Innovation becomes more complex and multidisciplinary, and consequently more challenging and expensive. One way to remedy this, is by using simulation technology, facilitating design iterations and reducing the number of failed experiments.

1. 2.3 Simulation technology, speed up your iterative process
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Template presentation Innovation Day 2016CONFIDENTIAL
Jan Buytaert
Consultant PhysicsLab
jan.buytaert@verhaert.com
Christophe Van Bavinchove
Coordinator PhysicsLab
christophe.vanbavinchove@verhaert.com
SIMULATION TECHNOLOGY:
SPEED UP YOUR ITERATIVE PROCESS
TRACK 2: TECHNOLOGY TO ACCELERATE

2. 2.3 Simulation technology, speed up your iterative process
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PhysicsLab – Systems Engineering
Christophe Van Bavinchove
Head of PhysicsLab
Jan Buytaert
Senior Systems Engineer
Consultant PhysicsLab

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CONTENT
Why use simulation technology?
What is simulation technology?
How to use simulation technology?
Simulation technology examples

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WHY USE
SIMULATION TECHNOLOGY?
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Problem statement & illustrations
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WHY USE SIMULATION TECHNOLOGY?
• Traditionally design and failure predictions are carried out by
• hand calculations
• experimental testing
• design trials
• As organizations strive to produce products
• that are better than the state-of-the-art
• and better than their competitors
• and to do so in a shorter time span
they need sophisticated tools
and methodologies to assist them.
• One such tool is computer simulation software

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THESIS of this TALK:
• Innovation
• becomes more complex and multidisciplinary,
• and consequently more challenging and expensive.
• One way to remedy this, is by using simulation technology
• facilitating design iterations
• reducing the number of (failed) experiments
• reducing the number of (failed) prototypes
WHY USE SIMULATION TECHNOLOGY?

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
• Process
1. Establish the concept and the channel design constraints
2. Perform benchmark tests to fine-tune simulation parameters
3. Optimize microfluidic channel design based on simulations
4. Verify simulation results by performing tests on prototype device
5. Make final design
Confluence concept
Designspace
Simulations
Prototypes & experiments
Design choice
Time
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Simulation parameters

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
3. Optimize microfluidic channel design based on simulations

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
Engineer Jef Aernouts

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WHY USE SIMULATION TECHNOLOGY?
sim
breadboard
• Case 1: Microfluidic channel design for sample dilution

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WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution

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WHY USE SIMULATION TECHNOLOGY?
• For design space exploration
• Virtually try-out new concepts/designs
• Sweep a range of design parameters
• For risk limitation
• Verify upfront the process performance
• Understanding robustness/failure of your design
• For design verification
• Supports physical verification tests which can be reduced in number
• Allows extrapolation of test results to non-testable cases
• For problem solving
• Understanding existing product failure/requirements/constraints
• Optimizing an existing design by low cost design iterations
PRODUCT
DEVELOPMENT
early stage
intermediate
before release
after release

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WHY USE SIMULATION TECHNOLOGY?
• Risk limitation & design verification
• by analyzing design performance upfront
• Example
• PCB air fan cooling
• Multi-physics model (CFD & Heat transfer)
Engineer Jan Buytaert

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WHY USE SIMULATION TECHNOLOGY?
• Design verification
• of a physically non-testable case
• Example
• Cooling of a reaction vessel
• Multi-physics model (CFD & Heat transfer)
Engineer Jan Buytaert & Wouter Vleugels

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WHY USE SIMULATION TECHNOLOGY?
• Problem solving
• by design optimization
• Example
• Beer bottle interlayer
• Structural model
Engineer Wouter Vleugels & Jan Buytaert

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WHY USE SIMULATION TECHNOLOGY?
• Problem solving
• by design vs cost optimization
• Example
• Beer appliance door
• Structural model
Engineer Tom Beeldens

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WHY USE SIMULATION TECHNOLOGY?
• Benefits of numerical analysis
• Detailed understanding of product performance
• Design space exploration
• Optimization of performance
• Optimization of amount of material/weight economically
• Reducing testing costs
• Reduction of failure risks
• Reduction of incremental development risks
• Reduction of time to market
• Improved product quality

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WHAT IS
SIMULATION TECHNOLOGY?
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The finite-element method
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WHAT IS SIMULATION TECHNOLOGY?
• Simulation
• The imitation of the operation of a real-world process or system over time.
• Requires that a model be developed (containing geometry + loads).
• Simulation technology
• Physical model versus …
• … abstract mathematical model
• Computer simulation technology
• Software tool

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WHAT IS SIMULATION TECHNOLOGY?
• Finite-element analysis (FEA)
• the practical application of the finite-element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.

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WHAT IS SIMULATION TECHNOLOGY?
• Finite-element analysis (FEA)
• the practical application of the finite element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.

