simulation technology, speed up your iterative process (by jan buytaert)

2.3 Simulation technology, speed up your iterative process

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Template presentation Innovation Day 2016 CONFIDENTIAL

Jan BuytaertConsultant [email protected]

Christophe Van BavinchoveCoordinator [email protected]

SIMULATION TECHNOLOGY:SPEED UP YOUR ITERATIVE PROCESS

TRACK 2: TECHNOLOGY TO ACCELERATE


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PhysicsLab – Systems Engineering

Christophe Van BavinchoveHead of PhysicsLab

Jan BuytaertSenior Systems EngineerConsultant PhysicsLab


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CONTENT

Why use simulation technology?

What is simulation technology?

How to use simulation technology?

Simulation technology examples


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WHY USE SIMULATION TECHNOLOGY?

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Problem statement & illustrations

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• Traditionally design and failure predictions are carried out by • hand calculations

• experimental testing

• design trials

• As organizations strive to produce products • that are better than the state-of-the-art

• and better than their competitors

• and to do so in a shorter time span

they need sophisticated toolsand methodologies to assist them.

• One such tool is computer simulation software


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THESIS of this TALK:

• Innovation • becomes more complex and multidisciplinary,

• and consequently more challenging and expensive.

• One way to remedy this, is by using simulation technology• facilitating design iterations

• reducing the number of (failed) experiments

• reducing the number of (failed) prototypes



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• Case 1: Microfluidic channel design for sample dilution


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• Process1. Establish the concept and the channel design constraints

2. Perform benchmark tests to fine-tune simulation parameters

3. Optimize microfluidic channel design based on simulations

4. Verify simulation results by performing tests on prototype device

5. Make final design

Confluence concept

Desi

gn s

pace

SimulationsPrototypes & experiments

Design choice

Time

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Simulation parameters


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3. Optimize microfluidic channel design based on simulations


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Engineer Jef Aernouts


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simbreadboard



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• For design space exploration• Virtually try-out new concepts/designs

• Sweep a range of design parameters

• For risk limitation• Verify upfront the process performance

• Understanding robustness/failure of your design

• For design verification• Supports physical verification tests which can be reduced in number

• Allows extrapolation of test results to non-testable cases

• For problem solving• Understanding existing product failure/requirements/constraints

• Optimizing an existing design by low cost design iterations

PRODUCT DEVELOPMENT

early stage

intermediate

before release

after release


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• Risk limitation & design verification• by analyzing design performance upfront

• Example• PCB air fan cooling

• Multi-physics model (CFD & Heat transfer)

Engineer Jan Buytaert


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• Design verification • of a physically non-testable case

• Example• Cooling of a reaction vessel

• Multi-physics model (CFD & Heat transfer)

Engineer Jan Buytaert & Wouter Vleugels


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• Problem solving• by design optimization

• Example• Beer bottle interlayer

• Structural model

Engineer Wouter Vleugels & Jan Buytaert


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• Problem solving• by design vs cost optimization

• Example• Beer appliance door

• Structural model

Engineer Tom Beeldens


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• Benefits of numerical analysis• Detailed understanding of product performance

• Design space exploration

• Optimization of performance

• Optimization of amount of material/weight economically

• Reducing testing costs

• Reduction of failure risks

• Reduction of incremental development risks

• Reduction of time to market

• Improved product quality


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WHAT IS SIMULATION TECHNOLOGY?

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The finite-element method

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• Simulation• The imitation of the operation of a real-world process or system over time.• Requires that a model be developed (containing geometry + loads).

• Simulation technology• Physical model versus …• … abstract mathematical model

• Computer simulation technology• Software tool


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• Finite-element analysis (FEA)• the practical application of the finite-element method (FEM)• used by scientist and engineers• to mathematically model

and numerically solve very complex structural, fluid, and multi-physics problems.


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• Finite-element analysis (FEA)• the practical application of the finite element method (FEM)• used by scientist and engineers• to mathematically model

and numerically solve very complex structural, fluid, and multi-physics problems.


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• FEM simulation software tools consist of• pre-processing (meshing, boundary conditions)• solvers (actual calculations)• post-processing (results, visualization)

• Nowadays • all-in-one integrated (yet expensive) FEM software is available• hardware has become powerful (and affordable)


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What is simulation technology?


