Fostering Digital Industrial Innovation in Europe
BERLIN
17th & 18th of June 2014
Cloud based HPC simulation in advanced m...
Contents
1. Mega Trends
2.Advanced Manufacturing : Industry experiences
3. Conclusion & Outlooks
1.1. Technologies Overvie...
Copyright © ESI Group, 2014. All rights reserved.
ICT Mega Trends
Ray Kurzweil
Singularity is near
Compute power x 2 every...
Copyright © ESI Group, 2014. All rights reserved.
ICT Mega trends
Applications  Virtual Crash Test
~ .005 M
~ .5 M
~ 10 M...
Copyright © ESI Group, 2014. All rights reserved.
Movie extract
Holistic view of the value chain:
 Barrier ( safety Regulations / Region)
 Airbag & Dummies ( Safety Regulations / Regio...
Copyright © ESI Group, 2014. All rights reserved.
Performance
Human
&
Environment
Manufacturing
Control
Everybody believe ...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping:
for Concurrent Engineering
Master Design Margin to ...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : advantages
 Supply Chain : Different Domains / Te...
Copyright © ESI Group, 2014. All rights reserved.
Why Virtual Prototyping ?
Check the coupling effects
Strength, Vibro-aco...
Copyright © ESI Group, 2014. All rights reserved.
Gestamp
Industry Objectives & Use Cases
ESI
Virtual Prototyping
Platform...
Copyright © ESI Group, 2014. All rights reserved.
Fortissimo : Gestamp experiment
 Company overview
Courtesy of Gestamp
R...
Copyright © ESI Group, 2014. All rights reserved.
Competitive edge
Press Hardening  Light Weight
Scale up
 Regionalizati...
Copyright © ESI Group, 2014. All rights reserved.
Development based on a single numerical model instead of one per applica...
Copyright © ESI Group, 2014. All rights reserved.
+ Chassis
+ Engine
+ Exhaust
+ Seats
Stiffness/NVH
Analysis
Crash
Analys...
Copyright © ESI Group, 2014. All rights reserved.
USNCAP FR 56kph
(Rigidwall 100% overlap)
EURONCAP SIDE 50kph
EIGEN MODES...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Manufacturing
 Hot forming value chain (AP&T)
Movie extract
Copyright © ESI Group, 2014. All rights reserved.Heating Oven ( > 1000°C) Secured Automated Production Line
Movie : Courte...
ProductionLine
VirtualPrototype
Hot Forming Simulation
(Press Hardening)
Phase transformation control Cooling System Desig...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Body Manufacturing
 Next Challenges to secure competitive Mfg.
...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : Aero
 Expliseat Success Story
Reference:
Explisea...
Copyright © ESI Group, 2014. All rights reserved.
Virtual Prototyping : Aero
 Expliseat Experience
Copyright © ESI Group, 2014. All rights reserved.
Reference:
Expliseat – EGF 2014
Virtual Prototyping : Aero
 Expliseat E...
Copyright © ESI Group, 2014. All rights reserved.
Better test
Virtual Test
Virtual Prototyping
Virtual Engineering
Benefit...
Copyright © ESI Group, 2014. All rights reserved.
Private
Investment
Co-Creation
Public-Private
Investment
Co-Creation
Aut...
THANK YOU
FOR YOUR ATTENTION
Dr.-Ing. Fouad el KHALDI
Email: fouad.el.khaldi@esi-group.com
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Fouad el KHALDI | Cloud based HPC simulation in advanced manufacturing

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Fouad el KHALDI | Cloud based HPC simulation in advanced manufacturing

  1. 1. 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. 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. 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. 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
  5. 5. Copyright © ESI Group, 2014. All rights reserved. Movie extract
  6. 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
  7. 7. Copyright © ESI Group, 2014. All rights reserved. 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. 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. 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
  10. 10. Copyright © ESI Group, 2014. All rights reserved. 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
  11. 11. Copyright © ESI Group, 2014. All rights reserved. Gestamp Industry Objectives & Use Cases ESI Virtual Prototyping Platform & Methodology Bull Cloud Based HPC Fortissimo : Gestamp experiment
  12. 12. Copyright © ESI Group, 2014. All rights reserved. Fortissimo : Gestamp experiment  Company overview Courtesy of Gestamp Ref : EGF – May 2014
  13. 13. Copyright © ESI Group, 2014. All rights reserved. Competitive edge Press Hardening  Light Weight Scale up  Regionalization Fortissimo : Gestamp experiment  Company overview & challenges Courtesy of Gestamp Ref : EGF – May 2014
  14. 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
  15. 15. Copyright © ESI Group, 2014. All rights reserved. + Chassis + Engine + Exhaust + Seats Stiffness/NVH Analysis Crash Analysis Fortissimo : Gestamp experiment  Industrial Relevance
  16. 16. Copyright © ESI Group, 2014. All rights reserved. USNCAP FR 56kph (Rigidwall 100% overlap) EURONCAP SIDE 50kph EIGEN MODES Analysis Fortissimo : Gestamp experiment  Work In Progress
  17. 17. Copyright © ESI Group, 2014. All rights reserved. Virtual Manufacturing  Hot forming value chain (AP&T) Movie extract
  18. 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)
  19. 19. ProductionLine VirtualPrototype Hot Forming Simulation (Press Hardening) Phase transformation control Cooling System Design Transfer line Continuous feeding Press forming Movie : Courtesy of AP&T
  20. 20. Copyright © ESI Group, 2014. All rights reserved. Virtual Body Manufacturing  Next Challenges to secure competitive Mfg. Fatigue evaluation StrengthBush insert Paint baking Weldingholding Weldingholding TrimmingStamping TrimmingStamping TrimmingStamping
  21. 21. Copyright © ESI Group, 2014. All rights reserved. Virtual Prototyping : Aero  Expliseat Success Story Reference: Expliseat – EGF 2014 Established : 2011 Product Certification : 2014
  22. 22. Copyright © ESI Group, 2014. All rights reserved. Virtual Prototyping : Aero  Expliseat Experience
  23. 23. Copyright © ESI Group, 2014. All rights reserved. Reference: Expliseat – EGF 2014 Virtual Prototyping : Aero  Expliseat Experience
  24. 24. Copyright © ESI Group, 2014. All rights reserved. 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. 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. 26. THANK YOU FOR YOUR ATTENTION Dr.-Ing. Fouad el KHALDI Email: fouad.el.khaldi@esi-group.com

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