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2010-02-10 ©SKF Slide 2 [Code] SKF [Organisation]
Parametric Studies in Product Development using SKF BEAST on Multi-Processor Platforms
MODPROD 2010, Linköping, SwedenDag Fritzson,SKF ERC2010-02-10
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2010-02-10 ©SKF Slide 3 [Code] SKF [Organisation]
Outline of presentations
BEAST?
SKF Product Development Process and Simulation
Example of using Design For Six Sigma (DFSS) tools (quality, parameter studies, and statistics)
Parallel Computation
Summary
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2010-02-10 ©SKF Slide 4 [Code] SKF [Organisation]2010-02-10 ©SKF Slide 4SKF [ERC]
BEAring Simulation Tool-The devil is in the details
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2010-02-10 ©SKF Slide 5 [Code] SKF [Organisation]
•Multi-body simulation software
•Specialized in contact problems
•Detailed surface description
•Accurate tribology
•Application operating conditions
•Focus on creating understanding of systems with contacts
•BEAST was originally developed for rolling bearings, but can be used for any “contacting” machine element
BEAST - a virtual test rig
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2010-02-10 ©SKF Slide 6 [Code] SKF [Organisation]
The Product Development Process and Simulation
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2010-02-10 ©SKF Slide 7 [Code] SKF [Organisation]
Product Development Process (PDP)
Scoping
Requirementsspecification
Conceptgeneration & selection
EmbodimentDesign
DetailDesign
Verification
Validation
Handover
TG1
TG2
TG3
TG7
TG6
TG4
TG5
Technical feasibility
Design and verification
Validation
Handover
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2010-02-10 ©SKF Slide 8 [Code] SKF [Organisation]
PDP and Design for Six Sigma (DfSS) integrated
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2010-02-10 ©SKF Slide 9 [Code] SKF [Organisation]
The EASY work process
Load case date bases10-100 dynamic load cases
Design parameters(e.g., geometry, tolerances,
surface properties, material, etc)
Manufacturing process parameters
Requirements
Performance criteriaBSL criteria
Sensitivity/robustness analysis
Multi-criteria optimization(DoE or “automatic”)
Automatic simulation of selected load cases with one command
Automatic data reduction from 4D/3D to scalar values
Automatic translation
Translation
Improve/optimize product
Comprehensive presentation
Tables or diagrams, load case versus criteria
Reduced or full model
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2010-02-10 ©SKF Slide 10 [Code] SKF [Organisation]
The EASY work process – Concept studies
Load case date basesA few selected load cases
A few main design parameters(e.g., geometry, tolerances,
surface properties, material, etc)
Manufacturing process parameters
Requirements
Performance criteriaBSL criteria
Sensitivity/robustness analysis
Multi-criteria optimization(DoE or “automatic”)
Automatic simulation of selected load cases with one command
Automatic data reduction from 4D/3D to scalar values
Automatic translation
Translation
Improve/optimize product
Comprehensive presentation
Tables or diagrams, load case versus criteria
Reduced or full model
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2010-02-10 ©SKF Slide 11 [Code] SKF [Organisation]
The EASY work process – Detailed design
Load case date basesSelected load cases
All relevant design parameters(e.g., geometry, tolerances,
surface properties, material, etc)
Manufacturing process parameters
Requirements
Performance criteriaBSL criteria
Sensitivity/robustness analysis
Multi-criteria optimization(DoE or “automatic”)
Automatic simulation of selected load cases with one command
Automatic data reduction from 4D/3D to scalar values
Automatic translation
Translation
Improve/optimize product
Comprehensive presentation
Tables or diagrams, load case versus criteria
Reduced or full model
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2010-02-10 ©SKF Slide 12 [Code] SKF [Organisation]
The EASY work process - Verification
Load case date basesLoad cases that
cover requirement space
Fixed design parameters(Possible study of tolerances).
Fixed manufacturing process parameters
Requirements
Performance criteriaBSL criteria
Automatic simulation of selected load cases with one command
Automatic data reduction from 4D/3D to scalar values
Automatic translation
Translation
Comprehensive presentation
Tables or diagrams, load case versus criteria
Reduced or full model
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2010-02-10 ©SKF Slide 13 [Code] SKF [Organisation]
Examples of tools that can be used
Minitab statistical software (www.mintab.com)
is a standard SKF DfSS and Six Sigma tool
it covers statistics, DoE, optimization, etc.
DoEBeast/Beauty
it is small but focused on DfSS usage, i.e.,
parametric studies (DoE), sensitivity/robustness analysis
it has import/export to minitab
it has optimal connection/usage of BEAST
modeFRONTIER (www.esteco.com)
is a general tool focused on optimization
HyperStudy (www.altairhyperworks.com)
is a general tool
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2010-02-10 ©SKF Slide 14 [Code] SKF [Organisation]
Conclusion
The DFSS supports use of simulation.
There is an expressed intention in SKF to use modelling and simulation early in the PDP, and to larger extent.
.
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2010-02-10 ©SKF Slide 15 [Code] SKF [Organisation]
Examples of a Parametric Study using DFSS tool
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2010-02-10 ©SKF Slide 16 [Code] SKF [Organisation]
A BEAST model is turned into a parameter study by adding a parameter_study node (right click environment):
Setting up a screening design
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2010-02-10 ©SKF Slide 17 [Code] SKF [Organisation]
Screening...(cont.)
The Setup Parameterstudy window:
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2010-02-10 ©SKF Slide 18 [Code] SKF [Organisation]
Screening...(cont.)
Add variables by right-clicking them in the Variable window:
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2010-02-10 ©SKF Slide 19 [Code] SKF [Organisation]
Screening...(cont.)
