in a fluid mixing scenario or ion a COMSOL-specific solid modeling tool.
this mission—and the functionality pro- trajectories in an electromagnetic field. Sjodin says many geometric features or up-
vided with Version 4.2a is no exception. Per Sjodin, the most important aspect dates are solely to facilitate simulation.
COMSOL Version 4.2a was released of this module is flexibility. Essentially, “Consider a box that defines the flow
in October 2011. Two highlights of this COMSOL can plot the path of particles, or field domain around a part of interest.
release, the Particle Tracing Module and either with mass or massless, under the This box has no value in the design world,
the LiveLink for CREO Parametric, influence of any number of forces and but is critical to the flow or electromag-
the new modeling environment from effects. Fluid forces and electromagnetic netic solution,” he says.
Waltham, MA-based PTC, expand the forces are the most common applications. The integrated Parasolids engine allows
impact of multiphysics simulation and its However, the potential is theoretically users to maintain the integrity of the native
accessibility. Features like Image Import limitless. (See Figure 2.) CAD part while leveraging geometry-based
and Digital Elevation Map import are also meshing and model setup. (See Figure 3.)
enhancements, while many user interface COMSOL LiveLink Upgrades
improvements show COMSOL is listen- LiveLink, the bi-directional CAD interface Image-to-Material Conversion
ing and responding to customer needs. provided by COMSOL, supported Solid- Isotropic. Homogenous. Uniform. All are
(See Figure 1.) Works, AutoCAD, Autodesk Inventor, common assumptions used to simplify
Pro/ENGINEER and SpaceClaim in the the definition of a material for simulation.
Particle Tracing Module previous release. This has been extended to COMSOL customers have clearly com-
While particle tracing and streamline support the newest modeling environment municated to the developers that each of
mapping have been available as compu- from PTC, Creo Parametric. these assumptions must be questioned
tational-fluid dynamics (CFD) post-pro- Another upgrade for LiveLink custom- if they are to expand the boundaries of
cessing tools in COMSOL, the develop- ers is the inclusion of
ers have expanded its reach by introducing a Parasolids-based
new solver and visualization methods geometry engine at

FIGURE 3: A flow simulation using image-to-material

conversion, where the equivalent flow resistance is
FIGURE 2: The new LiveLink for Creo Parametric. computed for a porous structure.

30 DESKTOP ENGINEERING May 2012 /// deskeng.com

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 engineering-related fields. COMSOL
has been adapted to these applications,
which fall outside the domain of tradi-
tional FE solvers.

User Experience Improvements

FIGURE 4: An imported DEM was In post-processing, COMSOL has added
used to represent the underlying dynamic section and iso-surface control at
geometry for magnetic prospecting. the request of customers. This is a com-
monly used visualization tool in FE analy-
sis, and a long-awaited addition.
advanced material engineering. Non-ho- COMSOL supports cluster comput-
mogenous or porous material is particu- ing with a simple licensing structure,
larly problematic when local effects must which allows multi-node computing
be considered. with a floating license and multi-core
Historically, an engineer would use computing with a node-locked license.
CAD to manually trace around particles Large parametric sweep studies are ide-
or voids in an image to create a finite el- ally suited to leverage cluster comput-
ement mesh (FEM) that was representa- ing but can create enormous amounts
tive of local discontinuities. When you of data that must eventually be mined
consider the porous media illustrated in for trend plots. In Version 4.2a, COM-
Figure 3, where the black areas are open SOL allows users to run these resource
to flow and the wide regions represent ob- intensive studies but then save only the
structions, repetitive tracing—even with user-defined output required to generate
edge detection tools available in image- these plots.
editing software—would still make creat- Joined datasets have been added to
ing a mesh tedious. COMSOL Version 4.2a to allow cross-
COMSOL Version 4.2a now offers a study data comparison. Users are now
much more efficient means where a mesh allowed to compare results across similar
is created over the image itself, using the datasets at different points in the time his-
pixel content to determine mesh density tory—and even with dissimilar meshes.
and property distribution. The user has Output variations from boundary condi-
additional mesh control tools if needed. tion, flow media properties and even mesh
COMSOL can utilize binary (black-and- density can be readily evaluated for greater
white), grayscale and color images. Users insight to the problem at hand.
can define thresholds based on the image Looking ahead, COMSOL Version
color so clean edges aren’t required. 4.3 is set for release this month. Users
In addition to non-homogeneous can look forward to enhancements to the
materials, many electronics manufactur- nonlinear structural solver, which will
ers requested and are using this tool for provide more material models. Version
structural, thermal and electromagnetic 4.3 will also feature two new modules for
analysis of printed circuit boards (PCB). corrosion and pipe flow. DE
With trace density increasing yearly, this
image processing-based mesher has re- Vince Adams, an account manager for LMS,
duced simulation setup time significantly. is a simulation educator, consultant and speaker.
(See Figure 4.) He has authored three books on finite element
A fourth notable enhancement to analysis and many magazine articles. Contact
COMSOL Version 4.2a is the ability him via [email protected].
to import and mesh digital elevation
maps (DEMs). These standard 3D data
formats were developed to represent INFO ➜ COMSOL Inc.: COMSOL.com
geographic or terrain features in the For more information on this topic,
mining, oil and gas, and other civil visit deskeng.com.

deskeng.com /// May 2012 DESKTOP ENGINEERING 31

de0512_Review_COMSOL_Adams.indd 31 4/15/12 10:59 AM

 Simulate /// Direct Modeling & Simulation
Part 2
Direct Modelers as FEA Pre-Processors
Direct modeling and CAD-integrated FEA propels design optimization.
By Kenneth Wong

I
n the past, over-engineering was an IronCAD, the goal was to make both limits your models to 10,000 nodes. To an-
accepted way to cope with uncer- modeling paradigms available to the user alyze mesh models with a greater number
tainty. Today, design optimization has without the overhead of trying to figure of nodes, you’ll need to purchase a license.
replaced over-engineering as the recom- out which is right for a particular task and From within IronCAD’s model-
mended approach to dealing with uncer- what portions of the feature are what.” ing window, you’ll be able to mesh your
tainty. Two recent trends—the integration Many direct modeling operations rely model, add constraints, add loads, define
of direct editing into history-based CAD on the CAD software’s underlying kernel materials, and solve the analysis scenario.
modelers, and the marriage of sophisti- to resolve geometry conflicts when you The results can be displayed as contour
cated finite element analysis (FEA) soft- push and pull on faces, or create complex maps, displacement maps and animation
ware and design software—are poised to fillets and shells. IronCAD relies on two files. Integration with IronCAD’s model-
drive design optimization even further kernels—ACIS and Parasolid—to per- ing tools allows you to edit the model in
upstream. Parametric, or history-based form conflict resolution in its geometry. the same environment where you ran your
modeling, is favored by those trained in The software accommodates working analysis, with the mesh on or off. A modi-
classic CAD programs. Direct modeling in traditional history-based methods, but fied version of your design can be resub-
is favored by FEA experts who must adjust it also offers what it describes as direct face mitted to Nastran for updated results.
and refine the design, but don’t necessarily modification (DFM) to let you move faces
have the expertise required to dissect and by dragging and dropping. DFM opera- LiveShape Reshaped CATIA
understand the feature history of a design. tions let you break history dependency, ef- Dassault Systèmes’ direct modeling tech-
CAD-integrated simulation tools fectively throwing you in the direct-mod- nology, dubbed Live Shape, made its
have also become more sophisticated. In eling environment. debut in CATIA V6. Customers got their
higher-end design programs like NX and IronCAD uses a TriBall with dynamic first glimpse of it during Dassault Sys-
CATIA, users have the option to invoke handles to let you push, pull and reposi- tèmes’ European Customer Conference
analysis tools for heat transfer, fluid flow, tion geometry (and handle other aspects 2008 in Paris. Its Group Creation function
air flow and other scenarios beyond simple such as images and animations). The han- lets you select a feature and a series of re-
stress and load analysis. The couplings in dle may also be used to easily create dupli- lated surfaces (perhaps nearby blends and
both fronts—the merger of history-based cate copies of solid geometry and position extrusions) to create a group, then move
modeling and direct modeling, and the them in 3D space. the grouped faces and features to a new
merger of CAD and FEA—are opening With the dynamic handle, you don’t location by dragging and dropping.
new possibilities in design optimization. need to insert a construction plane to CATIA’s Live Shape also lets you add
place the new geometry, or refer to other relationships between groups (for exam-
A Overlooked, Familiar Name geometry for positioning. IronCAD also ple, a coincidence constraint between two
It’s quite possible that someone shop- allows the copies to be independently geometry groups). With such a constraint,
ping for a direct modeler might inad- edited and moved. The software’s Smart- when you move one group of geometry,
vertently overlook IronCAD, simply be- Snap function identifies snap-worthy lo- the related group follows to retain the
cause the company hasn’t made a great cations—such as midpoints of edges and constraint specified.
effort to pitch the software as such. But center points of radiuses—to let you place CATIA Live Shape, according to Das-
for the push-pull operations possible in and refer to features with precision when sault, is a direct-editing modeler which en-
IronCAD, and for the software’s accom- dragging and dropping. ables hybrid modeling such as solid, surface
modation of both history-based modeling or wireframe modeling. Jacque Leveille,
and history-free methods, it belongs in the Nastran for IronCAD Dassault’s vice president of product market-
hybrid modeler family. Recently, IronCAD struck a partnership ing for the CATIA product line, said direct
In a memo to the IronCAD user with CAE vendor NEi. The outcome is modeling is expected to offer greater flex-
community, IronCAD Vice President NEi Nastran for IronCAD, a FEA pro- ibility in “3D conceptual design phase, 3D
of Product Marketing Cary O’Connor gram that runs inside IronCAD software. collaboration, downstream use, especially
wrote, “Going back to the inception of The free version of Nastran for IronCAD analysis, and [editing] imported geometry.”

