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Simulation technology, speed up your iterative process (by Jan Buytaert)
The document discusses the importance and application of simulation technology in accelerating design processes and reducing experimental failures. It highlights how computer simulation software can optimize design iterations, facilitate innovation, and improve product development through practical case examples. Furthermore, it emphasizes the need for expertise and structured workflows to effectively employ simulation technology in engineering.
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Simulation technology, speed up your iterative process (by Jan Buytaert)
- 1. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 1 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 CONFIDENTIAL 2 PhysicsLab – Systems Engineering Christophe Van Bavinchove Head of PhysicsLab Jan Buytaert Senior Systems Engineer Consultant PhysicsLab
- 3. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 3 1 2 3 4 CONTENT Why use simulation technology? What is simulation technology? How to use simulation technology? Simulation technology examples
- 4. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 4 WHY USE SIMULATION TECHNOLOGY? CONFIDENTIAL Problem statement & illustrations 4
- 5. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 5 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
- 6. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 6 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?
- 7. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 7 WHY USE SIMULATION TECHNOLOGY? • Case 1: Microfluidic channel design for sample dilution
- 8. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 8 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 1 2 3 4 5 Simulation parameters
- 9. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 9 WHY USE SIMULATION TECHNOLOGY? • Case 1: Microfluidic channel design for sample dilution
- 10. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 10 WHY USE SIMULATION TECHNOLOGY? • Case 1: Microfluidic channel design for sample dilution 3. Optimize microfluidic channel design based on simulations
- 11. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 11 WHY USE SIMULATION TECHNOLOGY? • Case 1: Microfluidic channel design for sample dilution Engineer Jef Aernouts
- 12. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 12 WHY USE SIMULATION TECHNOLOGY? sim breadboard • Case 1: Microfluidic channel design for sample dilution
- 13. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 13 WHY USE SIMULATION TECHNOLOGY? • Case 1: Microfluidic channel design for sample dilution
- 14. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 14 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
- 15. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 15 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
- 16. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 16 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
- 17. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 17 WHY USE SIMULATION TECHNOLOGY? • Problem solving • by design optimization • Example • Beer bottle interlayer • Structural model Engineer Wouter Vleugels & Jan Buytaert
- 18. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 18 WHY USE SIMULATION TECHNOLOGY? • Problem solving • by design vs cost optimization • Example • Beer appliance door • Structural model Engineer Tom Beeldens
- 19. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 21 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
- 20. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 22 WHAT IS SIMULATION TECHNOLOGY? CONFIDENTIAL The finite-element method 22
- 21. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 23 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
- 22. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 24 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.
- 23. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 25 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.
- 24. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 26 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)
- 25. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 27 What is simulation technology?
- 26. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 28 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
- 27. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 29 WHAT IS SIMULATION TECHNOLOGY? • Case 2: BIB handle failure analysis and remedy
- 28. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 30 WHAT IS SIMULATION TECHNOLOGY? • Case 2: BIB handle failure analysis and remedy Engineer Michael Burm
- 29. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 31 WHAT IS SIMULATION TECHNOLOGY? • Case 2: BIB handle failure analysis and remedy
- 30. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 32 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
- 31. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 33 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
- 32. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 34 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
- 33. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 35 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
- 34. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 37 WHAT IS SIMULATION TECHNOLOGY? • Geometry • Meshing • Boundary conditions • Finite-element method solving • Matrices of partial differential equations • Analytical solving = mission impossible
- 35. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 38 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
- 36. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 39 • Case 2: BIB handle failure analysis and remedy WHAT IS SIMULATION TECHNOLOGY? stress safety factor Engineer Jan Buytaert
- 37. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 40 WHAT IS SIMULATION TECHNOLOGY? symmetry & boundary conditions • Case 2: BIB handle failure analysis and remedy Engineer Jan Buytaert & Tobe Wauters
- 38. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 41 WHAT IS SIMULATION TECHNOLOGY? • Case 2: BIB handle failure analysis and remedy Engineer Jan Buytaert safety factor stress
- 39. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 42 HOW TO USE SIMULATION TECHNOLOGY? CONFIDENTIAL Insights 42
- 40. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 43 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
- 41. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 44 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
- 42. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 45 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
- 43. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 46 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
- 44. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 47 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?
- 45. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 48 HOW TO USE SIMULATION TECHNOLOGY? • Case 2: BIB handle failure analysis and remedy Engineer Michael Burm & Jan Buytaert 5G
- 46. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 49 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
- 47. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 50 EXAMPLES SIMULATION TECHNOLOGY CONFIDENTIAL From beer to Darwin’s evolutionary theory 50
- 48. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 51 SIMULATION TECHNOLOGY EXAMPLES • Example Chimney with different flows inside • Multi-physics model • Particle tracing • CFD Engineer Jochem Grieten & Wouter Vleugels
- 49. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 52 SIMULATION TECHNOLOGY EXAMPLES • Example Gravitational oil drain • CFD model • Design optimization • Design verification Engineer Wouter Vleugels
- 50. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 53 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
- 51. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 54 QUESTIONS?
- 52. 2.3 Simulation technology,speed up your iterative process CONFIDENTIAL 55 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. Kruibeke Belgium Hogenakkerhoekstraat 21 B-9150 Kruibeke T +32 3 250 19 00 E info@verhaert.com www.verhaert.com Nivelles Belgium Noordwijk Netherlands Av. Robert Schuman 102 B-1400 Nivelles T +32 67 47 57 10 E info@lambda-x.com www.lambda-x.com Kapteynstraat 1 2201 BB Noordwijk T +31 71 760 05 50 E info@verhaert.com connect.verhaert.com INDUSTRY TECHXFER MEDICAL AEROSPACE TECHXFER FMCGCONNECT TECHXFER FMCGCONNECT MEDICAL Aveiro Portugal Av. Dr. Lourenço Peixinho 96D 4o 3800-159 Aveiro T +351 234 604 088 E info@load-interactive.com www.load-interactive.com CONNECT Gentbrugge Belgium Bruiloftstraat 55-57 B-9050 Gentbrugge T +32 9 330 27 90 E info@moebiusdesign.be www.moebiusdesign.com ON SITE CONSULTANCY