TM EXCELLENCE IN ENGINEERING SIMULATION ADVANTAGEVOLUME III ISSUE 1 2009 SPOTLIGHT ON ANSYS 12.0 FRAMEWORK MULTIPHYSICS HIGH-PERFORMANCE PAGE 6 PAGE 11 COMPUTING PAGE 25 EDITORIAL Engineering Simulation: t pa Needed Now © iStockphoto.com/Atra More Than Ever In a tough economy, forward-thinking companies are investing in leading-edge simulation technology to drive top-line revenue growth and bottom-line savings. Time and cost benefits of engineering simulation are this simulation method has the potential to reduce crack well documented. Predicting product performance and growth analysis time by over 90 percent compared determining optimal solutions early in the design phase help with manual methods. The productivity gain will enable to avoid late-stage problems and to eliminate trial-and-error engineers to analyze more designs annually, thus keeping testing cycles that drive up costs and bog down schedules. up with increased demand for turbochargers around the Simulation enables engineers to perform what-if studies world and strengthening the company’s leadership and to compare alternatives, processes that otherwise position in this competitive industry sector. would be impractical. Indeed, bottom-line savings are The prediction method is based on improved fracture one key benefit that prompts most companies to implement mechanics capabilities for calculating J integrals, one of simulation, and are most readily quantified in return-on- the many enhancements in ANSYS 12.0. Previewed in the investment calculations. Spotlight section of this issue, the release is a milestone A second, and potentially greater, benefit is boosting for the software supplier and a huge step forward for the top-line revenue growth. With simulation, companies can CAE industry in terms of advancements in individual develop innovative, winning products that stand apart from physics (structural, fluid, thermal and electromagnetics) others, make the status quo obsolete or create entirely new and integration of this functionality into a unified multi- market opportunities. Brand value can be enhanced physics framework for Simulation Driven Product by tuning product performance to specific performance Development — an approach leading to top-line revenue characteristics. Revenue streams may be expanded by growth and bottom-line savings for many companies. increasing design throughput of new products or tackling Discussion of the business value of simulation is projects that otherwise would not be attempted. particularly relevant in today’s world as manufacturers How specific companies leverage simulation in face the toughest economic climate of a lifetime. Indeed, achieving these benefits depends on their unique products, with their survival at stake, forward-thinking companies engineering challenges and business requirements. The recognize the need to invest in engineering simulation now possibilities are limitless. Case in point is detailed in this more than ever to withstand the current market turbulence issue’s article “Predicting 3-D Fatigue Cracks without a and to strengthen their long-term competitive position, Crystal Ball” from Honeywell Turbo Technologies. Engineers brand value and profitability as conditions improve in the used software from ANSYS to predict thermomechanical coming years. ■ fatigue cracks in turbochargers for internal combustion engines. Predicting crack failures early enables engineers to optimize designs upfront and helps to avoid qualification test failures that lead to additional rounds of tests — which can be very expensive and take weeks to complete. Further, John Krouse, Senior Editor and Industry Analyst www.ansys.com ANSYS Advantage • Volume III, Issue 1, 2009 1 CONTENTS Table of Contents SPOTLIGHT ON ANSYS 12.0 4 ANSYS 12.0 Launching a New Era of Smart Engineering Simulation A full generation ahead of other solutions, ANSYS 12.0 takes product design and development to the next level. 6 FRAMEWORK 4 Introducing ANSYS Workbench 2.0 Proven simulation technology is delivered in a truly innovative integration framework. 8 GEOMETRY AND MESHING Taking Shape in 12.0 ANSYS combines depth of simulation with industry experience to provide geometry and meshing tools that realize simulation results faster. 