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 SIMULIA, Dassault Systèmes’ port- tomatically prompt an update to the CAE
folio of simulation solutions, can be in- model and results.
tegrated with CATIA V5 and works on “NX CAE users can import geom-
the same platform than CATIA in V6. etry from another CAD system, modify
These integrated solutions, according to it using Synchronous Technology, capture
the company, “eliminate the transfer and the changes as parameters, and use that in-
translation of geometry and allow users to formation to drive design optimization—
perform analysis directly on their refer- all this without leaving the NX environ-
ence model in CATIA.” ment,” says Shankar.
Tim Webb, SIMULIA’s director of
marketing communications and programs, iPhone Convergence Lessons
notes that the integrated simulation solu- A little more than a decade ago, cameras,
tions that work with CATIA LiveShape BlackBerries and cell phones were dis-
also include ExSight for simulation spe- tinctly different devices. Each performed a
cialists and DesignSight for those without specialized communication function.
extensive FEA experience. They “leverage The genius of the iPhone was the el-
the full feature-based and direct modeling egance with which it consolidated these
capabilities of CATIA, while eliminating operations into a single device.
the transfer of geometry between CAD Similarly, when several subsets of de-
and FEA packages.” sign engineering are consolidated, we
benefit from the ability to take our digital
Design and Analysis in Synchronicity assets from conceptual phase to analysis,
In earlier incarnations of Siemens PLM then back to CAD without shuttling the
Software’s Synchronous Technology data back and forth among several differ-
(ST), the difference between NX with ent software programs, without the risk of
ST, the company’s high-end CAD/CAE/ data loss and corruption.
CAM solution, and Solid Edge with ST, It’s only a matter of time before di-
the company’s midrange CAD software, is rect editing becomes a standard tool-
much more apparent. set of mechanical modelers. Five years
Earlier versions of Solid Edge with ST from now, few CAD users will be asking
required users to fully commit to a history- whether a software program is a direct
free mode. By contrast, NX with ST gave modeler or a parametric modeler, just
users the option to work in a hybrid envi- as nobody today asks whether your cell
ronment. The difference, however, may be phone can also send and receive texts
getting slimmer as SE with ST begins to or take photos. And it’s only a mat-
incorporate the hybrid modeling mode, ter of time before design optimization
beginning in SE with ST3. For those who becomes part of every phase of design,
rely heavily on simulation and analysis, NX not just the quality control phase or the
CAE—a version of NX delivered with inte- post-production certification phase. No-
grated simulation tools—is available. body will ask whether your design has
“NX is one of the leading applica- been optimized, because, with the tool-
tions that integrate high-end simulation sets you have at your disposal, everyone
with direct geometry modeling,” says will expect it to be. DE
Ravi Shankar, Siemens PLM Software’s
director of simulation product market- Kenneth Wong is Desktop Engineer-
ing. “When ST was first introduced ing’s resident blogger and senior editor. Email
[about five years ago], people thought him at [email protected] or visit
this would be great for design. I think deskeng.com/facebook.
people didn’t realize the potential for
CAE engineers.” This article has been edited due to space
With NX CAE, the design model and constraints. Access the full version, and
the simulation remain associative; any all of DE’s recent direct modeling series,
changes made to the design model will au- at deskeng.com/direct.

deskeng.com /// May 2012 DESKTOP ENGINEERING 33

de0512_DirectModeling_Update_Wong.indd 33 4/15/12 11:01 AM

 Prototype /// Additive Manufacturing

Comparing Additive
and Subtractive Processes
Cost, volume, geometry and tolerancing are differentiators in what
technology to choose for mold making.
BY SUSAN SMITH

S
ince additive manufacturing (AM) has been on the scene, “We actually make molds via CNC injection molding in-house,
the technology has grown in its capabilities—including and we usually use our additive manufacturing for one-off proto-
expanding into the realm of mold making. The AM types to get the form working, and then we’ll make a mold for our
market itself is growing by leaps and bounds, according to the customers,” he continues. “But we do use additive manufacturing
Wohlers Report 2011. Wohlers Associates predicts that by 2016, in production for fixturing. So in production, we use 3D printing or
the sale of AM products and services will reach $3.1 billion additive manufacturing for post-processing and fixtures.”
worldwide. The industry is expected to hit $5.2 billion by 2020. For VistaTek, AM is used as a preliminary process before
AM offers some advantages to subtractive, computer nu- going to CNC. Some customers use it to build 100 small
merically controlled (CNC) and injection molding. parts before needing injection-molded parts that have to be
built somewhere else. For this, they may use PolyJet pro-
Case in Point cesses or Stratasys Fused Deposition Modeling (FDM).
As a service bureau, VistaTek’s customers range across a For 3D printing, VistaTek uses Objet’s Kryptogreen, a
number of industries. It has six 3D printers, five of which are newer material that is a blend of two materials. It is strong and
Objet machines. Based in Vadnais Heights, MN, its custom- durable, with good resolution. Objet RG5160 is popular for
ers include many medical, consumer electronics and consumer the soft-touch overmolding abilities. Overmolding is the use
goods firms. It also has a number of hobbyists who create their of two separate materials for a single cohesive component, a
own designs on Google SketchUp or lower-end CAD systems. technology for which Objet Geometries is well known.
Because VistaTek offers both subtractive and additive AM technologies really address complex geometries,
manufacturing, it can compare the two processes. Allen Mischek points out.
Mischek, director of AM for VistaTek, says the tolerancing “If people need parts quick, CNC is not typically done as fast
“isn’t there yet for AM.” as rapid prototyping,” he explains. “You can do overmolding in
However, the ability to make lower-volume prototypes is
one reason that AM is growing so fast, according to Mischek:
“We use additive manufacturing for patterns for room-tem-
perature vulcanization (RTV) or cast urethane.

Ring casting created with 3D Systems’

ProJet CPX wax printer.

34 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_AMmolds_Smith.indd 34 4/15/12 10:42 AM

 Objet where you can’t do overmolding in a CNC machine.”
With CNC, however, you can use real plastics and metals. ACCURATE | POWERFUL | INTEGRATED
“With 3D printing, you have a wide variety of technologies
and different metals and plastics, and powders. We have done
studies of direct digital manufacturing vs. additive manufactur-
ing and CNC machining and injection molding, and where it
makes sense to use each technology. There’s always that break
even usage related to material specifics and quantities,” says
Mischek. “Those are the main factors as to when you’d use
rapid prototyping vs. CNC machining or injection molding.”

