An Overview of Modeling and Simulation at 3M Company Dave Lindeman

An Overview of Modeling and Simulation at 3M Company Dave Lindeman

© 3M 2012. All Rights Reserved.

2



3



Working together to achieve more

Innovate with a core focus on helping customers tackle challenges and

enable progress in our fast–changing world

Promote a culture of curiosity and creativity

Collaborate to share knowledge and ideas between

84,000 employees

65 countries

46 technology platforms

5 market–leading businesses

Partner with customers to achieve tangible success

4


Sales & Marketing

Manufacturing/Converting

Technical Capabilities

Driving progress around the world

Mexico

Brazil

Colombia

Venezuela

Argentina

Chile

Costa Rica

El Salvador

Panama

Ecuador

Peru

Uruguay

Guatemala

Italy

France

UK

Turkey

Greece

Morocco

Canada

Jamaica

Dominican

Republic

Puerto Rico

Trinidad &

Tobago

Poland

Czech

Republic

Germany

Lithuania

Latvia

Estonia

Hungary

Romania

Ukraine

Kazakhstan

Russia

Japan

China

Taiwan

Vietnam

Thailand

Singapore

Indonesia

Hong Kong

Korea

Philippines

India

Israel

Egypt

Pakistan

UAE

Kenya

Malaysia

Sri Lanka

South Africa

Belgium

Portugal

Spain

Netherlands

Austria

Switzerland

Finland

Sweden

Norway

New Zealand

Australia

Denmark


USA

5


Forming connections between diverse technologies

Ab Abrasives

Ac Acoustics

Ad Adhesives

Am Advanced Materials

An Analytical

As Application Software

Bi Biotech

Ce Ceramics

Dd Drug Delivery

Di Display

Do Dental & Orthodontic Materials

Ec Energy Components

Em Electronic Materials

Fc Flexible Converting & Packaging

Fe Flexible Electronics

Fi Films

Fl Fluoro-materials

Es Electronics & Software

Fs Filtration, Separation, Purification

Im Imaging

In Inspection & Measurement

Is Integrated Systems & Design

Lm Light Management

Md Medical Data Management

Me Metal Matrix Composites

Mf Mechanical Fasteners

Mi Microbial Detection & Control

Mo Molding

Mr Micro-replication

Nt Nano-technology

Nw Nonwoven Materials

Op Opto-electronics

Pd Particle & Dispersion Processing

Pe Predictive Engineering & Modeling

Pm Polymer Melt Processing

Po Porous Materials & Membranes

Pp Precision Processing

Pr Process Design & Control

Rp Radiation Processing

Se Sensors

Sm Specialty Materials

Su Surface Modification

Tt Track & Trace

Vp Vapor Processing

We Accelerated Weathering

Wo Wound Management


6



Enabling customer success

Through our five market–leading business groups, we turn our ideas

into ingenious products and solutions that make life better for our

customers and end–users every day

Industrial From purification to aerospace –

changing how industry works

Health Care Promoting health and improving

quality care

Safety & Graphics Keeping you safe, your world secure and

enhancing visual communication and interactivity

Consumer Simplifying life and work

Electronics & Energy Enabling the global power and

telecommunications networks and the world's

electronic devices

7


Consumer From Simplifying Life at Home to Keeping You Organized at Work

Simplifying organization and communication

Cleaning and protecting the home

environment

Helping you feel better faster

Making home improvement easy with

professional results

Inspiring creativity, crafts and hobbies

Sales $4.2 billion


8


Electronics & Energy Enabling Tomorrow’s Lifestyle Today with Power, Communications and Electronics

Connecting the world's power grid

Enabling global telecommunications

Supporting high-tech electronic devices

Integrating with customers to create

innovative solutions

Powering projection to share information

Enabling opportunities for energy conservation

and generation

Sales $5.7 billion


9


Preventing infections

Caring for skin, healing wounds

Improving treatment coding, health care

reimbursement and hospital efficiency

Enabling delivery of medicine

Protecting the food supply

Making smiles brighter with advanced

dental and orthodontic solutions


Health Care From Preventing Infections to Making Smiles Brighter

Sales $5.0 billion

10


Industrial From Purification to Aerospace – Changing How Industry Works

Improving surfaces from orthopedic implants to

fine furniture

Purifying air and water, from residential to bio-

pharma and industrial

Modifying, bonding and protecting surfaces in

construction and manufacturing

Improving the design, manufacture and

maintenance of land, air and water transportation

Sales $9.6 billion


11


Safety & Graphics From Protecting People & Information to Enhancing Visual & Design Communication