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• FEM modeling software resembles the cockpit of a space shuttle …• A enormous amount of knobs and dials and controls ~ options

of which most aren’t usedthough they all have a function and reason for being there

• One can fly on automatic pilot however when deviating from the routine, expert flying is needed

• You do not take a space shuttlewhen a balloon flight can do the job

• Expensive way of travelingso make it worth the effort

• Trained pilots reduce the chance of failure


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• Case 2: BIB handle failure analysis and remedy


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Engineer Michael Burm


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• Geometry• Draw from scratch or start from a CAD model• Remove unnecessary detail & use symmetry

• Meshing• Subdivide a large problem (i.e. a CAD geometry)

into smaller, simpler, parts, called finite elements.• fine meshing = good resolution = long calculation times


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• Geometry• Draw from scratch or start from a CAD model• Remove unnecessary detail & use symmetry

• Meshing• Subdivide a large problem (i.e. a CAD geometry)

into smaller, simpler, parts, called finite elements.• fine meshing = good resolution = long calculation times

mesh


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• Geometry

• Meshing

• Boundary conditions• Mimic the physical loads and constrains

interacting with the model• … forces, displacements, pressure, fixations, heating/cooling …• Idealization/simplification is needed ~ approximation

symmetry & boundary conditions


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• Geometry

• Meshing

• Boundary conditions• Mimic the physical loads and constrains

interacting with the model• … forces, displacements, pressure, fixations, heating/cooling …• Idealization/simplification is needed ~ approximation



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• Geometry

• Meshing

• Boundary conditions

• Finite-element method solving• Matrices of partial differential equations• Analytical solving = mission impossible


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• Geometry

• Meshing

• Boundary conditions

• Finite-element method solving• Matrices of partial differential equations• Analytical solving = mission impossible (too many variables, degrees of freedom, equations)• Approximate solution• Calculation time …• Convergence to a solution …

• Post-processing and interpretation of the results


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stress safety factor Engineer Jan Buytaert


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Engineer Jan Buytaert & Tobe Wauters


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Engineer Jan Buytaert

safety factor

stress


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HOW TO USE SIMULATION TECHNOLOGY?

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Insights

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• Challenges• Optimal meshing of the geometry• Breaking down a problem into subsystems for simulation• The art of idealization (stripping away of unnecessary complexity)• Applying realistic boundary conditions• Interpreting the results correctly


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• How to go about these challenges• A critical mass of experts/expertise

• Knowledge of the physics

• Knowledge of the modeling and the modeling tool

• Understanding of the extent to which modeling decisions impact accuracy

• Understanding of the consequences on resources and time by modeling decisions


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• How to go about these challenges• A critical mass of experts/expertise• A structured workflow (and report)

Analysis intake

Analysis specifications

Geometry creation

Mesh grid generation

Model set-up

Solution process

Solution verification

Solution validation

Post-processing

Report writing


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• How trustworthy are simulation results?

Solution validation

Analysis validation is carried out to determine that the analysis solution represents the physical system it was designed to simulate. Validation is actually evaluation and can be done by:• Hand calculations• Physical testingIt should be remembered that test data contains experimental errors, and hand calculations contain assumptions as well.

Analysis intake

Analysis specifications

Geometry creation

Mesh grid generation

Model set-up

Solution process

Solution verification

Solution validation

Post-processing

Report writing


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"Nobody trusts a computer simulation except the guy who did it, and everybody trusts experimental data except the guy who did it.

Why not combine the two and get results everybody can mistrust a little."

- T. Kordyban -

• How trustworthy are simulation results?


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• Case 2: BIB handle failure analysis and remedyEngineer Michael Burm & Jan Buytaert 5G


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• ConclusionsSimulation technology serves agility in innovation

• Speed-up your innovative process

• Model and load case variations can be readily made

• At a reduced testing cost

• Concretize your product/process• Facilitated design space exploration

and the converge towards a chosen design

• Simulations and physical testing both have value

• User-centric development• Specification/discussion load cases

• Robustness/safety factor for use cases

Gate: Go/No-GoGate: Go/No-Go


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EXAMPLES SIMULATION TECHNOLOGY

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From beer to Darwin’s evolutionary theory

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SIMULATION TECHNOLOGY EXAMPLES

• ExampleChimney with different flows inside

• Multi-physics model • Particle tracing• CFD

Engineer Jochem Grieten & Wouter Vleugels


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• ExampleGravitational oil drain

• CFD model • Design optimization• Design verification

Engineer Wouter Vleugels


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• ExampleBiomechanical structural analysis of bird beak evolution

• Structural model• Mechanical stress, fracture risk and beak evolution

• Conceptual understanding

Joris Soons & Jana Goyens & Joris Dirckx


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QUESTIONS?


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simulation technology, speed up your iterative process (by jan buytaert)

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