EXCITING

Exact Geometry Simulation for Optimized Design of Vehicles and Vessels

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 Obiettivo del progetto (Objective)

'This project focuses on computational tools for the optimized design of functional free-form surfaces. Specific applications are ship hulls and propellers in naval engineering and car components, frames, and turbochargers in the automotive and railway transportation industries. The functionality of these products depends on the shape of the surfaces, and even small variations may have significant impact. Our vision is that all computational tools are based on the same exact representation of the geometry. This will lead to huge benefits for the entire chain of design, simulation, optimization, and life cycle management. For several reasons, an exact representation of the geometry is essential. The errors introduced by approximating the geometry may falsify the simulation results in challenging applications. This becomes even more important if the simulation is to be used as part of an optimization loop for goal-based design. Multi-physics models, such as fluid-structure interfaces, demand for exact interfaces. There exists a “great divide” between the CAD (Computer Aided Design) approaches for modeling complex geometries and the numerical simulation methods (FEM). The idea of bridging this gap has gained significant momentum by the introduction of isogeometric analysis (IA) by US-based researchers. The application and extension of IA to core components of vehicles and vessels is especially rewarding since with respect to functional free-form surfaces, the existing simulation and optimization methods are at the limit of their capabilities. The strategic objectives of the proposal are: (1) To establish a new class of computational tools for fluid dynamics and solid mechanics, simulations for vehicles and vessels based on IA, (2) To achieve seamless integration of CAD and FEM, (3) To apply the tools to product design, simulation and optimization of core components of vehicles and vessels.'

Introduzione (Teaser)

Computer-aided design (CAD) software is the tool of choice for designers and engineers who want to create new products or components. But the transition of a computer-generated model to a numerical simulation tool can introduce tiny errors which in transport can prove critical. Research underway aims to iron out this problem.

Descrizione progetto (Article)

These tiny geometric errors could affect simulation results. And incorrect simulation results could develop into potentially real-world problems which in vehicle and vessel manufacturing can prove fatal.

Computer generated free-form objects, in particular, are extremely difficult to simulate with absolute accuracy because their shapes have to be approximated by simple geometric primitives. Free-form objects have well-defined and smooth surfaces except at the vertices, edges and cusps. Examples include ship hulls, propellers, and car frames for the railway and the automotive industry.

To reduce and eliminate the potential for errors, one EU-funded project 'Exact geometry simulation for optimised design of vehicles and vessels' (Exciting), is bridging the gap between CAD and numerical simulation methods by using enhanced isogeometric analysis (IGA). IGA provides a new approach for the design and simulation of free-form objects.

Exciting, a consortium of academic and industrial institutions from Austria, France, Germany, Greece and Norway, were particularly interested in seeing how IGA could eliminate errors in the design process of vehicles and vessels.

According to project researchers, accurately designing the blades of a turbine is extremely challenging. But with Exciting's new IGA application, designers can now produce a CAD model for blades that is suitable for numerical simulation. Designers can also create an entire parametric ship-hull model that respects principal dimensions and other integral parameters. And they can now apply IGA to car components.

The project, which started in 2008 and ends in 2012, is currently working on tackling some of the more theoretical challenges that underpin the development of future applications. So far, they have gained a much greater insight into the isogeometric BEM wave-resistance calculations of an immersed spheroid. They have also found a solution to a persistent 2D test problem often encountered when modelling pipes and deformable walls. And they even managed to develop a proof of concept for isogeometric design optimisation in structural mechanics.

Exciting's results and continued progress will not only help the industry produce better products, but will also save them considerable time and money in their design and testing.