7th European Altair Technology Conference
Munich / June 24-26, 2014
Radioss Multi-Domain – Innovative Simulation
Technique...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
Motivation
Radioss Mul...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Motivation: Standard vs. refine...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Motivation 4
Accurate predictio...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
Motivation
Radioss Mul...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
What is Multi-Domain 6
Split gl...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Pre-Processing / Model Set-up 7...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Multi-Domain will be efficient ...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Parallelization of Multi-Domain...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
Motivation
Radioss Mul...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Method Development / Validation...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Coupon Level 12
source...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Coupon Level / Multi-D...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Component Level 14
3PB...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Component Level 15
CAE...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level 16
...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / M...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / R...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / F...
7th European ATC / Munich / June 24-26, 2014
A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Summary 20
The Multi-Domain sim...
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RADIOSS Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations

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Lightweight design and vehicle safety are just a few challenges during the vehicle development process. They can only be achieved by using innovative CAE approaches.

In order to be able to accurately represent crash events the complexity of Finite Element models is continuously increasing. This is true for the discretisation of component geometries as well as for the description of material properties with models including advanced failure criteria (material failure and failure of any kind of joining). Such detailed full vehicle crash models for explicit solvers may become computationally very expensive.

For this reason the innovative Multi-Domain simulation process was developed by Altair for the FE code RADIOSS. It allows the simulation of complex full vehicle crash models with highly detailed components. By splitting the model in multiple domains with own explicit time steps the computational performance can be maintained compared to conventional approaches (mono-domain with a single time step).

The RADIOSS Multi-Domain approach has been implemented on the Ford Motor Company high performance computer cluster. First benchmarks at Ford R&A Europe have shown promising results, revealing a further potential within the industrial environment of crash analyses.

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RADIOSS Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations

  1. 1. 7th European Altair Technology Conference Munich / June 24-26, 2014 Radioss Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations Aleksandar Bach (Ford Research and Advanced Engineering Europe) Hüseyin Cakir Vincent Dampure (Altair Engineering GmbH)
  2. 2. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Contents Motivation Radioss Multi-Domain Approach Validation + Examples Summary 2
  3. 3. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Motivation: Standard vs. refined Mesh 3 Accurate prediction with refined mesh only Discplacement [mm] ImpactorForce CAE_STANDARD CAE_REFINED TEST
  4. 4. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Motivation 4 Accurate prediction of crash events requires increased model complexity o Local mesh refinement (shell / solid elements) o Advanced material models incl. failure criteria Increase of model size + reduction of explicit time step Increase of total CPU time beyond acceptable range of industrial applications Objectives of RADIOSS Multi-Domain approach Improve CPU time efficiency by maintaining the accuracy (compared to standard Mono-Domain approach) test CAE
  5. 5. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Contents Motivation Radioss Multi-Domain Approach Validation + Examples Summary 5
  6. 6. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) What is Multi-Domain 6 Split global model into physically equivalent “sub-domains” Each domain using its own time step (tF » tS) Force and momentum transfers between domains will be calculated by a separate program (RAD2RAD) RAD2RAD full domain (tF) sub-domain (tS) full full explicit time step t tF: full domain tS: sub-domain
  7. 7. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Pre-Processing / Model Set-up 7 User-friendly environment single input file format (since Radioss V11.0.201) - Define parts to be treated as sub-domain - Define additional engine file per sub-domain - Define cross contact between full domain and sub-domain Possible links between domains - Common nodes - Kinematic condition (/INTER/TYPE2: non-conforming meshes, beam2shell or solid2shell connections) - General contact (/INTER/TYPE7, 11, 18, 24, …)
  8. 8. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Multi-Domain will be efficient if … 8 Minimize communication between domains Size of sub-domain is less than 30% of full domain (nodes/elements) Time step ratio between full domain and sub-domain ≥ 3 Keep cross contact between full and sub-domain as small as possible Minimize size of cross contact Use only segments of full domain which are potentially impacting parts of sub-domain (manual work) Development of automated contact optimization urgently needed (development ongoing)
  9. 9. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Parallelization of Multi-Domain Architecture 9 No benefit of previous Multi-Domain release with more CPUs Due to parallelization of RAD2RAD process the performance of current Multi-Domain release was significantly improved
  10. 10. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Contents Motivation Radioss Multi-Domain Approach Validation + Examples Summary 10
  11. 11. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Method Development / Validation Procedure 11 COUPON LEVEL COMPONENT LEVEL FULL VEHICLE LEVEL SYSTEMATIC VALIDATION PROCEDURE New CAE methodologies have to be checked by systematic validation procedure in order to guarantee accuracy and robustness of application for further industrial use
  12. 12. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Coupon Level 12 source: Research project FOSTA/AVIF Nr. P 806/06/2009 / A262 / S24 / 10162/08 Frauenhofer (IWM) material properties tensile test / 22MnB5 sample Metallurgical notch is significantly impacting the crash performance
  13. 13. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Coupon Level / Multi-Domain vs. Mono-Domain 13 test data by Frauenhofer (IWM) CAE Model CAE vs. Test CAE correlates well with test data No differences between Multi-Domain and Mono- Domain simulation sub-domain full domain
  14. 14. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Component Level 14 3PB of 22MnB5 beam Geometrical notch is significantly impacting the crash performance
  15. 15. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Component Level 15 CAE vs. Test Coarse mesh is not able to predict material failure correctly Fine mesh correlates perfectly with test data No differences between Multi-Domain and Mono-Domain simulation coarse mesh (7mm) fine mesh (1mm)
  16. 16. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Full Vehicle Level 16 full domain sub-domain with detailed SW model (incl. HAZ) side impact / run with 48 CPUs full vehicle crash model number of elements ~ 2 millions element ratio: sub-domain / full domain ~ 4% time step ratio: full domain / sub-domain 2
  17. 17. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Full Vehicle Level / Multi-Domain vs. Mono-Domain time time energies intrusion 17 global energies intrusion (@ B-pillar lower) The results are comparable for the Multi-Domain and Mono-Domain simulation
  18. 18. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Full Vehicle Level / Run Time 18 „Multi-Domain #1 sub-domain in global contact side impact Mono-Domain Multi-Domain #1 global contact Multi-Domain #2 cross contact run time [h] ~ 27 ~ 100 ~ 15 Multi-Domain #2 sub-domain in cross contact slow-down 3.7 speed-up 1.8 For efficiency reasons it is essential to optimize the contact between the sub-domain and full domain Automated routine urgently required (development ongoing) major improvement
  19. 19. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Example: Full Vehicle Level / Further CPU Benchmarks 19 case number of elements element ratio sub- / full domain time step ratio full / sub-domain Speed-up Multi-/Mono 0.5 m 4% 4 3 1.2 m 2% 3 4 2.3 m 5% 4.4 / 10 3 / 4 0.35 m 20% 5 2 1.5 m 5% 7 6 CPU speed-up highly depending on modeling conditions (ratio of elements and time step, size of cross contact)
  20. 20. 7th European ATC / Munich / June 24-26, 2014 A. Bach, H. Cakir (Ford), V. Dampure (Altair) Summary 20 The Multi-Domain simulation approach is very important for Ford Multi-Domain is available and in use on Ford high performance computing cluster, improvements regarding user friendliness and performance were achieved Benchmarks on full vehicle level are showing promising potential of CPU time reduction at increased computing accuracy Next Steps Optimization of cross contact Automated mesh refinement of critical parts and part replacement in full vehicle model

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