All Things Ansys 058: Combining Mechanical Simulation with Additive Manufacturing

 

Published on: March 9th, 2020
With: Eric Miller, Matt Humrick & Pam Waterman
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by 3D Printing Applications Engineer Pamela Waterman and Advatech Pacific’s Engineering Manager Matt Humrick for a discussion on real world applications for topology optimization, and it’s value when it comes to creating parts though additive manufacturing.

If you would like to learn more about this topic and what Advatech Pacific is doing, you can download our case study covering these topics here: https://bit.ly/38Bqu2b

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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3D Design Updates in ANSYS 2020 R1 – Webinar

The ANSYS Discovery 3D Design family of products enables CAD modeling and simulation for all design engineers. Since the demands on today’s design engineer to build optimized, lighter and smarter products are greater than ever, using the appropriate design tools is more important than ever. With ANSYS you can explore ideas, iterate, and innovate with unprecedented speed early in your design process. Delve deeper into design details, refine concepts and perform multiple physics simulations — backed by ANSYS solvers — to better account for real-world behaviors.

Capabilities in this tool-set allow engineers to increase speed and reduce costs from the start of the design cycle, all the way to product launch. Improve engineering productivity and accelerate development time, create higher-quality products while reducing development & manufacturing costs, and respond quickly to changing customer demands while bringing new products to market faster than the competition.

Join PADT’s Training & Support Application Engineer, Robert McCathren for a look at whats new & improved when it comes to these tools in ANSYS 2020 R1. This update includes new releases for ANSYS Discovery Live, AIM, and SpaceClaim, focusing on areas including:

  • Simulation of Thin Parts
  • Topology Optimization in Discovery Live
  • Structural Material Properties
  • Physics Aware Meshing
  • Beam and Shell Modeling
  • And much more

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All Things ANSYS 057: Simulation for Additive Manufacturing in ANSYS 2020 R1

 

Published on: February 24th, 2020
With: Eric Miller & Doug Oatis
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by Lead Mechanical Engineer Doug Oatis for a discussion on the latest advancements in simulation for additive manufacturing and topology optimization in ANSYS 2020 R1.

If you would like to learn more about what this release is capable of, check out our webinar on the topic here:

https://www.brighttalk.com/webcast/15747/384528

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Additive Manufacturing & Topology Optimization in ANSYS 2020 R1 – Webinar

ANSYS offers a complete simulation workflow for additive manufacturing (AM) that allows you to transition your R&D efforts for metal additive manufacturing into a successful manufacturing operation. This best-in-class solution for additive manufacturing enables simulation at every step in your AM process. It will help you optimize material configurations and machine and parts setup before you begin to print. As a result, you’ll greatly reduce — and potentially eliminate — the physical process of trial-and- error testing.

ANSYS additive solutions continue to evolve at a rapid pace. A variety of new enhancements and features come as part of ANSYS 2020 R1, including the ability to work with EOS printers, using the inherent strain approach in ANSYS Workbench Additive, and new materials in ANSYS Additive Print and Science.

Join PADT’s Lead Mechanical Engineer Doug Oatis for an exploration of the ANSYS tools that help to optimize additive manufacturing, and what new capabilities are available for them when upgrading to ANSYS 2020 R1. This presentation includes updates regarding:

  • Level-set topology optimization
  • Density based topology optimization
  • Inherent strain method in workbench Additive
  • Improved supports in Additive Prep
  • Additive Wizard update
  • And much more

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

All Things ANSYS 056: A Unique Perspective on a Unique Solution – PADT Sales Talks ANSYS Applications

 

Published on: February 10th, 2020
With: Eric Miller, Bob Calvin, Dan Christensen, Brian Benbow, Heather Dean, Ian Scott & Will Kruspe
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by Bob Calvin, Dan Christensen, Brian Benbow, Heather Dean, Ian Scott, and Will Kruspe from PADT’s ANSYS sales team to discuss the benefits they see in ANSYS as a solution for their unique customer bases, as well as for manufacturers and engineers as a whole. With a combination of technical know-how and knowledge of positioning within different industries, the PADT sales team shares a unique perspective on the value of the various tools that make up the ANSYS suite and how users can best take advantage of them in order to help them succeed.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Introducing the Stratasys J826 – Full-color, multi-material printing for the enterprise design world

Taking risks attempting to capture design intent at the end of the process requires a lot of post-processing (coloring, assemblies, a mix of technologies, etc.) – when its too time consuming, expensive and late to make changes or correct errors. Stratasys PolyJet 3D printing technology is developed to elevate designs by realizing ideas more quickly and more accurately and taking color copies to the next level.

