Following on from our earlier preview, free access to SonoAnalyzer Version 3 is now available at:
https://v3free.powerultrasonics.com/
No login is required to access the page, view the built-in documentation or load examples but to run new analyses you will need to sign in.
From the early betas and version 1 in 2011-2012 to version 2 in 2020, the story of SonoAnalyzer over fifteen years has been one of gradual slow growth — new element types, new sonotrode geometries, better solver integration. It's been a native desktop app throughout that time, with built-in OpenGL graphics and a connection to remote CalculiX servers for the FEA work. Now AI has changed the pace of software development and version 3 brings the first major architectural change: the whole workbench moves to the browser.
Here's what's coming.
A common ultrasonics application involves driving several probe sonotrodes from a single large block. This arrangement allows for a significant step-up ratio and wide separation between the probe tips. This article goes step-by-step through the process of creating a model of such a system in SonoAnalyzer and optimizing its performance.
Announcing the release of a new SonoAnalyzer, version 2.3.2, in Pro, OE and Free editions. This is the fully-functional release of the new STEP multi-element model, which allows for a combination of multiple STEP files containing geometry, or a single STEP file containing the geometry for multiple components, or both. No matter how the component geometry is defined, different materials can be selected for each individual component.
As on the earlier beta version a simple demo model is included in the package, which will load when the model type is selected. This is a concept for an ultrasonic scraper with a common utility-knife blade clamped into an aluminium stepped sonotrode using two small screws. All four components are defined in a single STEP file and entered as three geometry sub-tabs in SonoAnalyzer (one tab for each material - the two screws are selected together on the third tab). Defining all four components in the same STEP file makes it simple to establish their relative locations.
Where multiple components are defined in separate files, they will not usually be correctly positioned. In this case new "Advanced" options allow for rotation and alignment of each individual part. This can also be used to add multiple copies of a component in different positions. Furthermore components need not necessarily be additive; if the special "Subtract" material type is selected then the component will be treated as a hole or slot in the other (solid) components.
Some further changes in the SonoAnalyzer graphics window for this new model type only. On the geometry view (after redraw, before analysis) and on the animation view (after analysis) the area on the left of the graphics window, normally used for a key on contour plots, now shows a list of materials used in the model. Click on any one of the material labels to show only that material, or click on the "All materials" label to return to the standard view of all components. This feature works alongside the existing sectional views (double-click on the graphics window to toggle through available sections) but the sectional view options are now also shown in the key on the left side of the graphics window.
Some deprecated features are not available in this model / version, notably external graphics using the CalculiX cgx program, .stl file import and the use of Netgen for mesh generation. If any users have a specific need for these please contact me to discuss your options.
To support the new analysis, new pro analysis servers are also required (designated v3, replacing the earlier v2 servers). For cloud-server users there is an option within SonoAnalyzer to request an upgrade - just click the OK button on the warning popup that appears when the new model type is selected with a v2 analysis server. For users of locally-installed analysis servers a new Windows binary is available to download from the Pro support packages page (FEAServer setup.exe version 3).
As always, if you find any issues please let me know. More details follow.
Announcing the long-awaited release of a new SonoAnalyzer Pro, version 2.3.0 beta. This introduces a new, much requested model type called "STEP multi-element". As the name implies this allows combining multiple STEP files containing geometry, or a single STEP file containing the geometry for multiple components, or both. No matter how the component geometry is defined, different materials can be selected for each individual component. As this is a beta release and the new model type is for SonoAnalyzer Pro only, new versions of SonoAnalyzer OE and Free will not be released this time.
To demonstrate the new model type a simple demo model is included in the SonoAnalyzer Pro package. This is a concept for an ultrasonic scraper with a common utility-knife blade clamped into an aluminium stepped sonotrode using two small screws. All four components are defined in a single STEP file and entered as three geometry sub-tabs in SonoAnalyzer (one tab for each material - the two screws are selected together on the third tab).
In the SonoAnalyzer graphics window there is an additional option for this new model type only: Single material display. On the geometry view (alfer redraw, before analysis) and on the animation view (after analysis) the area on the left of the graphics window, normally used for a key on contour plots, now shows a list of materials used in the model. Click on any one of the material labels to show only that material, or click on the "All materials" label to return to the standard view of all components. This feature works alongside the existing sectional views (double-click on the graphics window to toggle through available sections).
Some deprecated features are not available in this model / version, notably external graphics using the CalculiX cgx program, .stl file import and the use of Netgen for mesh generation. If any users have a specific need for these please contact me to discuss your options.
