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Simulation Apps for automated Design Space Exploration
Simulation Apps:
Simulation for EveryoneMalcolm Panthaki, Founder & CTO, Comet Solutions, Inc.
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
Design Space Exploration vs. Design Optimization
“Design optimization strategies have two distinct parts:
formulate and converge. Here it is assumed that the problem
can be formulated before the search and convergence begins.”
“Design exploration strategies, on the other hand, are based
on the belief that the problem formulation evolves during the
process of searching and converging, thus ultimately leading
to a more informed optimal solution. In this way, design
exploration is both divergent and convergent.”
Dr. Chris Mattson
Director, Design Exploration Research Group, Brigham Young University (BYU)
mattson@byu.edu
Simulation Apps for automated Design Space Exploration
From Optimization to Design Space Exploration
Copyright 2016 Ora Research, Bruce Jenkins
Simulation Apps for automated Design Space Exploration
Goal: Automated Design Space Exploration (DSE)
Simulation process automation – at any
level of model fidelity – is key to making
automated DSE work, for both experts
and non-experts
– By enabling…
• Robust and safe simulation automation
• At all levels of model fidelity
…everyone on the product development team
can explore the design space and refine their
designs, at all stages of the design process
Simulation Apps for automated Design Space Exploration
Goal: Non-Experts in the Concept Phase
• In the concept phase, the automation templates
should allow any user, expert or non-expert, to:
– Explore various architectures at any “reasonable” level
of model fidelity
– Swap out entire subsystems/components
to rapidly find a better initial architecture and design
• Makes it easy for all relevant engineering team
members, not just simulation experts, to
contribute their expertise to design exploration
Result: Better product architecture & design, faster, cheaper
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
A Wider Audience of Users Can Benefit from CAE
20 MillionEngineers Globally
(2015)
8 MillionEngineers of a type who can benefit from
CAE use
Significant barriers to broader adoption of CAE within the enterprise
Formal education: Most expert users are PhD’s and MS engineers
Requires specific product training and experience, for many years
Many engineers and employees engaged in product development are not able or capable of participating in simulation today, even though this would be highly advantageous for the product development process
Current Simulation (CAE) End-User Realities
750 K Engineers actually
using CAE today
750,000 simulation experts 8 million engineers 20M potential users*Source (2014): Cambashi
Simulation Apps for automated Design Space Exploration
Simulation Team
Simulation status quo: The Problems
Simulation in the hands of too few, for too longHow can we get complex simulation safely and effectively to “Everyone Who Needs It”?
CAECode 1
CAECode 2
CAECode 25
CAECode 13
CAECode 32
CAECode 35
CAECode 40
CAECode 38
Excel
Matlab
Optimization
Product Managers
Product Development Engineers
Systems Engineers
Test Engineers
Salespeople
…everyone needs simulation!
Product Development Team
Simulation Data: in silos, inconsistent, non-integrated
Simulation Processes: manual, error-prone, highly inefficient
5 days to “clean up” geometry and create a “perfect” mesh??
4-6 weeks to complete a single analysis?
How can simulation be a driving force in design?
Simulation Experts: often the bottlenecks
Simulation Apps for automated Design Space Exploration
Why is simulation limited to experts?Simulation is hard, especially when dealing with product
assemblies and complex phenomena
Simulation environments are general-purpose100’s-1000’s of functions, and keep growing
Extracting “good”, usable results from a particular
simulation tool takes years of experienceNeeds expertise in both the physics and the tools
Precisely because they are easier to use, garbage-in/garbage-out is a real danger!“Pretty” pictures are not only worth a 1000 words, but can easily deceive!
Simulation Apps for automated Design Space Exploration
Attempts to Solve These Problems
Use “Excel”, early and often (750M active users!!)
