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Structural Optimization Using the New RBF Morph ANSYS ACT Extension

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Marco E. Biancolini
Marco E. Biancolini

This document describes an ACT extension for ANSYS Mechanical that allows structural mesh morphing using Radial Basis Functions (RBF). The extension is developed by RBF Morph and integrated into ANSYS Mechanical with the same look and feel. It uses a hierarchical multi-step RBF approach to control mesh morphing. Various geometric modifications like translation, scaling, rotation, and surface/curve targeting can be applied to morph meshes parametrically. The extension leverages high performance RBF solvers for fast morphing of large meshes.

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www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Structural Optimization Using the New RBF Morph ANSYS ACT Extension Prof. Marco Evangelos Biancolini University of Rome Tor Vergata act@rbf-morph.com biancolini@ing.uniroma2.it
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Company Introduction • RBF Morph Software Line • ACT Extension • Industrial Applications Outline
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph is a pioneer and world-leading provider of numerical morphing techniques and solutions conceived to efficiently handle shape optimization studies concerning most challenging industrial applications. We are an independent software-house and vendor. Our main product is RBF Morph™, that is a unique morpher that combines a very accurate control of the geometrical parameters with an extremely fast mesh smoothing properly designed to be integrated in advanced computational optimization procedures. The RBF Morph tool is currently available in the market as an add-on of the CFD commercial code ANSYS® Fluent®, as a stand alone product and as an ANSYS ACT Extension. Company Introduction
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA The RBF Morph tool had its inception in 2008 as on-demand solution for a Formula 1 top team. The need was a novel technology able to change the shape of large CFD numerical models as fast as possible. The final result had been so good that the technology was packaged in a commercial software product and launched onto the market. At present, Dr. Marco Evangelos Biancolini is the unique owner of the RBF Morph technology and, as Director, avails himself of the collaboration of several experts for the deliver of products and services. Company Introduction
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA  Morphing-based numerical tools and services  RBF Morph Milestones  2008: tool implementation for Formula 1 top team consultancy activity  2009: founded in Italy  2009: Software Partner of ANSYS  2009: at EASC RBF Morph won the Most Advanced Approach Award Most Innovative Approach using Simulation Methods  2011: strategic partnership with Tor Vergata University (Rome)  2012: OEM partner of ANSYS  2013: beneficiary of an FP7 AAT Project RBF4AERO  2013: at ASWC RBF Morph awarded for the Best use of HPC  2013: Partner of Enginsoft  2014: beneficiary of FP7 Project RIBES  2014: beneficiary of FP7 Fortissimo Company Introduction
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Knowledge Galaxy
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph software line
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Mesh Morphing with RBF • A system of Radial Basis Functions is used to fit a solution for the mesh movement/Morphing, from a list of source points and their displacements. • The RBF problem definition does not depend on the mesh • Radial Basis Function interpolation is used to derive the displacement in any location in the space, each component of the displacement is interpolated: • RBF are recognized as on of the best mathematical tool for mesh morphing. The main issue is about performances required for the solution of large dataset.                              zyxsv zyxsv zyxsv zzzz N i k z izz yyyy N i k y iyy xxxx N i k x ixx i i i 4321 1 4321 1 4321 1    xxx xxx xxx
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA One pt at center and border (80 pts)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Effect on surface (gs-r)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Effect on surface (cp-c4)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Control of volume mesh (1166 pts)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Morphing the volume mesh
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • HPC RBF general purposes library (state of the art algorithms, parallel, GPU). This is the numerical kernel of our software. Millions of RBF centers can be fitted in a short time. • Awarded mesh morphing software available as an add-on for ANSYS Fluent CFD solver • Stand alone morphing software + smoothing commands for different mesh formats • ANSYS Mechanical ACT module (Released in May 2015!). RBF Morph software line
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Add on fully integrated within Fluent (GUI, TUI & solving stage), Workbench and Adjoint Solver • Mesh-independent RBF fit used for surface mesh morphing and volume mesh smoothing • Parallel calculation allows to morph large size models (many millions of cells) in a short time • Management of every kind of mesh element type (tetrahedral, hexahedral, polyhedral, etc.) • Support of the CAD re-design of the morphed surfaces • Multi fit makes the Fluent case truly parametric (only 1 mesh is stored) • Precision: exact nodal movement and exact feature preservation (RBF are better than FFD) Fluent add-on
