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)
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ICT Mega Trends
Ray Kurzweil Singularity is near
Compute power x 2 every 18 months
Challenges &
Opportunities
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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
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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
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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
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Virtual Prototyping : advantages Supply Chain : Different Domains / Teams / Locations
Painting
Casting
CFD
Safety
Vibration
Comfort
Welding
Virtual Prototype
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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
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Gestamp
Industry Objectives & Use Cases
ESI
Virtual Prototyping
Platform & Methodology
Bull Cloud Based HPC
Fortissimo : Gestamp experiment
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Fortissimo : Gestamp experiment Company overview
Courtesy of Gestamp Ref : EGF – May 2014
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Competitive edge Press Hardening Light Weight
Scale up Regionalization
Fortissimo : Gestamp experiment Company overview & challenges
Courtesy of Gestamp Ref : EGF – May 2014
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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
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+ Chassis
+ Engine + Exhaust
+ Seats
Stiffness/NVH Analysis
Crash Analysis
Fortissimo : Gestamp experiment Industrial Relevance
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USNCAP FR 56kph (Rigidwall 100% overlap)
EURONCAP SIDE 50kph
EIGEN MODES Analysis
Fortissimo : Gestamp experiment Work In Progress
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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
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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
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Virtual Prototyping : Aero Expliseat Success Story
Reference: Expliseat – EGF 2014
Established : 2011 Product Certification : 2014
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Virtual Prototyping : Aero Expliseat Experience
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Reference: Expliseat – EGF 2014
Virtual Prototyping : Aero Expliseat Experience
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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