By putting realistic models in a designer’s hands earlier in the process, companies can promote better decisions and a superior final product. Now, with the Stratasys J8 Series, the same is true for prototypes. This tried and tested technology simplifies the entire design process, streamlining workflows so you can spend more time on what matters –creating, refining, and designing the best product possible.

PADT is excited to introduce the new Stratasys J826 3D printer 

Based on J850 technology, the J826 supplies the same end-to-end solution for the design process and ultra-realistic simulation at a lower price point.
Better communicate design intent and drive more confident results with prototypes that realistically portray an array of design alternatives.

The Stratasys J826 3D Printer is able to deliver realism, shorter time to market, and streamlined application thanks to a variety of unique attributes that set it apart from most other Polyjet printers:

  • High Quality – The J826 can accurately print smaller features at a layer thickness of 14µm to 27µm. As part of the J8 series of printers it is also capable of printing in ultra-realistic Pantone validated colors.
  • Speed & Productivity – Three printing speed modes (high speed, high quality & high mix) allows the J826 to always operate at the most efficient speed for each print. It can also avoid unnecessary down-time associate with material changeovers thanks to it’s built-in material cabinet and workstation.
  • Easy to Use – A smooth workflow with the J826 comes from simple integration with the CAD format of your choice, as well as a removable tray for easy clean up, and automated support creation and removal.

Are you ready to learn how the new Stratasys J826 provides the same quality and accuracy as other J8 series printers at a lower cost?

Provide the requested information via the form linked below and one of PADT’s additive experts will reach out to share more on what makes this new offering so exciting for the enterprise design world.

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All Things ANSYS 055: Introducing ANSYS 2020

 

Published on: February 3rd, 2020
With: Eric Miller, Josh Stout, Sina Gohds, Ted Harris & Tom Chadwick
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by Josh Stout, Sina Gohds, Ted Harris, and Tom Chadwick from the simulation support team to discuss their thoughts on ANSYS 2020 R1, and what specific capabilities they are excited about exploring after attending the annual ANSYS sales kickoff in Florida.

This new release covers updates for the entirety of the ANSYS suite of tools, so there is a lot to talk about.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Fluent Updates in ANSYS 2020 R1 – Webinar

Computational fluid dynamics (CFD) can be challenging for a multitude of reasons, but not with ANSYS Fluent. Anyone can get great CFD simulation results with ANSYS solutions. Fluent software contains the broad, physical modeling capabilities needed to model flow, turbulence, heat transfer and reactions for industrial applications. These range from air flow over an aircraft wing to combustion in a furnace, from bubble columns to oil platforms, from blood flow to semiconductor manufacturing and from clean room design to wastewater treatment plants.

Fluent spans an expansive range, including special models, with capabilities to model in-cylinder combustion, aero-acoustics, turbomachinery and multiphase systems. The latest innovations and updates simplify and speed setup and meshing while adding even more accurate physical models. The outcome: great results, without compromise.

Join PADT’s Senior CFD & FEA Application Engineer, Sina Ghods, for a look at what’s new and improved in this latest version of ANSYS Fluent, including:

  • User Interface/Graphics
  • Meshing Workflows
  • Multi-phase Robustness
  • Solver Enhancements
  • And much more

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Mechanical Updates in ANSYS 2020 R1 – Webinar

With ANSYS structural analysis software, users are able to solve more complex engineering problems, faster and more efficiently than ever before. Customization and automation of structural solutions is much easier to optimize thanks to new and innovative finite element analysis (FEA) tools available in this product suite.

Once again, ANSYS is able to cement their role as industry leaders when it comes to usability, productivity, and reliability; adding innovative functionality to an already groundbreaking product offering. ANSYS Mechanical continues to be used throughout the industry, and for good reason as it enables engineers to optimize their product design and reduce the costs of physical testing.

Join PADT’s Senior Mechanical Engineer & Lead Trainer Joe Woodward, for an in-depth look at what’s new in the latest version of ANSYS Mechanical, including updates regarding:

  • External Modeling
  • Graphics
  • Composites
  • Linear Dynamics
  • And much more

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Reduce EMI with Good Signal Integrity Habits

Recently the ‘Signal Integrity Journal’ posted their ‘Top 10 Articles’ of 2019. All of the articles included were incredible, however, one stood out to me from the rest – ‘Seven Habits of Successful 2-Layer Board Designers’ by Dr. Eric Bogatin (https://www.signalintegrityjournal.com/blogs/12-fundamentals/post/1207-seven-habits-of-successful-2-layer-board-designers). In this work, Dr. Bogatin and his students were developing a 2-Layer printed circuit board (PCB), while trying to minimize signal and power Integrity issues as much as possible. As a result, they developed a board and described seven ‘golden habits’ for this board development. These are fantastic habits that I’m confident we can all agree with. In particular, there was one habit at which I wanted to take a deeper look:

“…Habit 4: When you need to route a cross-under on the bottom layer, make it short. When you can’t make it short, add a return strap over it..”