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • RBF solutions are fully compatible and exchangeable between add-on and standalone versions • Support for STL and CGNS file formats. Selected morphed surfaces can be exported in STL format and back to CAD is possible via STEP files • Add-on-like interface • Solver independent process currently supports many mesh formats • Functions scriptable via tcl • Global supported bi-harmonic functions and C0, C2, C4 compact supported functions available RBF Morph Stand Alone
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Deeply integrated in ANSYS Mechanical: same look & feel, same interaction logic • Nested in the usual Mechanical tree as an added object, shares its scoping tools for geometrical and mesh elements selections • Written in python and xml, uses external RBF Morph core libraries • Child hierarchical logic for complex morphings (two steps, three steps, …, n steps setups) ACT module for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA ACT Extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Why FEM mesh morphing? • It allows to have parametric shape mesh that preserves the original topology. Remeshing noise is avoided. • It allows to update the shape of a validated FEM model without rebuilding a new mesh. • New shapes can be investigated even if the underlying CAD geometry is missing. • The mesh can be updated to measured shapes (i.e. accounting for manufacturing tolerances) • It’s usually faster than remeshing (short time required to morph, quick set-up of shape variations)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Why RBF morphing? • RBF Morph is a best in class product crafted to deal with challenging CFD application (huge meshes) • 7 years of experience on industrial applications of Radial Basis Functions (RBF) • RBF are recognized as one of the best mesh morphing tool available in the industrial and scientific community • A new vision (we have started the new project from scratch) to put in the hands of ANSYS Mechanical Users the fastest and easiest mesh morphing tool • Satisfy the needs of many users asking for such a kind of technology available in ANSYS Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Video number 1 https://youtu.be/KxZzq0F3mQ8
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • The evaluation of RBF at a point has a cost of order n. • The fit has a cost of order n3 for a direct fit (full populated matrix); this limit to ~10.000 the number of source points that can be used in a practical problem. • Using an iterative solver (with a good pre-conditioner) the fit has a cost of order n2; the number of points can be increased up to ~70.000. • With parallelization and fast RBF methods (OpenMP GPU) we are able to scale up to very large problems Accelerating the solver
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Size: 160.000 nodes CPU: 497 s CPU OMP: 53 s K2000: 55 s K40: 34 s Registered Time Conrod testcase
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Fully embedded in ANSYS Mechanical with same “look & feel” • Integration in the tree and founded on the working principles of ANSYS Workbench • Based on the ACT (Application Customization Toolkit) extension concept • Geometrical and mesh scoping to set-up the mesh morphing problem • Parametric • RBF fast solver (including parallel and GPU support) ACT extension specs
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Easy to use, flexible and expressive. • Powered by multi-step RBF technology (which effectiveness has been extensively proven in RBF Morph) • RBF fitting and mesh morphing happen as a unique HPC process at each shape update. This allows the maximum flexibility with respect to parameterization • RBF component set-up data stored and persistent with the ANSYS Mechanical project. • Advanced interaction with DM to enable CAD resynchronization after morphing ACT extension specs
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Hierarchical multi-step RBF approach • Each morphing target can be controlled using the superposition of a local modifier and an RBF field generated by its sources (if any) • Source points are extracted using the motion of all the children • If the child is a leaf its movement is known otherwise it becomes a target and has to be solved descending the tree ACT extension specs
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Translation
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Translation
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Scaling
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Scaling
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Rotation
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Rotation
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface offset
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface offset
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve offset
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve offset
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve targeting
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve targeting
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Morphed mesh! RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Inspection of the morphing field using post processing tools of Mechanical. RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Automatic sculpting using field data available in the FEA solution. RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now manually it will be automated. RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now manually it will be automated. RBF Morph ACT extension for Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Industrial Applications