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WHAT IS SIMULATION TECHNOLOGY?
• FEM simulation software tools consist of
• pre-processing (meshing, boundary conditions)
• solvers (actual calculations)
• post-processing (results, visualization)
• Nowadays
• all-in-one integrated (yet expensive) FEM software is available
• hardware has become powerful (and affordable)

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What is simulation technology?

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WHAT IS SIMULATION TECHNOLOGY?
• FEM modeling software resembles the cockpit of a space shuttle …
• A enormous amount of knobs and dials and controls ~ options
of which most aren’t used
though they all have a function and reason for being there
• One can fly on automatic pilot
however when deviating from the routine,
expert flying is needed
• You do not take a space shuttle
when a balloon flight can do the job
• Expensive way of traveling
so make it worth the effort
• Trained pilots reduce the chance of failure

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WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy

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WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Michael Burm

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WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times
mesh

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
symmetry & boundary conditions

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
symmetry & boundary conditions

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible

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WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible (too many variables, degrees of freedom, equations)
• Approximate solution
• Calculation time …
• Convergence to a solution …
• Post-processing and interpretation of the results

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• Case 2: BIB handle failure analysis and remedy
WHAT IS SIMULATION TECHNOLOGY?
stress safety factor Engineer Jan Buytaert

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WHAT IS SIMULATION TECHNOLOGY?
symmetry & boundary conditions
• Case 2: BIB handle failure analysis and remedy
Engineer Jan Buytaert & Tobe Wauters

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WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Jan Buytaert
safety factor
stress

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HOW TO
USE SIMULATION TECHNOLOGY?
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Insights
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HOW TO USE SIMULATION TECHNOLOGY?
• Challenges
• Optimal meshing of the geometry
• Breaking down a problem into subsystems for simulation
• The art of idealization (stripping away of unnecessary complexity)
• Applying realistic boundary conditions
• Interpreting the results correctly

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HOW TO USE SIMULATION TECHNOLOGY?
• How to go about these challenges
• A critical mass of experts/expertise
• Knowledge of the physics
• Knowledge of the modeling and the modeling tool
• Understanding of the extent to which modeling decisions impact accuracy
• Understanding of the consequences on resources and time by modeling decisions

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HOW TO USE SIMULATION TECHNOLOGY?
• How to go about these challenges
• A critical mass of experts/expertise
• A structured workflow (and report)
Analysis intake
Analysis specifications
Geometry creation
Mesh grid generation
Model set-up
Solution process
Solution verification
Solution validation
Post-processing
Report writing

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HOW TO USE SIMULATION TECHNOLOGY?
• How trustworthy are simulation results?
Solution validation
Analysis validation is carried out
to determine that the analysis
solution represents the physical
system it was designed to
simulate. Validation is actually
evaluation and can be done by:
• Hand calculations
• Physical testing
It should be remembered that test
data contains experimental errors,
and hand calculations contain
assumptions as well.
Analysis intake
Analysis specifications
Geometry creation
Mesh grid generation
Model set-up
Solution process
Solution verification
Solution validation
Post-processing
Report writing

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HOW TO USE SIMULATION TECHNOLOGY?
"Nobody trusts a computer simulation except the guy who did it,
and everybody trusts experimental data except the guy who did it.
Why not combine the two and get results
everybody can mistrust a little."
- T. Kordyban -
• How trustworthy are simulation results?

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HOW TO USE SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Michael Burm & Jan Buytaert
5G

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HOW TO USE SIMULATION TECHNOLOGY?
• Conclusions
Simulation technology serves agility in innovation
• Speed-up your innovative process
• Model and load case variations can be readily made
• At a reduced testing cost
• Concretize your product/process
• Facilitated design space exploration
and the converge towards a chosen design
• Simulations and physical testing both have value
• User-centric development
• Specification/discussion load cases
• Robustness/safety factor for use cases
Gate: Go/No-Go
Gate: Go/No-Go

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EXAMPLES
SIMULATION TECHNOLOGY
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From beer to Darwin’s evolutionary theory
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SIMULATION TECHNOLOGY EXAMPLES
• Example
Chimney with different flows inside
• Multi-physics model
• Particle tracing
• CFD
Engineer Jochem Grieten & Wouter Vleugels

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SIMULATION TECHNOLOGY EXAMPLES
• Example
Gravitational oil drain
• CFD model
• Design optimization
• Design verification
Engineer Wouter Vleugels

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SIMULATION TECHNOLOGY EXAMPLES
• Example
Biomechanical structural analysis of bird beak evolution
• Structural model
• Mechanical stress, fracture risk and beak evolution
• Conceptual understanding
Joris Soons & Jana Goyens & Joris Dirckx

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QUESTIONS?

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Innovation Day is an initiative of Masters in Innovation,
the umbrella brand of the Verhaert Group which aims
to connect, train and accelerate professional innovators.
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