Several different experimental designs are available:
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2010-02-10 ©SKF Slide 20 [Code] SKF [Organisation]
Screening…(cont.)
Choose fractional factorial and enter the lower and upper limits of your parameters #simulations = 2(parameters – #generators):
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2010-02-10 ©SKF Slide 21 [Code] SKF [Organisation]
Screening...(cont.)
Information about the chosen design is displayed:
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2010-02-10 ©SKF Slide 22 [Code] SKF [Organisation]
Screening...(cont.)
Choose Chart of Effects from menu. We decide to look at E_slip_perf:
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2010-02-10 ©SKF Slide 23 [Code] SKF [Organisation]
Screening...(cont.)
Graph displaying Pareto effects (N.B. Only first order effects are shown):
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2010-02-10 ©SKF Slide 24 [Code] SKF [Organisation]
Sorting out confounding factors
To make sure we are not being fooled by confounded effects we run a full factorial with the top three factors:
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2010-02-10 ©SKF Slide 25 [Code] SKF [Organisation]
Confounding...(cont.)
We first remove all parameters except the ones with top three effects according to the screening design...:
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2010-02-10 ©SKF Slide 26 [Code] SKF [Organisation]
Confounding...(cont.)
Read the results into DoEBeast and again display the Pareto effects:
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2010-02-10 ©SKF Slide 27 [Code] SKF [Organisation]
Confounding...(cont.)
Aha! Ircurv was confounded by the second order effect RaIR*FilmThick:
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2010-02-10 ©SKF Slide 28 [Code] SKF [Organisation]
Optimising with response surface
Only two factors left. Let’s optimise the model with regard to them. Use a space-filling design (Sobol):
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2010-02-10 ©SKF Slide 29 [Code] SKF [Organisation]
Optimising...(cont.)
Export the results to a file readable by Minitab:
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2010-02-10 ©SKF Slide 30 [Code] SKF [Organisation]
Optimising…(cont.)
The response surface:
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2010-02-10 ©SKF Slide 31 [Code] SKF [Organisation]
Sensitivity analysis:
If the user knows the standard deviations of his modelparameters he can setup a design that lets DoEBeastcompute approximations of the mean and standard deviations of output data.
Derivatives are computed as finite-differences.
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2010-02-10 ©SKF Slide 32 [Code] SKF [Organisation]
Other features: Parallel coordinate plot
DoEBeast can plot results in several ways.
Parallel coordinate plot:
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2010-02-10 ©SKF Slide 33 [Code] SKF [Organisation]
Parallel coordinate plot, cont …
Restrict FilmThick and RaIR
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2010-02-10 ©SKF Slide 34 [Code] SKF [Organisation]
Other features: Pareto optimal plot
Pareto optimal front. Useful when more than one criteria is important:
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2010-02-10 ©SKF Slide 35 [Code] SKF [Organisation]
Conclusion – Practical DFSS simulation
Reduce the number of parameters, i.e., screening designs.
Investigate confounding effects.
Do full DoE for remaining parameters (very few).
Investigate robustness.
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2010-02-10 ©SKF Slide 36 [Code] SKF [Organisation]
Parallel Computation
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2010-02-10 ©SKF Slide 37 [Code] SKF [Organisation]
Spherical Roller Thrust Bearing (SRTB)
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2010-02-10 ©SKF Slide 38 [Code] SKF [Organisation]
1U rack nodes [76 cores]:• 16 × Opteron 248 (single core 2.2GHz), 2GB memory• 60 × Opteron 250 (single core 2.4GHz), 2GB memory
IBM Blade Centers [280 cores]:• 3 × 14st IBM BladeServer HS21 XM
• 2 × AMD Opteron 2218 (Dual core 2.6GHz) [3*14*2*2 = 168 Cores]• 4GB RAM [168GB]
• 1 × 14st IBM BladeServer HS21 XM• 2 × Intel XEON E5420 (Quad core 2.5GHz) [14*2*4 = 112 Cores]• 16GB RAM (8 × 2GB) [224GB]
DEA Cluster – 356 cores
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2010-02-10 ©SKF Slide 39 [Code] SKF [Organisation]
Hardware and Performance:• 805 Nodes (HP ProLiant DL140 G3)
•Two Intel Xeon E5345 Quad Core Processor 2.33GHz per Node•16GB or 32GB RAM per node
•Infiniband ConnectX interconnect•Combined peak performance of 60 Tflops
Software:•Operating System: CentOS 5 x86_64•Resource Manager: SLURM•Scheduler: MOAB•MPI: OpenMPI and Scali MPI
Neolith cluster at NSC – 6440 cores
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2010-02-10 ©SKF Slide 40 [Code] SKF [Organisation]
Hardware and Performance:• 16 Streaming Multiprocessors (SM)
•32 CUDA cores per SM•4 Special Function Units per SM•64 KB Shared Memory/L1 Cache
•ECC Memory Support•Single Precision Floating Point Capability: 512 FMA ops/clock•Double Precision Floating Point Capability: 256 FMA ops/clock•Support for up to 16 concurrent Kernels
NVIDIA FERMI a future platform?
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2010-02-10 ©SKF Slide 41 [Code] SKF [Organisation]
Summary
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2010-02-10 ©SKF Slide 42 [Code] SKF [Organisation]
Summary
Use simulation early in the product development process.
The Six Sigma/DFSS effort stimulate use of analytical tools.
Heavy simulations & Parametric studies:
•Eliminate parameters with screening designs.
•Find optima with space filling designs.
•Check robustness in design points.
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2010-02-10 ©SKF Slide 43 [Code] SKF [Organisation]