What's new in LMS Virtual.Lab Rev 6

With Rev 6 of Virtual.Lab, LMS delivers a unified modeling environment, which integrates all the required model creation, meshing and multidisciplinary simulation capabilities to accurately assess system-level performance for a complete car, a full aircraft or any other complex mechanical assembly. 
The new meshing, modeling and assembly solution offers extensive capabilities to flexibly build full-system simulation models starting from multiple component and sub-system models.

Working from a single data model, users can efficiently analyze the system’s behavior in multiple performance aspects. 

This new solution eliminates the tremendous effort to create individual models for separate disciplines, saving tremendous time and avoiding the accumulation of modeling errors and inaccuracies. In addition, the unified modeling solution allows easy and smooth cross-attribute analyses.

Handling complex models with higher speed and accuracy

LMS Virtual.Lab provides multiple innovative technologies like Waved Based Substructuring, Fast Trim Modeling or advanced CAD Contact for multibody simulation, which make it more practical to handle complex models with high accuracy, while significantly reducing calculation times. The 64-bit data processing support in Rev 6 provides the required processing power to easily handle extensive and highly detailed simulation models.

These accelerating technologies open up new application areas and allows users to analyze specific performance phenomena in greater detail. LMS Virtual.Lab succeeded in processing a vibration analysis based on 600,000 high-resolution FRFs of a 4-component wind turbine assembly in less than 3 hours. This analysis is required to reliably qualify the vibration performance of the wind turbine, but would be practically impossible to run without the 64-bit support. 

The new release of LMS Virtual.Lab also marks the introduction of a new value-based licensing system. Through the combination of base configurations with the new value-based licensing system, users get flexible access to the full portfolio of LMS Virtual.Lab modules via a token based licensing system. Starting from a pool of so-called tokens, users can access a specific application according to their punctual needs, without having to systematically extend their software investment.

LMS Virtual.Lab Motion allows designers and engineers to realistically simulate the ride and handling of a full-vehicle design, the operation of a new excavator, or the reliability of a mechanical switch, for example. LMS Virtual.Lab Motion is a leading MBS solution that combines an integrated environment with automated procedures and an extensive set of vertical applications, including powertrain, suspension, tracked vehicles, etc. In addition, simulation results, including dynamic internal loads predicted by highly accurate solvers covering all frequency ranges, can be used to drive subsequent durability or noise and vibration related investigations. 

To provide accurate results, MBS models need to capture all aspects of real-life operation, including specific mechanism details, contact characteristics and locations as well as dynamic forces and friction definitions. In this regard, LMS Virtual.Lab Motion Rev 6 further enhances its CAD contact capability by including the possibility to define CAD solids and to calculate the interacting contact forces. Compared to alternative methods, the CAD contact approach offers simplified modeling and higher accuracy. CAD contact simulation additionally occurs at a higher pace, as solver speed increased with factor 8! Another enhancement featured in LMS Virtual.Lab Motion Rev 6 concerns the modeling of standard contacts. By defining standard contacts as extrude/revolve surface profiles that are in contact with idealized spheres, the computation speed increases considerably. This accelerates the simulation of extensive models that consist of thousands of contacts. Typically, the performance improvement is most significant for track system modeling and models including chains and sprockets.

Besides introducing innovative contact definitions, LMS Virtual.Lab Motion further extends its Finite Element (FE) modeling offering. After successfully launching an automated approach to flexible body generation, with easy setup and geometry-associative FE modeling inclusive, LMS Virtual.Lab Motion Rev 6 now introduces FE load transfer. This feature makes it possible to conveniently apply the loads from any selected time step of a dynamic FE-driven multibody simulation to a structural component model that is used for component stress investigation. Automating the error-prone process of linking the correct loads to the right connection points on the structure translates into considerable time savings and contributes to more consistent stress analysis.

A new modeling capability introduced in LMS Virtual.Lab Motion Rev 6 is automatic substructuring of flexible bodies. Using this feature, users can correctly capture non-linear geometric deformation by dividing any flexible body in multiple substructures, and generate their individual FE load cases and body connections automatically. LMS Virtual.Lab Motion Rev 6 further extends its modeling edge by adding frequency-dependent bushings to its extensive list of bushing models. Editing the required relationship between dynamic stiffness and frequency is all it takes to realistically model hydraulic mounts or rubber bushings.

