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BMW GroupF. ChristelPRACE07.09.2009
Virtual Prototyping at BMW Group.
BMW Group
F. Christel
PRACE Industry Seminar
September 7-8, Toulouse, France
07.09.2009
BMW GroupF. ChristelPRACE07.09.2009Slide 2 of 23
Virtual Prototyping at BMW Group.
Overview.
1. Hardware / Architecture
2. Simulations at BMW
3. FEM-Simulation
4. CFD-Simulation
5. CFD Thermal Management & Aerodynamics
6. Future Development
7. Summary & Conclusion
BMW GroupF. ChristelPRACE07.09.2009Slide 3 of 23
Virtual Prototyping at BMW Group.
Hardware: Evolutionary process.
1990s Central Computing
Cray Mainframe
1994 RISC SMP
UNIX Servers
2001 Commodity Systems
Intel, Linux
2007 HPC Cluster Grid
BMW GroupF. ChristelPRACE07.09.2009Slide 4 of 23
Virtual Prototyping at BMW Group.
Architecture.
High Performance Computing Service:
• Optimized infrastructure for computational applications.
• Complete infrastructure platform for application integration.
• Transparent access to compute capacity via jobflow.
• Central resource/workload management.
BMW GroupF. ChristelPRACE07.09.2009Slide 5 of 23
Virtual Prototyping at BMW Group.
Hardware / Architecture.
Engineers, Virtual Development
Jobflow Portal transparent resource pool
Technology Standards
• Intel® Xeon® EP (5160, 5570)
• Ethernet GBit
• NAS Storage
HPC Linux Cluster
BMW GroupF. ChristelPRACE07.09.2009Slide 6 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 7 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 8 of 23
Virtual Prototyping at BMW Group.
FEM Passive Safety: Side Impact Crash.
Tool: Abaqus
Calculation Time: On 8 CPUs: 20-50 h
BMW GroupF. ChristelPRACE07.09.2009Slide 9 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 10 of 23
Virtual Prototyping at BMW Group.
FEM Production: Deep Drawing.
Tool: LS Dyna
Calculation Time: On 4 CPUs: 10 h
BMW GroupF. ChristelPRACE07.09.2009Slide 11 of 23
Virtual Prototyping at BMW Group.
Overview.
PassiveSafety
Production
Chassis
Powertrain
Structural mechanics
Thermal Management & Aerodynamics
BMW GroupF. ChristelPRACE07.09.2009Slide 12 of 23
Virtual Prototyping at BMW Group.
Structural Mechanics: Thermal Expansion.
Tool: Abaqus
Calculation Time: On 2 CPUs: 30 min
hot cold
BMW GroupF. ChristelPRACE07.09.2009Slide 13 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 14 of 23
Virtual Prototyping at BMW Group.
CFD Powertrain: Incylinder Simulation.
Tool: ANSYS-CFX
Calculation Time: On 8 CPUs: 240 h
BMW GroupF. ChristelPRACE07.09.2009Slide 15 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 16 of 23
Virtual Prototyping at BMW Group.
CFD Chassis: Brake Cooling.
Tool: Star-CD
Calculation Time: On 16 CPUs: 120 h
BMW GroupF. ChristelPRACE07.09.2009Slide 17 of 23
Virtual Prototyping at BMW Group.
Overview.
Passive
Safety
Production
Thermal
Management &
Aerodynamics Chassis
Powertrain
Structural
mechanics
BMW GroupF. ChristelPRACE07.09.2009Slide 18 of 23
Virtual Prototyping at BMW Group.
CFD: Thermal Management.
Conduction and Radiation
Convection
Automatically coupled calculation
BMW GroupF. ChristelPRACE07.09.2009Slide 19 of 23
Virtual Prototyping at BMW Group.
CFD: Thermal Management.
Tool: Star-CD coupled with RadTherm
Calculation Time: On 8 CPUs: 240 h
BMW GroupF. ChristelPRACE07.09.2009Slide 20 of 23
Virtual Prototyping at BMW Group.
CFD: Thermal Management.
Future Development Simulation of “Thermal Soak”
BMW GroupF. ChristelPRACE07.09.2009Slide 21 of 23
Virtual Prototyping at BMW Group.
CFD: Thermal Management.
Future Development “Thermal Soak”
Tool
Transient “All-in-one calculation” (convection, conduction, radiation
and heat storage) in Star-CCM+.
Hardware
Calculation duration of a complete vehicle model (> 40 million cells)
in the order of months.
BMW GroupF. ChristelPRACE07.09.2009Slide 22 of 23
Virtual Prototyping at BMW Group.
Summary & Conclusion.
Summary
• 7 FEM applications running on HPC Cluster Grid.
• 8 CFD applications running on Cluster.
• High utilization of the cluster (> 80 %).
Conclusion
Using more complex models or considering more
design alternatives in a shorter time frame requires
access to faster and secure “on demand” resources.
BMW GroupF. ChristelPRACE07.09.2009Slide 23 of 23
Virtual Prototyping at BMW Group.
Thank you very much
for your attention!
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