ABAQUS for CATIA V5: Proven Technology for Nonlinear Finite Element Analysis from within CATIA V5 PLM

Completely integrated with CATIA V5, ABAQUS for CATIA V5 puts nonlinear FEA simulation technology at the center of product design. The software extends the CATIA V5 finite element modeling environment and enables the use of proven ABAQUS technology in Dassault Systemes' powerful PLM solution.

ABAQUS, Inc. continues to work closely with a team of joint Dassault and ABAQUS customers—including BMW, Boeing, Honda, PSA, and Snecma—to focus product development on the application workflows of greatest interest and value to end users. ABAQUS for CATIA V5 addresses customer-identified workflows for real world simulation, delivering results which users can rely on for making decisions during the design process.

Continuing with an aggressive, six-month release cycle, the Version 1.2 release in August was the second major release of ABAQUS for CATIA V5.

Fully Integrated with CATIA V5Integrating simulation with product design is a major initiative among engineering organizations because it helps reduce the number of physical prototypes to build and test. ABAQUS for CATIA V5 allows engineers to perform nonlinear simulation from within the CATIA V5 analysis environment, utilizing the fully associative geometry of the CATIA V5 product model.

"We are very pleased with the initial progress of integrating ABAQUS capability into CATIA V5, the Boeing standard engineering design system," said Rod Dreisbach, Senior Technical Fellow and Vice Chairman of the Boeing Technical Fellowship at The Boeing Company. "This initial product introduces nonlinear simulations that are fully associated with the CATIA V5 digital geometry of a product. Preliminary application of this capability during early stages of structural design has allowed more realistic simulations to be performed more rapidly and more cost effectively, and has resulted in more robust structural component designs."

Proven Nonlinear FEAThe ABAQUS software suite enjoys a well-known reputation for technology, quality and reliability, with leading companies such as Airbus, Honda and Motorola all having published papers on their use of this software. ABAQUS is particularly well-known for its nonlinear capability, having pioneered several important technologies in this area over the past two decades.

ABAQUS for CATIA V5 makes nonlinear FEA simulation easier and more productive for engineers working at every stage of product development. With ABAQUS for CATIA V5, engineers are able to minimize time-consuming model re-definition and respond quickly to changes as a design evolves. Familiar modeling constructs such as points, surfaces, and bodies are the basis for familiar analysis constructs such as boundary condition, loads, and contact associations.

"ABAQUS for CATIA V5 is a great example of technical collaboration-between ABAQUS, our PLM customers and us-to produce a practical and innovative solution to an essential step in many organizations' processes," said Severin Lanfranchi, Director of Research and Development, Dassault Systèmes. "This new V5 PLM solution is highly integrated, easy to use, and will widen implementation of CAE across all manufacturing organizations."

Enables ABAQUS TechnologyLeveraging proven ABAQUS nonlinear technology, CATIA V5 simulations can now include nonlinear geometric effects such as arbitrarily large rotations, stress stiffening, intermittent contact, plasticity, and temperature-dependent thermal film conditions. Contact capabilities in ABAQUS for CATIA V5 can model complex surface interactions in product assemblies.

"We developed ABAQUS for CATIA V5 in close cooperation with several key customers in the automotive and aerospace industries," said Ken Short, vice president of marketing for ABAQUS. "We knew they wanted to get more from their investment in simulation technology. This new software offers tremendous efficiencies to ABAQUS users, and it offers product engineers working in the CATIA V5 user environment an unprecedented capability to understand and design for real-world nonlinear behavior."

Structural and Thermal Analysis WorkbenchesABAQUS for CATIA V5 is organized into two CATIA V5 workbenches. Using the Thermal Analysis Workbench, engineers define thermal attributes such as temperature-dependent film coefficients and gap heat conductance, along with heat transfer simulation steps. Using the Structural Analysis Workbench, engineers define mechanical attributes such as bolt-tightening connections and pressure loads, along with structural simulation steps. Simulation steps from both workbenches can be combined in a single CATIA V5 model to perform a coupled thermal-structural simulation.

Pictures and captionsClip for an automotive exhaust system. Shell modeling capabilities enable a number of new applications within ABAQUS for CATIA V5 Version 1.2.

