Engineering Simulation Solutions & High Performance Computing

Timothy Kwan Regional Business Manager CAD-IT Consultants © 2007 ANSYS, Inc. All rights reser ved.

1

June 2007 ANSYS, Inc. Proprietar y

CAD-IT Consultants • Brief History : – Formed in 1991 (Singapore) – Malaysian operations started in 1994 – China offices set up starting 1997 – Thailand representative office opened in 2001 • Regional channel partner for: – ANSYS simulation solutions: ANSYS Multiphysics, FLUENT, CFX, AUTODYN, Icepak etc – CEI visualization solutions: Ensight – SFTC’s metal forming processes simulation solution: DEFORM – Moldflow’s plastics flow simulation solutions: MPA, MPI etc – IMC’s problem solving and idea generation solution: Goldfire Innovator • HP, Microsoft WCCS and ANSYS collaboration partner © 2008 ANSYS, Inc. All rights reser ved.

2

ANSYS, Inc. Pr oprietary

What is CAE? • Computer-Aided Engineering (often referred to as CAE) is the use of information technology for supporting engineers in tasks such as – Analysis – Simulation – Design – Manufacture – Planning – Diagnosis – Repair • CAE tools, are software that have been developed: – for providing support to the activities above – to analyze the robustness and performance of components and assemblies – to help support design teams in decision making

© 2008 ANSYS, Inc. All rights reser ved.

3

ANSYS, Inc. Pr oprietary

What is CAE? •

CAE areas covered include: – Structural analysis on components and assemblies using FEA (Finite Element Analysis) – Thermal and fluid flow analysis using CFD (Computational Fluid Dynamics) – Rigid multibody dynamics or mechanical systems motion simulation – Analysis tools for process simulation of operations such as casting, molding, and die press forming – Optimization of the product or process

© 2008 ANSYS, Inc. All rights reser ved.

4

ANSYS, Inc. Pr oprietary

CAE Technology Application Trends: Need More Fidelity

o N

M

Where are the hotspots? • 10 load cases • Fatigue calculations • Known a priori? • Need to submodel? s is

ed

S ot H

t po

s!

© 2008 ANSYS, Inc. All rights reser ved.

5

ANSYS, Inc. Pr oprietary

CAE Technology Application Trends: Reduce Engineering Time

o N

Direct CAD to Mesh • No defeaturing • No mid-planing • No shells • No beams •… im S

if i pl

ca

ns t io

!

© 2008 ANSYS, Inc. All rights reser ved.

6

ANSYS, Inc. Pr oprietary

CAE Technology Application Trends: Model Complete Assemblies W a Ye kor

rs

Model Complete Assembly • No BC assumptions • All parts CAD-to-mesh • Automatic contact to

or W

k-

ay D s!

© 2008 ANSYS, Inc. All rights reser ved.

7

ANSYS, Inc. Pr oprietary

CAE Technology Application Trends: Include All Physics

o N

Include All Physics • Analyses closely match reality • Reduced assumptions that question certainty and compromise accuracy • Lower cost due to R&D process compression • Lower cost due to fewer analysis software tools to purchase, learn and manage ed if i pl m Si

Nano-sphere accuracy benchmark Courtesy: Andreas, Hieke

av eh B

io

r!

© 2008 ANSYS, Inc. All rights reser ved.

8

ANSYS, Inc. Pr oprietary

CAE Technology Application Trends: More Understanding Simulation Driven Product Development • Understand Completely • Innovate Consistently • Fail Early and Often

© 2008 ANSYS, Inc. All rights reser ved.

9

ANSYS, Inc. Pr oprietary

Why Use Clusters For CAE?

• Clusters enable bigger simulations (more accuracy) – Typical FEA models require 4-8 GB RAM • Today’s more demanding models might consume 100 GB

– Typical CFD models require 2-10 GB RAM • Today’s more demanding models might consume 50-100 GB

• Clusters deliver turnaround time – Clusters can yield nearly linear scaling • A typical simulation might run for 8 hours on a single CPU

→Becomes 1 hour on an eight-core cluster • Clusters can scale up with demand – More simulations (more design options) • Optimization studies might require 50-100 simulations

© 2008 ANSYS, Inc. All rights reser ved.

10

ANSYS, Inc. Pr oprietary

ANSYS and HPC

Computer Aided Engineering Software – for Simulation Driven Product Development • Deliver superior product designs – Explore innovations in features, function • Improve time to market – Faster and earlier than physical testing • Lower product development costs – Virtual prototyping vs. physical testing

© 2008 ANSYS, Inc. All rights reser ved.

11

ANSYS, Inc. Pr oprietary

Simulation Drivers for HPC

~ 25 Million DOF Stress Analysis of a Front Suspension Number of Parts Contact Pairs Nodes CONTACT Elements SOLID186/187 Elements CEs No. of Equations (DOFs)

75 291 8,080,601 382,492 5,438,005 0 24,241,803

Modeled on a Desktop Solved on a Cluster © 2008 ANSYS, Inc. All rights reser ved.

12

ANSYS, Inc. Pr oprietary

Simulation Drivers for HPC

• GE CRD test for parallel scalability… towards full 360°blade row simulations – One passage mesh • approx. 1 M nodes

– Full annulus of 92 passages • 88M nodes

Number of Passages

Mesh Nodes

Definition File Size

Number of True Wall CPUs Clock Time

1

1.0M

20Mb

1

7.22 hrs

92

88M

2407Mb

90

7.75 hrs

Courtesy GE Corporate R&D Center © 2008 ANSYS, Inc. All rights reser ved.