Material Durability
Ido Eylan from Objet Geometries in Israel says the com-
pany’s ABS-like material that is being printed on Connex
platforms allows users to print the same molds and geom-
etries with their previous materials. ABS-like demonstrates a
longer life length of the printed tools.
“If I print a certain mold with VeroGray and use it, it will
probably last for less shots than the ABS-like material,” says
Eylan. “That’s why we feel this application is going quite well
together with ABS-like material.”
The two ABS-like materials Objet manufactures are not
as good as metal tools, according to Eylan. Metal tools last
longer; they can also have better accuracy and edges.
“On the other hand, it takes weeks to produce them—and
with us, it’s only a matter of hours,” says Eylan. “Also, cost
is an issue, that depends on where you are. In the Far East,
CNC is much cheaper than in Europe and the U.S.”
The prototypes printable on Objet printers can be first-run
or short-run for the injection molder to test parts. If customers
have to test a design over certain parts, they can print a pro-
totype, but if they want a prototype to be actually tested, the
functional testing has to go hand-in-hand with the end material.
“In this case, there is no prototyping platform that can
actually do this,” says Eylan. “What we can do now is print • Reverse engineering
the first tool very quickly and very cheaply, inject the real directly into CAD
material and then you get the first rough prototype with the
end material. This may require more than one tool, depend- • Data directly into 3D polygons
ing on complexity, and tool lifespan.”
3D Systems, a company that has acquired a number of • 3D Inspection and metrology
companies over the past year in order to offer a broad range of using scan and probe data
services, helps people get parts printed or developed through
a variety of molds and/or patterns—either for multiple prints
or even a one-to-one print using some of its technology. 3D
Systems currently offers three different categories of devices: www.geomagic.com
• Personal devices, such as ProJet 1000 for BitsforBytes products. Download Your Free Trial Now
• Professional products for office environments.
• Industrial professional products.
The latter two categories would use stereolithography
(SLA), selective laser sintering (SLS) or Multijet modeling © 2012 Geomagic, Inc. All rights reserved. Geomagic, the Geomagic
logo, Geomagic Studio, Geomagic Qualify, Geomagic Wrap, Wrap,
printhead technology (MJM). Geomagic Qualify Probe and ‘the magic of making it simple’, are all
Scott Turner, a 3D Systems researcher, says the company trademarks or registered trademarks of Geomagic, Inc.
started direct metal printing with its technology several years ago.

deskeng.com /// May 2012 DESKTOP ENGINEERING 35

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 Prototype /// Additive Manufacturing
“It was a two-step process, using SLS as the baseline and
infiltration to get you to a near-metal part, but since then
we’ve moved forward with other technologies—and even at
that same time, we were doing molds and patterns,” he says.
“People can get the outputs they want without having to wait
for the miracle of direct metal, which is turning out to be
very expensive and time-consuming, and also not necessarily
perfect for any parts that are over a certain size.”
The quick turnaround, geometry, affordability, automa-
tion and lack of waste are key criteria to why people choose
an AM process over CNC for making prototypes and molds.
“For a shape that is complex, organic, that has to have
fine-featured detail that’s super smooth, it really is better
served by using something like additive manufacturing,”
Turner concludes. DE

Susan Smith is a contributing editor for Desktop Engineering mag-

azine. Send e-mail about this article to [email protected].

3D Systems’ iProTM 9000 SLA Production Center INFO ➜ 3D Systems: 3DSystems.com

“prints” QuickCast Patterns that reduce the time ➜ Matsuura: Matsuura.co.jp
and cost of producing turbines used in custom-
➜ Objet Geometries: Objet.com
ized hydro-electric power plants.
➜ VistaTek:VistaTek.com

W W
Design. Print. WOW!
WITH THE MATRIX 300

Join us at RAPID 2012, stand 126 and experience www.mcortechnologies.com

unfettered innovation™ low cost, high quality, ecofriendly 3D printing [email protected]
Prepare to be WOWED…

36 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_AMmolds_Smith.indd 36 4/15/12 10:43 AM

 Reusing Models /// Design

Designs Live On and On

From collaboration and rendering to technical manuals, your design can live on through
neutral file formats.
BY KENNETH WONG

Y
our job as a design engineer may
end with the delivery of your 3D
CAD files to the manufacturer, but
not so for your CAD files. They continue
to serve as the basis for photorealistic ren-
derings in a glossy product catalog, illus-
trations in an instruction booklet, or web-
hosted movies showing how to remove
the internal components of your assembly.
Sometimes, even before you have finalized
your design, you may need to share it with
others so they can produce certain assets AutoCAD WS, available for free from Autodesk, lets you view, edit and annotate
that are ready when the product ships. DWG files from a browser, effectively eliminating the need to install a professional
Those who are expected to work with software title (such as AutoCAD) to interact with the popular 2D format.
your design may have little or no CAD
exposure. For effective reuse of your de- DoubleCAD XT (free, with the option to Inventor. But because of the different ge-
sign, you need to provide it to them in an upgrade to a professional version); Das- ometry kernels they license and employ,
appropriate format, with enough informa- sault Systèmes’ DraftSight (free, runs on and variations in the way they process and
tion for them to do what they need to do. Windows, Mac, and Linux); and Gräbert’s translate 3D data, you may need to apply
Here are a few basic rules to guide you ARES ($795, runs on Windows, Mac, and fixes and healing operations to complex
through the neutral-file jungle. Linux). SolidWorks offers the free desktop surfaces post-import.
DWG viewer, eDrawings; Autodesk’s Au- Almost universally, major 3D CAD
DWG Rules toCAD WS, available for free, gives you the packages support neutral formats, such as
Many engineers and designers have mi- ability to view, edit, and share DWG files IGES, STEP, JT, STL, ACIS and Para-
grated from their 2D drafting systems to from a browser window; and IMSI/De- solid. They serve as an intermediary step
3D mechanical CAD programs. But for sign’s TurboViewer, also free, brings view- when sending the original CAD file is not
legal contracts and paper archives, 2D is ing functions to mobile devices. Bentley possible (the recipient doesn’t have a way
still preferred. The dominant format is Systems and Autodesk software can read to open it) or advisable (you have con-
DWG, the standard output of Autodesk’s and write each other’s formats. Bentley’s cerns that your design could be reverse-
AutoCAD. It’s also possible to use Intelli- free Bentley View software, for instance, engineered). They offer the recipient the
CAD Technology Consortium’s and Open lets you read not just Bentley’s DGN for- meat of your design—its geometric shape,
Design Alliance’s technologies to produce mat, but also Autodesk’s DWG files. mass, volume and a limited understanding
DWG files. of its substructure—but not the recipe to
The format is widely supported by 3D Exchange of Competing CAD your design, so to speak.
3D CAD programs, both for import and Say what you will of the CAD vendors Among these formats, STL has
export, because CAD users must still deal and their fierce rivalry, but you must give emerged as the standard for 3D printing.
with design documents saved as 2D draw- them credit for doing a fairly good job at With this format, you may send your de-
ings over the years. enabling interoperability. Many programs sign to a service bureau or use a 3D printer
In the last five years or so, several draft- can now, in fact, read parts and assemblies (from Objet, 3D Systems or Stratasys, for
ing programs that cost less than AutoCAD from competing vendors’ programs. example) to literally turn your digital de-
have emerged—giving you a way to read, For instance, you may open an Au- sign into solid shape. Being a collection of
edit and even create from scratch DWG todesk Inventor file in SolidWorks, and meshes, STL is also widely used for simu-
files. The list includes IMSI/Design’s you may also open a SolidWorks file in lation and analysis.

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 Design /// Reusing Models

PTC Creo MCAD View, an independent app, lets you With the formation of the 3D PDF Consortium, Adobe’s 3D PDF
view PTC Creo CAD formats, neutral 3D formats is poised to become a popular format for transmitting interactive
and native CAD file formats from other vendors. 3D documents. Shown here is Acrobat X Professional with Tetra
4D’s plug-in, allowing you to create 3D PDF documents.

