CAE and SDM and Beyond

1. CAE and SDM and Beyond Frank Popielas, Member NAFEMS Steering Committee Americas January 28, 2013

2. Content* General Market: Current State Needs and Trends CAE and it’s current and future Role Virtual Engineering Approach HPC / CAE Network Architecture Supporting Tools – The Role of SDM Conclusions • * Based on the following papers: • Frank Popielas: “CAE and its Role 2020 and beyond for the Engineering Community”, NAFEMS NA Congress, Washington D.C., 2012 • Rohit Ramkumar, et al: “Simulation Life Cycle Management - Game Changer in the CAE World “, NAFEMS NA Congress, Washington D.C., 2012 2

3. General Market:Current State, Needs, Trendsand how can we shape it

4. Engineering Approach It is the way we coordinate our engineering activities to generate results It spans over a wide range of milestones: Goal definition Idea inception Product development Product introduction Mass production In-field service

5. Market needs Working with customer upfront in very early project stage (providing simulations with quotations rather than after business award) Reducing time-to-market Improving turn-around in simulation Covering more details in simulation Improving simulation quality Reducing overhead cost per project Quality and performance guarantee of product at any point of time in development / product cycle System Engineering Development costs Traditional Development cycle Development costs Modern Development cycle

6. Drivers of Competitiveness in Engineering Design / Manufacturing: Single feature focus: like a new design feature or material Reduced costs: like tooling Larger material variety Support Technology System engineering Simulation driven design, testing, manufacturing with direct link to customer Further improved engineering support in all regions Partnership with customer

7. Supplier to Development Partner Development Partner SLM CAE Development in Partnership with Customer Analysis Driven Design CAE for Mfg Value System CAE Full Service Supplier System Testing System Design Dyno Testing Supplier Dedicated Program Managers Collaborative Tiers Product FEA On Site Engineers Product Testing Product Design

8. Components Forming Stress Strain Life Load balance Manufacturability …… 3D MLS gasket layer 2D Thermal-Acoustical Protective Shield Axle Carrier Exhaust gas cooler

9. System Stress Interaction Life Balance NVH …… Powertrain Axle assembly

10. Design that’s right the first time:Dana’s Philosophy Common Process – Optimum Design – Competitive Advantage Global Customer Base / Global Projects / Global Resource Global Footprint – 96 Facilities / 26 Countries

11. Simulation drives decisions throughout the product lifecycle Customer experience Voice of Customer Requirement Simulation and Test Correlation Low Fidelity System System Acceptance Functional Subsystems Simulation (Decomposition) Subsystem test Components Logical Integration Integration Test Physical High Fidelity

12. Market trends • Simulation data management • Optimization tools • CAE for manufacturing • System engineering tools • Transparency • Real-time access to data • Cloud computing • ….

13. CAE and it’s current and future Role- Virtual Engineering Approach- HPC / CAE Network Architecture- Supporting Tools

14. Current State of CAE • Pockets of simulation around CAE analysts • Very little interaction with / incorporation of other engineering areas in simulation activities for most of the companies • CAE still handled as a tool for top experienced and trained engineers • Within CAE team: • Too much one-off approach • Looked at like science • Not enough team work • Spending most time on requests instead of development work • Coordination within companies not enough Leaders in industry made and are making CAE mainstream in their organizations already

15. Huge Variety of Software Tools: Example Set Solvers Abaqus (FEA) HW-Suite (FEA, NVH,…..) CFD: StarCCM+ (core solver) FlowVision (oil metering for valve stem seals) MoldFlow (molding) RadTherm (Thermal) FE-Safe (durability) RADIOSS (NVH) Optimization OptiStruct ATOM Hyperstudy Isight • Fluid-Structure Interaction • direct coupling with Abaqus for both CFD codes • Preprocessor • Hypermesh • CAE (Abaqus) • Simlab • Postprocessor • Viewer (Abaqus) • Matlab • Flowmaster

16. Types of Analysis / Simulations: Example Set Stress Strain Life / Durability Load balance NVH: Modal Harmonic Sound/Absorption level Thermal: Conductivity Convection Radiation Heat Transfer Air- and oil separation Oil metering Oil slosh Oil pan Engine Molding Texture Warpage Optimization Formability System simulation System Engineering Decision criteria established for all products and simulation types