11 MULTIPHYSICS Multiphysics for the Real World 8 In ANSYS 12.0, multiphysics capabilities continue to increase in flexibility, application and ease of use. 14 ELECTROMAGNETICS ANSYS Emag 12.0 Generates Solutions Improved accuracy, speed and platform integration advance the capabilities of low-frequency electromagnetic simulation. 15 FLUIDS A Flood of Fluids Developments A new integrated environment and technology enhancements make fluids simulation faster, more intuitive and more accurate. 11 18 STRUCTURAL MECHANICS Designing with Structure Advancements in structural mechanics allow more efficient and higher-fidelity modeling of complex structural phenomena. 22 EXPLICIT DYNAMICS Explicit Dynamics Goes Mainstream ANSYS 12.0 brings native explicit dynamics to ANSYS Workbench and provides the easiest explicit software for nonlinear dynamics. 23 EIGENSOLVER Introducing the Supernode Eigensolver A new eigensolver in ANSYS 12.0 determines large numbers of natural frequency modes more quickly and efficiently than conventional methods. 15 25 HIGH-PERFORMANCE COMPUTING The Need for Speed From desktop to supercomputer, high-performance computing with ANSYS 12.0 continues to race ahead. 28 FUTURE DIRECTIONS Foundations for the Future The many advanced features of ANSYS 12.0 were designed to solve today’s challenging engineering problems and to deliver a platform for tomorrow’s simulation technology. 22 2 ANSYS Advantage • Volume III, Issue 1, 2009 www.ansys.com CONTENTS SIMULATION @ WORK DEPARTMENTS 31 AUTOMOTIVE 47 TIPS AND TRICKS Predicting 3-D Fatigue Cracks without Reusing Legacy Meshes a Crystal Ball ANSYS tools enable users to work with finite element models ANSYS tools quickly predict 3-D thermomechanical fatigue in various formats for performing simulations as well as cracking in turbocharger components. making changes to part geometry. 33 HEALTHCARE 49 ACADEMIC Electromagnetics in Medicine Expanding Stent Knowledge Electromagnetic and thermal simulations find use in medical Simulation provides the medical industry with a closer look applications. at stent procedures. 36 ELECTRONICS Keeping Cool in the Field A communications systems company gains millions of dollars by using thermal simulation to bring tactical radios to market faster. 38 BUILT ENVIRONMENT Designing Against the Wind Simulation helps develop screen enclosures that can better withstand hurricane-force winds. 40 ENVIRONMENT Stabilizing Nuclear Waste Fluid simulation solidifies its role in the radioactive waste 38 treatment process. 42 OPTIMIZATION Topology Optimization and Casting: A Perfect Combination Using topology optimization and structural simulation helps a casting company develop better products faster. 44 MARINE Fighting Fire with Simulation The U.K. Ministry of Defence uses engineering simulation to find alternatives to ozone-depleting substances for 49 fire suppression. For ANSYS, Inc. sales information, call 1.866.267.9724, or visit www.ansys.com. For address changes, contact [email protected]. To subscribe to ANSYS Advantage, go to www.ansys.com/subscribe. Executive Editor Editors Ad Sales Manager Circulation Manager About the Cover Fran Hensler Erik Ferguson Helen Renshaw Sharon Everts ANSYS introduces release 12.0, Shane Moeykens the next-generation technology Managing Editor Mark Ravenstahl Editorial Advisor for Simulation Driven Product Chris Reeves Kelly Wall Development. The spotlight Contributors begins on page 4. Senior Editor and Susan Wheeler Designer Industry Analyst Marty Mundy Miller Creative Group John Krouse ANSYS Advantage is published for ANSYS, Inc. customers, partners and others interested in the field of design and analysis applications. Neither ANSYS, Inc. nor the senior editor nor Miller Creative Group guarantees or warrants accuracy or completeness of the material contained in this publication. 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All other brand, product, wwwservice.ansys.com and feature names or trademarks are the property of their respective owners. ANSYS Advantage • Volume III, Issue 1, 2009 3 © 2009 ANSYS, Inc. All rights reserved. ANSYS 12.0: Launching a New Era of Smart Engineering Simulation A full generation ahead of other solutions, ANSYS 12.0 takes product design and development to the next level. By Jim Cashman, President and CEO, ANSYS, Inc. The current economic climate has completely changed simulation in much the