December 2013 / deskeng.com

Automate CAD to CAE P. 58 Change Engineering Culture P.26 Fight Data Overload TECHNOLOGY FOR DESIGN ENGINEERING with FEA P.54

Optimization Leadership Profi les P.29 One Shot at Perfection United Launch Alliance optimizes analysis data and processes to decrease its rocket design cycle without sacrifi cing quality. P.22

VIRTUALIZATION OPTIMIZES IT P.70

CYBER-PHYSICAL SYSTEMS P.66

SIMULATION CAPTAINS AMERICA’S CUP RACE P.49

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ANSYS.indd 1 11/14/13 10:27 AM Bluebeam.indd 1 11/14/13 10:28 AM Degrees of Freedom by Jamie J. Gooch Optimize the Design Cycle

s Desktop Engineering looks forward to its 19th year have to be trained to use them and managers have to ensure new of covering the hardware and software that design technology is actually being used effectively. engineers need, we see some amazing trends con- Millions of dollars of engineering technology investments verging that are changing the way you work, and too often never meet their full potential to shorten the design Athe way we cover the industry. cycle because people either don’t understand the benefit to The primary driver of this change is evident: electronics, the company as a whole, or are simply too comfortable doing software and embedded systems are increasingly needed in things the way they’ve always been done. more products, which in turn increases design complexity. De- “There’s always resistance to change. Always,” Rod Mach, spite the need for engineers to conceptualize, simulate and test president of IT service provider TotalCAE tells Contributing more complicated products, time-to-market deadlines continue Editor Mark Clarkson in a feature article that begins on page to shrink. To meet the demands of consumers, regulators, and 26. “Even if the change is better, people naturally resist change.” manufacturing in less time, engineers from different disciplines must collaborate with colleagues from different departments. Innovation Inertia Fortunately, the design, analysis, prototyping, computing and Resistance to change is increasingly encountered when compa- testing technologies Desktop Engineering has traditionally covered nies try to make sense of the massive amounts of data — from provide part of the answer. However, that’s not enough. consumer preferences to regulatory specifications to simulation and analysis — that is part of the design cycle. To understand that data and make decisions based on it, company leaders need People change much more to see a complete picture. One way to paint that picture is for slowly than technology does. everyone involved to add to it via a centralized system, such as a product lifecycle management platform. This is often where human nature thwarts process innovation. Cultivate a Culture of Collaboration People accustomed to doing things the way they always Not enough? How can the ridiculous advancements in engi- have, the way they are sure will work, are reluctant to change neering computing speeds, coupled with the ability to design their workflow to give someone in another department, pos- and accurately simulate entire systems not be enough? Because sibly on another continent, some additional information that people make processes that efficiently integrate technologies, may or may not help them make a decision. Because design and people change much more slowly than technology does. engineers are the creators and keepers of so much information Perhaps no one sees the people and process challenges as that is crucial for making smart business decisions, any such clearly as engineering service providers who work with mul- reluctance on their part can magnify workflow inefficiencies. tiple companies, and so have the opportunity to familiarize On the other hand, it’s easy to see why design engineers would themselves with the details of various engineering workflows. be reluctant to take on additional responsibilities. You’re already “The current workflow is so bad. While it’s very common, it’s being asked to do more complicated work in less time. Efficient horribly wasteful — and I fought for the last 20 years for compa- collaboration can help decrease time-to-market, but inefficient nies to realize it,” laments ATA Engineering Inc.’s H. Clark Briggs collaboration takes precious time away from the design engineer. to Senior Editor Kenneth Wong on page 58. “I spend most of my Desktop Engineering’s goal in 2014 is to bring you the in- process consulting time trying to get organizations to realize it.” formation you need to break that chain, optimize your work- Why, after 20 years, with all of the technological advance- flow, and integrate the best-in-class technologies using best ments that have been introduced over that time, does Briggs practices. We’ll do that by expanding our coverage of process still battle against inefficient workflows? Because the techno- and data management tools, introducing engineering services logical tools are not the most significant hurdle. that can help alleviate roadblocks, and explaining ways to “Tools only provide a link between your expertise and your overcome cultural barriers to optimization. ideas for the product you design,” Stefano Picinich, founder of You can help. If you have success stories or lessons learned to space and defense contractor Airworks, tells Contributing Editor share on design cycle optimization, we’d love to hear them. DE Beth Stackpole in her page 64 feature. To make use of those tools, people up and down the corporate ladder have to accept them. Jamie Gooch is the managing editor of Desktop Engineering. C-level executives have to authorize their purchase, engineers Contact him at [email protected].

