design exploration and robust design - ansys · engineers face numerous obstacles that prevent them...
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© 2011 ANSYS, Inc. 8/29/111
Design Exploration and Robust Design
Judd KaiserProduct Manager,ANSYS Workbench Platform
© 2011 ANSYS, Inc. 8/29/112
Agenda• What is Robust Design?• At ANSYS• Workbench Principles• DesignXplorer• ANSYS Vision
© 2011 ANSYS, Inc. 8/29/113
What is Robust Design?
© 2011 ANSYS, Inc. 8/29/114
The Path to Robust Design
Single Physics Solution• Accuracy, robustness, speed…
Multiphysics Solution• Integration Platform
“What if” Study• Parametric Platform
Design Exploration• DOE, Response Surfaces, Correlation, Sensitivity, etc.
Optimization• Algorithms
Robust Design
• Probabilistic Algorithms
• Adjoint solver methods
Increasing understanding,
innovation, R
OI Doesn’t account
for physics interactions
Doesn’t provide direction for
design improvement
?
??
Solutions compared, but
design is not well understood and no optimum is
found
Provides design understanding,
but optimization is not
automated
Solutions may be too sensitive
to input variability
Input distribution
Output distribution
© 2011 ANSYS, Inc. 8/29/115
ANSYS Vision
ANSYS Has a very clear vision for Simulation Driven Product Development!• Best-in-class solvers combined for multiphysics• Ease of use, knowledge capture, integration platform…• Parametric, persistent, automated• Design exploration & robust design!
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Design Exploration and Robust Design at ANSYS
© 2011 ANSYS, Inc. 8/29/117
Optimization tools at ANSYS• ANSYS DesignXplorer
– Unified Workbench solution
• ANSYS Fluent – Has built-in morphing
and optimization tools– Has an adjoint solver
• ANSOFT Optimetrics• ANSYS MAPDL
– DX VT• And more
Baseline Design
Optimized Design
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ANSYS DesignXplorerIntegral with Workbench• Parametric multiphysics modeling with automated updates• Bi-directional CAD, RSM, scripting, reporting and more...
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Optimization PartnersANSYS simulation software has
been effectively used to drive innovation in concert with optimization partners
• MATLAB (Mathworks)• ModeFrontier (Esteco)• OptiSLang (Dynardo)• RBF-Morph• Sculptor (Optimal)• Sigma Technology (IOSO)• TOSCA (FE-DESIGN)• Qfin (Qfinsoft)• and more…
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Workbench Principles
(It’s built for SDPD)
© 2011 ANSYS, Inc. 8/29/1111
ANSYS Workbench Schematic Workflow
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Workbench
Integrates ANSYS tools and solvers
Parametric, persistent and scriptable environment
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DesignXplorer in Workbench(It’s built for SDPD)
© 2011 ANSYS, Inc. 8/29/1114
ANSYS DesignXplorer
DesignXplorer is everything under this Parameter bar…• Low cost & easy to use!• It drives Workbench • Improves the ROI!
DX
CAD Connections & DM ANSYS Workbench
Solvers
EKM &
HPC
© 2011 ANSYS, Inc. 8/29/1115
ANSYS DesignXplorer Design of Experiments
With little more effort than for a single run, you can use
DesignXplorer to create a DOE and run many variations.
© 2011 ANSYS, Inc. 8/29/1116
Correlation Matrix
Understand how your parameters are correlated/influenced by other
parameters!
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Sensitivity
Understand which
parameters your design is most
sensitive to!
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Response Surface
Understand the sensitivities of the output parameters
(results) wrt the input parameters.
3D Response
2D Slices Response
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Goal-Driven Optimization
Use an optimization algorithm or screening to understand tradeoffs or discover optimal design
candidates!
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Robustness EvaluationInput parameters have variation!
Output parameters vary also!
How will your performance vary with your design
tolerances?
Make sure your design is robust!
Six Sigma, TQM
How many parts will likely
fail?
Which inputs require the
greatest control?
© 2011 ANSYS, Inc. 8/29/1121
ANSYS DesignXplorerInitial vs. Optimized Design
Output Initial Design Optimized
Tt Ratio 1.116 1.126
pt Ratio 1.674 1.709
η [%] 71.65 76.25
Power [MW] 1.208 1.268
© 2011 ANSYS, Inc. 8/29/1122
DesignXplorer Vision
(It’s built for SDPD)
Disclaimer: plans for future releases are preliminary, and subject to change.
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Engineers face numerous obstacles that prevent them from using optimization fully
Our plans are largely based on removing those obstacles so our customers can get more out of simulation
Remove the Road Blocks
0% 5% 10% 15% 20% 25% 30% 35% 40% 45%
Design not Suitable
Understanding Results
Other
Algorithms
Faith in Results
Baseline Model
Parameter Information
Integration Issues
Resouces
Parametric Model
Too Much Time
Main obstacles to Optimization
Linked in Survey, Q1 2011
Do you use optimization software?
Matlab16%
18.6%41.9%
21.8%
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Many ways to reduce the time requirements
• Speedup of individual components– Geometry import, meshing, solve, etc.
• Speedup between design points– “DOE Sorting” at 14.0 – Mesh morphing
• Reduce the number of design points required
– Improved Sparse Grid DOE at 14.0– New Auto-Kriging at 14.0– New KMOGA adaptive optimization
coming at 14.5– Researching ways to use Adjoint
information or ROM to dramatically reduce the number of solves required
• HPC to distribute the solve– New distributed design point solve
with RSM at 14.0
Running all those design points takes too long!
Dynamic convergen
ce feedback
Resolution w/
fewer points
R14
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Removing RoadblocksEasier to build a parametric model
– “Pervasive Parameters” across WB• Manufacturable values, R14• Extend discrete parameters, R15
– Material selection, Booleans, string parameters, etc.
• System Level Modeling, ROM, RS Systems, etc.
Easier to connect various tools together
– Workbench + External Connection + SDK
– ANSYS ICEM CFD Meshing at R14.5– Extend the External Connection
Easier access to resources– Hardware
• Cloud computing– Software Licensing
• Simultaneous Design Point (SDP) packs, R14.5
R14
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~1/3rd of Engineers would prefer to use their own algorithms for Optimization
Algorithms R15
• Opening up our Optimization Platform (R15)– Matlab optimization toolbox– API for customized optimization algorithms– Flexible process with custom cost functions
and convergence criteria• This flexibility will be in addition to our “out of
the box” functionality designed to please the other 2/3rds.
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• New Charts– Added 2D slices, local
sensitivity curves and convergence plots; R14
– Significant enhancements planned
Charting & Reporting
R14
R14
• Unified Reporting– Auto-generate project level
reports, R14– Strategic theme for R15
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Strategic Theme• Already available
– Six Sigma analysis– Sensitivity / Determination
• Research and future development – Probabilistic optimization– Adjoint methods
Robust Design
R12
High sensitivity – changes to shape have a big effect on drag
Low sensitivity
High sensitivity – Shape on Downforce
R14
© 2011 ANSYS, Inc. 8/29/1129
The Path to Robust Design
Single Physics
Multiphysics
“What if” Study
Design Exploration
Optimization
Robust Design
• Build on the solid foundation of Workbench as a platform for parametric simulation
• Develop DX as an optimization platform
• Build up to probabilistic optimization
© 2011 ANSYS, Inc. 8/29/1130
Thank You
Join Simon’s DesignXplorer user group on Linked-In
Search Groups for “DesignXplorer” to join.
[email protected] 734-213-1266
[email protected] 734-812-6528