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • Practical problem example: a connecting rod optimization. • Geometry in Solidworks. Meshing, parameterization (RBF Morph) and structural analysis in Workbench. 161493 nodes mesh. • The shape of the two lightening holes is varied, translating and resizing them
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • Offset+rigid translation for the holes • Null movement for other surfaces
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • 2395 N traction load acting on big head • Titanium Ti-6Al-4V (Grade 5) • Cumulated damage map over the testing spectrum
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod Optimized 334.4g (-6.7%) Original 358.7g
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study The objective here is to show how RBF Morph can be used in BGA Solder Joint Reliability simulations to show how geometric parameters can be morphed to itemize their effect on stress calculations DIE DIE UNDERFILL MOLD COMPOUND SUBSTRATE SOLDER BALLS PCB
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study 12 3 2 3 1
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study Baseline Optimized (22% stress reduction)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study Baseline Optimized (22% stress reduction)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Load Scenario representing TUV test simulated using ANSYS Mechanical
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Baseline 7.58kg
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Optimized 6.98kg (-8%)
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • The novel mesh morphing tool implemented in ANSYS Mechanical using ACT extension technology has been introduced • Radial Basis Functions are used for multistep set-up • The new software tailored for FEM benefits of past experience on RBF Morph ANSYS Fluent add-on (mainly CFD) • Nevertheless we have restarted all the developments from scratch i.e. reusing knowledge and ideas (no cross compatibility between tools) • Applications relevant for the automotive industry are demonstrated. • The software has been released in May 2015 • How can we do better? Please do not hesitate to tell us your needs! Conclusions
www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Many thanks for your kind attention! Prof. Marco Evangelos Biancolini E-mail: act@rbf-morph.com Web: www.rbf-morph.com Goo.gl/1svYd Twitter.com/RBFMorph linkedin.com/company/rbf-morph youtube.com/user/RbfMorph

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Structural Optimization Using the New RBF Morph ANSYS ACT Extension

  • 1. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Structural Optimization Using the New RBF Morph ANSYS ACT Extension Prof. Marco Evangelos Biancolini University of Rome Tor Vergata act@rbf-morph.com biancolini@ing.uniroma2.it
  • 2. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Company Introduction • RBF Morph Software Line • ACT Extension • Industrial Applications Outline
  • 3. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph is a pioneer and world-leading provider of numerical morphing techniques and solutions conceived to efficiently handle shape optimization studies concerning most challenging industrial applications. We are an independent software-house and vendor. Our main product is RBF Morph™, that is a unique morpher that combines a very accurate control of the geometrical parameters with an extremely fast mesh smoothing properly designed to be integrated in advanced computational optimization procedures. The RBF Morph tool is currently available in the market as an add-on of the CFD commercial code ANSYS® Fluent®, as a stand alone product and as an ANSYS ACT Extension. Company Introduction
  • 4. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA The RBF Morph tool had its inception in 2008 as on-demand solution for a Formula 1 top team. The need was a novel technology able to change the shape of large CFD numerical models as fast as possible. The final result had been so good that the technology was packaged in a commercial software product and launched onto the market. At present, Dr. Marco Evangelos Biancolini is the unique owner of the RBF Morph technology and, as Director, avails himself of the collaboration of several experts for the deliver of products and services. Company Introduction
  • 5. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA  Morphing-based numerical tools and services  RBF Morph Milestones  2008: tool implementation for Formula 1 top team consultancy activity  2009: founded in Italy  2009: Software Partner of ANSYS  2009: at EASC RBF Morph won the Most Advanced Approach Award Most Innovative Approach using Simulation Methods  2011: strategic partnership with Tor Vergata University (Rome)  2012: OEM partner of ANSYS  2013: beneficiary of an FP7 AAT Project RBF4AERO  2013: at ASWC RBF Morph awarded for the Best use of HPC  2013: Partner of Enginsoft  2014: beneficiary of FP7 Project RIBES  2014: beneficiary of FP7 Fortissimo Company Introduction
  • 6. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Knowledge Galaxy
  • 7. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph software line
  • 8. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Mesh Morphing with RBF • A system of Radial Basis Functions is used to fit a solution for the mesh movement/Morphing, from a list of source points and their displacements. • The RBF problem definition does not depend on the mesh • Radial Basis Function interpolation is used to derive the displacement in any location in the space, each component of the displacement is interpolated: • RBF are recognized as on of the best mathematical tool for mesh morphing. The main issue is about performances required for the solution of large dataset.                              zyxsv zyxsv zyxsv zzzz N i k z izz yyyy N i k y iyy xxxx N i k x ixx i i i 4321 1 4321 1 4321 1    xxx xxx xxx
