The Future of Simulation in Engineering - Ansys · ANSYS 14.0 is a major, feature ... •...

© 2012 ANSYS, Inc. February 24, 20121

Dipankar Choudhury, Ph.D.VP, Research

February 7, 2012

The Future of Simulation in Engineering


Overview

Simulation in engineering

ANSYS R&D vision & strategy

Recent progress at ANSYS with Release 14

Technology directions: Release 14.5 and beyond

Summary


Simulation in Engineering


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Consolidated Company Geographic Revenue

Percent of Net Sales Revenue by Industry

Academic8%

Aerospace & Defense17%

Automotive15%

BioMedical2%Construction

2%Consumer Products

2%

Electronics19%

Energy and CleanTech10%

Industrial Equipment13%

Materials & Chemical Processing

12%

Americas34%

Asia32%

Europe34%

Our Customer Base is Diversified(With a Common Overarching Need!)


Insertimagehere

“ANSYS simulation software is incredibly reliable and

accurate. Simulation enables us to drastically reduce lead

times and get solutions to the circuit much quicker, so we

are more competitive race to race.”

A promise that it will perform properly, not fail unexpectedly, and even exceed

the expectations of its designers and users. ANSYS helps power these promises with

the most robust, accurate and flexible simulation platform available.

Steve NeveyBusiness Development ManagerRed Bull Technology

Every Product is a Promise


Top Business Pressures Driving Product Design Improvement

Biggest Hurdles for Product

Design

Getting Product Designs RightSource: Aberdeen Group, April 2011


Smart Products/Smart Processes• Interconnected systems • Adapt to environment• Adapt to user• Lack test experience

Smart Products Drive Complexity

Image of wind turbine system

“Today’s increased complexities require a system‐level approach in

designing wind turbines and evaluating performance based on

real‐world conditions.”

Ahmad HaidariGlobal Industry Director Energy and Power ANSYS


ANSYS R&D Vision and Strategy


Our Vision: Simulation Driven Product Development

ConceptPhysicalPrototype

Production

Simulation‐DrivenProduct Development

Concept Design PhysicalPrototype Testing Analysis Production

CAD CAE CAM

Yes

No

Detailed Design


Click to edit Master text stylesDemocratize Simulation

Process Automation

Enable Best Practices

Focus on Engineering

Complete Systems

Simulated Environments

Multiphysics

Fluids Dynamics

Structural Mechanics

Explicit Dynamics

Low‐Frequency Electromagnetics

High‐Frequency Electromagnetics

Thermal Mechanics

Acoustics

Span Organizational and Geographic Silos

Share Engineering Insights

Better Decisions Faster

Our Strategy


Comprehensive Capabilities TodayExample: Hybrid Electric Vehicle System


Increasing Investment in R&D

Millions

110

100

80

60

40

20

0

Fluent

Year1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

ICEM CFD

CFXCDI

Ansoft

Investment In Acquired R&D

Internal Investment In R&DOver 600 Product Creation Staff

in 2010 Apache


A Complete Ecosystem Example: Electronics

Mission: To enable our customers to realize their product promise by providing the leading and most comprehensive simulation tools.

Leading simulation software provider for advanced, low power solutions in the electronics industry.

Integrated Circuit


R&D Acceleration Through Sponsored Research at Universities (Selected List, 2011‐2012)

University Professor Technical TopicLaMCoS, Lyon Gravouil, Dureisseix,

Combescure, BibouletX‐FEM, Fracture Mechanics, Nonlinear

MIT Various Adjoint and advanced optimization methods

Ohio State University Lee Methods: DGTD, IPDDM

Stanford University (IAP) Iaccarino et. al. Turbulence, combustion, uncertainty analysis

Toulouse University Masmoudi Optimization, acceleration methods

TU Dresden Kaliske Nonlinear Materials

University of British Columbia Ollivier‐Gooch Solution quality, FVM numerics

University of Koblenz Ulrich Semiconductor Modeling/Characterization

University Politécnica de Madrid Various Power Converter Modeling, Parameterization and Validation

