The Ohio Supercomputer Center Blue Collar Computing Initiative

1. The Ohio Supercomputer Center Blue Collar Computing Initiative Stanley C. Ahalt, Ph.D. Executive Director April 21, 2009

2. Organization of Talk • Three programs within OSC • Blue Collar Computing Initiative • Instrument and Analytics Services • Ralph Regula School for Computational Science • Some Lessons Learned • Questions

3. Blue Collar Computing: a focused industrial solution OSC introduced the idea of Blue Collar Computing at SC2004 Invited Talk: Towards a High Performance Computing Economy: Blue Collar Computing Presented by: Stanley C. Ahalt, Ph.D., Ohio Supercomputer Center Pittsburgh, Pa., November 6-12, 2004 Blue Collar Computing (BCC) provides industrial clients with supercomputing resources, training, and expertise to enhance their competitiveness

4. Industry Competitiveness Transformation Challenge Filling the Expertise Gap National Labs, University HPC Centers & Commercial HPC Services Moving Users Forward Number of Applications Number of Users Never Ever Users National Productivity Opportunity Entry Level HPC Users World Class/Leadership Computing Leading HPC Users (Heroes) Experienced Industry HPC Users 0 1 2 4 64 Nodes 1,000 10,000+ Adapted from OSC Graphics Council and USC ISI Proprietary

5. Blue Collar Computing: Filling in the missing middle

6. Two classes of industrial clients: Experienced HPC users who need access to larger systems for specific tasks (“peaking” facility) Users new to HPC who want to solve a specific problem and typically do not want to deal with the complexity of using HPC BCC approach to novice – and some experienced – users is to develop industry-specific portals in collaboration with industry trade groups and industry-focused consulting firms Blue Collar Computing now focused on novice and experienced industrial uses

7. Edison Welding Institute: An Ohio Success Story EWicreates high-paying manufacturing technology-based jobs in Ohio: Total Return on Ohio’s Investment in EWi:$305,005,000 • 136 current employees • >65% engineers and technicians • >50% advanced degrees • >7 years average tenure • $84,000 average compensation EWifuels manufacturing technology advancement for companies throughout Ohio: • 149 Ohio companies • 234 Ohio manufacturing plants • 6 Ohio regions

8. E-Weld Predictor: Partnership between OSC and Edison Welding Institute (EWi) E-Weld Predictor is accessed using a web browser

14. E-Weld Predictor Example Output

15. E-Weld Updated Features • New weld geometries • Bead on plate, Bevel Groove, Compound Bevel • Weld bead customization • Weld engineer can shape and place weld beads for use in virtual prototype • Automatic bead recognition • Weld engineer can use image of existing weld cross-section to create a weld bead

16. Yes Customer Needs (Re-) Design the Tire (Re-) Design the Part Build a Prototype Build a Prototype Test the Prototype Test the Prototype Release to Production OK? OK? No Use Experience & Empirical Rules Generate a Numerical Model Analyse the Model Customer Needs (Re-) Design the Part Build a Prototype Yes OK? No Test the Prototype Use Experience & Numerical Results No OK? Yes Release to Production Modeling and Simulation in the Design Process Explore Digitally… …Confirm Physically From Loren Miller (Goodyear) And Tom Lange (P&G)

17. Polymer Portal - Partnership between OSC and Polymer Ohio Polymers and plastics is a large industry sector in Ohio (2800 companies, 175,000 employees), est. $49B industry Many are Tier 2 and Tier 3 suppliers Many have adopted automation (“lights out” operation) in the manufacturing process Most do not use modeling and simulation The polymer portal will provide: Access to expertise in polymer science and engineering Computational resources and software for modeling and simulation Databases with relevant material properties Access to Advanced instrumentation Training Vendor relevant material Business intelligence and strategy

19. Polymer Portal Computational Application: Prediction of Nanofiber Composite Processing • Problem: Carbon nanofibers are added to compound before mixing and extrusion to improve material properties. The mixing breaks up the nanofibers, and this affects the final material properties • Proposed solution: Use multi-physics modeling and simulation to identify optimum processing routes for nanotechnology based fiber composites

