Assembly Simulation Considering Thermal Deformation

Category: 解析 | Integrated 2026-04-06
CAE visualization for thermal assembly theory - technical simulation diagram
熱変形を考慮した組立シミュレーション

Theory and Physics

Overview

🧑‍🎓

Teacher! Today's topic is about assembly simulation considering thermal deformation, right? What is it like?


🎓

Changes in clearance between parts due to temperature changes. Engine assembly, precision equipment.



🧑‍🎓

I see. So, if there's clearance between parts due to temperature changes, it's basically okay for now?


Governing Equations




$$ \delta=\alpha L\Delta T $$
$$ \text{Clearance}=f(T_{assembly}) $$



🧑‍🎓

I see... Assembly considering thermal deformation seems simple at first glance, but it's actually very profound, isn't it?


Discretization Methods

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How do you actually solve these equations on a computer?


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We use spatial discretization by the Finite Element Method (FEM). We assemble the element stiffness matrices and construct the global stiffness equation.


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We perform transformation to the weak form (variational form) and use formulation by the Galerkin method using test functions and shape functions. The choice of element type (low-order elements vs. high-order elements, full integration vs. reduced integration) directly affects the trade-off between solution accuracy and computational cost.




Matrix Solution Algorithms

🧑‍🎓

What exactly are matrix solution algorithms?


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We solve the simultaneous equations using direct methods (LU decomposition, Cholesky decomposition) or iterative methods (CG method, GMRES method). For large-scale problems, preconditioned iterative methods are effective.



Solution MethodClassificationMemory UsageApplicable Scale
LU decompositionDirect MethodO(n²)Small to Medium Scale
Cholesky decompositionDirect Method (Symmetric Positive Definite)O(n²)Small to Medium Scale
PCG MethodIterative MethodO(n)Large Scale
GMRES methodIterative MethodO(n·m)Large Scale / Non-symmetric
AMG PreconditionerPreprocessingO(n)Very Large Scale
🧑‍🎓

So, if you cut corners on the finite element method part, you'll pay for it later. I'll keep that in mind!


Implementation in Commercial Tools

🧑‍🎓

So, what software can be used to perform assembly simulation considering thermal deformation?


Tool NameDeveloper/CurrentMain File Formats
Ansys Mechanical (formerly ANSYS Structural)Ansys Inc..cdb, .rst, .db, .ans, .mac
Abaqus FEA (SIMULIA)Dassault Systèmes SIMULIA.inp, .odb, .cae, .sta, .msg
MSC MarcHexagon (MSC Software).dat, .t16, .t19
COMSOL MultiphysicsCOMSOL AB.mph

Vendor Lineage and Product Integration History

🧑‍🎓

Are the origins of each software quite dramatic?



Ansys Mechanical (formerly ANSYS Structural)

🧑‍🎓

Tell me about "Ansys Mechanical"!


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Developed in 1970 by Swanson Analysis Systems Inc. (SASI). APDL (Ansys Parametric Design Language) based.

Current Affiliation: Ansys Inc.



Abaqus FEA (SIMULIA)

🧑‍🎓

What exactly is Abaqus FEA?


🎓

Developed in 1978 by HKS (Hibbitt, Karlsson & Sorensen). Acquired by Dassault Systèmes in 2005 and integrated into the SIMULIA brand.

Current Affiliation: Dassault Systèmes SIMULIA


🧑‍🎓

After hearing this, I finally understand why development is so important!



MSC Marc

🧑‍🎓

Tell me about "MSC Marc"!


🎓

A nonlinear FEA solver developed by MARC Analysis Research Corp. Acquired by MSC Software. Strong in large deformation and contact.

Current Affiliation: Hexagon (MSC Software)


🧑‍🎓

Wow, the story of development is super interesting! Tell me more.


File Formats and Interoperability

🧑‍🎓

Are there any points to note when transferring data between different software?


FormatExtensionTypeOverview
STEP.stp/.stepNeutral CAD3D CAD data exchange format compliant with ISO 10303. Supports geometry + PMI.
IGES.igs/.igesNeutral CADEarly CAD data exchange standard. Has issues with surface data compatibility. Migration to STEP is progressing.
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When converting models between different solvers, attention is needed regarding the correspondence of element types, compatibility of material models, and differences in the representation of loads and boundary conditions. Particularly, high-order elements and special elements (cohesive elements, user-defined elements, etc.) often cannot be directly converted between solvers.


🧑‍🎓

I see... Formats seem simple at first glance, but they're actually very profound, aren't they?


Practical Considerations

🧑‍🎓

Are there things like "field wisdom" that aren't written in textbooks?

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