engineering simulation solutions and hpc - open grid · pdf fileautodyn ideal scaling blast...

© 2007 ANSYS, Inc. All rights reser ved. 1 June 2007 ANSYS, Inc. Proprietar y

Timothy Kwan

Regional Business Manager

CAD-IT Consultants

Engineering Simulation Solutions &

High Performance Computing

© 2008 ANSYS, Inc. All rights reser ved. 2 ANSYS, Inc. Pr oprietary

CAD-IT Consultants

• Brief History :

– Formed in 1991 (Singapore)

– Malaysian operations started in 1994

– China offices set up starting 1997

– Thailand representative office opened in 2001

• Regional channel partner for:

– ANSYS simulation solutions: ANSYS Multiphysics, FLUENT, CFX, AUTODYN, Icepak etc

– CEI visualization solutions: Ensight

– SFTC’s metal forming processes simulation solution: DEFORM

– Moldflow’s plastics flow simulation solutions: MPA, MPI etc

– IMC’s problem solving and idea generation solution: Goldfire Innovator

• HP, Microsoft WCCS and ANSYS collaboration partner


What is CAE?

• Computer-Aided Engineering (often referred to as CAE) is the use of

information technology for supporting engineers in tasks such as

– Analysis

– Simulation

– Design

– Manufacture

– Planning

– Diagnosis

– Repair

• CAE tools, are software that have been developed:

– for providing support to the activities above

– to analyze the robustness and performance of components and

assemblies

– to help support design teams in decision making


What is CAE?

• CAE areas covered include:

– Structural analysis on components and assemblies using FEA

(Finite Element Analysis)

– Thermal and fluid flow analysis using CFD (Computational Fluid Dynamics)

– Rigid multibody dynamics or mechanical systems motion

simulation

– Analysis tools for process simulation of operations such as

casting, molding, and die press forming

– Optimization of the product or process


CAE Technology Application Trends:

Need More Fidelity

Where are the hotspots?

• 10 load cases• Fatigue calculations• Known a priori?• Need to submodel?

No M

issed Hot S

pots!



Reduce Engineering Time

Direct CAD to Mesh

• No defeaturing• No mid-planing• No shells• No beams• …

No Sim

plifications!



Model Complete Assemblies

Model Complete Assembly

• No BC assumptions• All parts CAD-to-mesh• Automatic contact

Work-Years to W

ork-Days!



Include All Physics

Include All Physics

• Analyses closely match reality

• Reduced assumptions that question certainty and compromise accuracy

• Lower cost due to R&D process compression

• Lower cost due to fewer analysis software tools to purchase, learn and manage

No Sim

plified B

ehavior!

Nano-sphere accuracy benchmark

Courtesy: Andreas, Hieke



More Understanding

Simulation Driven Product Development• Understand Completely• Innovate Consistently• Fail Early and Often


Why Use Clusters For CAE?

• Clusters enable bigger simulations (more accuracy)

– Typical FEA models require 4-8 GB RAM• Today’s more demanding models might consume 100 GB

– Typical CFD models require 2-10 GB RAM• Today’s more demanding models might consume 50-100 GB

• Clusters deliver turnaround time

– Clusters can yield nearly linear scaling• A typical simulation might run for 8 hours on a single CPU

→Becomes 1 hour on an eight-core cluster• Clusters can scale up with demand

– More simulations (more design options)• Optimization studies might require 50-100 simulations


ANSYS and HPC

Computer Aided Engineering Software

– for Simulation Driven Product Development

• Deliver superior product designs

– Explore innovations in features, function

• Improve time to market

– Faster and earlier than physical testing

• Lower product development costs

– Virtual prototyping vs. physical testing


Simulation Drivers for HPC

~ 25 Million DOF Stress

Analysis of a Front Suspension

Modeled on a Desktop

Solved on a Cluster

75291

8,080,601382,492

5,438,0050

24,241,803

Number of Parts Contact PairsNodesCONTACT ElementsSOLID186/187 ElementsCEsNo. of Equations (DOFs)


Simulation Drivers for HPC

• GE CRD test for parallel scalability…towards full 360°blade row simulations

– One passage mesh• approx. 1 M nodes

– Full annulus of 92 passages• 88M nodes

Number of Passages

Mesh Nodes

Definition File Size

Number of CPUs

True Wall Clock Time

1 1.0M 20Mb 1 7.22 hrs

92 88M 2407Mb 90 7.75 hrs

Courtesy GE Corporate R&D Center


ANSYS Mechanical HPC

11.0 SP1 Benchmark Suite


Performance Results - ANSYS

“ANSYS parallel processing has been a key enabler

for our simulation group. We are now tackling jobs

that we simply wouldn’t have before by moving

towards complete system level analysis from single component analysis. The analysis team is now

responding to the design team much faster with

accurate results from ANSYS!”