Providing personal and worker safety

Protecting people, privacy and property

Improving performance and productivity

of building operations and infrastructure

Creating transportation safety and

vehicle registration solutions

Enhancing viewing and interactive

experiences

Inspiring light and surface capabilities

Sales $5.5 billion


12


Working from a position of leadership and growth

Global sales: $29.6 billion (66% international)

Net income: $4.3 billion

R&D related investment: $1.6 billion

Earned 514 U.S. patents

Global reach: sales in ~200 countries

One of 30 companies in DJIA stock index


13


One strong brand with many strategic brands

3M named one of the Best 100 Global Brands by strategic brand

consultancy Interbrand in 2012

Proud of the household names we have created with our market–leading

strategic brands


14


My background

Grew up in Woodbury, MN

Graduate of the University of Minnesota

BSAE completed in 1985

MSAE completed in 1987

Emphasis on structural mechanics and numerical methods

Participated in the co–op program at NASA Johnson Space Center during

graduate school

Worked as a consulting engineer for KIT Corporation following graduation

Joined 3M in 1990

25 years of modeling experience


15


My first modeling experiences

FEMPAC

Used in AEM 5800

Developed at the U of M

Basic linear static analysis of planar, truss, and

torsion problems

Ran on a VAX computer

Used punch card input

ANSYS 4.2B

Used in ME 5225 and CE 8606

Input defined using a scripting language (APDL)

Graphical output obtained using MacTerminal

running in Tektronix 4014 emulation mode


16


Modeling within 3M

Predictive engineering methods and tools are used throughout the

company, both organizationally, and geographically

Due to the diversity of 3M’s products and technologies, modeling

expertise must be maintained in:

Acoustics

Chemistry

Electromagnetics

Fluid mechanics

Heat transfer

Optics

Structural mechanics


17


Modeling as a global activity

UK

Canada

Germany

Japan

China

Taiwan

Singapore

Korea

India

Sweden

Australia


USA

18


Software resources

Like most companies, 3M relies primarily on commercial modeling

packages, including*:

ABAQUS™ Accelrys® AdvantEdge™

ANSYS® CAChe CFX™

COMSOL® Comet Acoustics Comet Trim

CST Microwave Studio Culgi DAKOTA

Fluent™ GOMA iSight®

Jaguar LAMMPS LightTools®

Mechanica™ Moldflow® NWChem

NX NASTRAN Remcom Wireless InSite® Star–CCM+

TracePro® VAOne

* 3M does not endorse the use of any particular simulation code


19


Software resources

Acoustics









TracePro® VAOne


20


Software resources

Chemistry









TracePro® VAOne


21


Software resources

Electromagnetics









TracePro® VAOne


22


Software resources

Fluid mechanics









TracePro® VAOne


23


Software resources

Heat transfer









TracePro® VAOne


24


Software resources

Optics









TracePro® VAOne


25


Software resources










TracePro® VAOne


26


Software resources

Multiphysics









TracePro® VAOne


27


Software resources

Optimization and probabilistic analysis









TracePro® VAOne


28


Acoustics


Applications include:

Room air purifiers

Projectors

Sound control materials for

automotive, aerospace, and

architectural markets

Stethoscopes

Active and passive hearing

protections devices

29


Chemistry


Adhesives

Ceramics

Polymer networks

Multiphase polymer systems

Nanoparticle surface chemistry

Molelcular self–assembly

Reaction energetics

Solubility

Catalysis


30


Electromagnetics


Electrical connectors and cables

RFID tags and antennas

Wireless systems

Sensors

Patient/offender monitoring and

tracking

Library systems

Electrosurgical grounding plates

and medical electrodes

EMI/EMC compatibility


31


Fluid mechanics


Mixing

Coating

Extrusion

Molding

Filtration products

Drug delivery systems

Paint spray nozzles

Fuel cells


32


Heat transfer



Reactions

Extrusion

Molding

Insulating products for automotive

and apparel applications

Electronics cooling

Fuel cells and batteries

33


Optics


Optical films

Light guides

LED lighting systems for

automotive, aerospace, and

architectural applications

LED light bulbs


34





Capital equipment

Adhesives

Films

Helmets and safety glasses

Filter cartridges and housings

Adhesive and tape dispensers

Abrasives

Fuel cells and batteries

Electronic devices and packages

35


Reasons for modeling

Predictive engineering can be used throughout the product, process, and

technology development process to:

Increase understanding

Verify performance

Identify critical design parameters

Assess the effects of variability

Optimize designs

Demonstrate compliance

Provide customer support


Hurricane–resistant window film

36


Benefits of modeling

Predictive engineering provides a virtual test platform that can result in:

Reduced prototyping and testing

Shortened development cycles

Improved quality and reliability


RFID tag

(Courtesy of Riki Banerjee)

37


Modeling trends

Advancements in simulation methods and computer hardware have led to

the following trends:

Component/sub–assembly simulation assembly/system level simulation

Single physics simulation multiphysics simulation

Linear/moderately nonlinear simulation highly nonlinear simulation

Design evaluation/verification design optimization

Homogenous computer resource diverse computer resources

Modeling as a luxury modeling as a necessity

Modeling as a competitive advantage modeling as a competitive imperative


38


Differentiation

Since the barriers to adoption of modeling methods have largely been

eliminated, companies must differentiate themselves from their

competitors through:

Early and broad adoption

Efficiency

Training and retaining staff

Standardizing and automating repetitive modeling tasks

Sophistication

Use of scripting languages and user–defined subroutines

Ability to use “advanced” features with confidence

Consistent investment in high–performance computing platforms


39


Customization and automation


Customized user–interfaces and client–side and/or server–side scripts

used to create automated analysis systems for specific, repetitive

modeling tasks

40


Hardware resources

High–performance computing resources include an SGI Intel® Xeon®

processor–based hybrid cluster that combines shared–memory, cluster

computing and virtualization environments

SGI Altix UV 100 with Intel Xeon processor X7560

SGI C2112–based cluster with Intel Xeon processor X5650

Red Hat Enterprise Linux® 6.1

624 cores

3.136 TB of RAM

Dell Force10 10 gigabit ethernet fabric

52 TB Panasas PAS network–attached storage

SGI ArcFiniti file–based archiving system


41


Electrosurgical grounding plates


3M “Safety–Ring” technology

minimizes current density

concentrations, allowing smaller pads

to be used, and permitting more

flexibility in pad placement and

orientation

Modeling was used to explore a large

design space, effectively evaluating

the behavior of hundreds of plate

designs on dozens of test subjects

The resulting product is now the

market–leader

Current density distribution in

idealized human thigh

42


Optical films


The unique optical properties

achievable with multilayered films have

enabled the generation of a wide range

of products that literally break the laws

of physics

Modeling was critical to understanding

the optical properties (and potential) of

multilayered film constructions

Modeling was also critical in the design

of the tentering, manifold, and die

systems required to produce these

films

Simulation of extrusion process

(Courtesy of Lori Holmes)

Light guide for backlit cell phone

(Courtesy of Dave Ender)

43


Cubitron™ II abrasives


Conventional ceramic abrasive grains

plow through the workpiece, causing

heat build–up, slower cutting, and

shorter life

The precision–shaped grains in 3M

Cubitron II abrasives continuously

fracture to form sharp points and

edges – slicing cleaner and faster,

staying cooler, and lasting many

times longer

Modeling played a significant role in

the development of a product that has

revolutionized the abrasives industry

Conventional ceramic abrasive grains

Cubitron II abrasive grains

Abrasive cutting simulation

(Courtesy of Fay Salmon)

44


Conclusion


The use of predictive engineering methods is increasingly critical to the

efficient development of robust and innovative products and processes

3M has made significant investments in the personnel, software, and

hardware required to use predictive engineering effectively, and is

committed to staying on the leading edge of this technology

Innovative Modeling

Enabling

Product Innovation



Documents

An Overview of Modeling and Simulation at 3M Company Dave Lindeman