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1 Louis Komzsik NAFEMS-2009, Greece
Industrial finite element analysis: Evolution and current challenges
Dr. Louis KomzsikChief Numerical AnalystOffice of Architecture and TechnologySiemens PLM, California, USA
Keynote presentation atNAFEMS World CongressCrete, GreeceJune 16-19, 2009
2 Louis Komzsik NAFEMS-2009, Greece
Topics
Evolution of technology
Design embedded analysis
Life-cycle simulation
Computational environment
Future directions
Evo
luti
on
of
tec
hn
olo
gy
3 Louis Komzsik NAFEMS-2009, Greece
The mid 1970s
Structural integrity
Stick models5,752 node points2,108 finite elements
(bars, beams, springs)28,924 degrees of freedom4 eigenvectors
2,679 CPU seconds1.1 hours elapsed time1 million words of memory36 million words of disk spaceMainframe computers
Evo
luti
on
of
tec
hn
olo
gy
4 Louis Komzsik NAFEMS-2009, Greece
The mid 1980s
Dynamic response
Car frames~50,000 node points~60,000 finite elements
(shells, solids)~264,000 degrees of freedom50 eigenvectors
2,505 CPU seconds0.9 hours elapsed time60 Mwords of memory173 Mwords of disk spaceSupercomputers
Evo
luti
on
of
tec
hn
olo
gy
5 Louis Komzsik NAFEMS-2009, Greece
The mid 1990s
Optimization of products
Full car body models~ 270,000 node points~ 275,000 elements
(spot-welds, constraints)~1.6 million degrees of freedom~1,000 eigenvectors
4,936 CPU seconds 221 GBytes of I/O1.7 hours elapsed time128 MWords of memory65 GBytes of disk usedWorkstation servers
Evo
luti
on
of
tec
hn
olo
gy
6 Louis Komzsik NAFEMS-2009, Greece
Simulation of product behavior
Trimmed body models~7 million node points~7.2 million elements(connection elements)
~35 million degrees of freedom~10,000 eigenvectors
~100,000 CPU seconds~11.5 Tera-bytes of I/O~680 minutes of elapsed time~16 GB memory used~630 Giga-bytes of disk usedPersonal computers
The mid 2000’s
Evo
luti
on
of
tec
hn
olo
gy
7 Louis Komzsik NAFEMS-2009, Greece
Topic
Evolution of technology
Design embedded analysis
Life-cycle simulation
Computational environment
Future directions
Des
ign
em
be
dd
ed
an
aly
sis
8 Louis Komzsik NAFEMS-2009, Greece
Design embedded analysis process
Fewer physical prototypes -> CheaperEasier decision making -> FasterMore reliable product -> Better
CAD Freeze
Prototype Build
Program Approval
Designfreeze
Conceptual Design Design TestingDetail Design
Analysis Impacts Design
Geometry changesGeometry changes Design changes
Analysis AnalysisValidationSimulation
Production Build
Des
ign
em
be
dd
ed
an
aly
sis
Optimization
9 Louis Komzsik NAFEMS-2009, Greece
Finite element assemblies
Des
ign
em
be
dd
ed
an
aly
sis
Geometric models of components from different sources
Meshing of component models executed separately
Connection of finite element mesh assemblies needed
10 Louis Komzsik NAFEMS-2009, Greece
Mesh connection technology
Assure displacement and stress continuity across connection
Apply connection technology in dynamic analyses
Dissimilar (different type and size) mesh connections
Des
ign
em
be
dd
ed
an
aly
sis
11 Louis Komzsik NAFEMS-2009, Greece
Mesh connection technology challenges
Non-coincident face connection
Non-parallel face connection
Edge-to-edge connections