2 DESKTOP ENGINEERING December 2013 /// deskeng.com

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12118 Smarter Embedded Design Ad_US.indd 1 6/26/13 10:22 AM NationalInstruments.indd 1 11/14/13 10:29 AM December 2013 VOLUME 19/ISSUE 4 SPECIAL ISSUE: OPTIMIZATION SIMULATE 49 Extreme Hydrofoiling, Powered by Simulation ANSYS CFD analysis software helped Emirates Team New Zealand Winning the Hearts bring new speed to the world’s oldest trophy event. By Pamela J. Waterman

and Minds of 53 America’s Cup: The Winning Edge CFD Software helps guide Oracle Team USA Hydrofoil to victory. Rocket Scientists By DE Editors 54 Big Data: Don’t Panic Fight the data explosion with smart FEA. 22 By Tony Abbey ULA set out to 61 Pulling Double Duty consolidate analysis COMSOL Multiphysics Software offers simulation and modeling for Sharp Corp.’s data and processes research and product development. in Siemens By Jim Romeo PLM Software’s Teamcenter 64 Making Optimization a Shared Experience By Kenneth Wong ESTECO’s Enterprise Suite allows teams to build the multidisciplinary optimization workfl ows that are critical to complex system design. By Beth Stackpole DESIGN 58 The Cleanup Headache CAD geometry cleanup stirs workfl ow questions in quest to quell CAD-to-CAE issues. By Kenneth Wong

ENGINEERING COMPUTING 66 The Impact of CPS Design What is the future for design methodology in 70 Speed Up Engineering IT the face of technology? Virtualization promises a solution to the budget con- By Randy Frank straints and challenges associated with deploying new engineering computing hardware. By Frank Ohlhorst SERVICES

72 Review: Lenovo ThinkPad Helix 26 Overcoming Corporate The new Lenovo ThinkPad Helix ultrabook is nimble Culture to Make a Change enough to run mainstream CAD applications. Looking to change things for the By David Cohn better? Don’t be surprised to fi nd all manner of obstacles in your path. OPTIMIZATION LEADERS By Mark Clarkson

PROTOTYPE 29 Optimization Leader Profiles In this special sponsored section, 20 industry experts share their solutions for optimizing design engineering. 75 Additive Manufacturing’s New Design Paradigm 3D printing allows companies to rethink previously impossible to manufacture designs, optimize their products, and support new business models. ON THE COVER: A rocket prepares for liftoff. By Jamie J. Gooch Image courtesy of United Launch Alliance.

4 DESKTOP ENGINEERING December 2013 /// deskeng.com

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© Copyright 2013 COMSOL. COMSOL, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, and LiveLink are either registered trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and its subsidiaries and products are not affi liated with, endorsed by, sponsored by, or supported by those trademark owners. For a list of such trademark owners, see http://www.comsol.com/tm