U of Wisconsin Rothamer IC Engine Modeling


Major Themes and Challenge Statements

Fast and Reliable SolversFast and Reliable Solvers

Smart ProductsSmart Products

Product Integrity through Robust Design

Product Integrity through Robust Design

Amplify EngineeringAmplify Engineering

Cost Effective and Scalable IT

Cost Effective and Scalable IT

Open Collaboration Platform

Open Collaboration Platform

ANSYS delivers tools which are fast, accurate, and robustANSYS delivers tools which are fast, accurate, and robust

Product performances evaluated from components to complete systemsProduct performances evaluated from components to complete systems

ANSYS provides tools to optimize product designANSYS provides tools to optimize product design

ANSYS solutions enable high engineering productivityANSYS solutions enable high engineering productivity

ANSYS provides scalable and cost effective solutions ANSYS provides scalable and cost effective solutions

ANSYS solutions are engineering collaboration enablersANSYS solutions are engineering collaboration enablers


Simulation‐Led Design: Extreme Performance, Fidelity and Engineering Ease of Use


Simulation Technologies for Extreme Fidelity and Performance

Comprehensive & Accurate Mathematical Models

Robust Design,Robust Simulation,Advanced Numerics

Extreme Problem Size & Speed,Optimum Hardware Utilization

ROMs and Advanced Coupling Methods, Cosimulation,Multiscale/Multiphysics

High Accuracy,Robust,Physics‐Aware,Efficient,Adaptive

Robust & Intelligent,Non‐linear,Transient

All mesh typesNon‐conformalAdaptive MeshesMoving/DeformingRezoning, Remeshing


Enabling Technologies for Extreme Engineering Ease of Use

Integrated, Immersive, Impressive, Responsive

EfficiencyReuse

Automated,Large‐Scale, Solver IntegratedRobust & Intelligent,Tolerant

Smartphones→ ClustersLAN →WAN, Cloud

ApplicationPhysics

CAD/CAE InteroperabilityPLM Process Integration

Data/Feature ExtractionRendering MethodsQuantitative Analysis


Workbench System‐Level Architecture

Compute

Compute Compute

Compute

GUI,Graphics

Commands,Application logic

Journal/Script

LightweightData

HeavyweightData

ComputationalServices

EngineeringIntent Computational

ServicesComputationalServices

HPCUserEnvironment

DataManagement

View Controller Model


Recent Progress at ANSYS with Release 14


Near‐Mid Term Release Timeline

ANSYS 14.0 is a major, feature‐rich release• Like ANSYS 13.0, driven by specific customer needs

ANSYS 14.5 will be another significant milestone

ANSYS 15.0 will be another major release

201220112010

ANSYS 13.0 ANSYS 14.0

R13 Service Pack 2 (Defect fixes only, Platform Support)

ANSYS 14.5

2013

ANSYS 15.0


Wrapper Strengths:+ Can ignore small features+ Can fill holes+ Ignores un-wetted surfaces+ Ignores intersections and overlaps

Wrapper Strengths:+ Can ignore small features+ Can fill holes+ Ignores un-wetted surfaces+ Ignores intersections and overlaps

CutCell/CutTet Strengths:+ Automatically connects multiple

regions+ Prioritization of objects allows

complete overlaps of different regions+ Automatically connects zero-

thickness baffles+ High surface mesh quality+ Excellent feature capturing

CutCell/CutTet Strengths:+ Automatically connects multiple

regions+ Prioritization of objects allows

complete overlaps of different regions+ Automatically connects zero-

thickness baffles+ High surface mesh quality+ Excellent feature capturing

R14 Meshing: CutWrap

Automatic hole detection and filling

Much better surface mesh quality than Wrapping

alone

Extremely “dirty” engine

with many holes

CutWrap Strengths:+ Automated meshing of highly

complex assembliesFill holesIgnore small featuresIgnore un-wetted surfacesIgnore intersections and

overlapsConnect multiple regionsConnect zero-thickness

baffles+ High surface mesh quality+ Excellent feature capturing+ Supports both CutCell & Tet, with

prism layers

CutWrap Strengths:+ Automated meshing of highly

complex assembliesFill holesIgnore small featuresIgnore un-wetted surfacesIgnore intersections and

overlapsConnect multiple regionsConnect zero-thickness

baffles+ High surface mesh quality+ Excellent feature capturing+ Supports both CutCell & Tet, with

prism layers


High‐Quality Prism Inflation Layers


Top‐down approach to mesh all parts at once• Automatically extracts internal regions from assemblies– Uses material points or groups of

faces/bodies to locate fluid regions• Supports:

– Meshing solids from sheet bodies– Conformal mesh between parts without

requiring multibody parts– Overlapping bodies– Tet and CutCell (hex‐dominant) mesh

types– Prism inflation layers

• Built upon TGrid CutWrap technology

Benefits:• Dramatically reduced time to mesh typical CFD models– Tedious geometry clean‐up eliminated or

greatly reduced

Workbench Assembly Meshing

CutCell withPrism Inflation Layers

Tet withPrism Inflation Layers


Solver Advancements Example: Fluids

Trend towards ever larger models:• Solved first one‐billion cell model in ANSYS Fluent 12 in 2009• Smart parallel processing: solver algorithms developed on much smaller meshes need to be revisited for these massive mesh sizes

Solver developments to stay ahead of the curve:• Pressure based coupled solver, pseudo‐transient relaxation, higher‐order term relaxation (HOTR), hybrid flow initialization, non‐iterative transient, hierarchy based hybrid AMG, higher‐order numerics improvements

• Physical model advancements in turbulence, multiphase, combustion, radiation, systems coupling and many others

Future: customers are contemplating models with tens of billions of cells, and we are committed to the development of robust, efficient, and accurate algorithms to solve these massive equation sets

Flow over a wall mounted bump

Contours of Q criterion


Rapid, Accurate and Robust Results• Pressure based solver, all‐speed formulation

– Coupled AMG solver– Pseudo transient solution method, 2nd order numerics

Best‐in‐class turbulence model• SST + Menter’s predictive transition model• Solves 2 Transport Equations

– Intermittency () Equation– Transition Onset Reynolds number Equation

• Multiple transition mechanisms– Natural, Bypass, and Separation induced transition

AIAA High Lift PredictionWorkshop Problem

28% Span on Main Airfoil28% Span on Main Airfoil

13 [deg] angle of attackUnst‐Hex‐FromOnetoOne‐A‐v113 [deg] angle of attackUnst‐Hex‐FromOnetoOne‐A‐v1


Solver Advancements Example: Electromagnetics

Finite Element Method• Efficiently handles

complex material and geometries

Integral Equations (IE)• Efficient solution

technique for open radiating and scattering of metallic objects

Physical Optics (PO)• Ideal for electrically

large, conducting and smooth objects

The right solver for the problem…

FEM Transient• Ideal for fields that

change versus space and time; scattering locations

New

The best of both… Hybrid Solver

Finite Element Method+

Integral Equation

FE-BI

IE Domains

HPCDDM with IE Domains

FE‐BI

FE‐BI Surface

IE

FEM

Hybrid method combines multiple solver techniques for efficiency.New Physical Optics Solver allows solution of extremely large models.Solve new problems that are 5x to 10x larger than before.

Reduced Volume

Solver Efficiency

Increased Productivity


HPC Leadership: Enabling Extreme Performance & Fidelity

Draw Just One Cell Let HFSS DDM Solve Thousands

Phased Array Antenna using Domain Decomposition (DDM) and HPC

384 832 1280 1728 2176 2624 3072

Performan

ce

Number of Processor Cores

F1 140M AMD Magny‐Cours

14.0.0

IdealANSYS is a clear leader in high‐performance computing • Linear scalability shown on > 3000

processor cores (using wall clock time)

• Parallel file I/O• Smart and efficient partitioning and

load balancing algorithms


Extended Analysis Tools for Robust Design and “Robust Simulation”