Regardless whether designing an aircraft, sports car, washing machine or power tool, LMS Virtual.Lab Structures Rev 6 provides a scalable solution for structural modeling and analysis. The software integrates advanced model creation and manipulation tools to efficiently generate component, subsystem and full-system models, starting from an orphan mesh or existing CAD geometry. Furthermore, LMS Virtual.Lab Structures Rev 6 steps up simulation productivity through the introduction of Wave-Based Substructuring (WBS), a non-linear ABAQUS interface  and an advanced, unified environment that is suitable for modeling full-vehicle structures.

With integral full meshing capabilities, LMS Virtual.Lab Rev 6 captures the complete modeling and analysis process, from CAD drawing to multi-attribute simulation results. Starting from a wireframe, surface or a solid geometry from CATIA V5 or another source, LMS Virtual.Lab Structures Rev 6 is able to generate different structural mesh types using a broad range of meshing methods. The software’s powerful meshing solution is unique in its kind, as it combines basic meshing functionality, advanced surface and beam meshing, advanced solid meshing, automatic solid tetra/hexa dominant meshing, and geometry healing into one single package!

To accelerate the creation of Finite Element (FE) models for surface parts and wireframe geometries, LMS Virtual.Lab Structures Rev 6 incorporates an advanced meshing solution that can handle complex geometries automatically. New methods for topological interpretation slash model preparation time by reducing the number of mesh elements that must be edited manually. In addition, as meshed parts always remain associated to their original surface geometries, they automatically reflect further modifications implemented on CAD level. Equally effective is the software’s ability to transform meshed parts by translation or rotation, or to capture existing meshes in creating new ones with respect to constraints. At all times in the mesh creation process, designers and engineers can rely on efficient mesh quality analysis tools, which excel in customization and visualization. 

Altogether, LMS Virtual.Lab Structures offers an unrivalled combination of high meshing automation with a large connections scope that is fully associative with the design. Also, when dealing with solid parts, LMS Virtual.Lab Structures integrates multiple meshing methods, among which the hybrid meshing approach is capable of generating complex solid meshes, such as combustion engine assembly models.

In addition, LMS Virtual.Lab Structures Rev 6 optionally offers advanced mesh morphing tools that enable designers to quickly tune a full-vehicle FE model according to product performance and styling requirements. When executing full-system mesh adaptations, dedicated control blocks intuitively guide designers in converting original mesh feature lines to the targeted shapes. New in this regard is vehicle concept modeling, which allows designers and engineers to create an incremental beam/joint model directly onto a morphed FE model. This approach is primarily used to quickly evaluate the influence of concept modifications of beam-like sections and joints on global dynamic performance characteristics. Automotive target applications typically include body, tuning of global torsion and bending modes, sensitivity analysis and beam force / strain energy analysis.

In Rev 6, the embedded solver support in LMS Virtual.Lab is expanded to cover non-linear as well as linear modeling and analysis cases through the addition of Abaqus pre/postprocessing and associative driving from within LMS Virtual.Lab. In this way, LMS Virtual.Lab establishes itself as the only environment that allows FE related processing to be passed on directly to any well-known linear or non-linear solver of choice. Starting from meshed CAD parts or from imported Abaqus or Nastran meshes, LMS Virtual.Lab Structures Rev 6 guides users through the complete process of setting up linear or non-linear analysis cases. Advanced pre- and post-processing capabilities and fully associative Abaqus driving help deal with any kind of modeling assignment in a consistent and time-efficient fashion.

The cornerstone of LMS Virtual.Lab Rev 6 is the newly introduced advanced and unified modeling environment. It contains a comprehensive toolset for assembly, trim and analysis, applicable to cars, airplanes, rail carriages and other full-vehicle structures. Using this productive environment, a rigidity analysis on full-vehicle level can be executed just as easily as generating derivative models for strength, noise, vibration and durability related post-processing. The new solution reduces the time required to create system-level models, and makes the complete assembly specification-driven while maintaining maximum model transparency. Reliable and high-performance system modeling and simulation are essential in driving product innovation from concept to release.

Brand new in LMS Virtual.Lab Structures Rev 6 is Wave-Based Substructuring. This revolutionary model assembly method increases body NVH simulation speed while retaining the accuracy of full FE models. Instead of defining component interconnections through numerous interface Degrees Of Freedom (DOF), the WBS method expresses the deformation of coupling interfaces using a limited number of basis functions called waves. Typically, system components whose modification are not under consideration are reduced following the WBS approach in order to obtain shorter analysis turnaround time, decreasing simulation time up to 90%! As such, WBS enables designers and engineers to rapidly evaluate chassis bead modifications or re-run full-vehicle simulations using frequency-dependent window glue characteristics, for example. When the WBS method is applied for spot weld optimization, more design variations can be evaluated in the same time window, typically translating into superior functional performance and fewer spot welds.

