Concurrent Engineering: Tools and Technologies for Mechanical System Design

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Series F: Computer and Systems Sciences Vol. 108

Concurrent Engineering: Tools and Technologies for Mechanical System Design

Edited by

Edward J. Haug The University of Iowa, Center for Computer-Aided Design 208 Engineering Research Facility Iowa City, IA 52242-1000, USA

Springer-Verlag Berlin Heidelberg New York London Paris Tokyo Hong Kong Barcelona Budapest Published in cooperation with NATO Scientific Affairs Division

Proceedings of the NATO Advanced Study Institute on Concurrent Engineering Tools and Technologies for Mechanical System Design, held in Iowa City, Iowa, May 25-June 5, 1992

CR Subject Classification (1991): J.6

Additional material to this book can be downloaded from http://extra.springer.com.

ISBN -13: 987-3-642-78121-6 e-ISBN -13 :987-3-642-78119-3 001: 10.1007/987- 3-642-78119-3

Library of Congress Cataloging-in-Publication Data. Concurrent engineering: tools and technologies for mechanical system design/edited by Edward J. Haug. p. cm. - (NATO ASI series. Series F, Computer and system sciences; vol. 108). Includes bibliographical references and index. ISBN -13 987-3-642-78121-6 1. Concurrent engineering-Congresses. 2. Engineering design-Congresses. 3. Mechanical engi­neering-Congresses. I. Haug, Edward J. II. Series: NATO ASI series. Series F. Computer and system sciences; v. 108. TA174.C587 1993 658.5-dc20 93-1624

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© Springer-Verlag Berlin Heidelberg 1993 Softcover reprint of the hardcover 1st edition 1993

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Preface

These proceedings contain lectures presented at the NATO Advanced Study Institute on Concurrent Engineering Tools and Technologies for Mechanical System Design held in Iowa City, Iowa, 25 May - 5 June, 1992. Lectures were presented by leaders from Europe and North America in disciplines contributing to the emerging international focus on Concurrent Engineering of mechanical systems. Participants in the Institute were specialists from throughout NATO in disciplines constituting Concurrent Engineering, many of whom presented contributed papers during the Institute and all of whom participated actively in discussions on technical aspects of the subject.

The proceedings are organized into the following five parts:

Part 1 Part 2 Part 3 Part 4 Part 5

Basic Concepts and Methods Application Sectors Manufacturing Design Sensitivity Analysis and Optimization Virtual Prototyping and Human Factors

Each of the parts is comprised of papers that present state-of-the-art concepts and methods in fields contributing to Concurrent Engineering of mechanical systems. The lead-off papers in each part are based on invited lectures, followed by papers based on contributed presentations made by participants in the Institute.

The basic concepts and methods presented in Part 1 provide an overview of Concurrent Engineering concepts and technical approaches to integrating tools and technologies for multidisciplinary Concurrent Engineering of mechanical systems. While it is not possible to be comprehensive in treatment of the extraordinarily broad field of Concurrent Engineering of mechanical systems, these papers provide a balanced introduction to and development of underlying methods that support the integration of a wide variety of tools and technologies that now constitute the scope of Concurrent Engineering of mechanical systems and will continue to evolve during the decade.

In order to be more concrete regarding implementation and use of tools and technologies for multidisciplinary Concurrent Engineering, specific application sectors are highlighted in Part 2. Even though technical aspects of the various mechanical system sectors addressed are quite different, a central theme of tool integmtion to support a broad range of discipline­specific applications, all deriving infonnation from a central database and returning results to the central database, is clearly evident. Much as in Part 1, the scope of applications addressed is only a modest sampling of the breadth of Concurrent Engineering applications that are currently under development and will continue to evolve in mechanical system design.

Of special importance in Concurrent Engineering of mechanical systems are manufacturing considerations presented in Part 3. The sampling of manufacturing approaches presented highlights the importance of trade-offs that exist between design of

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mechanical systems and manufacturing processes to be used in their fabrication. As indicated in the first two papers of Part 3, complex and diverse trade-offs exists between product design and the quality of the manufactured product, as well as approaches for optimizing designs for manufacturability and control of manufacturing processes.