Finite element analysis (FEA) ex- game, digital content creation and media Tech Pub, Markup and Mobile
perts who study and analyze 3D digital industries, but the rise of a new crop of Using a lightweight 3D file format for
design files for stress resistance, load ca- rendering programs targeting casual users collaboration—usually the domain of
pacity, thermal performance and other has made it possible for engineers un- viewing and markup applications—is a
simulated tests are not necessarily CAD trained in high-end rendering and anima- long-established market, but CAD soft-
software experts. Furthermore, a CAD tion software (such as Autodesk 3ds Max, ware developers’ attempt to conquer the
file often contains far more information Maya or Alias) to easily churn out render- technical publication market, along with
(feature history, manufacturing informa- ings from CAD files. the rise of mobile devices, adds new twists
tion, etc.) than FEA experts need. They Such CAD-friendly rendering pack- to the old usage.
need, most of all, the basic geometry of ages—Luxology’s modo 601 with CAD By and large, general 3D design file
the design, preferably with insignificant loaders, Luxion’s KeyShot, Bunkspeed’s viewers (like Oracle AutoVue, PTC Creo
details stripped out. For these reasons, SHOT, and Dassault Systèmes’ 3D VIA View MCAD, Dassault Systèmes’ 3D VIA
STL—or another neutral format—is Composer, to name but a few—can ac- Composer Player, and Lattice Technolo-
usually requested for analysts. cept and work with native CAD formats, gy’s XVL Player) support neutral formats
Initially developed by Siemens Product such as Autodesk Inventor, SolidWorks commonly exported from CAD programs
Lifecycle Management (PLM) Software, and Solid Edge files. However, users may and some native CAD formats. Recently,
JT has been accepted by the International find that, because of size and complexity, common preference seems to have shifted
Organization for Standardization (ISO). working with native CAD files may make from desktop and laptop machines to mo-
“Any company working with 3D the software less responsive. bile devices in performing collaborative
digital product data in a heterogeneous By contrast, loading the design as a tasks (annotating design proposals and
environment requiring interoperability neutral file format (IGES, STEP) may approving design changes, for example)
between internal departments or with make the software far more responsive. and data-management operations (verify-
external suppliers and partners can ben- Because of the nature of rendering op- ing project status, recording change his-
efit from the use of JT,” notes Bruce erations, formats that display the design tory, and managing read-write privileges).
Feldt, vice president of Open Tools, Sie- as polygons, meshes and surfaces work The wide range of mobile apps that have
mens PLM Software. “And now that its best. Leading rendering packages support recently sprung up indicates the move to
documentation has become an official COLLADA, FBX, OBJ and other formats lighter, portable, touch-enabled devices.
ISO publication, JT is reinforced as the better suited for rendering. It’s the Wild West of expansion in down-
benchmark for openness in the PLM do- Though not a professional design tool, stream 3D data use.
main—paving the way for virtually any Google SketchUp’s file format has also Most major CAD vendors, includ-
manufacturer to adopt JT as their com- found a place in many rendering pro- ing Siemens PLM Software and Das-
mon enterprise format for 3D workflows gram’s import menu. The abundance of sault Systèmes, provide mobile apps that
and long-term data retention.” free 3D models available in the SketchUp can open and view file formats associated
format at the Google 3D Warehouse with their primary 3D platforms. Siemens
Rendering for Engineers makes the file type attractive to beginners, PLM Software’s Teamcenter Mobility,
Photorealistic rendering or ray-traced casual users and those in the do-it-yourself for instance, opens and reads JT, the pre-
rendering is often the domain of film, maker community. ferred lightweight format exportable from

38 DESKTOP ENGINEERING May 2012 /// deskeng.com

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 how/// Design
Reusing Models
to:
the company’s Solid Edge and NX CAD Courting those who may want to PRINT
IN 3D
programs. Similarly, Dassault Systèmes’ repurpose 3D CAD data for technical
3DVIA Mobile and 3DVIA Mobile HD manuals, many CAD software makers are
lets you access and view 3D files that are releasing their own easy-to-use technical
uploaded and stored in a secure cloud on manual publishing software titles. The
3DVIA.com. Supported formats include lineup includes Autodesk Inventor Pub-
SolidWorks, CATIA, 3DVIA Shape, lisher, Dassault Systèmes’ 3D VIA Com- today
3DXML, 3DVIA Composer and a host of poser and PTC’s Creo Illustrate. With an e o n ly ship !
Th prints
other 3D formats. PTC’s newly released eye toward the same market, third-party
e r o f 3D
Windchill Mobile lets you view and in- software maker Lattice Technology also provid
terrogate Creo View MCAD models, a offers XVL Studio. Nearly all these pro-
lightweight format used by the company’s grams offer an option to export the results
Creo product line. as PDF. Because technical instructions are
Visit
Third-party tools, like CadFaster’s better delivered as animation files, these 1. zoomrp.com
QuickStep, by contrast, gives you a way programs also offer ways to export com- We’re your one-stop-
to view more neutral formats (IGES, mon movie file formats. shop for 3D printing. We
STEP, DWG, DXF and HSF). Another The differences among these CAD- offer PolyJet, SLA, SLS
alternative is Titansan Engineering’s based tech publishing software titles may and ABS.
VueCAD app for iPad. It supports a be twofold:
number of neutral files, including IGES, 1. the comprehensiveness of neutral
STL, JT, 3ds Max and Collada. With an and native file formats supported; and securely!
upgrade, the app lets you view some 2. the learning curve involved in mas- 2. upload file
native formats, including SolidWorks, tering the tools for producing interactive You can upload as many
Solid Edge, CATIA, Pro/ENGINEER, documents. files as you’re ready to
and Autodesk Inventor. print. Review quantities
For mobile apps addressing enterprise Lightweight Benefits and prices and select
data management (EDM) and PLM, ge- 3D CAD files with detailed feature his- your shipping option for
ometry alone may not be sufficient. The tories are the lifeblood of manufactur- all your parts at once.
neutral format must also be able to retain ing, but they also prove too unwieldy for
and display tolerances, material specifica- collaborators and subcontractors who
tions, supplier information, part numbers need only a fraction of the information
and other relevant metadata. For such (usually just its basic geometry, surfaces Place Order
applications, 3D XML, JT, and other or meshes). The primary advantage of
metadata-rich formats are more suitable using a neutral format is its compact- 3. push button
than strict geometric formats like IGES, ness, portability (via mobile apps), and It’s really that easy. Our
STEP or STL. metadata-housing capacity (its ability returning customers
With the formation of the 3D PDF to retain and display material info, part come back for simple
Consortium, 3D PDF is also poised to numbers and other attributes). convenience. We take the
become a commonly used format to de- But the formats themselves, like overhead, the guesswork,
and the wait out of
liver and communicate design changes, any computer file format, are just a
production every time.
technical instructions and design review series of binary codes. They’re useless
notes. As a format, PDF is already widely if they do not enjoy the support of a
accepted, thanks to the free PDF viewer’s wide range of independent viewers and
dominance outside engineering. mobile apps. DE
A plug-in from Tetra 4D enables
Adobe Acrobat Professional users to Kenneth Wong is Desktop Engineering’s
produce 3D PDF documents with em- resident blogger and senior editor. Email him
bedded annotations, animations and at [email protected] or share your
cross-sections, viewable by anyone with a thoughts via deskeng.com/facebook.
free PDF viewer. SHARE3D, a solution
from QuadriSpace, lets you create 3D For links to all the companies mentioned
PDF documents using a template-driven in this article, see the online version of
approach. the article on deskeng.com.

deskeng.com /// May 2012 DESKTOP ENGINEERING 39

de0512_Reusing_Models-Wong.indd 39 4/15/12 10:45 AM

 Engineering Computing /// Large-Format Printing and Scanning

Print & Scan via the Cloud

Manufacturers respond to an increasingly mobile engineering workforce.
BY JAMIE J. GOOCH

