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Effective Simulation Management
Getting Simulation Out of the Silos
Malcolm Panthaki | VP of Analysis Solutions | Aras
June 2019
© 2019 Aras2
Materials Advancements & Additive
Verification & Validation
Need for
Simulation
Increasing
Rapidly
Design Space Exploration
source: wirth research
source:yourcar
© 2019 Aras3
Connected & Autonomous
Digital Twin
MBSE / System Models
Future:
More & More
Simulations
across the
Lifecycle
source: autoevolution
source: squir
source: bmw
© 2019 Aras4
Silos:
Unable to
Achieve
Business of
Engineering
Strategies
Disconnected from Processes
FEA
CFD
Highly Diverse & Increasing
Thermal
EMI
0D / 1D
Composites
Embedded
Software / Firmware
wiring & bonding
Optics
nonlinear
analysis
vibro-acoustics
Co-simulation
materials
characterization plastic
flow metal
forming castingESD
chips &
circuits
Separate & Complicated to Manage
source: centers of grain excellence
© 2019 Aras5
Future Risks:
Without
New Approach
to
Simulation
Management
Risks
Design Quality Problems
Delays / Missed Deadlines
Cost Overruns
Operational Shutdowns
Regulatory Actions
Liability
Safety Issues
Loss of Life
Catastrophic Failures
Ramifications
Misdirected Actions
Wrong Design Simulated
Inaccurate Conclusions
source: ansys
Risks compounded by Multidisciplinary Products &
Use of Machine Learning and AI in Design
© 2019 Aras6
Simulation Management: Challenges
▪ Large number of tools
▪ Mixed-fidelity modeling (from systems models to 3-D models)
▪ Multi-physics modeling
▪ Multi-disciplinary modeling (including mechanical, software, electronics)
▪ Tools from multiple vendors
▪ Data models (tool file formats) are all different
▪ Each tool speaks its own language
▪ Simulation processes usually use multiple tools
▪ Simulation Processes are manual and only run by experts in silos
▪ Non-experts do not have access to simulation
▪ Large number of product variants and autonomous testing requires full automation
▪ Simulation data not connected to other engineering (PLM) data
▪ Tools from all vendors, all physics and all levels of fidelity must be integrated
▪ Results from all tools should be available to the enterprise for decision-making
© 2019 Aras7
Simulation Management: Challenges
• Statistical correlation with
Test results
• Notified about design /
model changes
• Aware of Variants / Options
• Mapped to Requirements
• Traceable for Liability issues
/ Digital Thread
Reduce Physical Test
• System architecture
representation of product
• Simulation available
on-demand
• Co-simulations / trade
studies / cross-discipline
• Mixed fidelity models,
Different data types
• Tool-agnostic connectors
MBSE / Systems
• Repeatable / reuse
• Proceduralized for
ops environment
• Access to Digital Twin
config & performance data
• Simulation data for
Machine Learning / AI
Predictive Maintenance
© 2019 Aras8
Simulation Management Should Enable
▪ Experts & Engineers
▪ Deliver better/timely requirements-driven simulation coverage
▪ Stay in sync with design / variant changes
▪ Eliminate redundant administrative tasks
▪ Analyze Variations Quickly
▪ Rapidly conduct analysis on product variations, options and concepts
▪ Provide “right-fidelity” simulation throughout the lifecycle
▪ Automate repeatable tool chain processes
▪ Digital Thread
▪ Across Concept Engineering, Detailed Design, Simulation & Test
▪ From Requirements through entire Lifecycle
source: gm
© 2019 Aras9
Systems
When systems models sit at the
center of designs, they become
the connective tissue
The Digital Thread runs through them
Seamless Integration
Systems Modeling to 3-D Simulation
MBSE