In view of the importance of trade-offs associated with Concurrent Engineering, design sensitivity analysis and optimization methods suitable for this purpose are presented in Part 4. Design sensitivity analysis methods that have emerged during the past decade are summarized and their use in design optimization involving a broad spectrum of disciplines is illustrated using selected applications. While work continues in developing and implementing design sensitivity analysis and optimization methods in specialized disciplines, a trend toward multidisciplinary trade-off analysis and design optimization is apparent.

The emerging field of virtual prototyping and human factors associated with simulation­based design of mechanical systems is addressed in Part 5. High-speed dynamic simulation methods developed in the late 1980s are shown to provide the foundation for revolutionary new tools for real-time simulation of mechanical systems, at a design level of detail and fidelity. This new capability will permit operator-in-the-Ioop simulation for tuning the design of mechanical systems to the capability of the intended population of human operators. Realization of this new capability is shown to be dependent upon fundamental human factors analysis methods that involve both engineering and psychology specialists. This emerging field represents the essence of Concurrent Engineering, bringing both mechanical and human performance into an integrated environment where trade-off analysis and design optimization of operator-machine systems is possible.

The extent and variety of the lectures and contributed papers presented in these proceedings illustrate the contribution of numerous individuals in preparation and conduct of the Institute. The Institute Director wishes to thank all contributors to these proceedings and participants in the Institute, who refused to be passive listeners and participated actively in discussions and contributed presentations. Special thanks go to M. Bender, L. Handsaker, R. Huff, M. Laverman, and D. Dawes for their efforts in planning and support for the Institute. Finally, without the financial support* of the NATO Office of Scientific Affairs, the US Army Tank-Automotive Command, and the NASA Goddard Space Flight Center, the Institute and these proceedings would not have been possible. Their support is gratefully acknowledged by all concerned with the Institute.

January 1993 EJ. Haug

* The views, opinions, and/or findings contained in these proceedings are those of the authors and should not be construed as an official position, policy, or decision of the sponsors, unless so designated by other documentation.

Contents

Part 1 Basic Concepts and Methods................................................................. 1

Wodd-Class Concurrent Engineering ..... .......... ........ ...... ........ ............ ............ ................ 3 D.P. Clausing

Virtual Team Framework and Support Technology ....................................................... 41 K.l. Cleetus

Integrated Tools and Technologies for Concurrent Engineering of Mechanical Systems........................................................................................................ 75 E.1. Haug

The Emerging Basis for Multidisciplinary Concurrent Engineering .............................. 111 R.G. Vos

Presentation and Evaluation of New Design Formulations for Concurrent Engineering .................................................................................................. 129 E.R. Stephens

Data and Process Models for Concurrent Engineering of Mechanical Systems............. 139 1.K. Wu, F.N. Choong

Storage and Retrieval of Objects for Simulations in Mixed Application Areas ............. 171 R.N. Zobel

Analysis of Structural Systems Undergoing Gross Motion and Nonlinear Deformations.................................................................................................. 181 1.A. C. Ambrosio

Multidisciplinary Simulation .......................................................................................... 203 M. Otter

Dynamic Analysis of Rigid-Flexible Mechanisms ......................................................... 217 M.S. Pereira, P.L. Proenra

Decoupling Method in Control Design ........................................................................... 255 M. Cotsaftis, C. Vibet

Part 2 Application Sectors ................................................................................... 273

Implementation and Applications of Multidisciplinary Concurrent Engineering .......... 275 R.G. Vos

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Simulation-Based Design of Automotive Systems ......................................................... 303 w.o. Schiehlen

Simulation-Based Design of Off-Road Vehicles ............................................................ 339 R.R. Beck

Modeling and Optimization of Aero-Space and Naval Structures ................................. 357 H.A. Eschenauer

Teleoperation of a Redundant Manipulator .................................................................... 375 K.H. Yae

Part 3 Manufacturing............................................................................................ 387