Generally speaking, this habit suggests to be very careful with the routing of signal traces over the gap on the ground plane. From the signal integrity point of view, Dr. Bogatin explained it perfectly – “..The signal traces routed above this gap will see a gap in the return path and generate cross talk to other signals also crossing the gap..”. On one hand, crosstalk won’t be a problem if there are no other nets around, so the layout might work just fine in that case. However, crosstalk is not the only risk. Fundamentally, crosstalk is an EMI problem. So, I wanted to explore what happens when this habit is ignored and there are no nearby nets to worry about.

To investigate, I created a simple 2-Layer board with the signal trace, connected to 5V voltage source, going over an air gap. Then I observed the near field and far field results using ANSYS SIwave solution. Here is what I found.

Near and Far Field Analysis

Typically, near and far fields are characterized by solved E and H fields around the model. This feature in ANSYS SIwave gives the engineer the ability to simulate both E and H fields for near field analysis, and E field for Far Field analysis.

First and foremost, we can see, as expected, that both near and far Field have resonances at the same frequencies. Additionally, we can observe from Figure 1 that both E and H fields for near field have the largest radiation spikes at 786.3 MHz and 2.349GHz resonant frequencies.

Figure 1. Plotted E and H fields for both Near and Far Field solutions

If we plot E and H fields for Near Field, we can see at which physical locations we have the maximum radiation.

Figure 2. Plotted E and H fields for Near field simulations

As expected, we see the maximum radiation occurring over the air gap, where there is no return path for the current. Since we know that current is directly related to electromagnetic fields, we can also compute AC current to better understand the flow of the current over the air gap.

Compute AC Currents (PSI)

This feature has a very simple setup interface. The user only needs to make sure that the excitation sources are read correctly and that the frequency range is properly indicated. A few minutes after setting up the simulation, we get frequency dependent results for current. We can review the current flow at any simulated frequency point or view the current flow dynamically by animating the plot.

Figure 3. Computed AC currents

As seen in Figure 3, we observe the current being transferred from the energy source, along the transmission line to the open end of the trace. On the ground layer, we see the return current directed back to the source. However at the location of the air gap there is no metal for the return current to flow, therefore, we can see the unwanted concentration of energy along the plane edges. This energy may cause electromagnetic radiation and potential problems with emission.

If we have a very complicated multi-layer board design, it won’t be easy to simulate current flow on near and far fields for the whole board. It is possible, but the engineer will have to have either extra computing time or extra computing power. To address this issue, SIwave has a feature called EMI Scanner, which helps identify problematic areas on the board without running full simulations.

EMI Scanner

ANSYS EMI Scanner, which is based on geometric rule checks, identifies design issues that might result in electromagnetic interference problems during operation. So, I ran the EMI Scanner to quickly identify areas on the board which may create unwanted EMI effects. It is recommended for engineers, after finding all potentially problematic areas on the board using EMI Scanner, to run more detailed analyses on those areas using other SIwave features or HFSS.

Currently the EMI Scanner contains 17 rules, which are categorized as ‘Signal Reference’, ‘Wiring/Crosstalk’, ‘Decoupling’ and ‘Placement’. For this project, I focused on the ‘Signal Reference’ rules group, to find violations for ‘Net Crossing Split’ and ‘Net Near Edge of Reference’. I will discuss other EMI Scanner rules in more detail in a future blog (so be sure to check back for updates).

Figure 4. Selected rules in EMI Scanner (left) and predicted violations in the project (right)

As expected, the EMI Scanner properly identified 3 violations as highlighted in Figure 4. You can either review or export the report, or we can analyze violations with iQ-Harmony. With this feature, besides generating a user-friendly report with graphical explanations, we are also able to run ‘What-if’ scenarios to see possible results of the geometrical optimization.

Figure 5. Generated report in iQ-Harmony with ‘What-If’ scenario

Based on these results of quick EMI Scanner, the engineer would need to either redesign the board right away or to run more analysis using a more accurate approach.