VisiCalc – 1979
Issues• Can get complex & hard to understand
• Obscured logic
• Too easy to modify
• Version control & distribution issues
• Limited math
Benefits• Targeted “Apps”
• Easy to create & modify
• Easy to use
• Simple to complex
• Affordable
• Ubiquitous
Simulation Apps for automated Design Space Exploration
Use CAD-embedded simulation tools
Make simulation environments easier & easier to useOngoing process, with huge progress over the last 20 years
Benefits• Integrated with the CAD environment
• Relatively simple interface
• Designers can run simulation directly
• Experts can work more efficiently in
their “general-purpose” tools
Attempts to Solve These Problems
IssuesCAD Embedded Tools
• Simple interfaces, but still general-purpose
• Limited simulation capabilities
• These are not the tools that experts use, so they often do not trust the results
• Have not seen widespread use as designers do not understand simulation and
are reluctant to trust the results
General-Purpose Expert Tools
• Though easier for experts to use, these still cannot be used by non-experts
Simulation Apps for automated Design Space Exploration
Attempts to Solve These Problems
Use Vertical (solution-specific) ApplicationsScripted, expensive to create/maintain, limited & brittle
Benefits• Targeted “Apps”
• Easy to use
Issues• Scripting/programming approach requires “programmers”
• Expensive to create
• Logic (including rules) is obscured within the program
• Difficult and expensive to enhance/modify
• Often break when the design changes by “too much”
• Often do not work across a product family
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
Simulation Market: New business drivers
What’s driving changes in the simulation market?
This has resulted in increased focus and investment
in simulation by major PLM software vendors
Simulation has seen continual, steady annual growth for 40 years
Simulation is now a significant portion of the Engineering
Software Market and a driver for future growth
Growing Business awareness that
Simulation is key to increased Competitiveness
Credit: Joe Walsh, intrinSIM (www.intrinsim.com)
However, more recently, due to strong market pressures…
The changing role of simulation is more about it’s
role in business than the changes in simulation technology
Simulation Apps for automated Design Space Exploration
Business Drivers
Expertise Available Expertise Required
MCAE Market Trends revolution
Credit: Joe Walsh, intrinSIM (www.intrinsim.com)
So, innovative Businesses are asking questions:How can we better leverage the power of Simulation to be more innovative, faster?
How can we deal with a small, ageing population of simulation experts?
The demand for simulation is rapidly increasing…
A Simulation Revolution
has begun:
“Fit for purpose”
“Smart”
“Integrated”
“Transparent”
Simulation Apps for automated Design Space Exploration
ASSESS Initiative
Analysis, Simulation & Systems Engineering
Software Strategies
Mission statement:
“Expanding the use and benefit of Model Based Simulation, Analysis and Systems Engineering”
2005 2015 2020?1 in 22
1 in 6-10 ALL
Next gathering is in Potomac, MD – Jan 20-22, 2016
http://assessevent.com/
Brad Holtz, Cyon Research
Joe Walsh, intrinSIM
Simulation Apps for automated Design Space Exploration
Potential economic impact of $5.2T to $6.7T per year in 2025
Disruptive Impact of Technology Waves
• Capture product engineering knowledge in
reusable system modelling templates
• Automate multi-fidelity, multi-disciplinary product
and design calculations related to performance,
manufacturing, maintenance, or cost
• Allow these automated calculations to be
safely & easily run using simple Simulation Apps
Simulation Automation
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
Simulation Apps: A Solution
Simulation Apps(author the Apps)
CAE
Code 1
CAE
Code 2
CAE
Code 3CAD Tool
Optimization
Simulation
Experts
Product Managers
Systems Engineers
Designers
Salespeople
…
(users of the
Simulation Apps)
Targeted Applications: answer particular questions,
on a particular product family, at a particular level of fidelity
Simple GUI’s that drive Simulation Automation Templates
that capture & enforce the expertiseSafe and robust for all users
Must speak the language of the user, not “Simulation”
Web-deployed on “The Cloud” – why does that matter?
Product Development & Sales Teams Simulation Team
Simulation Apps for automated Design Space Exploration
Simulation Apps: What are the Benefits?
