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CAE Numerical Quality Assurance and Model Release Auditing

30 Chapters

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CAE Numerical Quality Assurance and Model Release Auditing

scope, regulatory drivers, and the cost of unverified simulation.

Numerical quality dimensions

verification, validation, uncertainty quantification, and their roles in release decisions.

Numericaldimensions

Establishing a CAE quality management system

ISO 9001, ASME V&V 10/20, and FDA/EMA expectations for simulation evidence.

EstablishingCAE

Model requirements capture

translating design and certification questions into measurable simulation acceptance criteria.

requirementstranslating

Mesh quality auditing

metrics, thresholds, and automated checks for shell, solid, and CFD meshes.

auditingthresholds

Solver verification

order-of-accuracy testing, manufactured solutions, and code-to-code comparison for CAE solvers.

verificationorder-of-accuracy

Discretization error estimation

Richardson extrapolation, grid convergence index, and adaptive refinement audits.

Discretizationestimation

Iterative convergence auditing

residual criteria, force/moment balance, and solution stabilization checks.

Iterativeconvergence

Material model calibration and validation

traceability from test data to CAE input decks.

Materialcalibration

Boundary condition and load path verification

consistency checks, unit audits, and reaction force reconciliation.

Boundarycondition

Contact and nonlinear solution quality

penetration checks, energy balance, and convergence robustness audits.

nonlinearsolution

Transient and dynamic simulation auditing

time-step convergence, energy conservation, and aliasing checks.

Transientsimulation

CFD-specific quality assurance

y+ verification, turbulence model consistency, and mass/momentum conservation audits.

CFD-specificassurance

Uncertainty quantification for CAE

input variability, surrogate models, and propagation to release margins.

Uncertaintyquantification

Sensitivity and robustness auditing

parameter sweeps, design-of-experiments, and failure mode identification.

Sensitivityrobustness

Model release workflow design

gates, checklists, and role-based approvals in PLM and simulation data management.

workflowchecklists

Automated audit scripts

Python-based extraction of solver logs, metrics, and pass/fail criteria.

AutomatedPython-based

Audit trail and traceability

linking CAE models, assumptions, results, and decisions in a versioned repository.

traceabilityCAE

Independent review and peer check

reviewer competencies, conflict-of-interest rules, and sign-off protocols.

Independentreviewer

Regression testing and baseline management

detecting unintended changes in solver versions and model updates.

Regressionbaseline

Model credibility assessment

scoring rubrics, evidence hierarchies, and fitness-for-purpose statements.

credibilityassessment

Auditing CAE reports

completeness, clarity, and defensibility of assumptions and limitations.

Handling nonconformances

root cause analysis, corrective actions, and re-release criteria.

Handlingnonconformances

Supplier and third-party model auditing

data exchange, confidentiality, and verification of external CAE deliverables.

Supplierthird-party

Regulatory submission readiness

compiling verification and validation evidence for certification bodies.

Regulatorysubmission

auditing a structural FEA model for aerospace certification under ASME V&V 10.

auditingstructural

CFD model release audit for automotive aerodynamics with uncertainty quantification.

crash simulation quality assurance and release auditing for automotive safety.

simulationassurance

Auditing machine-learning surrogates and digital twins

data quality, extrapolation risk, and continuous validation.

Auditingmachine-learning

designing and executing a complete model release audit for a multi-physics CAE assembly.

Capstonedesigning