Basics of StressCheck + AFGROW Application …€¦ · What is StressCheck? StressCheck is an...
Transcript of Basics of StressCheck + AFGROW Application …€¦ · What is StressCheck? StressCheck is an...
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© 2009 ESRD, Inc. All Rights Reserved. StressCheck® is a registered trademark of ESRD, Inc.
Basics of StressCheck + AFGROW Application Development: An Engineering Perspective
Brent Lancaster
ESRD, Inc.
09/15/2011
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Overview
What is StressCheck? StressCheck and Fracture Mechanics StressCheck API and COM
• What is a COM API? StressCheck and AFGROW
• StressCheck->COM->AFGROW Data Flow for Typical StressCheck/AFGROW Plug-
Ins Case Study: Cracked Lug with Propped Hole
• Building a StressCheck Plug-in Addendum: Design of 3D Fracture Mechanics
Meshes
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What is StressCheck?
StressCheck is an advanced FEA software tool developed by ESRD, Inc. of St. Louis, MO
• Current Version: 9.2 • Primary Customers: Major Aircraft OEMs and Defense/Armed Forces
StressCheck is based on the “p-version” • DOF increased by increasing polynomial order of elements instead of
adding midside nodes or refining the mesh • Hierarchic nature of solutions allows for V&V and quality assurance
Verification: Solving the equations right (convergence) Validation: Solving the right equations (experimental observations)
Primary applications of StressCheck: • High-fidelity stress analysis • Detailed fracture mechanics extractions/crack analysis • Multi-body contact analysis • Plasticity analysis • Composite material analysis • Development of advanced engineering applications (i.e. SFAT) • Combinations of the above
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StressCheck and Fracture Mechanics
StressCheck contains many advanced features which aid the DTA analyst in fracture mechanics studies, including:
• 3D Crack Insertion and Advanced Automeshing
• Extraction of robust Stress Intensity Factors and Separated Energy Release Rates (SERR)
• 2D Crack Path Analysis
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What is a COM API?
Component Object Model (COM) • Formal Definition (Wiki)
A binary-interface standard for software componentry introduced by Microsoft in 1993.
• It is used to enable interprocess communication and dynamic object creation in a large range of programming languages.
• It is a platform for the realization of Object-Oriented Development and Deployment.
Application Programming Interface (API) • Formal Definition (Wiki)
An interface in computer science that defines the ways by which an application program may request services from libraries and/or operating systems.
• An API determines the vocabulary and calling conventions the programmer should employ to use the services
• It may include specifications for routines, data structures, object classes and protocols used to communicate between the requesting software and the library
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StressCheck and COM
The StressCheck COM API allows users access to all of the objects, methods and properties found within the StressCheck GUI
• You may build, solve and extract information as you would interactively
The major benefit is that the COM API allows for external applications to communicate with StressCheck, and vice versa
• Visual Basic/Visual Studio • Excel • MATLAB • Python • AFGROW • Any other COM-enabled utility/language
This means automation and scripting is possible!
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StressCheck and AFGROW
Since StressCheck and AFGROW are COM-enabled, “plug-in” modules can be written to perform advanced/custom computations in the event that existing solutions are unavailable or inappropriate for the analysis
• StressCheck/AFGROW Plug-ins allow StressCheck FEA K-solutions to be computed and passed directly to AFGROW for life prediction
Plug-in development typically requires Microsoft Visual Studio 2008 (or equivalent) and .NET Framework, in addition to AFGROW and StressCheck
• VB.NET or C# recommended
• Plug-ins are configured to appear in AFGROW under “Plug-In Models” by modifying afgrow.exe.config file
• Plug-in is typically installed with simple setup kit
Consult with LexTech, Inc. for additional details
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Data Flow for a Typical StressCheck/AFGROW Plug-In
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Data Flow for a Typical StressCheck/AFGROW Plug-In
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Case Study: Cracked Lug with Loaded Pin Problem Definition:
• Planar (constant thickness) lug with applied fastener loading
• Lug bore is propped with neat, clearance or interference fit fastener
• Crack is to initiate along lug bore • All relevant inputs to be parametric
Goal: • To determine the location of the
maximum first principal stress in the lug bore, initiate a crack at that location, and propogate crack until user-defined failure
Utilizes Scenario 2 (i.e. Interactive computation)
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Case Study: Cracked Lug with Loaded Pin Process Outline
Step 1: Define parametric StressCheck Handbook models, and ensure these models are valid for a wide range of inputs
• These models will be read into the plug-in during run-time • In this case, 2 Handbook models were defined:
Hand-mesh pristine version (no crack) “Crack-ready” AFGROW version (to be automeshed by StressCheck)
Step 2: Using Visual Studio 2008 or 2010, create a new solution and add a VB .NET project
• Make sure a reference to StressCheck DLL library is added to the VB project
Step 3: Add a VB class to the project, ensure the class is given an appropriate “ProgID”
• The “ProgID” will help AFGROW understand what plug-in should be called, and should also be listed in the afgrow.exe.config file included with the installation package
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Case Study: Cracked Lug with Loaded Pin Process Outline (cont.)
