© 2012 ANSYS, Inc. February 24, 20121
Dipankar Choudhury, Ph.D.VP, Research
February 7, 2012
The Future of Simulation in Engineering
© 2012 ANSYS, Inc. February 24, 20122
Overview
Simulation in engineering
ANSYS R&D vision & strategy
Recent progress at ANSYS with Release 14
Technology directions: Release 14.5 and beyond
Summary
© 2012 ANSYS, Inc. February 24, 20123
Simulation in Engineering
© 2012 ANSYS, Inc. February 24, 20124
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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!)
© 2012 ANSYS, Inc. February 24, 20125
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“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
© 2012 ANSYS, Inc. February 24, 20126
Top Business Pressures Driving Product Design Improvement
Biggest Hurdles for Product
Design
Getting Product Designs RightSource: Aberdeen Group, April 2011
© 2012 ANSYS, Inc. February 24, 20127
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
© 2012 ANSYS, Inc. February 24, 20128
ANSYS R&D Vision and Strategy
© 2012 ANSYS, Inc. February 24, 20129
Our Vision: Simulation Driven Product Development
ConceptPhysicalPrototype
Production
Simulation‐DrivenProduct Development
Concept Design PhysicalPrototype Testing Analysis Production
CAD CAE CAM
Yes
No
Detailed Design
© 2012 ANSYS, Inc. February 24, 201210
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
© 2012 ANSYS, Inc. February 24, 201211
Comprehensive Capabilities TodayExample: Hybrid Electric Vehicle System
© 2012 ANSYS, Inc. February 24, 201212
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
© 2012 ANSYS, Inc. February 24, 201213
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
© 2012 ANSYS, Inc. February 24, 201214
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
© 2012 ANSYS, Inc. February 24, 201215
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
© 2012 ANSYS, Inc. February 24, 201216
Simulation‐Led Design: Extreme Performance, Fidelity and Engineering Ease of Use
© 2012 ANSYS, Inc. February 24, 201217
Simulation‐Led Design: Extreme Performance, Fidelity and Engineering Ease of Use
© 2012 ANSYS, Inc. February 24, 201218
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
© 2012 ANSYS, Inc. February 24, 201219
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
© 2012 ANSYS, Inc. February 24, 201220
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
© 2012 ANSYS, Inc. February 24, 201221
Recent Progress at ANSYS with Release 14
© 2012 ANSYS, Inc. February 24, 201222
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
© 2012 ANSYS, Inc. February 24, 201223
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
© 2012 ANSYS, Inc. February 24, 201224
High‐Quality Prism Inflation Layers
© 2012 ANSYS, Inc. February 24, 201225
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
© 2012 ANSYS, Inc. February 24, 201226
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
© 2012 ANSYS, Inc. February 24, 201227
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
© 2012 ANSYS, Inc. February 24, 201228
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
© 2012 ANSYS, Inc. February 24, 201229
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
© 2012 ANSYS, Inc. February 24, 201230
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
© 2012 ANSYS, Inc. February 24, 201231
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
© 2012 ANSYS, Inc. February 24, 201232
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
© 2012 ANSYS, Inc. February 24, 201233
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
© 2012 ANSYS, Inc. February 24, 201234
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
© 2012 ANSYS, Inc. February 24, 201235
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
© 2012 ANSYS, Inc. February 24, 201236
Solutions From 3‐D to 0‐D
Initial Design
PExprtMagnetics
RMxprtMotor Design
Electromagnetic Components StressTemperature
WB System wide optimization using CAD parameters
0‐DSystem
© 2012 ANSYS, Inc. February 24, 201237
Technology Directions: Release 14.5 and Beyond
© 2012 ANSYS, Inc. February 24, 201238
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
© 2012 ANSYS, Inc. February 24, 201239
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
© 2012 ANSYS, Inc. February 24, 201240
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
© 2012 ANSYS, Inc. February 24, 201241
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
© 2012 ANSYS, Inc. February 24, 201242
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
Number of Processor Cores
Truck (111 million cells)
13.0.0
14.0.0
384 832 1280 1728 2176 2624 3072
Performan
ce
Number of Processor Cores
F1 140M AMD Magny‐Cours
14.0.0
Ideal
© 2012 ANSYS, Inc. February 24, 201243
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
© 2012 ANSYS, Inc. February 24, 201244
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.
© 2012 ANSYS, Inc. February 24, 201245
Blending Cosimulation and ROMs
DOE Funded Development Project for Battery Modeling
© 2012 ANSYS, Inc. February 24, 201246
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
© 2012 ANSYS, Inc. February 24, 201247
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
© 2012 ANSYS, Inc. February 24, 201248
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