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PLM AND 64-BIT: THE POWER TO DO MORE

Dassault Systèmes PLM Solutions

PLM and 64-bit: The power to do more.

Today’s manufacturers have never been under more pressure. Competition is global, customers are fickle, and financial markets unforgiving. Beating the competition, creating customer loyalty, and delivering strong business results are essential to survival. These factors depend on repeatedly delivering the right product, at the right time, and at the right price. However, balancing increasing complexity with rising performance and quality requirements is a constant business challenge.

Product Lifecycle Management (PLM) solutions are essential to creating a collaborative environment to help manufacturers accelerate product development across all lifecycle processes, deliver innovative new products on time, improve quality, and reduce costs. As PLM system capabilities have increased over time, the complexity of challenges has also escalated. However, problems that were nearly impossible to resolve only a few years ago using the fastest and most advanced computers available, are now routinely tackled using only desktop systems. With this in mind, these systems still have limitations. One persistent area of concern has been 32-bit memory.

32-bit versus 64-bit In theory, computers using a 32-bit processor have up to 4GB of addressed memory space which can be utilized by an application. Most of the time, however, the processors are actually only able to capitalize usage between 1.8 and 3.5GB of memory due to hardware and configuration constraints.

Using a 64-bit architecture, memory capacity is extended to 16 Terabyte (TB) − almost 4 billion times the 32-bit capacity. Like 32-bit processors, 64-bit processors still face limitations from swap space, RAM, and the other runtime applications, however the expanded capacity more than compensates for such shortcomings. The huge amount of available memory provided by 64-bit allows PLM systems to handle larger amounts of data in virtual memory, as well as manipulate high-precision data more rapidly. Moving forward, the 64-bit architecture will play a critical role in improving product quality and development processes across distributed PLM environments.

The Benefits of V5 64-bit Applications Streamlining Product Development: Optimizing Processes One immediate benefit of using a 64-bit architecture with V5 is the reduction or complete elimination of time-intensive, workaround processes previously required due to hardware limitations. The common practice of bypassing “natural” processes in order to complete tasks, such as visualizing a digital mock-up or performing stress analysis, is commonplace. For example, designers are often forced to split a large assembly into several sub-components to circumvent hardware constraints, repeating the same actions for each individual component. With a 64-bit architecture, the additional virtual available memory allows designers to load a complete assembly into

As PLM system capabilities have

increased over time, the complexity of

challenges has also escalated.

The huge amount of extra memory made

available [with 64-bit] allows PLM solutions to handle larger amounts

of data in virtual memory, as well as to

manipulate high-precision data more rapidly.

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memory and manipulate it as easily as a single component. By reducing or eliminating repetitive processes, 64-bit-based applications dramatically reduce task cycles, streamlining the overall development time required to design and test new products and, ultimately, to take a product to market.

Customer examples of 64-bit gains was recently published in a white paper produced by ABCG, an independent consulting group, on CATIA V5 and ENOVIA V5 64-bit applications (V5R14 and V5R15):

“At one customer site, an entire design for a new light aircraft could be opened, viewed, and manipulated in a DMU V5 session. The assembly contained over 38,000 components. In another case study, a new car design with over 5000 components could be loaded, sectioned, and used for collision detection in DMU V5. Note that in both these cases, the amount of data that could be loaded was limited only by the data the customer had available, not by any DMU V5 limitation.”

These studies reveal dramatic process improvements had been achieved using 64-bit applications. No longer is it necessary to break out a 5000-component automobile and perform endless sub-assembly runs. This entire assembly can now be completed using tet-10 elements, at much faster performance speeds, with a single set of results. Likewise, when reviewing the 38,000-component assembly, the entire aircraft is now easily viewed and manipulated in a single DMU session. Not only is this a major advancement, it is remarkable considering this assembly could not be loaded in any form using 32-bit DMU. More recently, as a result of the certification in V5R16 of V5 DMU applications on Windows® XP 64-bit architecture, tests performed internally have demonstrated the ability to load 220,000 components in a single session, once again pushing the limits of 3D design.

Capacity gains are also extremely important when dealing with finite elements analysis (FEA). Now, with the ability to mesh models made up of 25 millions degree of freedom, the FEA V5 solutions help customers bring virtual product development even closer to reality.

Streamlining Product Development: Improving Performance Another key benefit of the 64-bit architecture is the ability to support efficient management of complex associative operations among multiple product variants, enabling advanced design methodologies such as Relational Design. Significant performance breakthroughs have been achieved. For example, a V5 user replaced an assembly component and made updates to a complex stamping die design. This set of actions was completed in less than a minute on a 64-bit processor. Likewise, the design steps required to generate 23 section views of an assembly comprising 90 complex parts was completed in a few minutes. In addition to these examples of performance benefits, gains of up to 80% on finite element model computations have been verified on models of 2.5 MDOF containing 5,000 contact joins.

No longer is it necessary to break out a 5000-component automobile and perform endless sub-assembly runs.

64-bit maximizes the design intelligence and associativity necessary for rapid and efficient propagation of design changes.