Extended Analysis

Design Explorer

MMO in Fluent

Sensitivity Analysis

Tangent Adjoint

Gradient‐based

Optimization

Mesh Morphing

Back –to‐CAD/DM

Robust Simulation Goodness of Simulation Uncertainty Quantification


Optimization Case Study

SAE publication: automation of vehicle shape exploration and optimization using integrated mesh morphing and CFD (Khondi, Sovani, Verma, 2011)Response surfaces with drag as a function of tumblehome angle, windshield angle, backlight angle

Fluent mesh morpher and optimizer DOE (design of experiments)

Response surfaces


Shape Optimization With Adjoint Methods

Shape sensitivity: Sensitivity of the observed value with respect to (boundary) grid node locations

mesh

nn xwDownforceLiftDrag .)//(

Shape sensitivity coefficients:Vector field definedon mesh nodes

Node displacement


Shape Optimization With Adjoint Methods

Shape sensitivity: Sensitivity of the observed value with respect to (boundary) grid node locations

mesh

nn xwDownforceLiftDrag .)//(

Shape sensitivity coefficients:Vector field definedon mesh nodes

Node displacement

Downforce (N)

Geometry Predicted Result

Original ‐‐‐ 425.7

Modified 447.4 451.1


Two‐way surface force/displacement coupling between Fluent and ANSYS Mechanical via Systems Coupling

• Steady/static and transient two‐way FSI• Workbench based setup and execution• Integrated post‐processing with CFD‐Post• Windows and Linux• Alternative execution from command line• Parallel processing with ANSYS HPC• Parameterization, design exploration and optimization

New in Release 14.0 – FSI with Fluent

Non‐Newtonian blood flow through a three leaf mitral valve


More at R14.0: Maxwell Multiphysics

New Parallelization of 3‐D non‐transient solvers• OpenMP is used to speed up the field solver 3X using different cores sharing same memory

New 2‐way Coupling With ANSYS Fluent• Full coupling and management in ANSYS Workbench

New 2‐way Stress Coupling with ANSYS Mechanical

Maxwell FLUENT

Loss

Temperature

Maxwell Mechanical

Force Distribution

Node DisplacementMinimum at 0 mm

Maximum at 3.6mmMinimum at 0 mm

2‐Way Coupling With Fluent

2‐Way Coupling With Mechanical

EM loss distribution

Rigorous simulation flow needed for high fidelity and complete simulations


Solutions From 3‐D to 0‐D

Initial Design

PExprtMagnetics

RMxprtMotor Design

Electromagnetic Components StressTemperature

WB System wide optimization using CAD parameters

0‐DSystem


Technology Directions: Release 14.5 and Beyond


Guided Assembly Meshing for high complexity• Simplified GUI to guide users through process– Hole, gap, overlap resolution tools – Access to Wrapper as geometry conditioner

– New baffle handling• Improved surface mesh quality• Improved prism inflation layer robustness

• Supersedes CutWrap

Parallel Meshing (Beta at R14.5, Full release at R15)

Meshing in Release 14.5: Assembly Meshing


Major Research Areas in Fluids and Mechanical Core Technologies

Numerical/Solution Methods• Solver acceleration (steady & transient), robustness

• High Performance Computing• Advanced optimization methods

Mathematical Models & Physics• Composites, Fracture, Acoustics• Material behavior, Linear dynamics

Special Methods/Physics• IC systems• Turbomachinery modeling• Integrated Multiphysics• Solver‐meshing integration Image Courtesy of Archus Orthopedics

Model Courtesy of

Hot Rolling Structural Steel

Structural Composite Simulation


ANSYS Mechanical at ANSYS 14.5

Mechanical and its core solver• Performance: Large models, cyclic symmetry, post‐processing, results file size reduction

• Fracture Mechanics and Fatigue: Crack tip meshing, analysis in Mechanical, XFEM research. nCode Partnership

• Composites: Solid composites from ACP in Mechanical, progressive failure using CDM. EVEN Partnership.