Interdisciplinary Collaboration with Systems Thinking
© 2019 Aras10
Concept of
Operations
Requirements
capture &
breakdown
System
Architecture
& behavior
Detailed
domain design
System
Verification
& Validation
Integration,
Test &
Verification
Operation &
MaintenanceVerify & Validate
Design
“Right-Fidelity” simulation available on-demand
Digital Thread• Traceability
• Support Iterative-Development
Systems Models (Agile, Spiral…)
Simulation On-Demand from Concept to Operation
© 2019 Aras11
Repository
Clients
Modeling Engine
Platform Services V12 SP1
Simulation in an Integrated, Open, Extensible Platform
▪ Simulation integrated with all core PLM services
▪ Configuration, ECO, and Lifecycle processes
▪ Visual Collaboration
▪ Configurator
▪ Branch/Merge
▪ Graph Navigation
▪ Open unified data model and API
▪ Consistency for all users/implementations
▪ Supports simulation data and processes
▪ Custom extensions (data model, process,
applications)
▪ Connectors for commercial and in-house tools
Tool-Agnostic, Open
Product Innovation Platform
Platform Services
Co
nn
ecto
rs
Platform ServicesPlatform Services
Applications
Simulation Framework
© 2019 Aras12
source: GM
In-house
tools
FE Mesher
CAD
Thermal Analysis
MBD
Analysis
CFD
Structural
FEA & Life
Systems Analysis
System Architecture
System Requirements
System Parameters
Component Representations
▪ Complete representation of the Product:
A Systems-Centric view
▪ System intent & System requirements
▪ System Architecture & System Parameters
▪ Multiple component representations
▪ System constraints & Operating conditions
▪ Performance metrics
▪ Product variants/configurations
▪ Tool-agnostic data & processes
▪ Commercial, in-house custom, etc.
▪ Fully-automated processes
▪ Robust automation across design changes
and product family variants
Simulation Process
Black-Box, File-Based
Vendor/Tool-Specific
Systems-Centric, Template-Driven Simulation Management
What’s Missing in SPDM – a Systems-Centric View
© 2019 Aras13
File VaultsFile Vaults
Secure User Access
Scripting & Process Definition
Process Execution
To
ol C
on
ne
cto
rs
& O
pe
n A
PIs
Scalable Back End
Unified Data Model
Web Client
Remote Execution
Workstation Client
Scripting & Process Modeler
Process Engine
Remote Job Engine
PLM Platform Server
High Performance
Open APIs
File Vaults Metadata RepositoryPersistent & Transient Data Temp Files
External ToolsCAD / CAE / Math / In-House
Systems Modelling
Tool
ToolTool Tool
Tool Tool
Tool Tool
ToolTool
ToolTool
Tool
Tool ToolTool
HPC NodesHPC Nodes
Simulation Framework Architecture
© 2019 Aras14
File VaultsFile Vaults
To
ol C
on
ne
cto
rs
& O
pe
n A
PIs
Scalable Back End
Unified Data Model
PLM Platform Server
File Vaults Metadata RepositoryPersistent & Transient Data Temp Files
External ToolsCAD / CAE / Math / In-House
Systems Modelling
Tool
ToolTool Tool
Tool Tool
Tool Tool
ToolTool
ToolTool
Tool
Tool ToolTool
HPC NodesHPC Nodes
Product Data Model (tool-independent)
Simulation Data Model (tool-independent)
Tool-Specific Data Model
Mixed-Fidelity models (systems to 3-D)
Multi-Physics models
Multi-Disciplinary models (incl., software, electronics)
Automation of assembly model generation, including connections
Requirements-Driven, Systems-Centric, Template-Enabled Simulation Management
Modelin
g E
ngin
e
Scalable Back End
Unified Data Model
Tool-Agnostic Unified Data Model
<5%
>95%
© 2019 Aras15
Platform ServicesMo
deli
ng
En
gin
e
Applications
Clients
Co
nn
ecto
rs
Open architecture encourages
integration with other enterprise
systems and tools
MBSE
Simulation
ALM
ECAD
PDM
MCAD
PDM
ERP
MES
IOT
Aras Platform – Connectors
© 2019 Aras16
Application Landscape – Simulation Management