Acoustic trim with multiple layers sets specific modeling challenges at higher frequencies, in particular when acoustic decoupling as well as porous and visco-elastic effects dominate the acoustic performance. LMS Virtual.Lab Acoustics Rev 6 overcomes these complex challenges through the introduction of a fast and efficient acoustic multilayer modeling approach. After setting up the multilayered layout of a panel and defining the properties of its constituting layers, the transfer admittances of the complete trim structure are calculated as function of frequency. 


In a subsequent vibro-acoustic FE (Finite Element) analysis, LMS Virtual.Lab Acoustics Rev 6 simulates the performance of the multilayer trim in the presence of flexible panels from a vehicle body or airplane fuselage. Short simulation runs that reliably predict interior acoustics at higher frequency allow engineers to better exploit the tremendous potential of acoustic trim.

In support of the engine acoustics simulation process, LMS Virtual.Lab Acoustics Rev 6 introduces the vector processing case. Engineers use this efficient processing case to obtain sound power densities on the surface estimated on the basis of engine surface vibrations, rather than performing a complete Boundary Element (BE) analysis up-front. Besides investigating particular frequencies of interest, the vector processing case allows RMS values to be generated for the entire frequency spectrum or specific frequency bands of interest, such as specific third octave bands of interest at specific RPM values. It also offers the possibility to evaluate overall sound power, as function of engine RPM and orders. Altogether, the vector processing case provides a fast way to perform “first-shot” engine acoustics, allowing engineers to quickly gain insight into the sound emission of a new engine design.

Brand new in LMS Virtual.Lab Acoustics Rev 6 is the capability of the software to provide the opportunity to actually listen to the radiated sound of engines, gearboxes and other rotating machinery. For an engine runup, for example, the software is able to simulate the radiated sound field and play the synthesized sound as it would be perceived from any location of choice. By allowing development teams to listen to the sound of a new design, they are able to gain clearer insight into the way radiated sound changes when defining structural modifications.

Aircraft frames or train structures are excited by turbulent boundary layers. To be able to define this kind of random loading as input for acoustic simulation, LMS Virtual.Lab Acoustics Rev 6 introduces a dedicated modeling solution. The modeling tool, based on the Corcos theory, is capable of generating the necessary pressure cross power matrix. To obtain this excitation spectrum, engineers only require specifying a few straightforward physical parameters, such as mean velocity and local pressure values. When feeding the pressure cross power into LMS Virtual.Lab Random Vibro-acoustics, they are able to study the structural vibration and acoustic radiation that result from this pressure field.

Reducing vibrations and developing quieter products require powerful tools, especially since noise and vibration regulation become ever stricter and structural product complexity further increases. To successfully take up these challenges, LMS Virtual.Lab Noise & Vibration Rev 6 offers a versatile modeling environment that supports hybrid models, synthesizes realistic loads and performs high-speed simulation runs. To consistently maintain high accuracy standards, it includes efficient Finite Element (FE) model correlation and updating on the basis of physical prototype test data, which are provided as part of LMS Virtual.Lab Correlation Rev 6.

To further strengthen its diagnostics tools, LMS Virtual.Lab Noise & Vibration Rev 6 introduces Acoustic Source Quantification (ASQ) as part of its Transfer Path Analysis (TPA) offering. In combination with load identification, path contribution and forced response, ASQ helps efficiently retrieve the noise sources that cause specific acoustic problems. ASQ results are typically used as part of TPA calculations executed to identify the surface panels that contribute most to a given acoustic response. With the introduction of ASQ, LMS Virtual.Lab Noise & Vibration Rev 6 overall matches the capability of LMS CADA-X TPA. 

In addition, it includes simulation procedures that can be entirely automated for test engineers as well as customized scripts that facilitate data access, processing and reporting. A second TPA-related enhancement concerns the procedure to retrieve graphical data displays for any point of interest. LMS Virtual.Lab Noise & Vibration Rev 6 now supports an intuitive approach that is entirely graphical. After selecting the response point of choice and indicating the preferred display type, engineers immediately see the specific curve that is relevant for that particular point. To conjure up a standard 2D response or advanced TPA display, engineers formerly needed to return to the specification tree, search the appropriate display, indicate the display type and select the point of interest. The intuitive graphical approach saves a lot of burden and many mouse clicks, and is therefore beyond comparison in terms of productivity.