• Submodeling: General mapping of displacement/forces

• Multiphysics: Nonlinear material support, coupled acoustics, thermal solver performance

• Misc: Brake squeal, rotordynamics enhancements in Mechanical, contact options

Explicit and Rigid Body Dynamics (RBD)• Progress towards seamless Implicit‐Explicit‐RBD integration


Fluids at ANSYS 14.5ANSYS Fluent:• Workflow: Integrated meshing (Fluent–TGrid), ANSYS Workbench integration advancements

• Combustion:More accurate, robust, and efficient gas turbine combustion and internal combustion engine simulations, including WB‐ICE

• Optimization: Adjoint and mesh morpher optimization methods

• Solver: Numerics, parallel/HPC (including GPUs)• Advanced physics:Multiphase, wall film, sprays and particles, radiation, reacting flow, turbulence, etc.

Polyflow virtual prototyping for packaging

Minimize drag Maximize lift

3d piston; Adiabatic compression; SHM2nd order time for deforming meshes

Adjoint solver: compound observables

ANSYS CFX: • Turbomachinery: Focus especially on advanced blade row modeling and turbo tools

ANSYS Polyflow: • Prototyping: advanced virtual prototyping via tight coupling with structural (MAPDL) and explicit


HPC Advancements in R14.5 and Beyond

Ongoing improvements in computation scalability and data transfer.

Targeting tens of thousands of processors and GP GPU’s

Hybrid parallel: fast shared memory communication (OpenMP) within a machine to speed up overall solver performance; distributed memory (MPI) between machines

0 768 1536 2304 3072 3840

Perfrorm

ance


Truck (111 million cells)

13.0.0

14.0.0

384 832 1280 1728 2176 2624 3072

Performan

ce


F1 140M AMD Magny‐Cours

14.0.0

Ideal


Fluid‐structure interaction (FSI)

• Extensions Mechanical – Fluent coupling

• Temperature transfer

• More robust: Solve more difficult problems

Coupling between Fluids (Fluent, ANSYS Icepak), Mechanical and Electromagnetics (HFSS, Maxwell, Sentinel TI, etc.)

Multiphysics at ANSYS 14.5

Package

Package in System

Icepak temperature profile from Sentinel TI power data

Fluent – Mechanical coupling


Multiphysics at ANSYS 14.5: 2‐way FSI example: Mechanical/Fluent

Milk carton “gulping” phenomena demonstrating Fluent 14.5 enhancements: FSI stabilization with increased damping leads to a converged solution.


Blending Cosimulation and ROMs

DOE Funded Development Project for Battery Modeling


HFSS Solver• Domain decomposition• GPU acceleration of HFSS transient• Hybrid MoM‐PO solver• More efficient HFSS‐IE/FEBI for large problems (>100 wavelengths)

Maxwell Solver• Vector hysteresis modeling

– Be able to model real physics of hard materials

Coupling 3D to Systems• S‐Parameter Fitting and Passivity Enforcement– Improved speed and capacity (up to 50x)– Build passive ROMs for much larger systems (200+ to 400+ ports in 0.5‐4 hrs)

Major Research Areas in Electromagnetics

Integral Equation

Physical Optics

M

h

-MS

MS

M+

M-

ch-hS

hS

Hysteresis Motor

MagneticRecordingHeader


Advanced Post‐Processing Methods:Data/Features, Graphics & Visualization

• Quantitative Post‐processing & Data Analysis

• Data/Feature Extraction• Transient analysis• Visualization• Performance with large datasets• Multiphysics post‐processing

Vortex Cores Used for Visualization


Summary

The future of simulation in engineering is bright• New and exciting opportunities, rapid progress in technology and innovative use of simulation tools by customers

Vital for simulation tools to exhibit Extreme Fidelity, Performance and Engineering Ease of Use• ANSYS delivers tools which are fast, accurate, and robust• Modeling components to complete systems• ANSYS provides tools to optimize product design• ANSYS solutions enable high engineering productivity• ANSYS provides scalable and cost effective solutions• ANSYS solutions are engineering collaboration enablers

The Future of Simulation in Engineering - Ansys · ANSYS 14.0 is a major, feature ... •...

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