Large Scale Industrial Simulations Using HPC · 2020. 1. 16. · modelling, etc. Multi-Disciplinary Design & Optimization Search large design space Produce Best Design Higher Fidelity

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Large Scale Industrial Simulations Using HPC

Leigh Lapworth Fellow – Computational Sciences Rolls-Royce plc

HPC-AI Advisory Council – 2019 UK Conference Leicester, 16-17 September 2019

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2

Business overview

01

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3

Rolls-Royce at a glance

Civil Aerospace

£7.4bn

Defence

£3.2bn

Power Systems

£3.5bn

13,000 engines in service around the world

35 types of commercial aircraft powered by Rolls-Royce engines

24,600 employees

16,000 engines in service around the world

Over 150 Customers in over 100 countries

9,800 employees

>20,000 Reciprocating engines sold per year

>1,200 Development, service production, and dealership locations

11,400 employees

£1,378m R&D spend (gross)

Global presence in

50 countries

892 patents approved for filing


4

Digitisation

Growing demand for cleaner, safer and more competitive power

Electrification

Our Future Increasing demand for travel, trade and sustainable energy

Fusion of mechanical and electrical technologies

Fusion of physical and digital technologies

As pioneers, we must continuously innovate to provide the best solutions in the markets we serve.

In the coming years, we believe that the three key trends will define the world’s future power needs.


5

Digitisation

Cyber Protection

Cyber Protection

Design Manufacturing Services & support

Digital thread

Supply chain

• Virtual Reality, e.g. for design visualization

• Internet of Things, e.g. for parts tracking

• Machine Learning and Artificial Intelligence, e.g. for in-service analytics


6

Reinvent with digital

• Refining the Digital Twin

• Improving our productivity

• Generating new service offerings

• Pioneering new possibilities for design

• Broadening markets for Rolls-Royce services

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7

Modelling and Simulation

02

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The challenge of gas turbines

Fuel burns in the Trent engine's combustion chamber at temperatures up to 2,000°C, which is well above the 1,300°C at which some component metals used would start to melt.

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Simulation categories

Simulations include computational fluid dynamics, structures and dynamics, impact, combustion, thermo-mechanics, aero-mechanics, aero-acoustics, materials structure, process modelling, etc.

Multi-Disciplinary Design &

Optimization

Search large design space

Produce Best Design

Higher Fidelity Physical

Modelling

Increase accuracy

Improve Understanding

Virtual Product Modelling

Replace product tests

Reduce Cost & Risk


The Trent XWB

The most intense and comprehensive development programme ever undertaken by Rolls-Royce.

Six times the computing power applied than the previous generation

https://www.rolls-royce.com/products-and-services/civil-aerospace/airlines/trent-xwb.aspx#section-overview

Compressor: Module weight savings of 15% and

aerodynamic efficiency improvements via the use of compressor blisk technology

Fan: World-beating

levels of performance and

noise with reduced operational cost

Optimised internal air system:

reduces core air demand and reduces fuel consumption

Combustor: proven reliability

that is also cleaner than all current

and future emissions targets.

Turbine: the highest

efficiency turbine system of any Trent engine.


The Trent XWB

The world's most efficient large aero-engine

15% Fuel Consumption advantage over the

original Trent engine

$2.9M Savings per year

per aircraft on fuel alone

50,000 Horsepower

generated by 68 high pressure turbine blades

1,600+ Trent XWB

engines on order worldwide

Trent XWB for the Airbus A350 XWB family

https://www.rolls-royce.com/products-and-services/civil-aerospace/airlines/trent-xwb.aspx#section-overview



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High Performance Computing

03


Computational research and innovation model Work with leading universities and pre-competitive access to national e-Infrastructure to scale codes, develop new physics and design concepts.

Physical Science R&I Validation of codes and

new physical understanding

Break-through test cases

Production systems Proven capabilities

Computational Science R&I Scaling codes to run large

models efficiently

Design Science R&I Use of codes in

optimisation and novel design concept

Future business requirements


Developing large scale applications

18-24 months pre-competitive code scaling.

Codes running on new RR production systems from outset.

Trying to do this on a production system is more difficult and capability takes longer to develop with end-users adversely affected.

Archer 2

Archer

Sp

eed

/Cap

ab

ilit

y

Year

Archer pilot +

Leadership Scheme

EPSRC Prosperity

Partnership

In-house

HPC

In-house

HPC


Scaling from steady to unsteady CFD

Weak scaling due to many more aerofoils in the simulations.

Strong scaling due to unsteady simulations needing many more time steps than a steady simulations.

Model Type

Mesh Type Run Type Core hours

Steady

Single passage with

O(10) blades

Convergence acceleration

used

O(102)

Unsteady

Full annulus With approx.

O(1000) blades

Tiny time steps for several revolutions

O(107)

>50,000 times increase in computing

times


Large scale CFD

Our first ever 2 billion cell simulation.



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Future directions

04


Our ambition

High-fidelity simulation of a complete gas-turbine engine during operation, simultaneously including thermo-mechanics, electromagnetics, and computational fluid dynamics.

• Challenge: Coupled multi-discipline/scale – not a single code

• Complexity: > 1 trillion cells

• Usage: ~ 1 billion core hours per calculation

• Data files: 10-100 Petabytes per solution

• Energy: 10GWh (using today’s technology)


Strategic computational themes

Extreme Computing

• Highly scalable simulations

• Coupled multi-scale and multi-disciplinary codes

• Access to leadership class systems

Trusted Computing

• Verification and validation at extreme scales

• Secure use of 3rd party systems

• Software & data protection

• Software Quality • Skills

development

Lean Computing

• Optimal asset utilisation

• Dashboards • Cost minimisation • Productivity

improvements • Web portals and

apps

Computing Platforms

• Supercomputers • Cloud computing • Emerging

hardware • Visualisation • Augmented and

Virtual Reality • Optimised data

access

Holistic view of factors influencing industrial application of exascale computing.


Thermo-Mechanical Grand Challenges

Computational Science

Physical Science

New science and novel designs

Ultra high resolution and extreme scaling

Modelling what cannot be

modelled today

Several orders of magnitude improvement

in computational performance

Trillion cell simulations running on millions of computing cores

Unique new 5-year partnership

• Combining Computational and Physical Science Research.

• Aim is to achieve the world’s first high-fidelity simulation of a complete gas-turbine engine during operation.

• Launched 1st October 2018.

Partners

• Rolls-Royce (lead), CFMS, Zenotech, Universities of Edinburgh (lead), Bristol, Cambridge, Oxford, Warwick.

Associate partners

• Intel, Arm, Microsoft, NCSA.

EPSRC Prosperity Partnership Award

Strategic Partnership in Computational Sciences for Advanced Simulation and Modelling of Virtual Systems (ASiMoV)

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Documents

Large Scale Industrial Simulations Using HPC · 2020. 1. 16. · modelling, etc. Multi-Disciplinary Design & Optimization Search large design space Produce Best Design Higher Fidelity