Relationship Between Design for Manufacturing, a Responsive Manufacturing Approach, and Continuous Improvement ....................................................................... 389 J.E.Ashton

Defect Preventive Quality Control in Manufacturing ..................................................... 405 S.M. Wu, S.J. Hu

An Approach for PDES/STEP Compatible Concurrent Engineering Applications ....... 433 T.H. Liu, G. W. Fischer

Concurrent Engineering Tools for Forging Die and Process Design.............................. 465 R. V. Grandhi, R. Srinivasan

Effects of Structural Dynamics on Chatter in Machine Tools and Its Evaluation at Design Stage ............................................................................................. 501 M.S. Tekelioglu

Part 4 Design Sensitivity Analysis and Optimization ................................ 521

Concurrent Engineering Design Optimization in a CAD Environment ............. ............ 523 N. Olhoff, E. Lund, J. Rasmussen

Design Sensitivity Analysis and Optimization Tool for Concurrent Engineering.......... 587 K.K. Choi, K.H. Chang

Concurrent Engineering Design with and of Advanced Materials ......... ................ .... .... 627 P. Pedersen

Optimization of Automotive Systems............................................................................. 671 D. Bestle

Multicriterion Optimization of Large Scale Mechanical Systems .................................. 685 S. Jendo, W.M. Paczkowski

Design Sensitivity Analysis for Coupled Systems and their Application to Concurrent Engineering .................................. ............................................................ 709 D.A. Tortorelli

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Configuration Design Sensitivity Analysis for Design Optimization............................. 721 S.L. Twu, K.K. Choi

Shape Design Sensitivity Analysis and What-if Tool for 3-D Design Applications ...... 737 K.H. Chang, K.K. Choi

Optimal Design of Vibrating Structures ......................................................................... 767 T. Lekszycki

The Problem of Additional Load of Minimum Work in a Thin Plate ............................ 787 S.S. Ligaro

Layout Optimization of Large FE Systems by New Optimality Criteria Methods: Applications to Beam Systems ... .......... ........ ........ ........ ...... ........ ............ ................ ........ 803 O. Sigmund, M. Zhou, G./.N. Rozvany

Analysis and Design of Structural Sandwich Panels Against Denting ........................... 821 O. T. Thomsen

Part 5 Virtual Prototyping and Human Factors ......................................... 849

Virtual Prototyping for Mechanical System Concurrent Engineering ...... .............. ........ 851 E.J. Haug, J.G. Kuhl, F.F. Tsai

An Open Software Architecture for Operator-in-the-Loop Simulator Design and Integration ................................................................................... 881 J.G. Kuhl, Y.E. Papelis, R.A. Romano

ManIMachine Interaction Dynamics and Performance Analysis ................................... 901 H.P. Frisch

Simulated Humans, Graphical Behaviors, and Animated Agents .................................. 929 N.I. Badler

Human Factors in Vehicle Driving Simulation............................................................... 945 P.A. Hancock

Evaluating In-Vehicle Collision Avoidance Warning Systems for IVHS ...................... 947 PA. Hancock

Tools and Methods for Developing Easy to Use Driver Information Systems .............. 959 P. Green

The Perception of Visually Simulated Environments ..................................................... 971 J.K. Caird

Effective Vehicle Driving Simulation: Lessons from Aviation..................................... 979 A.D. Andre

Active Psychophysics: A Psychophysical Program for Closed-Loop Systems ............. 987 J.M. Flach

Keyword Index.......................................................................................................... 995

Sponsors

NATO Advanced Study Institute

Concurrent Engineering Tools And Technologies For Mechanical System Design

Iowa City, Iowa USA 25 May - 5 June, 1992

NATO: North Atlantic Treaty Organization TACOM: The US Anny Tank-Automotive Command NASA: The US National Aeronautics and Space Administration

Director: E. 1. Haug, The University of Iowa, USA

Organizing Committee

N. OlhotT, Aalborg University, Denmark W. Schiehlen, University ·of Stuttgart, Germany C. Soares, Technical University of Lisbon, Portugal