COMSOL.indd 1 11/14/13 10:32 AM December 2013 VOLUME 19/ISSUE 4 DEPARTMENTS 18 Engineering on the Edge A bionic man in DC, next-gen helicopters, solar challenge winner, electricity via 2 Degrees of Freedom condensation, and a wave-stabilizing ship. Optimize the design cycle. By Jamie J. Gooch 20 Rapid Ready Tech EDITORIAL Microsoft, additive manufacturing, and Jamie J. Gooch | Managing Editor 10 Virtual Desktop the Internet of Things; EnvisionTEC’s Kenneth Wong | Senior Editor Anthony J. Lockwood | Editor at Large Cloud-based PLM, COMSOL multiphysics, new Digital Light Processing 3D printers; Heather Pi˜ inger | Copy Editor RTT buys Bunkspeed and Siemens tries Arburg’s new freeformer 3D; Lockheed CONTRIBUTING EDITORS out SaaS. Martin’s digital manufacturing plans; and Tony Abbey, Brian Albright, Mark Clarkson, By Kenneth Wong & Beth Stackpole HP plans to enter the 3D printer market. David S. Cohn, Randy Frank, John Newman, Frank Ohlhorst, Jim Romeo, Beth Stackpole, Peter Varhol, Pamela J. Waterman 21 Editor’s Picks PUBLISHER Products that have Steve Robbins | Publisher grabbed the ADVERTISING SALES editors’ attention. 603-563-1631 • Fax 603-563-8192 By Anthony J. Lockwood Erich Herbert | Sales Executive (x263) 16 Conference Recaps Jeanne DuVal | Sales Executive (x274) Siemens PLM Software’s NX CAE 52 Spotlight ART & PRODUCTION Symposium, The Product Directing your search to the companies Darlene Sweeney | Director (x257) Innovation Congress that have what you need. A LEVEL 5 COMMUNICATIONS PUBLICATION featuring PLM Roadmap, Steve Robbins | Chief Executive Offi cer and Stratasys’ 77 Advertising Index Thomas Conlon | President Manufacturing the ADVERTISING, BUSINESS, & EDITORIAL OFFICES Future Summit. 78 Fast Apps Desktop Engineering ® magazine Level 5 Communications, Inc. By Jamie J. Gooch Engineering case studies. 1283D Main St., PO Box 1039 • Dublin, NH 03444 603-563-1631 • Fax 603-563-8192 E-mail: [email protected] www.deskeng.com

deskeng.com SUBSCRIBER CUSTOMER SERVICE Desktop Engineering ® magazine RAPID READY TECH BLOG PO Box 677 • Northbrook, IL 60065-0677 Read all about making digital designs physical @ rapidreadytech.com. 847-559-7581 • Fax 847-564-9453 E-mail: [email protected] ENGINEERING ON THE EDGE BLOG Desktop Engineering® (ISSN 1085-0422) is published See the future of engineering technology @ engineeringontheedge.com. monthly by Level 5 Communications, Inc., 1283D Main Street, P.O. Box 1039, Dublin, NH 03444, 603-563-1631. MOBILE ENGINEER Periodicals postage paid at Dublin, NH, and at additional mailing offi ces. Desktop Engineering® is distributed free Incorporate mobile technologies into your workflow. to qualifi ed U.S. subscribers. @ mobileengineer.com. SUBSCRIPTION RATES: for non-qualifi ed; U.S. $108 one year; Canada and Mexico $126 one year; all other VIRTUAL DESKTOP BLOG countries $195 one year. Read Kenneth Wong and Beth Stackpole @ deskeng.com/virtual_desktop for LIST RENTALS: For information on list rentals, contact a closer look at lifecycle components via articles, podcasts and video reports. Statlistics, Danbury, CT: 203-778-8700. POSTMASTER: Send all address changes to Desktop NEWSLETTER REGISTRATION Engineering, P.O. Box 677, Northbrook, IL 60065-0677. Address all editorial correspondence to the Editor, Desktop Newslink; Editor’s Pick of the Week; Check It Out; Virtual Desktop; Focus on Engineering. Opinions expressed by the authors are not Analysis and Simulation; Focus on Engineering IT & Computing; Focus necessarily those of Desktop Engineering . Unaccepted on MCAD; and Focus on Rapid Technologies. manuscripts will be returned if accompanied by a self-addressed envelope with suffi cient fi rst-class postage. Not responsible for lost manuscripts or photos. DE MOBILE BETA Each separate contribution to this issue, and the Check out our mobile app for Android and iOS by visiting issue as a collective work, is copyright © 2013 Level 5 wbxapp.com/de-mobile on your mobile device, or scan the Communications, Inc. All rights reserved. Copying for other than personal or internal reference use without the QR code to the right. permission of Level 5 Communications, Inc. is prohibited. Requests for permission should be addressed in writing DE ON TWITTER to Desktop Engineering Permissions, 1283D Main Street, Follow us @ DEeditor P.O. Box 1039, Dublin, NH 03444. PRINTED IN THE USA. LIKE DE ON FACEBOOK Visit DE @ deskeng.com/facebook