13

ANSYS, Inc. Pr oprietary

ANSYS Mechanical HPC 11.0 SP1 Benchmark Suite

© 2008 ANSYS, Inc. All rights reser ved.

14

ANSYS, Inc. Pr oprietary

Performance Results - ANSYS

“ANSYS parallel processing has been a key enabler for our simulation group. We are now tackling jobs that we simply wouldn’t have before by moving towards complete system level analysis from single component analysis. The analysis team is now responding to the design team much faster with accurate results from ANSYS!” –

Jason Longstaffe, Principal Engineer

© 2008 ANSYS, Inc. All rights reser ved.

15

ANSYS, Inc. Pr oprietary

FLUENT 6.3 HPC on WCCS

FLUENT 6.3.26 – FL5L1 (.86M), FL5L2 (3.6M ( 3.6M) ) Microsoft Windows CCS HP CP3000 ProLiant BL460c Xeon Dual Core 3.0GHz Voltaire IB

Over 26x faster on 32 cores

© 2008 ANSYS, Inc. All rights reser ved.

16

ANSYS, Inc. Pr oprietary

Performance Results - FLUENT

“The ability to deploy a cluster using Windows Compute Cluster Server was very attractive to us, because it leverages our expertise and fits into our current computing environment. The deployment was quite smooth: we had our cluster up and running FLUENT within two weeks. The integration of FLUENT with the Microsoft Job Scheduler is especially valuable, giving us the ability to manage and monitor multiple simulations on the cluster”. – Charles Ulrich, IT Manager, Alden Research Laboratory Inc. © 2008 ANSYS, Inc. All rights reser ved.

17

ANSYS, Inc. Pr oprietary

AUTODYN HPC

30

Relative Performance

25

AUTODYN

20

Ideal Scaling 15

10

5

0 1

2

4

8

16

24

Number of Cores

© 2008 ANSYS, Inc. All rights reser ved.

18

Blast Containment Analysis

ANSYS, Inc. Pr oprietary

Performance Results - AUTODYN

“By conducting these AUTODYN simulations prior to the physical test, WTD 52 is able to reduce the number of costly tests and to enhance the quality of the experimental investigations. As a result, time and cost savings can be achieved in most cases.” – Michael Klaus, Deputy Director WTD 52 © 2008 ANSYS, Inc. All rights reser ved.

19

ANSYS, Inc. Pr oprietary

DEFORM and HPC ♦

♦

Metal forming involves very complex nonlinear processes DEFORM is used to: •

•

•

♦

Predict process behaviour before it’s tried on the shop floor Identify root cause of defects which occur in production Investigate alternatives

Example: •

•

•

Hot forging with flash of steering link About 50,000 elements Single stroke pressing

Link Time Test Results

Best affordable performance

Great performance under $1000

Computer

Approx Cost

Run Time hr:min

Hp xw8400 Intel 3.00GB 2x dual core Xeon. 8GB Ram

$5500

4 proc: 1:24

HP DL 360 Intel Xeon 2 x Quad core (18 month old computer)

Quad core chips are currently not recommended

2 proc: 2:33 4 proc: 2:08

HP XC Cluster – 4 nodes Each node 1 Xeon dual core Infiniband networking

$40,000-$60,000 (custom ordered)

2 proc: 1:55 4 proc: 1:11 8 proc: 0:57

HP a6130 AMD Athlon64 X2 5000+ Dual core processor 3 GB RAM

$700

2 proc: 2:50

HP xw9400 AMD Opteron \ Dual Processor (about 3 years old)

$6000 (2 years ago)

2 proc: 3:03

Dell 1.7 GHz Dual Xeon processor (about 6 years old)

About $3000 (5 years ago)

2 proc: 7:31

8 proc: 2:22

Cluster Performance – Large Model Weld Yoke forging CG-Direct Rigid Plastic w/p Non-isothermal - 600K tet

8 processors CG

FEM Remesh Total Time

15h 48m 8h 50m (#56) 24h 38m

HP Linux Cluster, 4 nodes, 8 processors, 3.0GHz 5160 Xeon, 4GB memory

Weld Yoke courtesy American Axle and Manufacturing

Ensight and HPC • Extreme post-processing and visualization solutions for CFD/FEA/CAE systems • Ensight takes full advantage of parallel processing and cluster based rendering for analyzing, visualizing and communicating highend scientific and engineering datasets

Ensight and HPC “Using EnSight as a communication tool is as important as the FEA analysis itself” Kumar Kulkarni, Lead FEA Analysis, VISTEON “The more realistic my analysis results look, the better my customers understand them, and the larger my budget grows.” Jim Johnson, CFD Technical Lead, GM

EnSight images courtesy of Sauber Petronas F1

Ensight DR Distributed Rendering with Vis Clusters Render client 1

Render client 3

Composite 4 servers sending data to 4 clients Render client 3

Render client 4

Ensight Animation

EnSight animation by Advantage CFD for Honda F1 team

Ensight Animation

POV-Ray animation of periodic ship oscillation Courtesy of Dr. Kenji Takizawa, Tokyo Institute of Technology

Thank You.

Email: [email protected] URL: www.cadit.com.sg