Lecturers

J. Ashton, FMC Naval Systems Division, USA N. Badler, University of Pennsylvania, USA R. Beck, US Anny Tank-Automotive Command, USA K. Choi, The University of Iowa, USA D. Clausing, Massachusetts Institute of Technology, USA J. Cleetus, West Virginia University, USA D. Eschenauer, University of Siegen, Germany D. Frisch, NASA Goddard Space Flight Center, USA P. Hancock, University of Minnesota, USA E. Daug, The University of Iowa, USA E. Mettala, Defense Advanced Research Projects Agency, USA N. OlhotT, Aalborg University, Denmark P. Pedersen, The Technical University of Denmark, Denmark W. Schiehlen, University of Stuttgart, Germany

R. Vos, Boeing Aerospace and Electronics Company, USA S. Wu, University of Michigan, USA

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Participants

M. Acar, Loughborough University of Technology, United Kingdom M. Akkurt, Instanbul Technical University, Turkey C. Alessandri, University of Florence, Italy J. Ambrosio, Technical University of Lisbon, Portugal A. Andre, NASA Ames Research Center, USA J. Baatrup, The Technical University of Denmark, Denmark J. Bals, DLR Institute for Flight Systems Dynamics, Germany N. Bau-Madsen, Aalborg University, Denmark D. Bestle, University of Stuttgart, Germany H. Bordett, The University of Texas at Arlington, USA M. Bossak, Warsaw University of Technology, Poland M. Botz, Technische Hochschule Darmstadt, Germany J. Caird, University of Minnesota, USA K. Ciarelli, US Army Tank-Automotive Command, USA J. Cyklis, Cracow University of Technology, Poland P. De Castro, Universidade do Porto, Portugal P. Dehombreux, Faculte Poly technique de Mons, Belgium R. DeVries, Ford Motor Company, USA J. Downie, Brighton Polytechnic, United Kingdom N. Ertugrul, Dokuz Eyliil University, Turkey J. Flach, Wright State University, USA K. Grabowiecki, Industrial Institute of Construction Machinery, Poland R. Grandhi, Wright State University, USA P. Green, University of Michigan, USA J. Hansen, The Technical University of Denmark, Denmark C. Inan, Dokuz Eyliil University, Turkey S. Jendo, Polish Academy of Sciences, Poland O. Kaynak, Bogazici University, Turkey A. Keil, Institute of Mechatronics, Germany

P. Kiriazov, Bulgarian Academy of Sciences, Bulgaria L. Krog, Aalborg University, Denmark E. Kurpinar, Ege Universitesi, Turkey

T. Lekszycki, Polish Academy of Sciences, Poland P. Level, University of Valenciennes, France

S. Ligaro, University of Pisa, Italy E. Lund, Aalborg University, Denmark N. Maia, Technical University of Lisbon, Portugal L. Markov, Bulgarian Academy of Sciences, Bulgaria J. McPhee, University of Waterloo, Canada M. Otter, DLR Institute for Flight Systems Dynamics, Germany T. Ozel, Dokuz Eyliil University, Turkey

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M. Pereira, Technical University of Lisbon, Portugal G. Pratten, ICL, United Kingdom R. Riesenfeld, University of Utah, USA P. Rosko, Slovak Technical University, Czechoslovakia J. Santos, Technical University of Lisbon, Portugal O. Sigmund, Essen University, Germany A. Stensson, Lulea University of Technology, Sweden E. Stephens, Georgia Institute of Technology, USA S. Strzelecki, Institute of Machine Design 1-6, Poland K. Svendsen, Technical University of Denmark, Denmark M. Tekelioglu, Dokuz Eyliil University, Turkey O. Thomsen, Aalborg University, Denmark D. Tortorelli, University of lllinois at Urbana-Champaign, USA S. Twu, Cummins Technical Center, USA F. U1dum, Technical University of Denmark, Denmark G. U1usoy, Bogazici University, Turkey C. Vibet, University of Paris, France J. Wargo, Defense Advanced Research Projects Agency, USA C. Wilmers, Technical University of Hamburg-Harburg, Germany R. Zobel, University of Manchester, United Kingdom