A shell model of a soft drink bottle is first pressurized and then compressed between two rigid plates. The nonlinear stress stiffening effects from the pressurization step substantially increase the bottle's ability to resist compressive deformation.

Using the job management capability, you can create job specifications, submit analysis jobs to ABAQUS, and continuously monitor solution progress.

ABAQUS for CATIA V5 adds ABAQUS structural and thermal analysis workbenches to CATIA V5. These workbenches provide the tools necessary to define and perform ABAQUS simulations from within the CATIA V5 user environment.

The CATIA V5 Specification Tree shows the hierarchy of modeling components. ABAQUS properties and analysis cases fit into the Specification Tree along with other CATIA V5 modeling information.

Complete ABAQUS nonlinear material properties are defined through the CATIA V5 interface. You can store material properties in a local CATIA V5 material database so that other ABAQUS for CATIA V5 users at your site can access the same set of ABAQUS material properties.

For more information, visit http://www.abaqus.com/products/products_afc_v5.html.

superDimension Receives FDA Approval on Lung Monitoring Tool Designed with PLM Solutions from IBM and Dassault Systèmes

superDimension cuts development time of innovative lung cancer diagnostic device by 30% using SMARTEAM

IBM and Dassault Systèmes announced that superDimension Ltd., a medical equipment manufacturer that specializes in minimally invasive diagnosis and treatment of lung disease via CT-guided bronchoscopy, has developed and received US Food & Drug Administration (FDA) approval of its superDimension™/Bronchus system using their Product Lifecycle Management (PLM) technology.

IBM PLM Solutions, with SMARTEAM for collaborative product data and lifecycle management developed by Dassault Systèmes, have enabled superDimension to develop and deliver a real-time minimally invasive lung navigation system an estimated 30% faster than originally planned. The innovative medical device, the superDimension/Bronchus system, improves the success rate in diagnosing and treating lung cancer and other lung diseases via CT-guided bronchoscopy by enabling access to the peripheral areas of the lungs in a minimally invasive manner.

superDimension used SMARTEAM’s regulatory approval template to speed superDimension/Bronchus through regulatory approvals, in this case, the U.S. government’s Food and Drug Administration (FDA) certified Code of Federal Regulations (CFR) 21 Part 11. The template feature stores thousands of pages of superDimension’s design reviews, market data and engineering data in an easily searchable, organized, secure, and audited structured platform with electronic signatures for accountability.

“Using SMARTEAM, the cycle time at superDimension for developing superDimension/Bronchus was reduced dramatically, and we expect even more time-savings once we start production and begin outsourcing components,” said David Tolkowsky, President and CEO at superDimension. “PLM technology has helped us develop a tool that was affordable and could be delivered very rapidly.”

“In addition to data management, SMARTEAM was also used to create a complex workflow for engineering change orders and change requests in the development of the Bronchus System,” said Denis Senpéré, vice president PLM Europe, Dassault Systèmes. ”Using SMARTEAM for the entire process, changes are quicker, more accurate, paperless, and can easily be updated and accessed online.”

superDimension/Bronchus has also received the CE Mark approval, which indicates that a product complies with the essential requirements of European laws, and has successfully completed clinical trials in Germany and Israel.

About superDimension superDimension is an emerging leader in the minimally-invasive diagnosis and treatment of lung disease via CT-guided bronchoscopy. The superDimension TM/Bronchus system answers one of the most critical needs in the field, namely to accurately reach lung locations that are far beyond the bronchoscope’s own vision in a minimally-invasive manner. Such locations are already where the majority of lung procedures are aimed at and include peripheral lesions as well as lymph nodes. For more information, visit http://www.superdimension.com.

Christopher P. Sciacca Manager, Media Relations Integrated Supply Chain IBM Corporation 590 Madison Avenue , 15th Floor, New York, NY 10022 (212) 745 4732 [t/l 243] (917) 434 9777 csciacca@us.ibm.com

Northrop Grumman: The Next Generation of Surface Combatants will Lead Worldwide Shipbuilding to V5 PLM

Company Overview An operating sector of Northrop Grumman Corporation, Northrop Grumman Ship Systems (NGSS) is a world leader in the design, engineering, production and lifecycle support of major surface ships for the U.S. Navy, U.S. Coast Guard and international navies. With expertise in complex surface combatants, amphibious ships, auxiliary ships and large commercial vessels, NGSS offers an extraordinary blend of capabilities. NGSS can also be counted among the leaders in the global shipbuilding industry for its pioneering efforts in the customization, use and integration of 3D computer-aided modelling to support both design and construction processes.

