fouad el khaldi | cloud based hpc simulation in advanced manufacturing
TRANSCRIPT
Fostering Digital Industrial Innovation in Europe
BERLIN 17th & 18th of June 2014
Cloud based HPC simulation in advanced manufacturing
Dr.-Ing. Fouad el KHALDI, Industry Strategy & Innovation General Manager, ESI GROUP(FR)
Contents
1. Mega Trends
2.Advanced Manufacturing : Industry experiences
3. Conclusion & Outlooks
1.1. Technologies Overview
1.2. Industry Challenges & Opportunities
1.2. Automotive : Gestamp / Fortissimo experiment
2.2 Manufacturing : AP&T
2.3 Aeronautic : Expliseat (SME)
Copyright © ESI Group, 2014. All rights reserved.
ICT Mega Trends
Ray Kurzweil Singularity is near
Compute power x 2 every 18 months
Challenges &
Opportunities
Copyright © ESI Group, 2014. All rights reserved.
ICT Mega trends Applications Virtual Crash Test
~ .005 M
~ .5 M
~ 10 M
~ 20 M
DACIA Lodgy 2013
Optimistic Moore: Y = 1.5 Years
Virtual Crash Test : 30 Y of innovation experience
Better Test
Virtual Test
Leverage ICT, HPC
& Cloud,
etc
Clo
ud
Co
mp
utin
g
Copyright © ESI Group, 2014. All rights reserved.
Movie extract
Holistic view of the value chain: Barrier ( safety Regulations / Region) Airbag & Dummies ( Safety Regulations / Region) Complex interactions ( Cause & Effects, …)
BIW Full integrated Vehicle (BIW, Closers, Engine, transmission, …)
Enable collaborative Decision Support for the Stakeholders (Trade-offs, …)
Virtual Crash: State of Art
Courtesy of Audi
Copyright © ESI Group, 2014. All rights reserved.
Performance
Human &
Environment
Manufacturing
Control
Everybody believe in test results except the test engineer !
Typical Tests : Automotive Mostly One Domain Test - Expect final product !
Major Shortfall Overall Tradeoff & MDO
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping: for Concurrent Engineering
Master Design Margin to enable reliable Trade-Offs (Regionalization; Manufacturing,…)
Coupling & Cause-Effect upfront (before prototype test)*
Transformation : Leverage HPC & Focus Experts on Value Added Tasks
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : advantages Supply Chain : Different Domains / Teams / Locations
Painting
Casting
CFD
Safety
Vibration
Comfort
Welding
Virtual Prototype
Copyright © ESI Group, 2014. All rights reserved.
Why Virtual Prototyping ?
Check the coupling effects Strength, Vibro-acoustics, durability,…
Control the fabrication defects Manufacturability, tolerances, materials
Design Performance (Verif. & Valid.) Normal use, mis-use, accidental conditions
Enables Concurrent & Upfront Decisions
Marketing, Engineering, Assembly, C level,… 1
3
4
2
“All models are wrong … but some are useful” …“within identified circumstances and limits”
1
2
3
4
1
2
3
4
Copyright © ESI Group, 2014. All rights reserved.
Gestamp
Industry Objectives & Use Cases
ESI
Virtual Prototyping
Platform & Methodology
Bull Cloud Based HPC
Fortissimo : Gestamp experiment
Copyright © ESI Group, 2014. All rights reserved.
Fortissimo : Gestamp experiment Company overview
Courtesy of Gestamp Ref : EGF – May 2014
Copyright © ESI Group, 2014. All rights reserved.
Competitive edge Press Hardening Light Weight
Scale up Regionalization
Fortissimo : Gestamp experiment Company overview & challenges
Courtesy of Gestamp Ref : EGF – May 2014
Copyright © ESI Group, 2014. All rights reserved.
Development based on a single numerical model instead of one per application
Time saving
Converging model versions for several test cases
Synchronization of CAE and CAD models
Application 1 : Frontal Crash Application 2 : Side Crash Application 3 & 4 : Stiffness / NVH
Evolution &
Maintenance
Fortissimo : Gestamp experiment Industrial Relevance
Copyright © ESI Group, 2014. All rights reserved.
+ Chassis
+ Engine + Exhaust
+ Seats
Stiffness/NVH Analysis
Crash Analysis
Fortissimo : Gestamp experiment Industrial Relevance
Copyright © ESI Group, 2014. All rights reserved.
USNCAP FR 56kph (Rigidwall 100% overlap)
EURONCAP SIDE 50kph
EIGEN MODES Analysis
Fortissimo : Gestamp experiment Work In Progress
Copyright © ESI Group, 2014. All rights reserved.
Virtual Manufacturing Hot forming value chain (AP&T)
Movie extract
Copyright © ESI Group, 2014. All rights reserved. Heating Oven ( > 1000°C) Secured Automated Production Line
Movie : Courtesy of AP&T
Virtual Manufacturing Hot forming value chain (AP&T)
Pro
du
ctio
n L
ine
Vir
tual
Pro
toty
pe
Hot Forming Simulation (Press Hardening)
Phase transformation control Cooling System Design
Transfer line Continuous feeding
Press forming
Movie : Courtesy of AP&T
Copyright © ESI Group, 2014. All rights reserved.
Virtual Body Manufacturing Next Challenges to secure competitive Mfg.
Fatigue evaluation
Strength Bush insert Paint
baking Welding holding
Welding holding
Trimming Stamping
Trimming Stamping
Trimming Stamping
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : Aero Expliseat Success Story
Reference: Expliseat – EGF 2014
Established : 2011 Product Certification : 2014
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : Aero Expliseat Experience
Copyright © ESI Group, 2014. All rights reserved.
Reference: Expliseat – EGF 2014
Virtual Prototyping : Aero Expliseat Experience
Copyright © ESI Group, 2014. All rights reserved.
Better test
Virtual Test
Virtual Prototyping
Virtual Engineering
Be
nefits
Time
Simulation Model & data
Simulation Process
Knowledge's Engineering
Knowledge's Business & Engineering
Isolated silos
Disruptive &
Transformation
Major challenges
& Opportunities
!
Conclusion & Outlook
Simulation is not a tool, it is transformation vector
Copyright © ESI Group, 2014. All rights reserved.
Private Investment Co-Creation
Public-Private
Investment Co-Creation
Automotive
Aero
Energy
Medical & Health Care
Education
Education, …
Efficient, Scalable & Sustainable Ecosystem Enables Pull & Push Process to foster Innovation
Major Challenges & Opportunities !
Conclusion & Outlook
Simulation is not a tool, it is transformation vector
Industry : Competitiveness & Attractiveness
THANK YOU FOR YOUR ATTENTION
Dr.-Ing. Fouad el KHALDI Email: [email protected]