Platform Services
Product Portfolio Management
Quality Management [QMS]
Technical Documentation [TD]
Component
Engineering
[CE]
Program Management [PM]
Requirements
Engineering
[RE]
Manufacturing
Process
Planning
[MPP]
Manufacturing
Execution
Maintenance
Repair &
Overhaul
[MRO]
IOT
Systems
Architecture
[SA] Product
Engineering
[PE]
Verification & Validation
Functional
Safety
Compliance AdditiveSustainability
Planned
Available
In WorkM
od
eli
ng
En
gin
e
Co
nn
ecto
rs
Clients
© 2019 Aras17
Simulation Management [SPDM]
Application Landscape – Simulation Management
Platform Services
Product Portfolio Management
Quality Management [QMS]
Technical Documentation [TD]
Component
Engineering
[CE]
Program Management [PM]
Requirements
Engineering
[RE]
Manufacturing
Process
Planning
[MPP]
Manufacturing
Execution
Maintenance
Repair &
Overhaul
[MRO]
IOT
Systems
Architecture
[SA] Product
Engineering
[PE]
Verification & Validation
Functional
Safety
Compliance AdditiveSustainability
Planned
Available
In WorkM
od
eli
ng
En
gin
e
Co
nn
ecto
rs
Clients• EBOM mgmt
• Mass mgmt and rollup
• Performance mgmt
• Lumped-Parameter Parts
• CAD mgmt
• Requirements Engineering
• System Architecture
• Simulation Templates• Studies• Simulation BOMs• Simulations• Model Variables• Simulation Results/Reports
Aras Comet SPDM• Simulation automation with
connectors to Excel, MATLAB, MBD Tools, CAD, FEA Tools, Optics, etc.
© 2019 Aras18
Simulation Management [SPDM]
Application Landscape – Simulation Management
Platform Services
Product Portfolio Management
Quality Management [QMS]
Technical Documentation [TD]
Component
Engineering
[CE]
Program Management [PM]
Requirements
Engineering
[RE]
Manufacturing
Process
Planning
[MPP]
Manufacturing
Execution
Maintenance
Repair &
Overhaul
[MRO]
IOT
Systems
Architecture
[SA] Product
Engineering
[PE]
Verification & Validation
Functional
Safety
Compliance AdditiveSustainability
Planned
Available
In WorkM
od
eli
ng
En
gin
e
Co
nn
ecto
rs
Clients• EBOM mgmt
• Mass mgmt and rollup
• Performance mgmt
• Lumped-Parameter Parts
• CAD mgmt
• Requirements Engineering
• System Architecture
• Simulation Templates• Studies• Simulation BOMs• Simulations• Model Variables• Simulation Results/Reports
Aras Comet SPDM• Simulation automation with
connectors to Excel, MATLAB, MBD Tools, CAD, FEA Tools, Optics, etc.
Digital Thread
© 2019 Aras19Isight
Aras Comet SPDMParametric, Multi-Fidelity, Multi-Source, Multi-Discipline
Unified Data Model
Connectors to External Tools
Mesh Models
Systems Models
CAD Models
Product Representations
Analysis Models
(Auto-Generated)
Optimization Tools
MBD Tools
Systems ToolsFEA Tools
ANSA Mesher
Teamcenter
Teamcenter
PLM
OpticStudio
OpticStudio
Simulation Automation – Templates & Connectors
© 2019 Aras20
▪ Open & extensible Unified Data Model
▪ Across all physics, levels of model fidelity and disciplines
▪ Simulation data captured mostly independent of the underlying tools
▪ Vendor- & tool-agnostic
▪ Open & extensible Connector Architecture
▪ Cover in-house tools & data
▪ Enable commercial tools covering all required physics and levels of fidelity
▪ Tight integration between parametric CAD & parametric mixed-fidelity CAE models
▪ Robust Automation across significant design changes & configuration variants
▪ Simulation rules not based on CAD, instead product engineering / system architecture
▪ Part of mainstream engineering processes across lifecycle – Digital Thread
▪ Connected to Requirements, System Architecture and variant eBOMs
Foundations of the Simulation Framework
© 2019 Aras21
Cluster 2
Cluster 3
Cluster 1
▪ Aras users can choose to run simulations on the