Business challenges

Producing highly competitive proposals for new ships that meet the Navy’s cost, performance and schedule targets

Meeting advanced performance targets for ships and shipboard systems through improved processes of design, production and lifecycle support

Enforcing standardization to enable lean manufacturing processes and enhance producibility of the design across multiple production locations.

SituationIn 2002, NGSS was awarded the role of prime contractor in the design of the U.S. Navy’s next generation of surface combatant, the DD(X). NGSS leads the overall system design, engineering, development, and production of the initial DD(X) platform, and testing of many technologies with Raytheon Company, General Dynamics, Lockheed Martin, United Defense, and more than 30 of the nation ’s top engineering and maritime industrial companies. Therefore, NGSS needed to standardize on a toolset that would be applicable to all divisions and teammates while

interoperating with legacy systems within the enterprise and allowing reuse of elements of design from one ship class to the other.

“Our vast experience in shipbuilding coupled with our expertise in next-generation technologies will result in a forward-looking approach to the design, production and support of ship systems for the DD(X) family of surface combatants. These ships will be built over the next 25 years and will be in service for the next 50 years. So, we need a toolset with strong capabilities and an architecture that is based upon a long-range vision. Then, the whole package must be supported by a team that will have the legs to stand up over the length of the program.” Dr. Philip A. Dur, Corporate Vice President, and President of the Corporation’s Ship Systems Sector

SolutionNGSS has defined and tested the world’s most advanced Shipbuilding PLM solution NGSS brought their expertise to design and build ships along with their requirements to Dassault Systèmes (DS) in order to develop a best-in-class shipbuilding PLM solution. IBM brought their unequaled project management skills and business Transformation expertise to ensure a smooth implementation. Moving from CAD to PLM requires major process changes that affect the way engineers work with designers. IBM implemented a “Proof of Concept” approach that convinced everyone of the value of PLM. Several pilots were conducted to demonstrate the benefits V5 would bring to the teams. Requirements were taken into account by Dassault Systèmes. The evaluation teams were quickly convinced that the new solution set will allow everyone to work closer together, in a more efficient, innovative and interactive way, thus saving time and money.

CATIA V5 and ENOVIA “Production worthy” CATIA V5 has been deployed to cover end-to-end design and systems engineering processes including space arrangement, ship structural design, electrical, piping, and heating ventilation/air conditioning (HVAC) system design, waveguide, and hanger design.

Improved teamwork ENOVIA Life Cycle Application (LCA) will be used by NGSS to manage product data through the entire surface combatant lifecycle from feasibility studies to operations and maintenance. The complexity of a surface combatant is much greater than that of an aircraft. “The DD(X) will include 3 million feet of electrical cable and fiber optics, and approx. 7,000 tons of steel. There will be hundreds of designers, planners and engineers from many different companies across the nation working together on this program” said Brian Cuccias, NGSS’ VP, DD(X) Program.

“To prepare for the next generation in ship design technologies, it is important to have effective design tools, such as those from Dassault Systemes and IBM PLM including CATIA V5, ENOVIA V5 LCA and ENOVIA V5 VPM.” Jan Rideout, Vice President & CIO, Northrop Grumman Ship Systems

Results Improved process It is very difficult to visualize a ship from a stack of drawings. By allowing design reuse, accelerating the exploration of design alternatives and providing advanced visualization and

early-validation tools, CATIA V5, ENOVIA DMU and DELMIA simulation enable NGSS to show the Navy 3D rendered early designs and how they will operate. They can easily adapt the design further to the customer’s request at a lower cost while shortening the design time.