  • 9. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA One pt at center and border (80 pts)
  • 10. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Effect on surface (gs-r)
  • 11. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Effect on surface (cp-c4)
  • 12. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Control of volume mesh (1166 pts)
  • 13. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Morphing the volume mesh
  • 14. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • HPC RBF general purposes library (state of the art algorithms, parallel, GPU). This is the numerical kernel of our software. Millions of RBF centers can be fitted in a short time. • Awarded mesh morphing software available as an add-on for ANSYS Fluent CFD solver • Stand alone morphing software + smoothing commands for different mesh formats • ANSYS Mechanical ACT module (Released in May 2015!). RBF Morph software line
  • 15. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Add on fully integrated within Fluent (GUI, TUI & solving stage), Workbench and Adjoint Solver • Mesh-independent RBF fit used for surface mesh morphing and volume mesh smoothing • Parallel calculation allows to morph large size models (many millions of cells) in a short time • Management of every kind of mesh element type (tetrahedral, hexahedral, polyhedral, etc.) • Support of the CAD re-design of the morphed surfaces • Multi fit makes the Fluent case truly parametric (only 1 mesh is stored) • Precision: exact nodal movement and exact feature preservation (RBF are better than FFD) Fluent add-on
  • 16. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • RBF solutions are fully compatible and exchangeable between add-on and standalone versions • Support for STL and CGNS file formats. Selected morphed surfaces can be exported in STL format and back to CAD is possible via STEP files • Add-on-like interface • Solver independent process currently supports many mesh formats • Functions scriptable via tcl • Global supported bi-harmonic functions and C0, C2, C4 compact supported functions available RBF Morph Stand Alone
  • 17. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Deeply integrated in ANSYS Mechanical: same look & feel, same interaction logic • Nested in the usual Mechanical tree as an added object, shares its scoping tools for geometrical and mesh elements selections • Written in python and xml, uses external RBF Morph core libraries • Child hierarchical logic for complex morphings (two steps, three steps, …, n steps setups) ACT module for Mechanical
  • 18. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA ACT Extension for Mechanical
  • 19. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Why FEM mesh morphing? • It allows to have parametric shape mesh that preserves the original topology. Remeshing noise is avoided. • It allows to update the shape of a validated FEM model without rebuilding a new mesh. • New shapes can be investigated even if the underlying CAD geometry is missing. • The mesh can be updated to measured shapes (i.e. accounting for manufacturing tolerances) • It’s usually faster than remeshing (short time required to morph, quick set-up of shape variations)
  • 20. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Why RBF morphing? • RBF Morph is a best in class product crafted to deal with challenging CFD application (huge meshes) • 7 years of experience on industrial applications of Radial Basis Functions (RBF) • RBF are recognized as one of the best mesh morphing tool available in the industrial and scientific community • A new vision (we have started the new project from scratch) to put in the hands of ANSYS Mechanical Users the fastest and easiest mesh morphing tool • Satisfy the needs of many users asking for such a kind of technology available in ANSYS Mechanical
  • 21. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Video number 1 https://youtu.be/KxZzq0F3mQ8
  • 22. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • The evaluation of RBF at a point has a cost of order n. • The fit has a cost of order n3 for a direct fit (full populated matrix); this limit to ~10.000 the number of source points that can be used in a practical problem. • Using an iterative solver (with a good pre-conditioner) the fit has a cost of order n2; the number of points can be increased up to ~70.000. • With parallelization and fast RBF methods (OpenMP GPU) we are able to scale up to very large problems Accelerating the solver
  • 23. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Size: 160.000 nodes CPU: 497 s CPU OMP: 53 s K2000: 55 s K40: 34 s Registered Time Conrod testcase
  • 24. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Fully embedded in ANSYS Mechanical with same “look & feel” • Integration in the tree and founded on the working principles of ANSYS Workbench • Based on the ACT (Application Customization Toolkit) extension concept • Geometrical and mesh scoping to set-up the mesh morphing problem • Parametric • RBF fast solver (including parallel and GPU support) ACT extension specs
  • 25. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Easy to use, flexible and expressive. • Powered by multi-step RBF technology (which effectiveness has been extensively proven in RBF Morph) • RBF fitting and mesh morphing happen as a unique HPC process at each shape update. This allows the maximum flexibility with respect to parameterization • RBF component set-up data stored and persistent with the ANSYS Mechanical project. • Advanced interaction with DM to enable CAD resynchronization after morphing ACT extension specs