T
he “paperless office” has gone from a seemingly reason- always-connected world. The company’s answer was to web-en-
able prediction popularized in a 1975 Business Week ar- able its printers via a set of features it dubs ePrint & Share, which
ticle, to a myth as paper consumption doubled between allows engineers to directly scan project files to the cloud, print
1980 and 2000, to a somewhat plausible scenario while U.S. and access plans from the road, share designs with remote project
office paper declined 40% from its peak in 2000. teams and collaborate with design partners around the world.
But engineering schematics are still easier to read on 44-in.- In addition to printing to registered printers via the ePrint &
wide sheets of paper than 10-in. tablet screens. Large-format Share desktop or iOS apps, Eric DuPaul, Designjet business devel-
printer and scanner manufacturers haven’t sat on the sidelines opment manager for HP, says users of AutoCAD 2009 and later can
as design engineers have become increasingly mobile though. print via a plug-in that allows them to create a PDF while printing
a file, including all the print settings, and save it in the cloud. Users
HP Shares can also access the ePrint & Share application from the front panel
“We’ve seen people becoming more mobile and the wanting of certain printers, including the HP Designjet T790 and T1300,
the ability to access content remotely, but there wasn’t really a and the HP Designjet T2300 eMultifunction printer.
clean way to handle secure access, revision control, and print- HP’s recent announcement of its plans to merge its printer
ing,” says Todd Hatfield, HP’s Designjet large format category and PC/workstation business could lead to further integra-
manager for the Americas. tion of web technologies into its printers, but it’s not the only
HP needed ways to make printers and scanners available in an manufacturer looking for expansion via the cloud.

Océ Launches New Large-Format Systems

O
cé recently announced three new large-format printing systems. The Océ PlotWave 350 monochrome printer, the Océ
ColorWave 650 printing system that can print in color or black and white, and the Océ PlotWave 900 monochrome print-
ing system, which is designed for high-volume production printing.
Océ says the WebTools-enabled PlotWave 350 can print up to six D-size plots in one minute, with virtually no warm-up time. It uses
the company’s new 2.0 print driver for Microsoft Windows, which includes a “What You See is What You Print” preview. It is designed to
print, copy and scan low volumes of technical documents.
The Océ ColorWave 650 printing system uses the company’s CrystalPoint solid toner technology to print in black and white and color
at up to 210 D-size prints per hour. The system can hold up to six media rolls and prints come out dry, cut to size and ready to use. It
also features copy and scan templates that can be customized to simplify routine tasks.
The Océ PlotWave 900 printing system is designed for high production users. It prints up to 10 E-size prints per minute, even when
printing mixed sets, according to the company. Users can print on different sizes of media from six media rolls, at consistent speeds,
with automatic switching for uninterrupted printing. It delivers 600 dpi print quality.

Océ PlotWave 350 printer Océ PlotWave 900 printing system Océ ColorWave 650 printing system

40 DESKTOP ENGINEERING May 2012 /// deskeng.com

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 Océ Goes Mobile of Océ’s customers are interested in adding cloud services
Océ, which joined the Canon Group of companies in 2010, to their workflow. Large enterprises often have their own
has introduced two cloud products: Océ Mobile Tools and cloud networks, allowing engineers to access their files from
Océ Mobile Plot. multiple office locations, for instance. But smaller firms often
With Océ Mobile WebTools software, users who have ac- don’t have that luxury. That’s where cloud printing services
cess to a Wi-Fi router on their network can retrieve techni- can really shine.
cal files from the cloud using their mobile device and send Both Océ’s Vecci and HP’s managers say they are still dis-
a print request to their Océ PlotWave 350 printing system. covering how engineers want to make use of being able to
Users can also print from, and scan documents to, a USB print and scan via the cloud.
flash drive or to their mobile devices using Océ Mobile “We want to present more options,” says Vecci. “As we see
WebTools software to capture changes and documents on more customers moving from print shops to internal, decen-
the go, or print via Océ Publisher Select software to produce tralized printing environments, we’re trying to develop tools
documents for complex projects. to accommodate any workflow out there.”
“That’s accessing the device via a browser from any mo- “As more and more people use the cloud, they’re find-
bile device,” says Andrew Vecci, director of Marketing at Océ ing it’s able to accelerate turnaround time for changes,” says
North America, Inc. “Users are able to submit prints to the HP’s DuPaul. “It helps facilitate a faster workflow. The use of
printer and pull scans from it to view on their devices.” tablets and smart phones is going to drive demand for print
Océ Mobile Plot is an iPad app that, after a one-time mobility much more significantly in the future.” DE
setup, allows users to print files they can access on their iPads
via email or other apps, including cloud-based apps such as Jamie Gooch is the managing editor of Desktop Engineering.
Dropbox, and print to up to five Océ TDS, TCS, PlotWave Contact him at [email protected].
and ColorWave plotters, old or new.
“As long as you can access the file on your iPad, you can
send it to the printer,” says Vecci. INFO ➜ HP: hp.com
He notes that, while mobile printing and scanning is ➜ Océ: oce.com
still in its infancy in the technical document market, many For more information on this topic, visit deskeng.com.

HP’s Large-Format Offerings

H
P’s portfolio of web-connected, large-format Designjet ePrinters includes the HP Designjet T1300 for large
work groups, the HP Designjet T790 for small, mobile technical design teams, and the HP Designjet T2300
eMFP that has print, scan and copy functionality.
The HP Designjet T790 is designed to enable small teams to produce computer-aided design drawings while
collaborating with colleagues in a connected work environment. It is available in 24- and 44-in. models, which fea-
ture a top-loading roll and 8GB of memory.
The HP Designjet T1300 has two media rolls and smart switching technology, as well as the ability to print up
to two A1-sized prints per minute. It can print on paper up to 44-in. in size.
The HP Designjet T2300 eMFP was designed for medium and large architecture, engineering and construction
firms and enterprise businesses. It has two online media rolls and simultaneous copy and scan functions, a color
touchscreen interface, and driverless printing for direct printing from a notebook PC or USB drive.

HP Designjet T790 HP Designjet T1300 HP Designjet T2300

eMultifuntion printer series

deskeng.com /// May 2012 DESKTOP ENGINEERING 41

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 Simulate /// Design Optimization
Part 1

Opting for Optimization

Find out how this powerful concept can rev up your analysis tools.
BY PAMELA J. WATERMAN

G
ood. Better. Best. You often see these terms on product
families ranging from carpeting to computers. The
choices span options including price, performance,
durability and visual appeal. But in many ways, this phraseol-
ogy also captures the vision of a typical engineering design
sequence—except that the process generally stops at “better.”
Product R&D schedules leave little time for finding the design
that goes beyond “better” to “best.” Robert Ryan, president and
CEO at Red Cedar Technology (developers of HEEDS MDO
optimization software), says that typically, “with CAE models,
once you prove they’re pretty good, you tweak the design within
the design space near what you’ve already done, and do a little
better. Rarely have designers gone for dramatic improvement.”
To do so requires a methodical optimization process that
searches among alternative designs, but a manual approach is Workflow example for VisualDOC multidisciplinary
time consuming and even an automated design-of-experiment optimization software, showing graphical user interface to
(DOE) approach may miss an opportunity in the big picture. set up, execute and automate a design optimization process.
Garret Vanderplaats, founder and CEO of Vanderplaats Image courtesy of Vanderplaats Research & Development.
Research & Development (VR&D), an optimization software
company, says that DOE tends to focus on individual parame- past several decades have also witnessed the development of
ters—yet valid design explorations require a systematic search generalized, standalone optimization packages.
process that emphasizes promising regions in the design space. These tools apply optimization to the design parameters
Designers often strive to tweak a design to give the best per- and functional results of pretty much any analysis software—
formance for a few critical conditions, ignoring the issues of real- whether structural, fluid dynamics, chemical or financial—as
world manufacturing variation (such as geometric variation) and well as to any task, from minimizing weight to maximizing cool-
operational variation (such as temperature variation). ing, to predicting the probability of part failure. Much of the
“Today, the challenge is not so much finding the global opti- power of these standalone solutions lies in their ability to link
mum, but the robust global optimum,” notes Alex Van der Velden, together multiple analysis tools for a single product design, and
director of Design Automation Products at SIMULIA. “Many optimize the product across broad performance characteristics.
optimization methods push the design against the failure limits, so
even small operational variations would lead to failure. If a prod- Power Players
uct design is based on a robust global optimum, such a product is Part of the reason optimization is not done more often is that
insensitive to variations. This is the definition of product quality.” few people teach it in the first place. Even so, according to
Optimizing, say, just for structure gives different answers than Vanderplaats, it tends to be taught as applied math, not engi-
optimizing a part for cost. Tackling this multi-faceted problem neering design, and then only at the graduate level.
demands software for multidisciplinary optimization (MDO), Vanderplaats certainly knows his field: In the early 1970s, he
whose beauty comes from the ability to automatically evaluate developed an optimization code, CONMIN, that is still widely
hundreds—or thousands—of design combinations. used. In the late 1980s, his company developed the optimiza-
Many finite element analysis (FEA) and computational tion capability for MSC Nastran. And in the early 1990s, VR&D
fluid dynamics (CFD) analysis packages offer some type of wrote its own GENESIS software that was “a little FEA and lots
optimization tool, such as in MSC.Software’s MSC Nastran; of optimization,” but today is quite a bit of both. Along the way, he
the Design Study Environment in Autodesk Simulation CFD created a general-purpose, multidisciplinary optimization prod-
(formerly known as CFdesign); and the NISAOPT module uct, COPES, which is now a VR&D package called VisualDOC.
for NISA Mechanical design/analysis software. However, the VisualDOC’s capabilities include optimization, DOE, re-