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This dramatic improvement in data processing and application performance allows 64-bit to maximize the design intelligence and associativity necessary for rapid and efficient propagation of design changes. When combined with the time and cost savings realized from the elimination of workarounds, 64-bit applications work faster and harder to optimize products designs.

Improving Product Quality: More Accurate Results The additional capacity offered by 64-bit not only allows engineers to manipulate and load more data at once, streamlining design and production processes, but it also impacts product quality. By allowing users to perform simulations on a complete product, instead of multiple runs using only partial components, or to visualize, analyze, and simulate larger mock-ups instead of multiple sub-assemblies, 64-bit helps manufacturers and their global supply chains make progress towards designing “right first time” − with few or no prototypes required.

For example, 64-bit now allows customers to load larger, more comprehensive digital mock-ups to perform interference and clearance analyses. To ensure consistency and ease of maintenance, a complex product can be reviewed and checked in one session:

“Loading of complete assemblies has clear process advantages for these customers. The primary benefit comes in the area of component collision detection and visualization. Invariably, huge DMU assemblies are created by large numbers of individuals working in different groups, companies, countries, and time zones. It is essential that new or redesigned components be checked for inference with the current versions of other components within the total product. In the visualization case, fly-throughs, design reviews, and presentations are enhanced when the most complete and accurate depiction of a product can be shown. When memory limitations prohibit loading of the total assembly, the customer is forced to pick and choose components to use for the reviews and presentations without complete “in context” information. In the case of interference analysis,

Performance gains: 2 times faster to compute this model of 4.4MDOF with more than 48.000

kinematic relations.

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64-bit now allows customers to load

larger, more comprehensive digital mock-ups to perform

interference and clearance analyses.

customers often have to make multiple interference runs of a specific component against each sub-assembly of the total product. In addition to being time consuming, these approaches can lead to errors or misinterpretations if important components or sub-assemblies are left out.

At an automotive company, not only could the entire car design be loaded with DMU, but they were also able to perform interference analysis of selected components against the entire design in a single step. In addition it was possible to generate section views through the entire assembly.”

Capacity gains: Creation of a realistic rendering movie for Dassault Aviation. 241 pictures; 10.6 millions of triangles; real material textures.

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Another example from the ABCG study describes a customer who was able to use more precise meshing to check the mechanical behavior of assemblies:

“The ability to solve more complex FEA analysis problems can have an immediate and significant impact on a company’s design process. For example, one customer case study involved doing an assembly analysis on a critical aircraft sub-assembly. Until now, it was impossible for the entire assembly to be meshed and solved using the desired parabolic tetrahedral elements at the desired mesh size. To work around this limitation, the customer was forced to perform multiple runs of the assembly, concentrating each run on a specific component of the assembly that was meshed using tet-10 elements, while other components were meshed using tet-4 elements. The results of all of these runs had to be stored and interpreted separately, wasting time and disk space. Using 64-bit V5 R15 running on AIX 5.2 ML 04, the customer was able to make the entire run using tet-10 elements, creating just one set of results. Not only is this new process faster, but it’s also potentially more accurate, as all components are being simultaneously evaluated using the desired tet-10 elements.”

These studies clearly indicate how designers have more tools at their fingertips to quickly and correctly analyze designs with 64-bit. As demonstrated by the ABCG study, analyzing the data at this capacity level provides a more precise results set, leading to improved decision making, product quality, manufacturability, and maintenance. At the same time, large,

distributed organizations are gaining time and cost benefits from greater performance, less utilization of disk space, and fewer time-consuming, repetitive tasks. Using 64-bit, stakeholders across the value chain can make more accurate decisions on product integrity and performance at an earlier stage of virtual product development − increasing the potential for cost savings and market success.

Conclusion With the recent V5R16 announcement, all DS PLM solutions, including CATIA V5, ENOVIA V5 VPM, ENOVIA V5 DMU, and DELMIA V5, are now supported on both AIX and Windows 64-bit architectures, providing the broadest 64-bit portfolio on the market. Furthermore, to enable a smooth transition from one architecture to another while preserving previous investments, the 32-bit / 64-bit environment is also supported; there are no additional charges to use the V5 64-bit applications.

Manufacturers requiring large assembly management, clash, and CAE analysis in the Automotive, Aerospace and Shipbuilding industries are the first to implement 64-bit technology. As prices slide downward and the competitive advantages become apparent, we can expect broader adoption in the near future.

*The ABCG report is available on http://www.ibm.com/servers/deepcomputing/dassault.

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Dassault Systèmes 10330 David Taylor Dr Charlotte, NC 28262 UNITED STATES Phone: +1-800-382-3342 WWW : http://www.3ds.com The Dassault Systèmes home page can be found on the World Wide Web at http://www.3ds.com ENOVIA, CATIA, DELMIA are registered trademarks of Dassault Systèmes, S.A. Other company names, product names, and service names may be trademarks, regis-tered trademarks, or service marks of others. This publication is for general guidance only. © Copyright 2006 ENOVIA Corporation. All rights reserved.

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