Developing High Performance Products and Processes The entire V5 shipbuilding solution was developed to support design progression. It includes 21 new products that allow productivity gains vs. legacy systems. A few examples are :

Developing high performance products and processes. The capability to evolve the design data from stage to stage. The early stage designers

can work in surfaces - defining molded volumes with the hull form as the outer skin. They can then reserve volumes designated for equipment, piping, HVAC and cable runs - populating these volumes later as the design matures.

The highly automated Detail design work. The Rule-driven design and parametric capabilities that make the creation of features

almost automatic. The catalogs associated with the Knowledge Rules that automate the proper selection of

hangers for different support conditions based on project specifications, safety standards, accessibility, or local temperature considerations.

“Data management, data exchange and visualization with ENOVIA will be key to reduce costs, meet quality and deadlines and stay ahead of our competition.” Said Brian Cuccias, Vice President Program, Northrop Grumman Ship Systems

Interference checking and easy change management One of the major reasons for choosing V5 was its object-oriented architecture. Strong interoperability between CATIA and ENOVIA make product structuring and ship configuration management easy for end users. Storing subassemblies in work packages greatly increases product data management performance and makes it easy to manage changes. With real-time interference checking, designers are instantly alerted to hard and soft conflicts while in their CATIA session. They can be corrected immediately, or the designer can invoke ENOVIA’s workflow management to resolve them. Special capabilities are on-line to manage the creation of penetrations and their associated fixtures in water-tight bulkheads.

Lean manufacturing with DELMIA The work breakdown and build strategies have already been developed and analyzed in DELMIA months before detail design will begin. The build units have been analyzed to make sure that they can be manufactured at both NGSS and their partners. As soon as the early CAD designs are available these strategies will be tested in 3D to provide feedback to the designers on what changes would make fabrication, construction and outfitting more efficient resulting in savings

Secure real time management of multi-site collaboration with ENOVIA The DD(X) program requires hundreds of designers, planners and engineers -located at NGSS in Mississippi and at GD/BIW in Maine -to work together. The ENOVIA vault makes data check-in

and checkout easy and secure -as needed. Efficiencies are expected in storing models for action, finding information, understanding what other disciplines are doing, and why.

Knowledge reuse and lean manufacturing New ship programs constantly reuse parts of previously designed ships. CATIA V5 delivers specification driven, and knowledge-driven capabilities that allow engineers to build their intent into the system. Designer’s choices are driven by engineering and can be limited to a smaller set of parts that do the job.

“In shipbuilding, all things positive begin with predictable business. We needed new processes and a Product Lifecycle Management (PLM) solution to help us minimize costs from the early bidding process to the servicing phase 25 years down the road.” Arnie Moore, Vice President of Engineering, Northrop Grumman Ship Systems

Challenges Met With CATIA V5, ENOVIA LCA, and DELMIA, NGSS sets new standards in the shipbuilding industry for using advanced technologies to meet the nation ’s 21st century defense needs. The IBM PLM solutions have given NGSS confidence to streamline a 50-year ship design and servicing process resulting in greater predictability and cost savings.

Data will be seamlessly shared between NGSS and over 30 partners. Secured 3D visualization and checking of rendered digital mock-ups will make the virtual ship of tomorrow a reality.

Future NGSS is considering the use of the V5 Shipbuilding Solution for new Navy shipbuilding programs beyond the DD(X). NGSS is currently considering the implementation of DELMIA digital manufacturing capabilities to further integrate their design and production team. The vision is to build a modeling and simulation-based framework for their Manufacturing Process Planning System. The expectation is that a solution based on DELMIA’s Process Engineer could streamline production planning, and provide a powerful tool to cut production costs in the shipyard. Process Engineer could be used to capture and retain process knowledge in a systematically reusable form that links product and process data with shipyard systems and facilitates the assessment of process alternatives before construction.

Conclusion NGSS chose IBM PLM solutions for their ability to support, over the next 50 years, the development, construction and maintenance of the 21st century high tech complex surface ships. The military nature of NGSS requirements has driven the development by DS of a very advanced IBM PLM shipbuilding solution. It is therefore expected to benefit the shipbuilding industry at large.

“We have a unique vision and strategy that will ultimately transform ship design. As with our counterparts in the aircraft business, we needed the tools that would enable a better way of designing and building ships. This technology will drive a new stream of opportunities to support ships we build over the lifecycle, to enhance collaboration with our suppliers, and to exceed our customers’ challenging expectations.”