To support the new analysis, new pro analysis servers are also required (designated v3, replacing the earlier v2 servers). For cloud-server users there is an option within SonoAnalyzer to request an upgrade - just click the OK button on the warning popup that appears when the new model type is selected with a v2 analysis server. For users of locally-installed analysis servers a new Windows binary will be available to download shortly.
As always, if you find any issues please let me know. More details follow.
Announcing the long-awaited release of SonoAnalyzer version 2 - now available to download in the usual Pro, OE and Free editions. This is designated version 2.2.0. It includes dramatic improvements in performance and responsiveness on large models, several new features and many bug-fixes. As always, if you find any issues please let me know. Notable changes include:
Performance: Changes to the internal data structures and processing reduce load times by 50 to 90% on larger models.
New features: Auto-tune restored, new displacement contour options, new sectional views, improved control over startup and loading results from cache.
Bug-fixes: Several issues addressed.
More details follow.
A significant update release of SonoAnalyzer version 2 is now available to download in the usual Pro, OE and Free editions. This is the sixth(!) pre-release, or PR6. It includes some bug-fixes, some improvements to reduce memory usage and support for another auto-mesher: Gmsh. As always, if you find any issues please let me know. Notable changes include:
More details follow.
A significant update release of SonoAnalyzer version 2 is now available to download in the usual Pro, OE and Free editions. This is the fifth (and possibly final) pre-release, or PR5. It includes several useful new features particularly for the new user-geometry models and fixes some bugs. As always, if you find any issues please let me know. Notable changes include:
For full details, read on...
I've uploaded a new build of the FEAServer package (CalculiX, FreeCAD and NetGen free software in a convenient standalone package), replacing FEAServer-setup.exe from June 2020. The new version FEAServer2.01-setup.exe contains the same software but with updated documentation and an improved RunOnce.exe program.
The Windows versions of FreeCAD and NetGen were compiled using Microsoft Visual C++ and have dependencies on two different versions of the Microsoft Redistributable package - FreeCAD uses the 2013 edition and NetGen the 2015. These libraries are also installed by a wide variety of other software and (in the case of 2015) even included in some versions of Windows 10, so in most cases there is no need to reinstall them. But if you do have a system on which these libraries aren't already installed, eg. a brand new PC, the included software will not run without them, whether standalone or through SonoAnalyzer.
In the case of FreeCAD and the 2013 edition the installer was included but instructions on how to install it were buried in the README.txt file. The installer for the 2015 edition required by NetGen was not even in the package. I apologise for this oversight on my part.
In the new package (version 2.01), both installers are included (in the Utilities directory) and will be installed automatically by the "RunOnce" program on completion of the install. In addition this program now creates Windows batch files in the Utilities directory to manage paths (for the different Python versions) and other environment variables so that FreeCAD and NetGen can be conveniently run as standalone programs. There is also a "startx" batch file to start the Cygwin X11 (graphics) server used by cgx (the CalculiX pre and post-processor) and a cgx batch file to run cgx itself.
If you have already downloaded an earlier version, either FEAServer-setup.exe or FEAServer.zip you can download only the new content in the much smaller package FEAServer2.01Utils-setup.exe. When running the installer please choose the same directory where you previously installed the full package.
The two new packages can be obtained from the links on the Downloads page.
Another update release of SonoAnalyzer version 2 is now available to download in the usual Pro, OE and Free editions. This is the fourth "pre-release", or PR4, and fixes several bugs particularly in the user-geometry models. As always, if you find any issues please let me know.
This update includes mostly bug-fixes as follows.
Problems loading user-geometry models: In certain circumstances SonoAnalyzer would fail to read the original STEP file. Making this worse, the error messages produced were not representative of the real issue (eg. "Unknown / missing or conflicting units definition..."). This could occur even with the demo model provided.
"Save results" on STEP import models was failing to include the original STEP file in the package, requiring the separate loading of both the model (.sa1) and results (.saz).
Negative axis options (-x, -y and -z) were not working properly in demo mode - SonoAnalyzer Free and OE.
Meshing error handling: In the event of an unrecoverable meshing error the user has the option to send information about the problem to help improve SonoAnalyzer. However in the case of user-geometry models the critical STEP file was not included in the package of information. From 2.0.9 it will be. Note that all such information will be held in strict confidentiality and used only for the development of SonoAnalyzer.
"Preparing to save results. Please wait" status was being removed before the preparation was complete.
Additional interpretation of messages generated by Netgen (also shown in console).
Added additional information in Pro servers dialog - now includes "This server is currently selected for use."
Added option in File menu: "Reset SonoAnalyzer" - clears cache and returns SonoAnalyzer to initial state.