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 sponse surface approximations and probabilistic (robust and reli-
ability-based) optimization. It can be used to add these capabili-
ties to almost any analysis program. Its optimizers are also used by
GENESIS, and can handle more than 2 million variables. GEN- Safety-design optimization
ESIS includes second-generation, physics-based approximations of roof crush and side impact for
that are more accurate than gradient linearization—and generate an automotive passenger compartment,
an optimum structural design for the cost of about 20 FEAs. performed with HEEDS MDO software. This problem had
SIMULIA, the Dassault Systèmes brand for realistic simula- 120 design variables and constraints on intrusion during side
tion products, markets both Abaqus nonlinear analysis software impact, minimum roof crush force, natural frequencies and
and Isight design optimization and process automation software. bending/torsional stiffness. The HEEDS optimized design
Since its acquisition in 2008 from Engineous, Isight has been met all constraints—while reducing the mass of the safety
continually enhanced (now at version 5.6), and offers direct in- cage by 23%. Image courtesy of Red Cedar Technology.
terfaces that support more than 30 FEA and CFD applications, first because it’s a simple way to get a handle on understanding
along with Excel and ASCII files. Much of the user interface is what’s important in the problem. To find the best dimensions
visual drag-and-drop, and results can be viewed in real time. for a part, for instance, Isight can combine and extrapolate re-
Van der Velden says that Isight gets designers out of their sults from 50 Abaqus runs to create a curve between the points,
“thought-ruts. It doesn’t ‘know’ you’re designing an airfoil or filling in expected response values for additional input values.
a beam,” he says. “It just takes the inputs it’s given, and drives Users can employ graphic “sliders” to see, in real time, the ef-
a solution toward the objectives of the design challenge. Be- fects of changing up to eight dimensions at once. Isight will then
cause an optimization algorithm has no preconceptions about perform a Six Sigma optimization to predict the probability of
results, it may very well give you answers—like an unexpected meeting a certain value (stress, for example), given variations in
shape or thickness—that are completely different from what another factor (material thickness, for example).
you envision. And they just may be better answers.” Red Cedar Technology’s HEEDS MDO software also per-
Van der Velden recommends using Isight to automate DOE forms process automation, design optimization, DOE and ro-

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deskeng.com /// May 2012 DESKTOP ENGINEERING 43

de0512_Optimization_Waterman.indd 43 4/15/12 10:51 AM

 Simulate /// Design Optimization
bustness/reliability calculations. Ryan notes that optimization and creates what company president Craig Collier calls “a level
tools have traditionally asked users to choose one of a dozen op- playing field for all the possible design candidates.”
timization algorithms, plus dozens of tuning parameters—tasks HyperSizer Pro imports FE models as well as FEA-com-
that generally required a doctorate to successfully complete. puted loads. Using non-FEA failure methods, the software
HEEDS MDO eliminates this complexity by providing a analyzes and quantifies safety factors, and eliminates negative
default search method called SHERPA. This hybrid process margins of safety for thousands of mechanical and thermal
uses multiple search strategies simultaneously, and dynami- load sets. It then optimizes to determine the lightest weight
cally adapts to the problem as it learns about the design space. combination of material systems, cross-sectional dimensions,
Users define the objective of the study, then just specify the and ply layups for all panels and beams in the structure, and
parameters to be varied, the fixed constraints and the number automatically iterates with FEA for load convergence.
of desired iterations. HEEDS does the rest. “What industry wants,” says Collier, “is not necessarily to let
Because automation can have its dark side, Red Cedar (the optimizer) run overnight, and come back in the morning.
Technology has made sure that its optimization process is not The software needs to expose what’s going on and be interactive.”
a “black box.” Users are encouraged to view a run’s progress He says a critical aspect for today’s large designs is that teams
and results, and change the direction in real time if the en- work independently, but must be able to bring all the subsystem
gineer’s intuition prompts a move in a different direction as designs together and have them be manageable for evaluating
results unfold. The software offers direct input/output portals throughout the design process.
for Abaqus, Adams, ANSYS Workbench, Nastran, LS-DYNA, Next month, in part two of DE’s design optimization cov-
Moldflow, SolidWorks, Excel and NX (input only). Generic erage, we’ll explore other contributors to this field, including
interface links also connect to any ASCII format file. Sigma Technology, ESTECO Phoenix Integration, Optimal
Collier Research HyperSizer software applies optimization Solutions Software and Openeering. DE
techniques to metal and composite structures for weight, strength
and durability, with strong support for certification procedures. Contributing Editor Pamela Waterman, DE’s simulation ex-
The software targets designs for aerospace, wind blades, com- pert, is an electrical engineer and freelance technical writer based in
mercial and military aircraft, high-speed rail and ship-building, Arizona. You can send her e-mail to [email protected].

Design Optimization 101

D
Design variables: Specifications the designer can con-
esigners can apply optimization techniques to a trol, including physical dimensions, material choice, and
single discipline (structures or aerodynamics, for parameters such as the number of blades in a turbine.
example) or a multidisciplinary problem (structures Design objectives: User-defined performance char-
plus aerodynamics plus propulsion plus control-theory acteristics to be maximized or minimized, such as fuel
plus economics, for example). A good introduction to the efficiency or mass.
subject can be found in a presentation by Il Yong Kim of Constraints: Typically, these are performance character-
the Department of Mechanical and Materials Engineering, istic levels that need not be maximized or minimized, but
Queen’s University, Ontario, Canada, at must be kept above or below a certain level.
qcse.queensu.ca/conferences/documents/IlYongKim.pdf. Solutions: Optimization algorithms combine the design
The process requires formulating the problem, then variables, constraints, objectives and models to find pos-
choosing and implementing a computational solution. sible sets of values that satisfy the defined problem. The
Here are some of the general components involved: software automatically feeds these values back to the
Simulation process flow: User-defined workflow of appropriate analysis software packages for a new round of
simulations and analyses to be performed, including task evaluation. Users choose the number of iterations to try,
order, software tool selection and data transfer. and specify what conditions define convergence.
Models: Each analysis in the process flow requires a The different optimization solutions fall into several
specific analytical or empirical model and representation. categories (listed with a sample type): gradient-based
These models connect inputs, such as design variables (feasible directions), gradient-free (Hooke-Jeeves pattern
and parameters, with output variables representing some search), population-based (genetic) and various others
measure of system performance. (simulated annealing and indirect optimization based on
Random variables: Parameters that are subject to self-organization, or IOSO). Some work better than others
variations due to chance, including manufacturing varia- on certain applications, and different packages may use
tion, material variation and operational variations such as different subsets. Improvements in HPC resources have
the ambient temperature of an electrical circuit or the wind definitely helped speed up calculations—and opened the
loads on a vehicle. door to parallelized functions. — PJW