Dr. Philip A. Dur, Corporate Vice President, and President of the Corporation’s Ship Systems Sector

*Findings based on an independent study performed by CIMdata, independent consultant.

IBM Eurocoordination Product Lifecycle Management Tour Descartes La Defense 5 2,avenue Gambetta 92066 Paris La Defense Cedex France

Sanyo Machine Works: Manufacturing Excellence with PLM Solutions

Company overview Sanyo Machine Works is a leading provider of industrial automation systems. With 500 employees, its main activity is the design, manufacture, and sale of automated assembly and welding line systems for the automotive and consumer electronic markets. The company has a worldwide presence, with its headquarters and plants in Japan, as well as production sites in the USA and Canada. Well-known Sanyo Machine Works Japanese customers include Honda Motor, Isuzu, Mazda, Matsushita, Mitsubishi Electric, Nissan Motor, and Toyota Motor Corporation. Sanyo Machine Works has also International customers like General Motors, DaimlerChrysler and Ford.

Business challenges

Offer more innovative products for greater competitiveness Bring value added and expertise to customers Enhance product quality and delivery time while controlling costs

Situation As a supplier in the highly competitive and rapidly changing automotive and consumer electronic markets, Sanyo Machine Works faces unique business challenges to provide its customers with superior manufacturing solutions. To maintain its position as a market leader, Sanyo Machine Works must make innovation a key differentiator in its solutions. It must also distinguish itself from other suppliers by not only responding to customer demand with high-quality products, but by proactively exceeding expectations with added-value proposals and expertise. Finally, to remain profitable and competitive, Sanyo Machine Works must constantly look for ways to improve product quality, while reducing costs and delivery time.

“We continually take on new challenges. Our objective is to master, before our rivals, the concepts and technologies that become the standards of tomorrow.” Keita Horiba, managing director, Sanyo Machine Works

Solution Determined to address these industry challenges, Sanyo Machine Works launched a corporate project in 2002 based on IBM PLM solutions including CATIA V5, SMARTEAM, and DELMIA developed by Dassault Systèmes (DS). “We named this project Sanyo machine Digital Innovation, Initiative, Integration, or SDI 3,” said Keita Horiba, managing director, Sanyo Machine Works. “Supported by PLM solutions, the project is key to maintaining the pre-eminence of Sanyo Machine Works technology, which will be essential for future business growth.”

CATIA V5 fosters innovation CATIA V5’s ergonomic and intuitive user interface enables Sanyo Machine Works engineers to concentrate on their designs and not on the tool. This permits them to explore more design alternatives and unleash their creativity. Moreover, as a collaborative 3D-based system, CATIA V5 enables designers to use 3D as a language and share ideas among development team. Thanks to CATIA V5, this synergy facilitates brainstorming and fosters innovation.

Digital Manufacturing drives initiative Sanyo Machine Works can load the 3D design data from CATIA V5 within DELMIA in order to simulate manufacturing processes in a virtual factory. This permits validation of equipment layout, robot reachability, cycle times, and ergonomic factors such as worker posture. These analyses enable Sanyo Machine Works to propose high-performance, added-value solutions that distinguish the company from its competitors.

SMARTEAM manages integration SMARTEAM is key to Sanyo Machine Works’ SDI project due to its powerful integration capabilities. Through SMARTEAM, Sanyo Machine Works links its product definitions and analysis in CATIA V5 with manufacturing simulations in DELMIA; connects its PLM data to ERP system; exchanges data across its extended enterprise, with its suppliers and with customers. “SMARTEAM enables us to share data with our customers and affiliates, and work together in close cooperation, which allows effective engineering collaboration,” said Kenji Kozakai, general manager, IT department, Sanyo Machine Works.

“Introducing PLM solutions has given us a technical advantage over our rivals and helped us to become more competitive through innovative product development. We have given this project top priority.”Keita Horiba, Managing Director, Sanyo Machine Works

Results Sanyo Machine Works has achieved clear and tangible benefits from its PLM implementation:

Reduced lead time CATIA V5’s associativity mechanisms and knowledge-based infrastructure enable Sanyo Machine Works to begin designing an assembly line before the OEM has finished defining the product itself. This synchronous rather than sequential engineering process dramatically reduces lead time at Sanyo Machine Works.