17. Future State of CAE • CAE is mainstream • Simulation activities are taking place throughout all engineering • Different workflows have been established • Ad-hoc • Guided • Automated • CAE team: • Works as a team • Focuses on requests which require manual interaction and deep knowledge and understanding of CAE and it’s tools • Spending about have if their time on developing new simulation techniques, expansion of CAE into all engineering • Everything is transparent and at everyone's fingertips

18. Current State of Infrastructure • High performance Work Stations for CAE analysts • Pockets of High Performance Computing (HPC) • Network bandwidth too slow to handle huge amount of data traffic • High-end laptops for mobility • Storage usually attached to HPC clusters

19. Future Direction • All CAE storage located at a single regional datacenter • The entire workflow is enabled through high throughput data links and locality • Users connect to virtual sessions on workstation hosts physically present at the data center, enabling them to be directly connected to the storage • Collaboration is simpler, since all sites share space on the same storage solution • Simulations are created in and never leave the data center

20. Location 1 Location 2 Location 3 Location 4 Private Cloud Simulations Never Leave the Datacenter • One Regional (for example NA) cluster provides greater capacity than individual clusters for same spend via the resource manager and hardware optimization • Files move on high speed data links, faster than possible over LAN/WAN technologies • Global Resource Manager smartly places work where it will get done the fastest for its priority

21. Simulation Lifecycle Management and Engineering Community Collaboration

22. What is Dana’s interest in SLM Dana global footprint Technical Centers in all Regions Manufacturing Application engineering Sales Supporting customers in over 125 countries Almost 50% of business outside of North America Global supply base to our local / global business Connect Resources – Share Information – Engage the Customer

23. 80% of Simulation Work In Process Simulation data is not tracked in a PDM/PLM system

24. SLM Program Scope The proposed SLM solution is capable of: Providing the necessary organizational structure and flexibility to capture and manage simulation process flows, Allowing automation of redundant tasks, Integrating with existing and future software requirements. Creating a centrally-managed structure for simulation data and activities, Ability to capture and manage simulation workflows, Ability to trace data and track design changes, Common hardware and software approach, and a searchable storage location for all simulation data. Facilitating a collaborative environment for a 24/7 engineering approach for all CAE activities globally, resulting in the ability to better allocate resources for significant time and cost savings.

25. Simulation Process Maturity Ad-Hoc Standard Guided Automated Centralized Searchable Attributed Traceability Pedigree Secure Centralized Searchable Attributed Traceability Pedigree Secure Centralized Searchable Attributed Traceability Pedigree Secure Knowledge Capture Best Practices Consistency Resource Utilization Knowledge Capture Best Practices Consistency Resource Utilization Productivity Design Exploration

26. Simulation Lifecycle Management Description of Files Activities in Analysis CAD Geometry Input Files File Images (displayed by passing mouse over box) Final PDF Report

27. 3DLive Turntable View for CHG Project • Expanding CAE activities into: • Application engineering • Prototype area • Testing (material data input) • Management interaction • Easy visual navigation through different analysis results • Clicking on object for more detailed information

28. SLM beyond CAE Integration of other functions through SLM Experimental link: Material data input generation Testing Correlation Validation Manufacturing link …….  SLM used everywhere where CAE content is created, used, or reviewed to support product development decisions

29. ….. SLM and Society SLM is changing: The way we do business in the simulation domain … and beyond How we communicate Real-time Visual intuitive Between engineering disciplines and other areas We have to re-evaluate the meaning of doing business with each other: What is a product really Links between customers – supplier – end user ……

30. Virtual Community • Easy access from anywhere • Transparent • Information available for everyone who needs access at any time • Virtual Engineering Communities • Tablets are being used to access systems • Apps for the simulation space will start to dominate • …

31. Conclusions • A new world and understanding of CAE is developing • All areas of engineering are becoming involved • Virtual Engineering is the direction • System Modeling and Simulationwill be at the heart of this • Simulation is part of everyone’s life • Job descriptions need to be re-written The World of iCAE is around the corner

32. Thank You!