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This advertisement prepared by: Magnitude 9.6 345 W. 13th Street New York, NY 10014 240-362-7079 [email protected] Intel_Left.indd 1 11/14/13 10:33 AM Virtual Desktop by Kenneth Wong & Beth Stackpole by Kenneth Wong & Beth Stackpole Virtual Desktop Sunny Forecast for Cloud-based PLM n-premise deployments and traditional-style prod- uct lifecycle management (PLM) still comprise the Olion’s share of the market and user im- plementations, and likely will for some time. However, interest in cloud-based PLM is definitely picking up. In addition to the splash made by Autodesk with its expanding family of cloud-based engineering tools, a slew of new cloud-based engineering col- laboration platforms and refinements to existing platforms have entered the market. According to research by Tech- Navio, the PLM market is expected Solair PLM easily integrates with a range of common business systems, to achieve a 9.7% compound annual including CAD systems and Microsoft Offi ce. Image courtesy of Solair. growth rate between 2011 and 2015. Cloud-based PLM, in particular, are may not be totally custom, but it solves plans to actively jump into the U.S. mar- expected to drive much of this growth. their problems.” ket by the first quarter of 2014. One of the companies expecting to Solair PLM was designed as a multi- capitalize on this anticipated growth New Arena Applications Released tenant, cloud-based system with a pay-as- spurt is Arena, which introduced one of In its fall 2013 release, Arena added you-go licensing model. It’s also designed the earliest cloud PLM platforms (they three new applications designed to give to be scalable and easy to implement: were referred to as “hosted” or “on- its customers (mostly from outsourced According to Founder and CEO Tom demand software” back then) more than manufacturing) the tools to help trans- Davis, the firm has a patent-pending a decade ago, and has been at it ever form their manufacturing operations technology that automatically configures since. Arena settled on what at the time and maximize business results: the system in the cloud, so users don’t was a disruptive software delivery model • Arena Demand helps OEMs calculate have to do any heavy lifting around cod- because it targeted companies in the aggregated materials needs across all of ing or integration. electronics sector, which typically rely their product lines so they can better Solair PLM covers the usual PLM on contract manufacturers and extended negotiate with suppliers. workflows, from full document manage- global supply chains while dealing with • Arena Projects connects the project ment and revisioning to bill of material extremely short product delivery cycles schedule directly to the product record, (BOM) management and integration/vi- and highly accelerated rates of change. increasing visibility so engineering and sualization of CAD data. Baldi, a Floren- “The outsourced manufacturing manufacturing groups can better facili- tine company that makes furniture and world works well with cloud applica- tate new product introductions and new accessories for the luxury market, plans to tions,” says Steve Chalgren, Arena’s vice quality processes, among other processes. move from a small traditional-style PLM president of product management and • Arena Exchange is a collaboration envi- program to Solair PLM in the cloud spe- strategy. “If you have on-premise PLM, ronment designed to look and feel more cifically because of its ease of use. everything is behind the firewall, which like a social media platform — connect- “Solair PLM allows us to open up requires a lot of user provisioning on ing multiple users at different supplier our PLM platform to all our suppliers enterprise applications to give suppliers levels throughout a global supply chain. and colleagues that aren’t into CAD access. It’s a huge IT cost for OEMs.” or technical software,” notes Leonardo Instead of spending millions of dol- A New Contender Boni, Baldi’s head of product and R&D. lars on an enterprise PLM deployment, Upstart Solair is also upping the ante The end game, Boni says, is improved electronics original equipment manu- for cloud-based PLM. The Italy-based collaboration across dispersed partners, facturers (OEMs) can take a couple of newcomer has just released Solair PLM, ultimately leading to shorter product hundred thousand dollars annually and its Software-as-a-Service (SaaS) PLM development cycles. get the same capabilities, he explains: “It offering, to the European market. It has — B. Stackpole

