automated bolt connection generation for cae model assembly

Automated Bolt Connection Generation for

CAE Model Assembly

Berk Yavuz Özberk,

GETRAG FORD Transmissions GmbH

2013 European Altair Technology Conference, Turin, Italy

© GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk 2

Agenda

• Company Profile

• Problem Definition

• Why Automation of Bolt Creation?

• Workflow

• Demonstration of Create Bolt Script

• Summary


GETRAG worldwide

(12/2

012)

24 locations worldwide in Europe, North America and Asia

14 individual companies

Largest independent supplier of passenger car transmissions worldwide

13.000 employees worldwide


GETRAG in figures

Some of our Customers

Turnover (in mill. €):

Volumes (in '000 items):


Problem Definition

Example

Transmission: Powershift MPS6

Parts: Clutch Case, Gear Box, Roll

Restrictor, Engine Mount, Bearing

Plates, Differential

Number of Bolts Required for Static

Analysis: 45

Time Required (without error

checking): 45 x 5 = 225 minutes

Time Required to make one model

run: 450 minutes


Why Automation of Bolt Creation ?

Save Time

- Model Assembly time is significatly shorter. No need to create pre-tension

surfaces, nodes, boundary conditions and contact surfaces manually

Error Free

- No assembling failures because of human error

Reusability

- - If you have the bolt coordinates of the initial design, you can use them for

later design stages or remeshing and assembling of a transmission

component


Workflow

Create Bolt GUI

Generates Hypermesh

command file(cmf) for the

selected bolt type

Hypermesh User Button

„Load Bolt“

Loads the generated

command file and sets

STEP Definitions


„Create Bolt“ Creates the bolt with Pretension surface,

Tied Contact at Thread and

Surface to Surface Contact at Bolt Head

CAE Model

Bolts have already been created

for this Transmission Part ?

no yes

Do it for all bolts


„Bolts from Coordinates“

Creates all bolts using the

coordinates from previous

bolt generation


Create Bolt Script GUI

Pre-Tension Force After Selecting the Bolt Type, the

values are generated from Bolt

Database Transmission

Orientation


Example

Clutch Case and Gearbox


Demonstration of Bolt Creation

conference3.wmv

automaticbolt.wmv


Bolt Contact Definition

The corresponding Pre-Tension definition and

Contact Surfaces are automatically created

Head Contact

Pre-Tension

Thread Contact

(tied)


Create Bolt Automatically using Previous

Coordinates

automaticbolt.wmv

automaticbolt.wmv


Input Data for Creating Bolts Automatically

1st to 6th Columns are used for the node coordinates at the bolt head

7th Column – Component Names

8th Column – Coordinate of Node at the thread surface

Hypermesh built-in functions are used to find the corresponding

nodes and elements.

(getclosestnode, *createmark elems 1 "by node“)


Summary

Create Bolt Script saves time in modelling and assembling. One can

save up to 8 hours for single application and design stage.

GETRAG has currently ongoing 10 New Transmission Projects with

many different applications and design stages.

Reduce potential modeling errors

Built-in Hypermesh functions make development easier (like rotation,

transformation, getclosestnode ...)

Power of command.cmf

- Every task in Hypermesh is written into this file

- Do changes in GUI and get the corresponding TCL code

- Use this TCL Code for script development

Thank you for your attention !

15

ManualShift

PowerShift

HybridDrive ExtendedDrive

automated bolt connection generation for cae model assembly

Technology

berk yavuz zberk12create

berk yavuz zberk14summary

berk yavuz zberk4getrag

bolt coordinates

berk yavuz zberk13input

bolt script summary

bolt headcae modelbolts

surface contact