Computational Research and Engineering Acquisition Tools and Environments (CREATE) Dr. Douglass Post CREATE Program Mana

1. Computational Research and Engineering Acquisition Tools and Environments (CREATE) Dr. Douglass Post CREATE Program Manager Chief Scientist DoD High Performance Computing Modernization Program

2. CREATE Program Concept • Enable major improvements in the acquisition process • Prevent defects and design flaws early in the acquisition process • Reduce rework thereby enabling faster system deployment • How? • Inject multi-physics based predictions early within the design and analysis process • Develop and deploy production quality design and analysis software that is adaptable and maintainable • Develop and deploy multi-physics based Computational Engineering tools that exploit next generation computer resources • CREATE is a multi-year program, funded at $40M to date • Funding started in FY2008 • Initiated by USD(AT&L) in 2008

3. CREATE – Four Projects, Ten Products • Air Vehicles • DaVinci- Rapid conceptual design • Kestrel - High-fidelity, full vehicle, multi-physics analysis tool for fixed-wing aircraft • Helios - High-fidelity, full vehicle, multi-physics analysis tool for rotary-wing aircraft • Firebolt- Module for propulsion systems in fixed and rotary-wing air vehicles • Ships • RDI - Rapid Design and Synthesis Capability—Partnership with ONR and NAVSEA • NESM - Ship Shock & Damage-prediction of shock and damage effects • NAVYFOAM - Ship Hydrodynamics-predict hydrodynamic performance • IHDE - Environment to facilitate access to Naval design tools • RF Antenna • SENTRI - Electromagnetics antenna design integrated with platforms • Meshing and Geometry • Capstone - Components for generating geometries and meshes

4. 32 Months After Program Start, CREATE Is Beginning To Deliver Usable Software. • 5 beta releases in FY09/10 with V&V and ~ 150 beta testers: • Helios 1.0—Accurate calculation of rotorcraft vortex shedding • Kestrel 1.0—Rigid body CFD fixed wing AV with preliminary aeroelastics • SENTRI 1.0 and 1.5—Initial RF antenna design and analysis with V&V • NESM 0.1—Initial ship shock vulnerability analysis for underwater explosions • IHDE 1.0—Iinitial user interface for ship hydrodynamics • 10 releases planned for FY10/11 and each succeeding year • Helios 2.0, Kestrel 2.0, SENTRI 2.0, NESM 1.0 and IHDE 2.0 plus: • Rapid design: RDI 1.0 for Ships, DaVinci 1.0 for Aircraft plus SENTRI 2.0 • Components: Capstone 1.0 for geometry and mesh, Firebolt 1.0 for gas turbines • Detailed ship hydrodynamics NavyFoam 2.0 (seakeeping, drag, resistance,…) • Developing approaches to improve scalability Antenna Radiation Near Fields Kestrel vs. F-16 Flight Data M=0.95, Alt.=10,000 ft More accurate vortex shedding Free Space

5. Path Forward • DoD has an opportunity to substantially reduce product development time • Requires adoption of multi-physics based software design and analysis tools by both government and industry • We don’t have a lot of insight into how these products can move into industry • Council on Competitiveness studies document that industry has been slow to adopt multi-physics software • How do we make this happen?

6. Back-up slides

7. Present Systems Engineering Iterated DesignBuildTest Cycles Build Physical Product Test Physical Product Requirements Design Market (Many) Design iterations F-22 Flight Test • Long time to deployment • Requires many lengthy and expensive design/build/test iteration loops • Process converges slowly, if at all • Design flaws discovered late in process

8. A Paradigm Shift in Product Development Is Underway • Past : • Repeated DesignBuildTest Cycles • Present: • Occasionally Augment DesignBuildTest with Limited Single-Physics Analysis by Use of Research or Commercial Codes • Future: • Design Through Analysis, Multi-Physics Design and Analysis with Supercomputer Power • Repeated CADMeshAnalyze Cycles Followed by a Few DesignBuildTest Cycles

9. Computer Power Testing Computational Design Weapon Capability 2010 1,000,000 GigaFlops/s Improved safety Improved robustness NIF Improved yield to weight • Increasing • Computational Design • Capability • Improvements over time: • Solution methods • Spatial resolution • Temporal resolution • Geometric fidelity • 1-D to 2-D to 3-D • Physics models • ……. MIRV (even lighter, smaller) Test ban SLBM (even lighter, smaller) Underground ICBM (lighter, smaller) Heavy Hydrogen Bombs 0.000000001 GigaFlops/s 1945 Atomic Bombs Air Tests Physics-based Engineering Software Helped The US Win Cold War. • Nuclear weapons are complex, expensive, and hard to test • ~ 5 to 10 tests per system • DOE NNSA uses computational tools for: • Design development, optimization, & analysis. • DOE NNSA labs own the biggest supercomputers

10. Critical Factors for Success • We analyzed what worked and what didn’t • Must have a lot of experience in computational engineering • Must have the right people—especially team leaders who have demonstrated that they can succeed • Must have highly skilled and experienced multi-disciplinary team • Must have stable support • We applied these principles to CREATE

11. The CREATE Approach • Software is being built by government-led teams • Each product has a roadmap • Each year there is a release of a usable application • Each release builds on the previous release and adds the increased capability called for in the roadmap • Each release is beta-tested by targeted user communities before production release • Releases are scalable for massively computers and responsive to user requirements • Users can access the applications, but we don’t plan to release source code

12. Early Success: Rapid Deployment of EP-3E • Shadow-Ops: CREATE staff use computational tools to support acquisition programs  provide experience and establish connections and value • Performed CFD analysis of impact of electronic countermeasure pod for EP-3E flight clearance--Not sufficient time for conventional process (flight tests) • Eliminated construction cost of wind tunnel model and tests and need for contractor flying quality report. • Provided aircraft flying qualities characteristics within required time frame. • Provided data required to issue flight clearance in time for direct deployment. • Reduced overall program cost and time. • Only 1 flying qualities flight test required – Saving between 3-4 flight tests. • System was deployed in the forward theatre in less than four months instead of twelve POC: Ms. Ryan Fitzgerald, FQ Engineer NAVAIR 4.3.2.5 New Forward Component

13. Another Early Success Improved Flight Certification Process for Marine Corps UAV 8 foot wingspan Engineers: Drs. Theresa Shafer / Gary N. McQuay - PMA-263 STUAS/Tier II UAS • Problem: Expensive and lengthy UAV flight certification for small-vendor designs due to physical testing required for flight data. • Solution: Joint Navy and CREATE Air Vehicles Shadow-Ops STUAS project used computational engineering tools to rapidly and cheaply develop the flight certification database. • Benefits to DoD Aircraft Programs • Reduced time and cost by eliminating the need for physical model testing • Enabled industry competitiveness through quick Services assessment of many vendor designs • Provided unbiased performance data to STUAS Program Office for assessment of contractor vehicles • Six new vendors are now able to compete for UAV contracts

14. Some companies have adopted this paradigm. Design and Mesh Virtual Product Analyze and Test Virtual Product Build and Test Physical Product Market Requirements • Reduced time to market from 3 years to less than 1 year • Increased new products delivery from 1 every 3 years to 5 per year Design iterations L. K. Miller, Simulation-Based Engineering for Industrial Competitive Advantage, 2010, Computing in Science and Engineering, 12, 14-21