Contenu connexe Similaire à Fouad el KHALDI | Cloud based HPC simulation in advanced manufacturing (20) Fouad el KHALDI | Cloud based HPC simulation in advanced manufacturing1. Fostering Digital Industrial Innovation in Europe
BERLIN
17th & 18th of June 2014
Cloud based HPC simulation in advanced manufacturing
Dr.-Ing. Fouad el KHALDI, Industry Strategy & Innovation General Manager, ESI GROUP(FR)
2. Contents
1. Mega Trends
2.Advanced Manufacturing : Industry experiences
3. Conclusion & Outlooks
1.1. Technologies Overview
1.2. Industry Challenges & Opportunities
1.2. Automotive : Gestamp / Fortissimo experiment
2.2 Manufacturing : AP&T
2.3 Aeronautic : Expliseat (SME)
3. Copyright © ESI Group, 2014. All rights reserved.
ICT Mega Trends
Ray Kurzweil
Singularity is near
Compute power x 2 every 18 months
Challenges
&
Opportunities
4. Copyright © ESI Group, 2014. All rights reserved.
ICT Mega trends
Applications Virtual Crash Test
~ .005 M
~ .5 M
~ 10 M
~ 20 M
DACIA Lodgy
2013
Optimistic Moore:
Y = 1.5 Years
Virtual Crash Test : 30 Y of innovation experience
Better Test
Virtual Test
Leverage
ICT, HPC
&
Cloud,
etc
CloudComputing
6. Holistic view of the value chain:
Barrier ( safety Regulations / Region)
Airbag & Dummies ( Safety Regulations / Region)
Complex interactions ( Cause & Effects, …)
BIW
Full integrated Vehicle (BIW, Closers, Engine, transmission, …)
Enable collaborative Decision Support for the Stakeholders (Trade-offs, …)
Virtual Crash: State of Art
Courtesy of Audi
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Performance
Human
&
Environment
Manufacturing
Control
Everybody believe in test results except the test engineer !
Typical Tests : Automotive
Mostly One Domain Test - Expect final product !
Major Shortfall Overall Tradeoff & MDO
8. Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping:
for Concurrent Engineering
Master Design Margin to enable reliable Trade-Offs (Regionalization; Manufacturing,…)
Coupling & Cause-Effect upfront (before prototype test)*
Transformation : Leverage HPC & Focus Experts on Value Added Tasks
9. Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : advantages
Supply Chain : Different Domains / Teams / Locations
Painting
Casting
CFD
Safety
Vibration
ComfortWelding
Virtual Prototype
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Why Virtual Prototyping ?
Check the coupling effects
Strength, Vibro-acoustics, durability,…
Control the fabrication defects
Manufacturability, tolerances, materials
Design Performance (Verif. & Valid.)
Normal use, mis-use, accidental conditions
Enables Concurrent & Upfront Decisions
Marketing, Engineering, Assembly, C level,…1
3
4
2
“All models are wrong … but some are useful”
…“within identified circumstances and limits”
1
2
3
4
1
2
3
4
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Gestamp
Industry Objectives & Use Cases
ESI
Virtual Prototyping
Platform & Methodology
Bull
Cloud Based HPC
Fortissimo : Gestamp experiment
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Fortissimo : Gestamp experiment
Company overview
Courtesy of Gestamp
Ref : EGF – May 2014
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Competitive edge
Press Hardening Light Weight
Scale up
Regionalization
Fortissimo : Gestamp experiment
Company overview & challenges
Courtesy of Gestamp
Ref : EGF – May 2014
14. Copyright © ESI Group, 2014. All rights reserved.
Development based on a single numerical model instead of one per application
Time saving
Converging model versions for several test cases
Synchronization of CAE and CAD models
Application 1 : Frontal Crash Application 2 : Side Crash Application 3 & 4 : Stiffness / NVH
Evolution
&
Maintenance
Fortissimo : Gestamp experiment
Industrial Relevance
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+ Chassis
+ Engine
+ Exhaust
+ Seats
Stiffness/NVH
Analysis
Crash
Analysis
Fortissimo : Gestamp experiment
Industrial Relevance
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USNCAP FR 56kph
(Rigidwall 100% overlap)
EURONCAP SIDE 50kph
EIGEN MODES Analysis
Fortissimo : Gestamp experiment
Work In Progress
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Virtual Manufacturing
Hot forming value chain (AP&T)
Movie extract
18. Copyright © ESI Group, 2014. All rights reserved.Heating Oven ( > 1000°C) Secured Automated Production Line
Movie : Courtesy of AP&T
Virtual Manufacturing
Hot forming value chain (AP&T)
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Virtual Body Manufacturing
Next Challenges to secure competitive Mfg.
Fatigue
evaluation
StrengthBush insert
Paint
baking
Weldingholding
Weldingholding
TrimmingStamping
TrimmingStamping
TrimmingStamping
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Virtual Prototyping : Aero
Expliseat Success Story
Reference:
Expliseat – EGF 2014
Established : 2011
Product Certification : 2014
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Virtual Prototyping : Aero
Expliseat Experience
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Reference:
Expliseat – EGF 2014
Virtual Prototyping : Aero
Expliseat Experience
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Better test
Virtual Test
Virtual Prototyping
Virtual Engineering
Benefits
Time
Simulation Model & data
Simulation Process
Knowledge's
Engineering
Knowledge's
Business & Engineering
Isolated silos
Disruptive
&
Transformation
Major
challenges
&
Opportunities
!
Conclusion & Outlook
Simulation is not a tool, it is transformation vector
25. Copyright © ESI Group, 2014. All rights reserved.
Private
Investment
Co-Creation
Public-Private
Investment
Co-Creation
Automotive
Aero
Energy
Medical & Health Care
Education
Education, …
Efficient, Scalable & Sustainable Ecosystem
Enables Pull & Push Process to foster Innovation
Major Challenges & Opportunities !
Conclusion & Outlook
Simulation is not a tool, it is transformation vector
Industry : Competitiveness & Attractiveness
26. THANK YOU
FOR YOUR ATTENTION
Dr.-Ing. Fouad el KHALDI
Email: fouad.el.khaldi@esi-group.com