Step 4: Implement the AfgrowBetaPlugin library in the VB class • Relevant properties/subroutines will automatically be
generated when implementing AfgrowBetaPlugin Instructions to tell AFGROW which parameters can be passed to
StressCheck, how events are handled, etc.
Not all functions/subroutines are necessary, as we will find
Step 5: Define a VB class for cracks in the VB project • This class will be used for defining AFGROW cracks in the
plug-in VB class
Step 6: Define parameters for plug-in class, and populate the AfgrowBetaPlugin functions/subroutines • Parameters will be exposed through AFGROW GUI
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Case Study: Cracked Lug with Loaded Pin Process Outline (cont.)
Step 7: Create a new AFGROW crack using Afgrow.AfgrowPredictManage
• Manages current cracks in AFGROW model
Step 8: Define local variables for plug-in class inputs/outputs and set default parameter values
Step 9: Import the StressCheck library and define local StressCheck variables
Step 10: Incorporate StressCheck COM API functions to drive crack embedding and solution
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Case Study: Cracked Lug with Loaded Pin Process Outline (cont.)
Step 11: Extract SIF’s from StressCheck
Step 12: Compute next crack increment in AFGROW
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Case Study: Cracked Lug with Loaded Pin Step 1: Handbook Model Design
Model 1: pristine model (no crack) for computation of max S1 location
• bulkhead_lug_handmesh.sci
Fastener
Element
Handmesh w/ h-Discretization
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Case Study: Cracked Lug with Loaded Pin Step 1 (cont.): Handbook Model Design
Model 2: AFGROW ready model (no crack) for computation of SIF’s
• bulkhead_lug_afgrow_ready.sci
• Most of model generated by plug-in
Crack embedded
during solution
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Step 2: Start a new solution and define a VB.NET Windows Forms Project
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Step 2 (cont.): Add “StressCheck DLL” Reference to Project
Note: This library will be imported to the plug-
in class as “StressCheckX” so we can use
StressCheck Black Box (SCBB) functions
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Step 3: Add a New VB Class and set up “ProgID” and config file
Plug-in VB class
Plug-in VB project
Name the Class and Assign “ProgID” (in this case,
“StressCheckCrackedLug.StressCheckCrackedLugClass”
Afgrow.exe.config
contents
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Step 4: Implementing the AfgrowBetaPlugin library in the VB class
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Step 5: Define VB class for cracks in VB project
Use an instance of the class in the “StressCheckCrackedLugClass.vb”
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
SC functions
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
Parameters will be exposed
through AFGROW GUI
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
Parameters will be exposed
through AFGROW GUI
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
Parameters will be exposed
through AFGROW GUI
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
Parameters will be exposed
through AFGROW GUI
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Step 6: Populate AfgrowBetaPlugin Functions and Subroutines
…
Parameters will be exposed
through AFGROW GUI
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Step 7: Create a new AFGROW crack using Afgrow.AfgrowPredictManage
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Step 8: Define local variables for plug-in class inputs/outputs and set default parameter values
“New” subroutine
used to create a new
Crack object and set
default parameters
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Step 9: Import StressCheck library and define local StressCheck variables
The StressCheck objects will
be called by the AFGROW
plug-in during run time
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Step 10: Calculate the crack location from Max S1
CalculateCrackLoc sub uses • SCStart
Starts StressCheck and opens a new database
Note: StressCheck instance will be used for duration of plug-in life
• ReadModel
Reads .sci files
• UpdateParameters
Based on Afgrow GUI input, updates SC model parameters
• ComputeCrackAnglefromS1
Uses max S1 information to compute location of crack
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Step 11: Calculate SC SIF’s from AFGROW crack information
CalculateSIFs sub uses • CreatePoints
Creates points representing current crack shape
• CreateSplineAndImprint Creates a spline curve from
points
Embeds spline curve in lug part
• FastenerSetup Adds a fastener element to hole
• MeshWithCrack Automeshes lug with crack
• SolveModel Solves fastener analysis
• ExtractK1K2 Extracts SIF’s
• SCEnd Closes StressCheck
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Step 12: Pass SIF’s to AFGROW for crack increment calcs
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Using the Cracked Lug Plug-in
The plug-in DLL, once
compiled, must be
registered in order to
appear in “Plug-In Models”
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Using the Cracked Lug Plug-in
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Using the Cracked Lug Plug-in
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Using the Cracked Lug Plug-in
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Using the Cracked Lug Plug-in
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© 2009 ESRD, Inc. All Rights Reserved. StressCheck® is a registered trademark of ESRD, Inc.
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