Conclusion

In this blog, we were able to successfully run simulations using ANSYS SIwave solution to understand the effect of not following Dr.Bogatin’s advice on routing the signal trace over the gap on a 2-Layer board. We also were able to use 4 different features in SIwave, each of which delivered the correct, expected results.

Overall, it is not easy to think about all possible SI/PI/EMI issues while developing a complex board. In these modern times, engineers don’t need to manufacture a physical board to evaluate EMI problems. A lot of developmental steps can now be performed during simulations, and ANSYS SIwave tool in conjunction with HFSS Solver can help to deliver the right design on the first try.

If you would like more information or have any questions please reach out to us at info@padtinc.com.

All Thing ANSYS 054: Talking CFD – Discussion on the Current State of Computational Fluid Dynamics with Robin Knowles

 

Published on: January 13th, 2020
With: Eric Miller & Robin Knowles
Description:  

In this episode we are excited to share an interview done with host and Co-Founder of PADT, Eric Miller and host of the Talking CFD podcast Robin Knowles, regarding the history of PADT’s use of simulation technology as a whole, and the current state of all things CFD.

If you would like to hear more of Robin’s interviews with various other CFD based companies both small and large, you can listen at https://www.cfdengine.com/podcast/.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Defining Antenna Array Excitations with Nested-If Statements in HFSS

HFSS offers various methods to define array excitations. For a large array, you may take advantage of an option “Load from File” to load the magnitude and phase of each port. However, in many situations you may have specific cases of array excitation. For example, changing amplitude tapering or the phase variations that happens due to frequency change. In this blog we will look at using the “Edit Sources” method to change the magnitude and phase of each excitation. There are cases that might not be easily automated using a parametric sweep. If the array is relatively small and there are not many individual cases to examine you may set up the cases using “array parameters” and “nested-if”.

In the following example, I used nested-if statements to parameterize the excitations of the pre-built example “planar_flare_dipole_array”, which can be found by choosing File->Open Examples->HFSS->Antennas (Fig. 1) so you can follow along. The file was then saved as “planar_flare_dipole_array_if”. Then one project was copied to create two examples (Phase Variations, Amplitude Variations).

Fig. 1. Planar_flare_dipole_array with 5 antenna elements (HFSS pre-built example).

Phase Variation for Selected Frequencies

In this example, I assumed there were three different frequencies that each had a set of coefficients for the phase shift. Therefore, three array parameters were created. Each array parameter has 5 elements, because the array has 5 excitations:

A1: [0, 0, 0, 0, 0]

A2: [0, 1, 2, 3, 4]

A3: [0, 2, 4, 6, 8]

Then 5 coefficients were created using a nested_if statement. “Freq” is one of built-in HFSS variables that refers to frequency. The simulation was setup for a discrete sweep of 3 frequencies (1.8, 1.9 and 2.0 GHz) (Fig. 2). The coefficients were defined as (Fig. 3):

E1: if(Freq==1.8GHz,A1[0],if(Freq==1.9GHz,A2[0],if(Freq==2.0GHz,A3[0],0)))

E2: if(Freq==1.8GHz,A1[1],if(Freq==1.9GHz,A2[1],if(Freq==2.0GHz,A3[1],0)))

E3: if(Freq==1.8GHz,A1[2],if(Freq==1.9GHz,A2[2],if(Freq==2.0GHz,A3[2],0)))

E4: if(Freq==1.8GHz,A1[3],if(Freq==1.9GHz,A2[3],if(Freq==2.0GHz,A3[3],0)))

E5: if(Freq==1.8GHz,A1[4],if(Freq==1.9GHz,A2[4],if(Freq==2.0GHz,A3[4],0)))

Please note that the last case is the default, so if frequency is none of the three frequencies that were given in the nested-if, the default phase coefficient is chosen (“0” in this case).

Fig. 2. Analysis Setup.

Fig. 3. Parameters definition for phase varaitioin case.

By selecting the menu item HFSS ->Fields->Edit Sources, I defined E1-E5 as coefficients for the phase shift. Note that phase_shift is a variable defined to control the phase, and E1-E5 are meant to be coefficients (Fig. 4):

Fig. 4. Edit sources using the defined variables.

The radiation pattern can now be plotted at each frequency for the phase shifts that were defined (A1 for 1.8 GHz, A2 for 1.9 GHz and A3 for 2.0 GHz) (Figs 5-6):

 Fig. 5. Settings for radiation pattern plots.

Fig. 6. Radiation patten for phi=90 degrees and different frequencies, the variation of phase shifts shows how the main beam has shifted for each frequency.