– Jason Longstaffe, Principal Engineer


FLUENT 6.3 HPC on WCCS

FLUENT 6.3.26 FLUENT 6.3.26 –– FL5L1 FL5L1 (.86M), (.86M), FL5L2 (FL5L2 (3.6M3.6M))Microsoft Windows CCSMicrosoft Windows CCSHP CP3000 ProLiant BL460cHP CP3000 ProLiant BL460cXeon Dual Core 3.0GHz Voltaire IBXeon Dual Core 3.0GHz Voltaire IB

Over 26x faster on

32 cores


Performance Results - FLUENT

“The ability to deploy a cluster using Windows Compute Cluster Server was very attractive to us, because it leverages our expertise and fits into our current computing environment. The deployment was quite smooth: we had our cluster up and running FLUENT within two weeks. The integration of FLUENT with the Microsoft Job Scheduler is especially valuable, giving us the ability to manage and monitor multiple simulations on the cluster”.

– Charles Ulrich, IT Manager, Alden Research Laboratory Inc.


AUTODYN HPC

0

5

10

15

20

25

30

1 2 4 8 16 24

Number of Cores

Re

lati

ve

Pe

rfo

rma

nc

e AUTODYN

Ideal Scaling

Blast Containment Analysis


Performance Results - AUTODYN

“By conducting these AUTODYN simulations

prior to the physical test, WTD 52 is able to

reduce the number of costly tests and to enhance the quality of the experimental

investigations. As a result, time and cost savings can be achieved in most cases.”

– Michael Klaus, Deputy Director WTD 52

DEFORM and HPC

♦ Metal forming involves very complex nonlinear processes

♦ DEFORM is used to:• Predict process behaviour before it’s tried on the shop floor

• Identify root cause of defects which occur in production

• Investigate alternatives

♦ Example:• Hot forging with flash of steering link

• About 50,000 elements

• Single stroke pressing

Link Time Test Results

2 proc: 7:31About $3000 (5 years ago)

Dell 1.7 GHz Dual Xeon processor

(about 6 years old)

2 proc: 3:03$6000 (2 years ago)

HP xw9400 AMD Opteron \

Dual Processor (about 3 years old)

2 proc: 2:50$700HP a6130 AMD Athlon64 X2 5000+

Dual core processor 3 GB RAM

2 proc: 1:55

4 proc: 1:11

8 proc: 0:57

$40,000-$60,000

(custom ordered)

HP XC Cluster – 4 nodes

Each node 1 Xeon dual core

Infiniband networking

2 proc: 2:33

4 proc: 2:08

8 proc: 2:22

Quad core chips are

currently not recommended

HP DL 360 Intel Xeon 2 x Quad core

(18 month old computer)

4 proc: 1:24$5500Hp xw8400 Intel 3.00GB 2x dual core Xeon. 8GB Ram

Run Time

hr:min

Approx CostComputer

Best affordable

performance

Great performance under $1000

Weld Yoke forgingCG-Direct Rigid Plastic w/pNon-isothermal

- 600K tet

Cluster Performance –Large Model

8 processors

CG FEM 15h 48m Remesh 8h 50m (#56)Total Time 24h 38m

HP Linux Cluster, 4 nodes, 8 processors, 3.0GHz 5160 Xeon, 4GB memory

Weld Yoke courtesy American Axle and Manufacturing

Ensight and HPC

• Extreme post-processing and visualization solutions for CFD/FEA/CAE systems

• Ensight takes full advantage of parallel processing and cluster based rendering for analyzing, visualizing and communicating high-end scientific and engineering datasets

Ensight and HPC

EnSight images courtesy of

Sauber Petronas F1

“Using EnSight as a communication tool is as important as the FEA

analysis itself”

Kumar Kulkarni, Lead FEA Analysis, VISTEON

“The more realistic my analysis results look, the better my customers

understand them, and the larger my budget grows.”

Jim Johnson, CFD Technical Lead, GM

Ensight DR

Render client 1

Composite

4 servers sending data to 4 clients

Render client 3 Render client 4

Render client 3

Distributed Rendering with Vis Clusters

Ensight Animation

EnSight animation by Advantage CFD for

Honda F1 team

Ensight Animation

POV-Ray animation of periodic ship oscillation

Courtesy of Dr. Kenji Takizawa, Tokyo Institute of Technology

Thank You.

Email: [email protected]

URL: www.cadit.com.sg

engineering simulation solutions and hpc - open grid · pdf fileautodyn ideal scaling blast...

Documents