20. DARPA Pilot: HMMWV CHASSIS WEIGHT REDUCTION OSC Approach • Genesis v10 is designed to fully exploit large scale SMP systems such as SGI Altix 3000. • Full 64-bit support means Genesis can optimize full vehicle models rather than only components. • Genesis can exploit dozens of processors using SMP parallel to optimize large systems 10x faster than the fastest desktop workstations • GENOA performs: • Composite Material characterization and uncertainty evaluation during service • Life assessment of the structure, durability and damage tolerance analysis/optimization • Reliability based evaluation/optimization • Building block verification for certification DESCRIPTION • SOCOM has recently awarded a Phase I SBIR to Alpha STAR Corporation to design, develop, fabricate and test structural driveline and chassis components to decrease the fixed mass of the Expanded Capacity Vehicle HMMWV. • Components for future production and current retrofit (aftermarket) will be conceptually evaluated. • Solution will include an advanced composite material to decrease weight. TECHNICAL APPROACH • A Value Analysis Value Engineering workshop will be conducted to rank potential candidate redesigns. • GenesisTM, an analysis and optimization FEA package from Vanderplaats R&D, will be used to perform the shape and design optimization to maximize weight savings most efficiently. • GENOATM, a Progressive Failure Analysis FEA package from Alpha STAR, will be utilized to ensure the redesigns will possess the fatigue or durability /reliability requirements for the field. • SOCOM will perform the field testing. MILESTONES AND DELIVERABLES • Phase I Month 3 – Run VAVE and Identify and Rank potential candidates for redesign. • Phase I Month 6 – Develop conceptual designs and business plan for technology commercialization • Phase II – Fabricate prototypes, test, confirm, and kick-off production. Desktop-Only Approach • Limited desktop computing resources, although greater in recent years, are limited to Quad CoProcessors and 8 GB RAM on the best of systems (64 bit OS). • This results in having to produce subassemblies, make assumptions on boundary conditions, optimize under these conditions, then plug subassembly change back into whole assembly for verification.

21. Status Quo and Opportunities • Current methods of replacing steel components with composite redesigns include: • Analysis of individual steel components • Obtain strength and stiffness matrices • Requires assumptions of boundary conditions and loading paths • Redesign with composite properties including shape and size optimization • Because metals are higher in moduli, geometry changes are often required to match part stiffness • Testing composite redesign in subsystem model to measure effects on neighboring parts • Optimization and testing with HPC • Enables composite design optimization across entire subsystems • Eliminates need for assumptions on boundary conditions and loading paths

22. Organization of Talk • Three programs within OSC • Blue Collar Computing • Instrument and Analytics Services • Ralph Regula School for Computational Science • Some Lessons Learned • Questions

23. OSC Instrumentation and Analytics Services • Remote instrumentation uses OSC’s state-wide resources • Networking, Storage, HPC, Analytics (web service)

24. Growing need for managing and analyzing data in many science and engineering areas Collaboration across geographically distributed teams essential for most research areas Cross-Collaboration between academia and industry increasingly important Many funding agencies require cyber-enabling research instruments and sensors For most researchers, developing, deploying and maintaining the required IT infrastructure takes away from doing the science OSC is well-positioned to provide the SHARED cyber-infrastructure that Ohio researchers can take for granted and simply use: Networking, Computing, Storage Motivation for Instrument & Analytic Services (IAS)

25. Remote Operation of Scanning Electron Microscope: Partnership betweenTimken Steel, Stark State University, Ohio State University and OSC Timken steel able to develop and improve products through remote use of high powered electron microscope Timken leveraged OSCnet connection between the OSU Center for Accelerated Maturation of Materials and Stark State

26. Portal for CAMM data harvesting and analysis

27. Parallel processing of image data sets • Parallel computation using Mathworks Distributed Computing Engine • 396 files processed in 6 minutes on 16 processors

28. Organization of Talk • Three programs within OSC • Blue Collar Computing • Instrument and Analytics Services • Ralph Regula School for Computational Science • Some Lessons Learned • Questions

29. Training and Education for Faculty & Students • Frequent free workshops assist faculty and graduate students with advanced research • Since July 1, 2005: 171 OSU faculty, researchers and students from 52 departments have attended 27 computational science workshops taught at OSC • New programs promote STEM education through project-based, interdisciplinary materials • Undergraduate minor in computational science • Certificate programs for workforce development • Collaborative efforts connect OSU with statewide and national communities • NSF supercomputing centers • DOD shared resource centers • DOE national labs

30. RRSCS Minor Program Overview • Undergraduate minor program • 6-8 courses per year • 2-year degree: minor in computational science • Instructional modules created from a matrix, competencies • Opportunities for other faculty to fill in with new modules, where necessary