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Desktop_engineering_ad_8.125x11_102513.indd 1 10/28/13 3:52 PM Virtual Desktop by Kenneth Wong & Beth Stackpole by Kenneth Wong & Beth Stackpole Virtual Desktop Diverse Multiphysics Modules Help COMSOL Achieve Real-world Accuracy hat do Moore’s Law, modeling, Woytowitz set out to explore Qidwai said the comprehensive mod- structural corrosion, and how computational modeling, in turn, eling of corrosion requires the coupling magnetostrictive trans- enables Moore’s Law — helping to of electrochemical relations and balance ducers have in common? promote progressively higher transis- of mass involving multiple species; con- Seemingly,W not much. Yet at the recent tor densities, better architectures, and stitutive descriptions of reaction rates COMSOL 2013 Conference in Boston, increased reliability and speed. Using and species diffusion mechanisms in they were showcased as three real-world COMSOL Multiphysics, he explored the electrolyte; and conditions govern- examples of open-ended design chal- wafer fabrication equipment modeling, ing the movement of metal-electrolyte lenges being effectively explored in the IC device-level modeling, and eventu- interface. Using COMSOL Multiphys- virtual world using COMSOL multi- ally molecular dynamics, all in an effort ics, Qidwai’s team takes a gradual ap- physics (MP). to see how modeling can advance semi- proach to this highly complex modeling While the three keynote speakers are conductor design. agenda, going from simpler to complex pursuing design problems that appear phenomena, to investigate the effect of to be worlds apart, they are indicative When to Stay with Single Physics microstructure on corrosion pit growth of two big goals among COMSOL’s As part of her presentation on how MP and the subsequent effect on mechanical growing user base: an obsession with models are used in magnetostrictive performance. accuracy and the aspiration to skip or transducer design, Julie Slaughter, Ph.D., cut back on physical testing, which is far a senior engineer at Extrema Products COMSOL 4.4 Debuts more time-consuming and expensive Inc., provided some insight into where While the upgrade adds some user- than virtual prototyping, according to different domain models and physics requested capabilities across many Valerio Marra, Ph.D., COMSOL’s tech- couplings come into play as part of the of its modules, there are a couple of nical marketing manager. design process. For example, Slaughter major highlights. One is the revamped If there is any common thread among says the team uses single physics model- user interface that delivers a Windows COMSOL’s user base, “it’s a desire for ing during the detailed design stage, but look and feel, including the addition real-world accuracy and a chance to then turns to coupled models as part of of the Microsoft ribbon for easier and mimic real-world results,” Marra says. the design validation process. faster access to functionality — and to “How many cool ideas don’t see the light “We don’t like to do coupled models keep users versed in Microsoft Office of day because there is no good tool to during detailed design, because it adds a products working in a familiar way. test them? This is why we invest in multi- lot of complexity to the system that you COMSOL is retaining its traditional physics — because our customers want to don’t need at that point,” she explained model builder interface for existing reduce the number of prototypes, and are during her presentation. users who might be more comfortable obsessed with getting good results.” with that approach. Corrosion Modeling The other major addition is the Mixer Modeling Enables Moore’s Law The third COMSOL user presenter Module, an add-on to the Computational Peter Woytowitz, Ph.D., who leads the was Siddiq Qidwai, Ph.D., a mechanical Fluid Dynamics (CFD) Module designed Computational Modeling and Reliability engineer at the Multifunctional Materi- to help users understand and design the group in Central Engineering at Lam als Branch of the U.S. Naval Research operation of mixers in the pharmaceuti- Research Corp., a supplier of wafer fab- Laboratory. Qidwai’s research was all cal, fine chemical, and food industries. rication equipment and services, was first about leveraging COMSOL to explore This new module, one of many highly up. He presented on using COMSOL structural corrosion, which he character- vertical add-ons COMSOL has an- to explore the symbiotic relationship be- ized as a formidable problem for both the nounced in the last few years, provides tween Moore’s Law, which dictates that naval and maritime industries. As part of full-moving mesh technology, free sur- the number of transistors on integrated his presentation, Qidwai said that the cost face modeling, and a number of ready- circuits (ICs) doubles every 18 months, of corrosion to the general populace con- made applications to help engineers and computational modeling. stitutes about 2% to 4% of the U.S. gross explore laminar and turbulent reacting While it’s known that Moore’s Law national product — an astounding figure flows in rotating machinery. is a driver for the use of computational and a hard one to ignore. — B. Stackpole