Edge to surface connections
Des
ign
em
be
dd
ed
an
aly
sis
12 Louis Komzsik NAFEMS-2009, Greece
Des
ign
em
be
dd
ed
an
aly
sis
Dissimilar mesh connection case study
13 Louis Komzsik NAFEMS-2009, Greece
Topic
Evolution of technology
Design embedded analysis
Life-cycle simulation
Computational environment
Future directions
Lif
e-c
yc
le s
imu
lati
on
14 Louis Komzsik NAFEMS-2009, Greece
Production phaseMaterial manufacturingAssembly process
Operational phaseOperational scenariosUser comfort optimization
Recycling phase Disassembly processMaterial recycling
Life-cycle simulations
Lif
e-c
yc
le s
imu
lati
on
15 Louis Komzsik NAFEMS-2009, Greece
Operational scenarios
Rough road vibrationTire patch inputsDriver seat acceleration
Wheel unbalanceWheel hub force inputsSteering wheel vibrationL
ife
-cyc
le s
imu
lati
on
16 Louis Komzsik NAFEMS-2009, Greece
Optimization of user comfort
Structural acoustics
Automotive vehicle interior noisedue to road load excitation,engine noise of wind shear
Airplane cabin interior acoustics due engine noise
Aero launch systems acoustics
Air-conditioning system noise
Lif
e-c
yc
le s
imu
lati
on
17 Louis Komzsik NAFEMS-2009, Greece
Acoustic coupling interface challenges
Normal tolerance = .75
Normal tolerance = .25
Lif
e-c
yc
le s
imu
lati
on
X
Y
Structure Face (Red)
Fluid Face (Grey)
Structure
Face
(Green)
Fluid face
X
Z
Structure faces
18 Louis Komzsik NAFEMS-2009, Greece
Acoustic analysis case study
Benchmark
NORML = .75
NORML = .5
NORML = .25
Full vehicle model ~ 1,400,000 fluid free faces~ 2,000,000 structural faces~ 2,500,000 structural grids
Compute response to 300 Hz
Coupled results agree well with measured benchmark resultsL
ife
-cyc
le s
imu
lati
on
19 Louis Komzsik NAFEMS-2009, Greece
Topic
Evolution of technology
Design embedded analysis
Life-cycle simulation
Computational environment
Future directions
Co
mp
uta
tio
na
l e
nvir
on
me
nt
20 Louis Komzsik NAFEMS-2009, Greece
Distributed processor clusters
4 Workstation Servers
4 Processors per server
1.5 GHz processors
16 GB Memory
1 Giga-bit Ethernet Adapter
2 Ultra3 SCSI disks (internal)
2 Ultra3 SCSI controllers for external disks
16x Ultra3 SCSI disks 36.4 GB per controller
Total external capacity: 2x580 GB = 1.1 TB
Computational environment challenge
Co
mp
uta
tio
na
l e
nvir
on
me
nt
21 Louis Komzsik NAFEMS-2009, Greece
Computational problem challenge
The constrained stiffness matrix of an
analysis problem
Number of rows: 35,734,709
Nonzero terms: 1,384,305,995
Nonzero terms in sparse factor matrix:
43,827,004,000
Memory used during factorization:
1,080,732,000 (4 byte) words
Actual elapsed time of sparse
factorization on a high performance
workstation: 335 minutes
Co
mp
uta
tio
na
l e
nvir
on
me
nt
22 Louis Komzsik NAFEMS-2009, Greece
Finite element model distribution as answer
Multilevel graph partitioning: coarsen, partition, refine
4
9 36
57
24
1
2 8
36
57
69
4 2
71
69
4
4 2
7
2
1
9 6
24
9 3
51
6
7
1 2 4
3
5
6
7
Co
mp
uta
tio
na
l e
nvir
on
me
nt 8 8
23 Louis Komzsik NAFEMS-2009, Greece
Distributed normal modes analysis case study
Car engine model~1,400,000 node points~790,000 finite elements~ 4.2 million degrees of freedom256 components, ~1000 modes