44 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_Optimization_Waterman.indd 44 4/15/12 10:50 AM

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Simulation & Analysis /// Composites

Options for Composites

Analysis and Simulation
Find your comfort zone with
today’s software tools.
BY PAMELA J. WATERMAN
Expand Your Industry Exposure Starts at
$1100

F
iber-reinforced technology is seeing extensive use for
its low weight-to-strength ratios—as well as other
benefits. But working with composites is rarely a
1-2-3 process. If ever there was a need for close coopera-
tion among designers, structural analysts and manufactur-
ing engineers, this is the time, and optimization plays a key
role across the board. With dozens of software packages
Modal analyses (left) of carbon-fiber sounding board
for a dulcimer musical instrument (right), are performed
with NEi Nastran software by consultants at ALLRed &
Associates. Image courtesy of ALLRed & Associates.

are high compared to ‘traditional materials,’” explains

with Article Reprints!
addressing these challenges, DE takes a look at what’s new, Markku Palantera, general manager at Componeering.

Printed reprints, as well as locked and unlocked PDFs

what’s critical and what challenges remain. “Therefore, the superior performance of the end product
must be achieved by careful design, which eventually in-
Composites: Why now? volves software.”
Simulation
Defining&
The term composite covers material compositions ranging
from glass-filled liquid resins to “fabric” sheets with em YourAnalysis
em- Role
/// Composites
bedded carbon fibers. (See “The Life of Composite MateriMateri- Componeering, which markets ESAComp, is one of a num-
als,” DE May 2007.) Just that difference helps explain the ber of companies focused on composites-specific software.
variety of software packages targeted to the field. How these firms can help you depends partly on your spe-
Depending on the exact formulation, composite materials cific project, partly on your existing CAD and CAE soft-
Seamless workflows be-

are available. Reprints are personalized with your

display such positive attributes as easy formability, strength ware, and partly just on your preferred approach to working
with light weight, excellent long-term weathering and resis
resis- with these materials. tween VISTAGY’s FiberSIM
tance to corrosion and chemicals. These advantages, in turn, Not surprisingly, opinions run strong and deep insoftware
this and MSC.Soft-
may make it easier to integrate multiple parts. Plus, proper
proper- ware’s SimXpert move a
corner of the design world. Dr. John Klintworth, Simulayt’s
ties such as good thermal stability and high thermal conduc
conduc- design from preliminary siz-
founder and managing director, points out the major source
tivity are increasingly useful in special applications. for differences in perspective is whether you operateinginto
a final part validation.
However, achieving these desirable properties is a chal-
chal CAD environment or an analysis environment. The parallel process helps
lenge at every step—from initial design to hand-done or designers and analysts
“Any conventional [finite element analysis, or FEA]
automated part creation. package cannot do design and manufacture, and cannot optimize the part based
“The material and manufacturing costs of composites even create a decent composites model,” he continues. on weight, performance,

company name and logo for better branding.

design specifications, and
manufacturing costs.
1 DESKTOP ENGINEERING May 2011 /// deskeng.com Image courtesy of VISTAGY.

ing the export plybook with flat patterns of the plies to be manu-
factured. All partners involved in this process can exchange data.
In addition, as a pre- and post-processor, Laminate Tools in-
terfaces with standard CAD and FEA applications to produce
composite-specific results. It also offers an embedded interface
with Solidworks, Nastran and ANSYS, as well as with Anaglyph’s
hand layup ply-placement software, PlyMatch. 
STRAND7 is a general-purpose FEA package with an op-
are deeply embedded in CATIA V5, Abaqus/CAE, SolidWorks
and Femap, and allow users to define plys on individual finite ele-
ments, reflecting the actual manufacturing process.
As an example of its power, you could define a part with 200
plies, then with the push of a button automatically generate 2,000
laminate properties—a task impossible to do by hand.

Multi-layered Challenges
Visit omega.com/omb-daq-2416
tional laminated composite module tightly integrated with the A metal is a metal, but composites are a whole ’nother ballgame.
rest of the system. Users can easily combine traditional plate/shell As Firehole Composites’ Shrader puts it, “The biggest software
composite elements with 1D prismatic beam elements, as well challenge in working with composites is simultaneously captur-
as 3D brick elements. The company notes that its price/perfor- ing all of the physics involved, while also maintaining reasonable
mance ratio in the FEA software arena is particularly appealing computational time and resources.”

omega.com
for small organizations because it supports the full spectrum of You definitely need specialized tools to achieve this balance.
design concept evaluation, detailed analysis and the production The good news is, as users realize there’s a good return on invest-
of layup schedules. ment in specifying these materials, the software developers are

Contact Jeanne DuVal

Simulayt’s solutions for the composites field have been in right there, expanding their support. DE
continuous development for 20 years. As the developer of Layup
Technology, which incorporates advanced fiber simulation and Contributing Editor Pamela Waterman, DE’s simulation expert, is
ply modeling capabilities, the company is positioned to offer soft- an electrical engineer and freelance technical writer based in Arizona.
ware tools running in both CAD and CAE systems. The products You can send her e-mail to [email protected].

6
Reprinted from May 2011 Desktop Engineering with adaptations.
Copyright© by Level 5 Communications, Inc., 1283 Main St., Dublin, NH 03444, All Rights Reserved.
For more information on this topic, please visit deskeng.com.

DESKTOP ENGINEERING May 2011 /// deskeng.com

603.563.1631 x274 • [email protected] © COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

deskeng.com /// May 2012 DESKTOP ENGINEERING 45

0512_DE_Spotlight.indd 45 4/15/12 10:05 AM

 Editor’s Picks by Anthony J. Lockwood

Each week, Tony Lockwood combs through dozens of new products to bring you the ones he thinks will
help you do your job better, smarter and faster. Here are Lockwood’s most recent musings about the
products that have really grabbed his attention.

Geometric Launches CAMWorksXpress

New 2.5D CAM solution runs inside SolidWorks; designed to be easy to use.
CAMWorksXpress is the smaller sibling operations like roughing, contour and face
to CAMWorks, Geometric’s full-featured milling, holes, and what have you. It has
CAM system. Smaller, however, does not interactive feature recognition, and it auto-
mean weakling. It means right-sized for matically recognizes holes. Changes made
many, many shops. Like its big brother, to a SolidWorks design propagate to the
CAMWorksXpress works inside of SolidWorks toolpaths automatically. As of this writing, it’s
and has things like a CNC tool database, priced at $595.
simulation step-throughs, and functions for MORE ➜ deskeng.com/articles/aabebg.htm

Correlate FEA and Strain Data for Load Measurements

Software predicts fatigue life and manages components subject to loads.
If your job requires predicting fatigue life Safe Technology recently released an
and managing components in applications extension toolset for fe-safe, its flagship
where your components undergo environ- system for the fatigue analysis of finite ele-
mental loading — say, chassis, bridges, sus- ment (FE) models. The new product, fe-safe/
pensions, landing gears, piping, or parts True-Load, helps you predict and manage
used in wind power generation — then this the fatigue life of structures with complex
pick should interest you. It could mean get- loadings over an entire loading event.
ting a load of time back. MORE ➜ deskeng.com/articles/aabecr.htm

Tools for Fatigue Analysis Enhanced

HBM’s nCode DesignLife 8 offers new fatigue analysis technologies.
Version 8 of HBM’s nCode DesignLife tool- Adhesive bonding joins steels, aluminum
box of fatigue analysis applications has alloys, and even different materials, and it
been upgraded with all sorts of new and affords good durability against fatigue even
expanded analysis methodologies deserv- when compared to traditional methods such
ing your attention. One toolset in particu- as spot welding and seam welding. Of course,
lar caught my eye: You can analyze the nCode DesignLife has robust toolsets for spot
durability of adhesive bonds in lightweight welding and seam welding as well.
vehicle structures. MORE ➜ deskeng.com/articles/aabeeb.htm