Today’s relentless development pace limits the time and opportunity for designers and engineers to optimize the noise and vibration performance of new products. To contribute to faster hybrid simulation execution, LMS Virtual.Lab Noise & Vibration Rev 6 extended its forced-response capability with SPOINT support. This feature allows noise and vibration analyses to be executed efficiently on product assemblies containing components being reduced using Wave Based Substructuring (WBS) or a modal reduction approach, for example. In this way, large (sub)system assembly models consisting of hundred thousands of DOFs, such as engine, compressor or chassis models or even an entire powertrain assembly model, can be reduced drastically. As a result of its huge impact on processing lead time, examples highlight savings of a factor of 50 or higher, many more simulation iterations can be executed in the same time span, while maintaining high simulation accuracy on full-system level.

Innovative solutions for virtual shaker table simulations 

The vibration fatigue solution of LMS Virtual.Lab Durability supports durability performance simulation in the frequency domain, covering excitation patterns ranging from road, engine up to shaker table loads. This ensures that prototypes are tested correctly, and enables engineers to design better and faster tests. It even allows harmonic (sine-based) loads to be applied in the virtual world. Harmonic vibration fatigue simulation increases the accuracy of frequency-based solutions, and outperforms sine sweep simulation speed of any time domain solution. 


One of the first companies to use LMS Virtual.Lab Vibration Fatigue was Isringhausen GmbH & Co, a well-known German manufacturer of seat systems. Dr.-Ing. Nguyen Van Son commented on the random fatigue software the company uses for car seat vibration testing. He stated that, “It is a very effective and easy tool for calculating the fatigue performance of the seat structure. With this random fatigue tool, it only requires a few steps to complete the entire fatigue analysis.” 

In addition to vibration fatigue, LMS Virtual.Lab Durability Rev 6 introduces a new acoustics fatigue solution, which predicts the stress distribution and durability performance that result from random sound pressure. This new application is specifically tuned to cover simulation requirements that typically apply to the space industry. The acoustics fatigue solution enables development teams to dedicatedly monitor the damaging impact of deafening launch noise on a rocket’s payload, which consists of numerous fragile mechanical and electronic components.

LMS Virtual.Lab Durability Rev 6 features effective load contribution analysis tools that help identify the loads that contribute most to local damage or high stress concentration. This completes the software’s local analysis tools, offering in-depth information on the root causes of failure, which is extremely useful in performing structural refinements with respect to strength and fatigue. In case damaged areas are under pressure or lie inside the structure, LMS Virtual.Lab Durability Rev 6 is able to analyze such phenomena using full 3-dimensional stress tensor analysis. In this regard, it additionally provides dedicated analysis capability to investigate the interior structure at a user-definable distance from the surface of the structure. This helps anticipate crack initiation inside cast structures or under the hardened surface as a result of the top surface being under pressure.

A key task in obtaining real-life simulation quality is systematically correlating FE models with prototype test results, or alternatively with validated models of similar designs. Virtual.Lab Correlation removes modeling errors and reduces uncertainty that may exist in small-size component models or large  system models. Its wide range of correlation tools efficiently provides the touch with reality, which in turn secures the reliability of simulation-driven product development. Virtual.Lab Correlation combines an integrated environment, a straightforward user interface and direct access to standard FE and test data formats, including a unique interface with LMS Test.Lab.

New in LMS Virtual.Lab Correlation Rev 6 is FE model updating that operates on the basis of Nastran SOL 200. The capability to drive Nastran SOL 200 enables designers and engineers to quickly derive the design sensitivities of new products they are working on. This is vital information when evaluating new product designs in regard to potential variations in material and properties composition. The SOL 200 sensitivities can then be used to drive the execution of FE model updating. After specifying target performance objectives, LMS Virtual.Lab automatically updates the model in such a way that preset objectives are met or approximated as closely as possible. Since the optimization procedure takes into account SOL 200 sensitivities, it runs very fast, allowing large FE models with a high number of parameters to be updated in a fraction of the time previously required.

Powerful MAC updating and property grouping

In the SOL 200 context, LMS Virtual.Lab Correlation Rev 6 now also supports MAC updating, the process of improving FE derived mode shapes to better match experimental mode shapes. The main advantage of MAC updating on the basis of Nastran SOL 200 sensitivities is that it radically increases the speed of mode shape updating. A feature that potentially saves even more time is the new grouping capability. Instead of going through the error-prone process of creating FE updating properties manually, LMS Virtual.Lab Correlation Rev 6 automatically splits predefined element groups into property groups that directly serve as input for FE model updating, saving significant time and user interaction.