Elapsed time in minutes
64 node Linux cluster1.85 GHz CPUs200 GB local disk space per node4 GB memory per nodeGigabit interconnect with MPI
Elapsed speedup
0
1000
2000
3000
4000
5000
6000
0 1 2 4 8 16 32 64
Total
Eigen
0
10
20
30
40
50
60
0 1 2 4 8 16 32 64
Total
Eigen
Co
mp
uta
tio
na
l e
nvir
on
me
nt
24 Louis Komzsik NAFEMS-2009, Greece
Distributed transient response calculation case study
Car body road excitation~1,096,000 node points~ 1,000,000 finite elements~ 6.5 million degrees of freedom~200 responses
Co
mp
uta
tio
na
l e
nvir
on
me
nt
0.00E+00
2.00E-09
4.00E-09
6.00E-09
8.00E-09
1.00E-08
1.20E-08
0 20 40 60 80 100 120 140 160 180 200
Global Lanczos method
256 components, 5. scale
128 components, 2. scale
Clock min I/O GB
4,728:18 23,839
894:22 7,570
392:47 2,786
25 Louis Komzsik NAFEMS-2009, Greece
Topic
Evolution of technology
Design embedded analysis
Life-cycle simulation
Computational environment
Future directions
Fu
ture
dir
ec
tio
ns
26 Louis Komzsik NAFEMS-2009, Greece
Future directions
Computational technology will use mixed precision and hybrid solutions on multi and many-core CPU clusters and will utilize graphical processing units (GPUs)
Design embedded analysis will continue to increase the geometric model complexity and will result in the advancement of geometry based mesh-free analysis approaches
The increased fidelity of life-cycle simulations will require stochastic analysis techniques considering manufacturing tolerances and load variations leading to robust designs
The future is integrated multi-disciplinary analysis in the industry
Fu
ture
dir
ec
tio
ns
27 Louis Komzsik NAFEMS-2009, Greece
MeshMesh--free free KantorovichKantorovich techniquetechnique
)y,x()y,x()y,x(u Φω=
FAc
bc)y,x(m
jjj
=
= ∑=1
Φ
∂∈=
∈>
Ω
Ωω
)y,x(;
)y,x(,)y,x(
0
0
0=
∈
=−
∂Ω
Ω
∆
|u
)y,x(
)y,x(f)y,x(u
0=∈
=−
∂ΩΩ
∆
|u;)y,x(
)y,x(f)y,x(u
Complete solution:
Boundary value problem: Physical field:Distance function:
Fu
ture
dir
ec
tio
ns
28 Louis Komzsik NAFEMS-2009, Greece
Stochastic analysis technique
1,00E+09
1,20E+09
1,40E+09
1,60E+09
1,80E+09
2,00E+09
2,20E+09
2,40E+09
2,60E+09
0,2
0,22
50,
250,
275
0,3
0,32
50,
350,
375
0,4
0,42
50,
450,
475
0,5
0,52
50,
550,
575
0,6
0,62
50,
65
Beam Height [m]
Str
ess M
axim
um
[N
/m^
2]
1,00E+09
1,20E+09
1,40E+09
1,60E+09
1,80E+09
2,00E+09
2,20E+09
2,40E+09
2,60E+09
0,2
0,22
50,
250,
275
0,3
0,32
50,
350,
375
0,4
0,42
50,
450,
475
0,5
0,52
50,
550,
575
0,6
0,62
50,
65
Beam Height [m]
Str
ess M
axim
um
[N
/m^
2]
∆σ∆σ∆σ∆σ1∆σ∆σ∆σ∆σ2
∆∆∆∆h ∆∆∆∆h
„DeterministicOptimum“
„ProbabilisticOptimum“
Deterministic optimization: Probabilistic optimization:
hopt, deterministic < hopt, probabilistic ∆σ1> ∆σ2,
Fu
ture
dir
ec
tio
ns
29 Louis Komzsik NAFEMS-2009, Greece
Result correlation
Electronic CoolingRadiation Space Systems
Response Simulation
YY- Stress PSD
RMS=19.7 MPa
Motion and Controls
Integrated multi-disciplinary analysis
Heat Flow Stochastic analysis
Fluid flow
Electro-magnetism
Structural Fatigue
Laminate Composites
Thermal
All analysis capabilities in one
system
Fu
ture
dir
ec
tio
ns
30 Louis Komzsik NAFEMS-2009, Greece
Thank you for your attention!
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