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BOXX_Full_Pg.indd 1 11/14/13 10:38 AM Virtual Desktop by Kenneth Wong & Beth Stackpole by Kenneth Wong & Beth Stackpole Virtual Desktop RTT Buys Bunkspeed, Reaches New Markets n October, RTT snatched up Los pabilities to our customers,” says Peter Angeles-based Bunkspeed, a fel- Stevenson, CEO of RTT USA. low rendering software developer. Although they cater to different au- So why is the company, already diences, both companies share a dedica- wellI known among automotive manu- tion to the parallel processing potential facturers for its DeltaGen 3D visualiza- of graphics processing units (GPUs). tion software, buying another renderer? When GPU maker NVIDIA began High-end rendering and visualization The answer lies with the different mar- promoting its Maximus technology — software developer RTT snatches kets the products target. a setup that lets you deploy more than up Bunkspeed, another rendering RTT’s DeltaGen is a high-end one GPU in a workstation — RTT software maker. product, by the company’s own descrip- DeltaGen was one of the featured ap- tion. By contrast, Bunkspeed SHOT plications. Bunkspeed SHOT was built over the upcoming months. During the is an easy-to-use rendering program, for GPU acceleration using NVIDIA’s interim period, clients will receive con- targeting CAD users with little or no compute unified device architecture tinued support and the same advanced training in the use of complex render- (CUDA) programming platform. quality product that they have come ing applications. RTT’s purchase of According to RTT’s press an- to expect from both RTT and Bunk- Bunkspeed gives the company a robust nouncement of the acquisition, “Bunk- speed.” The company also revealed that product to sell downmarket. speed will continue to operate under Steven Madge, RTT’s managing direc- “The addition of Bunkspeed’s spe- the same name and is now a wholly tor of the Pasadena office, has been cialty services and footprint will allow owned subsidiary of RTT. The incor- named CEO of Bunkspeed. RTT to provide a broader range of ca- poration of Bunkspeed will take place — K. Wong Siemens Dips Its Toe into SaaS with IntoSite he launch of IntoSite, an addi- to digitize and simulate tion to Siemens’ Tecnomatix every aspect of their work- suite, marks the company’s first flow. Siemens laid the steps toward a territory it has groundwork for IntoSite soT far sidestepped: the public cloud. when it introduced a Tec- Tecnomatix IntoSite, according to the nomatix plant simulation company, is “a cloud-based web applica- solution a year ago. But the tion that maintains a 3D representation latest product, IntoSite, is of a production facility, presents it in its augmented with location geographical context, and allows you to intelligence. navigate through the facility in the simple “The system allows any- 3D representation of a production facility shown and familiar way you navigate Google one in the organization to in Siemens’ Tecnomatix IntoSite software. Image Earth. IntoSite supports cooperation and add and contribute material, courtesy of Siemens PLM Software. collaboration on the shared information tips and tricks, best practices, in your enterprise, and harnesses the ‘wis- etc., that will immediately be immense value to automotive manu- dom of the crowd’ by enabling the shar- displayed in the appropriate 3D/Geo facturers, oil and gas businesses, and ing of best practices, tips and tricks.” context,” Segall explains. This social energy producers. With such a solu- Tali Segall, a senior product manager media-inspired feature is expected to tion, Software-as-a-Service (SaaS) at Siemens, clarifies that “the server is offer organizations to harvest the collec- deployment makes the most sense, as hosted and maintained by Siemens.” tive wisdom of its staff, possibly even the it’s most effective when field workers The solution is expected to launch in public, she adds. can remotely access it from a browser. monthly subscriptions at less than $100 The product targets facility owners Segall says the current version of In- per user per month. and operators. The ability to main- toSite has no mobile device support, Virtual factory and plant designs tain an accurate, up-to-date virtual but “it’s definitely on the road map.” stemmed from manufacturers’ moves representation of a plant could be of — K. Wong