31. Expanding RRSCS to Reach More Students and Current Employees • On March 31, 2008 NSF awarded $1M to OSC, OSU, and U Akron for workforce education in cyberinfrastructure • Associate degree in science with concentration in computational science • Grant from NSF with Owens, Sinclair, and Stark State • Funding from Board of Regents • Choose Ohio First Bioinformatics Scholarship Program awarded March 18, 2008 • Summer Academy in Computational Science and Engineering awarded February 19, 2008

32. Expert in Applications Engineers/ scientists in university and business Applying protein folding simulations to discover candidates for new drugs Certificate and graduate programs; OSC training courses Understand use of modeling for business and research Current workforce College graduates Using commercial computational package or service to test strength of new container design Certificate program Undergraduate minor program OSC training program Applying models to engineering and architecture fields Ohio PLTW students and teachers Modeling simple physics phenomena: statics, gravity, pendulum PLTW training course for teachers; course given to students Education: Building a workforce competent in computational science Level Audience Example Programs Cause and effect relationships and simple modeling principles Middle and high school students and teachers Model of disease transmission in human population Teacher professional development programs; workshops for middle and high school students

33. Organization of Talk • Three programs within OSC • Blue Collar Computing • Instrument and Analytics Services • Ralph Regula School for Computational Science • Some Lessons Learned • Questions

34. Phase Three Executive Summary • HPC focus must change from economic development to facilitating economic competitiveness • New metrics must be developed to measure improvements in economic competitiveness so HPC contributions can be identified • Supercomputing centers must market to and better support corporate users • Economic development focus has changed from the creating jobs to technology development and commercialization for long-term sustainable competitive advantage • Government should concentrate on creating collaborative networks between public and private sector players, fostering innovation and commercialization of new ideas, attracting investment in knowledge-based industries, and providing access to critical services for new value-add jobs • Ohio should shift its focus from the traditional measure of job creation within manufacturing industries to efforts that support the development of science and technology resources within the state • Joining and Biosciences are still the top priorities for BCC OSC BCC Economic Competitiveness Assessment | 4/21/2009

35. Traditional Economic Development Focuses on growth of jobs in industrial enterprises Manufacturing Distribution Transportation Sensitive to transportation, site selection, labor Facing tough competition from low labor cost regions Government assists with zoning, site selection, hard infrastructure and tax concessions Economic development has begun to transform as markets and industries become more and more competitive Collaborative Economic Competitiveness • Focuses on intellectual capital driven industries • Research • Technology • Services • Sensitive to access to ideas, collaboration, venture capital • Less susceptible to globalization • Government assists with value networks to promote collaboration and access to critical services Ohio must define and implement new strategies to be successful. Competitiveness in innovation and technology driven strategy will play a vital role in creating an impact on economic development in the state. OSC BCC Economic Competitiveness Assessment | 4/21/2009

36. Some Lessons Learned as an Academic Supercomputer Center • It is now clear that HPC can improve Economic Competitiveness – across the industrial spectrum. Eventually we will develop a healthy “industrial” HPC ecosystem. Economic Competitiveness feeds Economic Development. • “BCC” is a social experiment. The technology is not the most challenging issue, except at the adoption stage. • Economic development is both a contact sport and a team sport. OSC does not have a “sales” force, and teaming is critical. • Success appears to require that you work the problem along many facets (HPC, portals, software, consulting, instruments, training) and along the entire pipeline (small to large, novice to expert). This is hard to staff! • Choose the right partners – they will help you reach the community and help you understand requirements (CoC, Ewi, Goodyear, IBM, NCSA, Nimbis, P&G) • Academia and industry can use HPC as a connector – both benefit! • Commercial software and licensing is a HUGE bottleneck • Engage with your state economic development agency early. OSC is now required to do economic development – it’s the law. • Workforce development is very important. (leads to insatiable appetites!) • Clearly understand your costs, your value proposition, and your market if you want to provide industrial support. You have to have capabilities that people want. • We welcome partnerships.

37. LawrenceLivermoreNational Laboratory OSC Partnerships:Academic & Non-Profit Partners

38. OSC Partnerships:Business & Industry

39. Questions?

40. Login page

41. Weld Geometry Selection

42. Bead Placement Tool

43. Elliptical Bead Placement

44. Parabolic bead placement

45. Complex Bead Placement

46. Bead Finder

47. Bead Finder Image Selection

48. Bead Finder: Region Selection

49. …after image recognition

50. Find Bead bitmap