Simple, targeted, web-deployed Simulation Applications
Hydraulic Rod Calculator
Bumper Impact Calculator
• Targeted/Solution-SpecificAnswer specific questions about the design of a particular product at particular levels of fidelity
• Dirt Simple & often Cloud Available – Think Apps!Easy to use, speak the users’ language, and globally web-accessible
• Useful Across a Wide Range of Product DesignsWork across significant design changes and also across a product family whose members share a common functional architecture
• Safe To Use – Expert-Certified!Have the expertise of the experts embedded in them – company best practices are captured and enforced
• Harness the Full Power of the Expert Tools – Expert-Blessed!Use the same, underlying, validated expert CAE tools
• And Fast – All the Compute Power You NeedProvide access to the required compute hardware on the intra/public Cloud
Simulation Apps for automated Design Space Exploration
AweSim is a unique public-private partnership facilitating the adoption of affordable, effective and convenient simulation-driven design by small- and medium-sized companies by providing simple and easy-to-use access to:
• Online modeling and simulation apps and tools
• Educational materials and training courses
• Industry-specific expertise and consultants
AweSim Partners
AweSim Workflow
Ohio Supercomputer: AweSim Program
Simulation Apps for automated Design Space Exploration
AltaSim: Heatsink Simulation App
• Power electronics
– Long term reliable
operation
• High power density
– Increased functionality and
decreased size
• Operating temperatures
– Approach component
failure
• Thermal management considered earlier in development cycle
• Traditional assessment methods not sufficiently accurate
• Accurate solutions complex to implement
Credit: Jeffrey Crompton, AltaSim Technologies (www.altasimtechnologies.com)
Simulation using COMSOL
Simulation Apps for automated Design Space Exploration
Heatsink Simulation App: Inputs
Simulation Apps for automated Design Space Exploration
26
Simulation Apps for automated Design Space Exploration
Level 1: Results
27
Simulation Apps for automated Design Space Exploration
Level 2: ResultsOptimum heat sink design
• Conduction
• Convection
• Radiation
Simulation Apps for automated Design Space Exploration
GKN: Democratizing CAE with SPDM
Global Application
Engineers
User – Simulation Process Automation
Queue-Based Remote Execution
Web Tool: OutputsWeb Portal Web Tool: Interface
Fatigue: Life Prediction
CAD: Step files
Internal Loads
Solver & Post-processorPre-processor
Strength & Fatigue Modeling
Credit: Glenn Valine, GKN Driveline (http://www.gkn.com/)
Simulation Apps for automated Design Space Exploration
Simulation Process and
Data Management with
Run-Ready Input Decks
Simulation Recipes/Methods,
CAD-Attached CAE
Script-based
Simulation Process
Automation
Enterprise Deployed
Democratized CAE
Building Blocks to Democratizing CAE
Ad-Hoc Simulations with Traditional OTS Solvers
Num
ber
of
Users
and/o
r Job E
xecutions /
Year
Time
Credit: Glenn Valine, GKN Driveline (http://www.gkn.com/)
Simulation Apps for automated Design Space Exploration
FEA: Smart Web-Enabled Apps
1
2
3
4
5
Credit: Juan Betts, Front End Analytics (http://www.feasol.com/)
EASA for rapid web app development
Catia for CAD
Abaqus for finite element analysis
Simulation Apps for automated Design Space Exploration
American Axle: Driveline SimApps
Glen Steyer, American Axle’s Executive Director of Product Engineering, reports
major benefits from the new tool: • Average 75% time reduction for each analysis iteration.
• Approximately $130,000 in annual cost savings at a single engineering site.
• Improved quality through globally enforced modeling and NVH standards/practices which minimizes
opportunity for human error.
• Ability to run many more NVH analysis iterations, leading to more design decisions, earlier.
• Ability to redeploy resources as less experienced engineers are now able to safely run
simulations.
Teamcenter
Simulation Apps for automated Design Space Exploration
Kinetic Vision: Container Top-Load App
Credits: Kinetic Vision (http://www.kinetic-vision.com/) & Comet Solutions (www.cometsolutions.com)
Kinetic Vision SimApps Library
Top-Load Container Analysis SimApp
Family of containers
Send in 3-D CAD model and automatically
run a top-load crush analysis using 2-D mid-
surface shells
Uses EASA for Web App development
Uses ANSA for meshing
Uses Abaqus for finite element analysis
SimApp deployed in the Cloud
Used by product engineers who have
little prior CAE expertise
Simulation Apps for automated Design Space Exploration
•Perform physical testing on molded parts to validate performance
•Build/modify injection mold and produce samples.
•New Pail Mold: $120k
•Modifications: $5k-$10k
BWAY Corp: Sim-App Process (2015+)Injection Molded
Samples
Product Testing
•Evaluate test data
•Make “Go To Market” or “Back To Drawing Board” Decision
•1-2 design iterations required
Evaluate and Decide
GO TO
MARKET
•Upload model to product-specific Sim-App with minimal input.
•Many iterations possible.
