Software promises more efficient design process
March 01, 2006
Laptop Battery WEST LAFAYETTE, Ind. - Mechanical engineers at Purdue University
have developed software that promises to increase the efficiency of
creating parts for everything from cars to computer hardware by
making it possible to quickly evaluate and optimize complex
designs.
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Thinkpad The new approach integrates the design and analysis processes,
which are now carried out separately. Currently, the geometry of a
part is first created using computer-aided design, or CAD,
software. This geometry is then converted into a mesh of simple
shapes, such as triangles or rectangles, which, when analyzed using
a computer, indicates the part's strength and other
characteristics. The painstaking procedure, called finite-element
analysis, is extensively used in industry.
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Microsoft "It's like taking a continuous curve and breaking it into
pieces," said Ganesh Subbarayan, a professor of mechanical
engineering at Purdue. "Otherwise, the form is too complex to
analyze."
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Laptop Computers After the finite-element model of the part is created, the part
is analyzed to see how well it will perform. If a portion of the
shape is found to need redesigning, the part's entire mesh must be
recreated to reflect the change.
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Laptop Computer "After the designer designs the object, it is thrown over to the
analyst, and the analyst says, 'OK, I think, based on my analysis,
that your design has to be modified this way,' and then throws it
back to the designer, who makes the modification," Subbarayan said.
"That is not very integrated and not very efficient, and that's the
reason these problems take so much time and computational power to
solve.
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Desktop Computer "We are trying to speed up this process to make it more
efficient by rethinking the way analysis is carried out. Instead of
waiting until the end of the CAD process to do the analysis, we are
trying to unify both the CAD design and analysis so that they are
carried out concurrently."
Notebooks Information about the software tool is detailed in a research
paper recently published online and will appear in the May issue of
the journal Advances in Engineering Software. The paper was written
by doctoral student Xuefeng Zhang and Subbarayan. The software tool
is based on theoretical work by another doctoral student, Devendra
Natekar. Natekar graduated in 2002 and now works for Intel Corp.,
and Zhang graduated in 2004 and now works at General Electric's
Global Research Center.
Lenovo The method could be especially important when dealing with the
corporate sensitivities of global competition.
Hard Drive "The overall philosophy behind the design approach can be
extended to enable one to understand the impact of changes in
suppliers' components on the performance of a complex system
without revealing details of the components or the system,"
Subbarayan said. "This will enable suppliers to retain their
proprietary design knowledge without revealing each other's
intellectual property. Such strategies are critical as products are
increasingly designed and produced in a globally distributed
manner."
Travelstar The software application, which was written by Zhang as part of
his thesis, contains about 35,000 lines of Java code.
Gateway "That is a big and complex code," Subbarayan said. "If you take
problems like finding the optimal shape for common automotive and
aircraft structures, you have to somehow find the shape that has
the least weight but at the same time won't break. We call that
process shape optimization or topology optimization. These shapes
have holes in them for bolting them in place or to reduce their
weight. You have to decide whether to have one hole or two holes or
10 holes in a part, exactly where to put those holes and how to
shape the holes."
Laptop Parts Finite element modeling is the de facto analysis tool for
numerous industries, Subbarayan said.
Software "When you use finite elements, you convert the complex
differential equations that describe the physics of the part's
behavior into simpler algebraic equations that the computer can
solve," he said. "It's a powerful method because it enables you to
take any complex problem and solve it.
Hard Drives "To describe the geometry, you take this complex object and
break it into primitive objects like cubes, spheres or cones. With
our approach, if I only modify some portion of the part, I only
modify the primitives directly associated with that portion I am
changing and not all of the primitives. If I only change the shape
of a specific hole in the part, for example, the rest of the
primitive objects are the same shape, so why should I need to
reconstruct the whole geometry and remesh the whole geometry?"
Electronics Subbarayan calls the approach a "hierarchical, constructive,
meshless procedure" because it enables engineers to analyze the
changing design of a part without recreating the complex mesh of
elements.
Canon "The way it is now, the same CAD software used to make the shape
of the part can't be used to analyze the mesh," Subbarayan said.
"But now, the same CAD software or some similar CAD-friendly
software will be able to do the analysis, and in a much more
efficient manner because there is no remeshing."
Desktop Pc Subbarayan began working on the project in 1998.
Desktop Computers Purdue researchers are using the software tool to design new
materials at the microscopic level, and the method also promises to
help engineers create optimized shapes of droplets of solder to
ensure longer-lasting circuit boards. A similar application is
creating optimized arrangement of particles in "thermal interface
materials" as they are inserted into microprocessors for heat
dissipation. The material is sandwiched between silicon chips and
metal heat sinks to serve as a buffer between the two surfaces so
that the expanding and contracting metal does not cause the brittle
silicon to crack.
Think Pad "These are all problems in which a shape needs to be modified,"
Subbarayan said. "In the case of solder, you are talking about what
shape a droplet should take - the boundaries of the droplet are
constantly modified until the optimal shape is found."
Repair Purdue University
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