System Supports Mobile Printing Via WiFi

New Océ PlotWave 350 said to incorporate 50 enhancements.
The Océ PlotWave 350 builds off its predeces- until first print (A1 / D-size paper). Now that’s
sor, the Océ PlotWave 300, and starts with a all good stuff, but that’s not why you should
print speed that’s 50% faster. To be precise, consider looking into this printer.
6 D-sized pages a minute. But what makes See, the real wait you get rid of with the Océ
the speed even faster is that it has instant-on PlotWave 350 is the “you’ll have to wait until I
technology, which, according to the literature, get back to my desk” wait because it supports
means less than 1 second warm-up time and, printing via the web.
depending upon the mode, 31 to 40 seconds MORE ➜ deskeng.com/articles/aabefc.htm

46 DESKTOP ENGINEERING May 2012 /// deskeng.com

de0512_EditorsPicks.indd 46 4/15/12 10:31 AM

 Engineering Case Studies Fast Apps
Running by the Energy Efficiency
Numbers CFD guides breakthroughs in
Lotus F1 Team designers rely on Elysium CADdoctor powerful cooling fan systems.
for data transfer, software interoperability, reverse BY GUUS BERTELS
engineering and, of course, speed.
Extracting energy—either petroleum or natural gas—is a com-
Did you know that Formula One (F1) racing can garner plex process that itself consumes voluminous amounts of
speeds of up to 220 miles an hour on the straightaway, and energy. Much of this goes toward fuelling on-site generators
G forces can top five in the most extreme corners? It’s easy to that power the cooling systems needed to chill the gas or oil
see why this sport pushes both car and driver to the edge of as it emerges from the well heads.
what’s mechanically and humanly possible. Inside a gas- or oil-field cooling system, fans up to 33 ft. in
A cross between driving and flying, F1—with its maze-like cir- diameter move air across cooling coils (“bundles”) that carry
cuits—requires constant acceleration, braking and cornering the product. Dozens, or even hundreds of fan systems may be
that put tremendous stresses on the vehicle and demands on required, along with megawatts of electrical power to run them.
the car’s “pilot.” Drivers are literally form-fitted to their seats, Often, noise issues are as important as cost challenges. These
wearing the car like a second skin. Reflexes need to be on large industrial plants are subject to stringent noise regulations.
instinct. Vehicles must be precision-tuned. Speed is king. As a The fans used in such applications historically have delivered
result, there is no room for error with even the smallest detail. a maximum efficiency of about 50%. What would happen if
At a minimum weight of 1,410 lbs. (less than one-third that efficiency could be increased to 80% or more? What would
the average passenger car in the U.S.), today’s F1 racing be the effect on noise output if the fans could run at a lower
machine—including nose, cockpit, wings and diffuser— rpm, and still do the job? Fewer fans could do the same work
embodies the almost-perfect aerodynamic balance of maxi- with less energy, less noise and lower operational costs.
mum down force (to keep the car in contact with the road) The design engineering team at Bronswerk Heat Transfer BV
and minimum drag (to make sure it goes fast). New car (Nijkerk, The Netherlands) set out to create a new air-cooled
design for the Lotus F1 Team starts with a concept. cooling system that would solve the age-old problems.

MORE ➜ deskeng.com/articles/aabety.htm MORE ➜ deskeng.com/articles/aabetz.htm

➜ For the complete application stories visit at deskeng.com/fastapps

Advertising Index /// Publisher does not assume any liability for index errors or omissions.

ANSYS .................................................... CV2 Industrial Press .......................................... 45

CD-adapco ................................................. 11 Intel Corp. ................................................ 8-9
Ciara Technologies, Inc. .............................. 29 Kubotek USA, Inc. ...................................... 13
Ciara Technologies, Inc. .............................. 31 MCOR Technologies ................................... 36
Ciara Technologies, Inc. .............................. 33 Measurement Computing & IOtech ............. 19
Collaboration & Interoperability Congress .. 24-25 National Instruments ................................... 3
COMSOL ................................................... 5 Objet Geometries, Inc. ............................. CV3
Corning ..................................................... 45 Okino Computer Graphics, Inc. ................... 43
DE Reprints ............................................... 45 Omega Engineering ..................................... 1
EME Corp. ................................................. 45 Omega Engineering .................................... 45
Firehole Technologies, Inc. ......................... 22 OriginLab Corp. ......................................... 21
Formtek, Inc. .............................................. 45 Sabalcore Computing, Inc. .......................... 45
Geomagic, Inc. ........................................... 35 Solid Concepts, Inc. .................................... 39
HBM-nCode............................................... 23 Stratasys-Dimension 3D ........................... CV4
HSMWorks ApS, USA ................................. 20 Tormach LLC ............................................. 43
IMSI Design ............................................... 45 True Engineering Technology, LLC ............. 22

deskeng.com /// May 2012 DESKTOP ENGINEERING 47

de0512_FastApps.indd 47 4/15/12 10:34 AM

 Cool Tools BOXX Technologies’ renderPRO

4
3

TECH SPECS

• Processors: Intel Xeon 5600 Series

Processor; Intel 5500 Chipset with QPI
up to 6.4GT/S and the ICH10R.

• Memory: 12 DIMM Slots, supporting up

to 192GB of 1333/1066/800MHz ECC
Registered DDR3 in 1GB, 2GB, 4GB,
1 8GB and 16GB DIMM Sizes

• Bays: Two Internal 2.5-in. drive bays.

Pint-Sized Power
1 BOXX Technologies’ renderPRO is a render farm that sits on your
desk, or even atop your workstation tower. It measures 6.75 in. wide
x 3.8 in. high x 20 in. deep. It can be used to boost the rendering of
• Hard Drives: Up to two SATA 2.5-in.
160GB to 750GB 7200 RPM drives;
80GB to 600GB for SSD (solid
intensive 3D graphics, animation, visualizations and simulations. state drives)

Customizable Specs • Expansion Slots: One low Profile PCI

2 The renderPRO can be equipped with an Intel Xeon 5600 Series Express Gen 2 x16
processor that has up to 12 cores. It’s also expandable with up to
192GB of RAM. • System Management: One Intelligent
Platform Management Interface (IPMI)
Version 2.0 with KVM Over IP
Driving Up Speeds
3 The renderPRO is available with up to two SATA 2.5-in. drives, or
optional solid state drives (SSDs) for even faster performance. It can
be equipped with 160-750GB 7200 RPM drives or 80-600GB SSDs.
• Power Supply: 300 Watts

• Removable Storage: External USB

Floppy Drive or Dual Layer DVD+/-
Data Transfer RW+DL Burner Drive (Optional)

4 With two USB 2.0 ports and two Intel Gigabit Ethernet ports, the
renderPRO can transfer data to and from workstations quickly. It also
includes a VGA port, a COM port and an RJ45 IPMI.
• Graphics: Integrated Matrox
G200eW Graphics

• Operating Systems:
➜ DO YOU HAVE A COOL TOOL? Desktop Engineering editors are always Microsoft Windows, Linux
on the hunt for great tools to share with our readers. Send us your ideas
at [email protected]. For more information, visit boxxtech.com

48 DESKTOP ENGINEERING May 2012 /// deskeng.com

de05012_CoolTools.indd 48 4/15/12 10:30 AM

Objet.indd 1 4/15/12 10:11 AM
 N OW I T H I N K I N 3 D.
AND MY DESIGNS JUST KEEP GET TING BET TER.

With our Dimension ® 3D Printer, I know my model will represent my idea exactly.
And that makes it easier to improve my design with each iteration.
Our Dimension is right here in the office, and that helps us
get our products to market faster. The Dimension models we
create are made in ABS, so they’re also tough and durable. Overall,
Dimension gives me an amazing sense of freedom—and creativity.

Find out more at www.dimensionprinting.com/de4

©2012 Stratasys, Inc.

Stratasys_Dimension3D.indd 1 4/15/12 10:11 AM