local LAN or on an Azure VM (virtual machine)
▪ Currently, the Azure VM is pre-allocated, but will be
dynamically allocated in the future – the VM will be
sized based on the simulation compute needs
ARAS Server
Conversio
n Server
Innovator
Server
Sim
ToolsConversio
n ServerJob
Server
Introduction of Azure HPC for Simulation
Cycle
Clo
ud
Comet
Folder
Inputs
Start
Comet
Comet
Folder
Outputs
Comet
Folder
Inputs
Aras
Comet
SPDM
Sim
Tools
Start
Comet
Comet
Folder
Inputs
Aras
Comet
SPDM
Sim
Tools
Start
Comet
Comet
Folder
Inputs
Aras
Comet
SPDM
© 2019 Aras22
Air Force
Research Lab
American Axle
Magna Cosma
GKN Driveline
China Northern Railway
Superior Industries
SITP CIOMP
XIOPMIAPCM
CAST
TYUSTAVIC
CNIGC
BCC
ZHONGLI
BIRSE Changchun
University
Customers who use Aras Comet SPDM…
© 2019 Aras23
Call to Action
Aras is actively engaging in proof of concept initiatives for open reference architecture
development
Please share your use cases & best practices:
Simulation Management / Test Management / MBSE / Requirements
To collaborate & contribute your Simulation Management use cases, please contact:
Malcolm Panthaki | Aras
© 2019 Aras24source: GM
American Axle
▪ Market advantage based on engineering delivery
of new technology systems at cost
▪ Enable consistent & accurate data for traceability
▪ Create repeatable processes for global scalability
▪ Each program: 50-100 configurations, each
requiring 100’s to 1000’s of simulation runs
Solution Results
▪ Average 75% time reduction for analysis set up &
report generation
▪ Improved product quality & reliability through
greater simulation coverage
▪ Attained better reuse and repeatability of
simulation processes
Tools & Solvers
NX CAD
Simulia/Abaqus
NX/Nastran
Romax
Excel
Mathematica
© 2019 Aras25
NASA Langley Research Center
▪ Electro-Optical sensor systems for satellite data collection
▪ Instruments highly sensitive to solar thermal effects
▪ Previously each analysis iteration took 2-4 weeks
Solution Results
▪ Structural-Thermal-Optical-Performance Analysis (STOP)
with single repeatable process
▪ Ability to quickly conduct trade studies over many
concepts for high level of design confidence
▪ Analysis iteration now takes < 1 day
▪ Engineers are introduced to “Systems Thinking” when
using the Concurrent Engineering development process
Simulia/Abaqus
MSC/Nastran
Sigmadyne
C&R Technologies
MATLAB
Tools & Solvers
SpaceClaim
SolidWorks
Creo
OpticStudio
Code V Optics
source: NASA
© 2019 Aras26
source: GKN Driveline
GKN Driveline
▪ Bending Frequency influenced by many design variables
▪ Libraries of templates and design architectures
▪ Create repeatable processes for global scalability across
all engineering teams
Solution Results
▪ Democratize process for all engineers using Web GUIs
▪ Non-experts investigate design iterations rapidly before
the experts are involved
▪ Automation drives process refinement/improvement,
resulting in accuracy and consistency globally
▪ Improved product quality & reliability through greater
simulation coverage
Tools & Solvers
Creo
Mesher
MSC/Nastran
Excel
Credits: Glenn Valine
© 2019 Aras27
source: gm
Magna Cosma
▪ Configuration and barrier crash analyses of
bumper systems
▪ Manual process results in 6-8 hours per iteration
▪ CAD design change coordination issues resulted
in errors, added costs and reliability impact
Solution Results
▪ Enabled repeatable parameter studies for better
design decisions and traceability
▪ Process definition improved product quality
across global organization
▪ Model assembly and report generation reduced
from avg. 6-8 hrs to 15 minutes / iteration
Tools & Solvers
NX CAD
LS-Dyna
MSC/Nastran
Excel
ANSA Meshing
VCollab