  • 26. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Hierarchical multi-step RBF approach • Each morphing target can be controlled using the superposition of a local modifier and an RBF field generated by its sources (if any) • Source points are extracted using the motion of all the children • If the child is a leaf its movement is known otherwise it becomes a target and has to be solved descending the tree ACT extension specs
  • 27. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Translation
  • 28. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Translation
  • 29. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Scaling
  • 30. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Scaling
  • 31. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Rotation
  • 32. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Rotation
  • 33. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface offset
  • 34. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface offset
  • 35. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve offset
  • 36. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve offset
  • 37. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
  • 38. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
  • 39. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Surface targeting
  • 40. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve targeting
  • 41. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Available Modifications Curve targeting
  • 42. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 43. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 44. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 45. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 46. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 47. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Simple example of working logic behind the RBF Morph ACT extension RBF Morph ACT extension for Mechanical
  • 48. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Morphed mesh! RBF Morph ACT extension for Mechanical
  • 49. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Inspection of the morphing field using post processing tools of Mechanical. RBF Morph ACT extension for Mechanical
  • 50. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • Automatic sculpting using field data available in the FEA solution. RBF Morph ACT extension for Mechanical
  • 51. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now manually it will be automated. RBF Morph ACT extension for Mechanical
  • 52. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now manually it will be automated. RBF Morph ACT extension for Mechanical
  • 53. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Industrial Applications
  • 54. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • Practical problem example: a connecting rod optimization. • Geometry in Solidworks. Meshing, parameterization (RBF Morph) and structural analysis in Workbench. 161493 nodes mesh. • The shape of the two lightening holes is varied, translating and resizing them
  • 55. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • Offset+rigid translation for the holes • Null movement for other surfaces
  • 56. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod • 2395 N traction load acting on big head • Titanium Ti-6Al-4V (Grade 5) • Cumulated damage map over the testing spectrum
  • 57. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA RBF Morph ACT extension for Mechanical: conrod Optimized 334.4g (-6.7%) Original 358.7g
  • 58. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study The objective here is to show how RBF Morph can be used in BGA Solder Joint Reliability simulations to show how geometric parameters can be morphed to itemize their effect on stress calculations DIE DIE UNDERFILL MOLD COMPOUND SUBSTRATE SOLDER BALLS PCB
  • 59. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study
  • 60. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study 12 3 2 3 1
  • 61. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study Baseline Optimized (22% stress reduction)
  • 62. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA BGA Solder Joint study Baseline Optimized (22% stress reduction)
  • 63. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Load Scenario representing TUV test simulated using ANSYS Mechanical
  • 64. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Baseline 7.58kg
  • 65. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Wheel Rim Optimization Optimized 6.98kg (-8%)
  • 66. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA • The novel mesh morphing tool implemented in ANSYS Mechanical using ACT extension technology has been introduced • Radial Basis Functions are used for multistep set-up • The new software tailored for FEM benefits of past experience on RBF Morph ANSYS Fluent add-on (mainly CFD) • Nevertheless we have restarted all the developments from scratch i.e. reusing knowledge and ideas (no cross compatibility between tools) • Applications relevant for the automotive industry are demonstrated. • The software has been released in May 2015 • How can we do better? Please do not hesitate to tell us your needs! Conclusions
  • 67. www.rbf-morph.com RBF Morph, an ANSYS Inc. Partner ASWC 2015 June 2015 - Detroit, MI, USA Many thanks for your kind attention! Prof. Marco Evangelos Biancolini E-mail: act@rbf-morph.com Web: www.rbf-morph.com Goo.gl/1svYd Twitter.com/RBFMorph linkedin.com/company/rbf-morph youtube.com/user/RbfMorph