This document discusses fostering digital industrial innovation in Europe through cloud-based high-performance computing (HPC) simulation in advanced manufacturing. It highlights mega trends in computing power and challenges and opportunities for industries like automotive and aeronautics. Case studies are presented on using virtual prototyping and crash simulation through HPC cloud resources to enable concurrent engineering across global supply chains. The document concludes that simulation is a transformative technology that can boost industry competitiveness and attractiveness if supported through public-private partnerships and ecosystem development.

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. 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

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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

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Movie extract

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

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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

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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

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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)

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

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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