Superior design quality CATIA V5 has enabled Sanyo Machine Works to significantly improve the quality of its product designs. The precision of its digital designs has resulted a 30 to 40% reduction in the number of errors found at the final assembly stage.

Shorter development time For development of the pallet sub-structure of its assembly lines, Sanyo Machine Works loads CATIA V5 mechanical assemblies into DELMIA to simulate the manufacturing process. As a result, Sanyo Machine Works no longer builds prototypes of its assembly lines pallets, and consequently has halved overall pallet development time from eight to four weeks.

Fewer parts Previously, it was difficult for Sanyo Machine Works engineers using 2D drawings to detect design collisions and to quickly perform the verification process. With CATIA V5, the process can be abbreviated, which greatly contributes to reduce pallet design times. Using CATIA V5, Sanyo Machine Works designers have optimized design which has lead to a 25% reduction in the number of parts.

“Sanyo Machine Works measures the true value of a full PLM deployment when we take the 3D design data from CATIA V5 and use it in the manufacturing process, using DELMIA.” Kenji Kozakai, General Manager, Information Technologies Department

Streamlined manufacturing Thanks to CATIA V5 knowledgeware capabilities, Sanyo Machine Works is able to capture product definitions, related data, and best practices. Later, the company reuses and shares this knowledge to significantly reduce the development time of new projects. It has also enabled Sanyo Machine Works to reduce pallet manufacturing time by an outstanding 60%.

Improved collaborative environment 3D has become an important communications means for Sanyo Machine Works that fosters collaboration within its extended enterprise.

“Providing a 3D digital view really improves communication with customers,” said Kenji Kozakai. “When we discuss the design of an assembly line, we are able to get a clear understanding of what the customer wants. This improves collaboration and accelerates design validation.”

Increased business performance Sanyo Machine Works has improved its business performance in a number of different ways with the PLM solutions provided by IBM. For example, the company has increased its competitive advantage by adopting CATIA, the de facto 3D design standard in the automotive industry.

“The ability to handle 3D data in-house using CATIA V5 is a key to success in the automotive industry,” said Horiba. “Exchanging 3D data is taken as a matter of course and it was a major factor in our winning of a number of contracts.”

“Regarding design quality, we have achieved remarkable results. Errors found at the final assembly stage have decreased by 30 to 40%. In addition, we can respect increasingly severe customer demands to cut lead-time.” Satoshi Yasuda, manager, Mechanical Engineering Department

Future Sanyo Machine Works plans to use SMARTEAM to quickly and easily exchange all data related to the development of products, such as their manufacturing processes and related resources.

Sanyo Machine Works also plans to use SMARTEAM as an internal communications tool among all departments within the company to enable manufacturing, procurement and sales departments to visualize the 3D digital mock-up (DMU) of an assembly line through an easy-to-use browser.

Moreover, Sanyo Machine Works will add the ENOVIA DMU product suite to its PLM platform to strengthen virtual review of designs and thus further enhance collaboration among departments.

In addition, Sanyo Machine Works has started to implement Generative Tooling Solutions. These specialized PLM Industry Solutions will enable the company to further reduce tooling design time and cost while improve tooling quality through a generative approach.

This approach makes it possible for manufacturers and suppliers to improve design productivity by building on embedded experience from previous designs. Designers can easily ‘copy’ previously validated engineering rules and tooling definitions to automatically create new designs or modifications of a new product and its associated manufacturing processes.

The Generative Tooling Solutions are a perfect match for Sanyo Machine Works and its product-engineering philosophy of “always new.”

Conclusion IBM PLM Solutions have permitted Sanyo Machine Works to build a ground-breaking 3D digital manufacturing environment. Through the SDI 3 project and PLM technology, Sanyo Machine Works can realize its objective of “remaining one step ahead of the industry.”

IBM Eurocoordination Product Lifecycle Management Tour Descartes La Defense 5 2, avenue Gambetta 92066 Paris La Defense Cedex France

*Figures based on results for pallet design.