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BatchMeshing and CAE Data Management as Key Technologies for Six Sigma Compliant CAE Processes for LS-DYNA Simulations

J. Seybold (Altair Engineering) The effort to achieve a six sigma process is one of the important ongoing quality assurance activities at many companies. This means that from one million produced products only 3.4 error possibilities occur in manufacturing. Six sigma requirements to a CAE process is the consistency of design decisions, the repeatability of the process, and the robustness of the product. To achieve this for LS-DYNA simulations and for the complete CAE process, major uncertainties need to be identified and the overall CAE process and they need to be improved. BatchMeshing is a technology to reduce the cost and time for meshing and to improve the robustness of the created simulation models. If meshes are created manually by hand, the sensitivity and scatter of the results is higher than for meshes created with the BatchMesher. This means, that BatchMeshing is a contribution to a six sigma design, because it leads to a robust design, but only if the BatchMeshing process itself is controlled, to make the process reproducible. This can be achieved with an automated BatchMeshing process which has a connection to the CAD product structure and builds models automatically based on this information. It must be known from which CAD parts we have created the meshes, which quality and status the meshes have, which modules have been used, which load cases have been simulated, and what results, reports and documents belong to this simulation. All data from all simulation disciplines belonging to the simulated product need to be managed and consistency for design decisions is mandatory required. CAE data and process management is an enabler for this and available.

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