•Design product or product modification based on customer requirements and analysis data
Product Design
Cloud-Based Sim-App
Credit: Forrest Burney, BWAY Corp. (http://www.bwaycorp.com/)
Simulation Apps for automated Design Space Exploration
Top Load Simulation App: Process– Access the Simulation App directly through the Web
– User submits a 3-D SolidWorks CAD file and inputs the following:• Material
• Compression Distance (mm)
• Duration (ms)
• Mesh Size (mm)
– The simulation runs in ~6-15 hours and produces results
Credit: Forrest Burney, BWAY Corp. (http://www.bwaycorp.com/)
Simulation Apps for automated Design Space Exploration
Results • 3D view of deformation (Image and Video)
• Maximum reaction force
• Error %
• Force versus Deflection graph
Max ReactionForce Results
lbf N
Physical Test 2875.1 12,789
Simulation App 2379.6 10,585
Top Load Simulation App: Results
Credit: Forrest Burney, BWAY Corp. (http://www.bwaycorp.com/)
Simulation Apps for automated Design Space Exploration
Validation of the simulation app
• Error in results produced from the simulation app was <15%
(when compared to physical test results)
• Latest results show error <10%
Max ReactionForce Results
lbf N
Physical Test 2875.1 12,789.08
Simulation App 2379.6 10,585
Top Load Simulation App: Validation
Credit: Kinetic Vision (http://www.kinetic-vision.com/)
Validation of a Simulation App’s results is CRITICAL!!
Simulation Apps for automated Design Space Exploration
Simulation Apps: From “simple” to complex
Automotive subsystems
Off-Road vehicles
Plastics & containers
Consumer appliances
Aerospace subsystems
Optical Imaging systems
Laser systems
Electronics PCBs
Plastic Bottle DesignAutomotive Driveline Design
Automotive Spring Design
Vehicle Suspension Design
Engine Connecting Rod Design
Electronics Board ReliabilitySpace-Borne Optical Systems
with Thermal Controls Laser Systems Design
Heavy Equipment Design
Washing Machine Design
Automotive Bumper Design
Aircraft Metallic Seal Design
Simulation Apps for automated Design Space Exploration
Simulation Apps driving
Simulation Automation Templates
Let’s look at some examples “live”…
Simulation Apps for automated Design Space Exploration
• Expertise, expertise, and test results for validationCapture and leverage best practices & rules across the global org.
• Rapid Template Development Environment (Comet)Capture the model & the rules – single, integrated data model, minimize scripting & programming, days not months!
– Rules based on Functional ArchitectureWorks across geometry, topology & configuration changes,and across a Family of Products
• Libraries of Parametric Analysis CAD & SystemsOvercome the tyranny of “CAD for Manufacturing”Easily swap components at different levels of fidelity
• Rapid Web GUI Development Environment (EASA) Create SimApps that drive the templates
Simulation Apps: Key Ingredients
Simulation Apps for automated Design Space Exploration
Agenda
• Engineering Goal: Design Space Exploration
• Simulation Market: The status quo– Why is Simulation limited to the experts?
– Current attempts to solve this problem
• Simulation Market: The new business drivers
• Simulation Apps– What are they?
– Real use cases and the ROI
– Key ingredients
• Conclusions: Simulation Is For Everyone!
Simulation Apps for automated Design Space Exploration
Simulation Is Being Democratized Now!• Automated Design Space Exploration for the
whole product development team is here
• General-purpose simulation environments are not the solution for non-experts
• Simulation Apps must have embedded expertise
• Simulation Apps must work across a Product Family
• Rapid Template & Web App development platforms are a requirement to make SimApps economically feasible
• The advent of The Cloud makes it feasible and cost effective to access huge computing resources, as needed
Non-experts are using safe and robust Simulation Apps to
perform complex simulation routinely and efficiently.
This could increase the # of simulation users 10X to 100X!
Simulation Apps for automated Design Space Exploration
NAFEMS Webinar Series 2015
Democratization of CAE
UsabilityOct 1
Expert Knowledge Capture & ReuseSept 17
AccessibilityOct 26
Series Introduction Aug 27
Experts & Industry Analysts
End-User Companies presenting in each webinar
http://nafems.org/about/regional/americas/events/2020vision/
http://nafems.org/about/regional/americas/events/2020vision/democratization/
Simulation Apps for automated Design Space Exploration
Simulation Apps: Simulation for Everyone
Malcolm Panthaki
Comet Solutions, Inc.
January 2016
View the recording here:
http://www.engineering.com/resourcemain.aspx?resid=381
Engineering.com Webinar Recording
Simulation Apps for automated Design Space Exploration
Malcolm Panthaki
CTO & Founder
Comet Solutions, Inc.
Thank You!
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