Amplitude Variation for Selected Cases

In the second example I created three cases that were controlled using the variable “CN”. CN is simply the case number with no units.

The variable definition was similar to the first case. I defined 3 array parameters and 5 coefficients. This time the coefficients were used for the Magnitude. The variable in the nested-if was CN. That means 3 cases and a default case were created. The default coefficient here was chosen as “1” (Figs. 7-8).

A1: [1, 1.5, 2, 1.5, 1]

A2: [1, 1, 1, 1, 1]

A3: [2, 1, 0, 1, 2]

E1: if(CN==1,A1[0],if(CN==2,A2[0],if(CN==3,A3[0],1)))*1W

E2: if(CN==1,A1[1],if(CN==2,A2[1],if(CN==3,A3[1],1)))*1W

E3: if(CN==1,A1[2],if(CN==2,A2[2],if(CN==3,A3[2],1)))*1W

E4: if(CN==1,A1[3],if(CN==2,A2[3],if(CN==3,A3[3],1)))*1W

E5: if(CN==1,A1[4],if(CN==2,A2[4],if(CN==3,A3[4],1)))*1W

Fig. 7. Parameters definition for amplitude varaitioin case.

Fig. 8. Exciation setting for amplitude variation case.

Notice that CN in the parametric definition has the value of “1”. To create the solution for all three cases I used a parametric sweep definition by selecting the menu item Optimetrics->Add->Parametric. In the Add/Edit Sweep I chose the variable “CN”, Start: 1, Stop:3, Step:1. Also, in the Options tab I chose to “Save Fields and Mesh” and “Copy geometrically equivalent meshes”, and “Solve with copied meshes only”. This selection helps not to redo the adaptive meshing as the geometry is not changed (Fig. 9). In plotting the patterns I could now choose the parameter CN and the results of plotting for CN=1, 2, and 3 is shown in Fig. 10. You can see how the tapering of amplitude has affected the side lobe level.

Fig. 9. Parameters definition for amplitude varaitioin case.

 Fig. 10. Radiation patten for phi=90 degrees and different cases of amplitude tapering, the variation of amplitude tapering has caused chagne in the beamwidth and side lobe levels.

Drawback

The drawback of this method is that array parameters are not post-processing variables. This means changing them will create the need to re-run the simulations. Therefore, it is needed that all the possible cases to be defined before running the simulation.

If you would like more information or have any questions please reach out to us at info@padtinc.com.

All Things ANSYS 053: 2019 Wrap-up & Predictions for ANSYS in the New Year

 

Published on: December 20th, 2019
With: Eric Miller, Tom Chadwick, Ted Harris, Sina Ghods & Ahmed Fayad
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Simulation Support Team, including Tom Chadwick, Ted Harris, Sina Ghods, and Ahmed Fayad for a round-table discussion of their favorite ANSYS features released in 2019, along with predictions on what has yet to come.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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New 3D Design Capabilities Available in ANSYS 2019 R3 – Webinar

The ANSYS 3D Design family of products enables CAD modeling and simulation for all design engineers. Since the demands on today’s design engineer to build optimized, lighter and smarter products are greater than ever, using the appropriate design tools is more important than ever.

Rapidly explore ideas, iterate and innovate with ANSYS Discovery 3D design software, evaluate more concepts and rapidly gauge design performance through virtual design testing as you delve deeper into your design’s details, with the same results accuracy as ANSYS flagship products – when and where you need it.

Join PADT’s Training & Support Application Engineer, Robert McCathren for a look at the new 3D design capabilities available in ANSYS 2019 R3 for ANSYS Discovery AIM, Live, and SpaceClaim. These new updates include:

Mass flow outlets

Transient studies with time varying inputs

Structural beam support

Linear buckling support

Physics-aware meshing improvements

Mesh failure localization and visualization improvements

And much more

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

All Thing ANSYS 050: Updates and Enhancements in ANSYS Mechanical 2019 R3

 

Published on: November 4th, 2019
With: Eric Miller, Joe Woodward, & Ted Harris
Description:  

In this episode, your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Specialist Mechanical Engineer/Lead Trainer Joe Woodward, and Simulation Support Manager Ted Harris, for a discussion on what’s new in the mechanical release for ANSYS 2019 R3, as well as a look at their favorite features. This includes a focus on updates and enhancements to improve ease of use, reduce set-up time, and provide more valuable solutions.

If you would like to learn more about what this release is capable of, check out our webinar on the topic here: https://www.brighttalk.com/webcast/15747/376304

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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