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de1213_VD_Wong.indd 14 11/14/13 10:37 AM Conference Recaps by Jamie J. Gooch

Toward the Goal of Simulation Data Stratasys Defines Complete System Management is an Itself and the 3D Simulation On-ramp to PLM Printing Market

This year’s Siemens PLM Software Product Innovation Chicago featuring A year after NX CAE Symposium 2013 was held PLM Roadmap was hosted by industry the merger of at the University of Cincinnati last consultants CIMdata and MarketKey Ltd. Stratasys and month. It featured more than two dozen in October. They assembled experts from Objet, and presentations, roundtables, and panel engineering, research and development, just months discussions, as well as two workshop and information technology to share after its tracks. Siemens PLM Software NX their experiences implementing product acquisition of customers explained how they used the lifecycle management (PLM) solutions. MakerBot, the software to simulate everything from tiny The Commissioner and CIO of Chicago, company was 0.015mm cardiovascular stents to huge, Brenna Berman, and Adrian Micu, vice ready for its ship-based cranes and heavy-lift rockets. president of Engineering at CES Corp. close-up. In October, Stratasys hosted While the simulation projects were varied, kicked things off with keynotes in the the Manufacturing the Future Summit there was a common theme running PI Congress and PLM Roadmap tracks, at its headquarters in Eden Prairie, MN. throughout the symposium: the need to respectively. Other speakers represented About a dozen journalists were on hand, reduce cycle times via collaboration and the likes of Boeing, Dow Chemical, Rolls- and more dialed in, to hear Stratasys system-level engineering. Royce and Whirlpool. executives and customers explain how Keith Meintjes, practice manager, 3D printing is not only saving them time Simulation & Analysis for CIMdata, and money, but enabling new business explained how simulation can be models and new ways to design products. incorporated into a PLM system to The summit kicked off Tuesday help drive business decisions. He said night with a dinner and then resumed simulation and analysis was a $4 bil- early yesterday morning with a series lion industry in 2012, and is projected of speakers and a tour of RedEye by to grow 15-20% over next few years. Stratasys (formerly known as RedEye On But he cautioned companies to look Demand). First up was Stratasys CEO “The rate of innovation and the beyond just the technology aspect of David Reis, who answered a question he rate of development … and bringing building a collaborative system. is routinely asked: Why, after 27 years, is (products) to market is speeding along As if to illustrate that point, other 3D printing suddenly so popular? at a rate that most of the people in presenters shared their challenges in “One of the reasons has to do with this room can only imagine,” said the implementing PLM. Whirlpool’s Senior the improved accessibility and ease opening presenter Dave Shook, senior Engineering Manager, Ken Rashe, of use of the technology that makes it vice president and managing director, said the company is still fighting an possible for anyone – children, students, Americas, for Siemens PLM Software. engineering culture of working locally, and hobbyists or professionals – to use “You can’t take weeks or months to go rather than using the PLM system. 3D printing for whatever their needs,” do this. It needs to be done in hours, And, Dow Chemical Senior Asset man- he said, “whether it’s for fun, education, not days to bring together the mechan- ager Mike Williams explained how the design or manufacturing.” ics and the software … It’s the whole company’s Manufacturing department Reis predicted today’s students will closed-loop process.” formed an alliance with Finance and graduate expecting 3D printing to be That vision of a closed-loop process R&D to propose a PLM process to used in the workplace, underscoring — one platform for the entire design upper management. why education is such a valuable market cycle, including testing — is what drove Next year’s European congress will be for the company. Outside of education, the $750 million acquisition of LMS by held in Berlin, and the U.S. conference Stratasys breaks down the markets it Siemens that we reported on last year. will be held in San Diego. now serves into personal, augmented and alternative manufacturing sectors. MORE ➜ deskeng.com/ MORE ➜ picongress.com and virtual_desktop/?p=7839 us.picongress.com MORE ➜ rapidreadytech.com/ ?p=5693

➜ For more coverage, visit deskeng.com and follow DE on Twitter @DEeditor

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de1213_News.indd 16 11/14/13 4:16 PM Design Optimization Sponsored Report /// Intel® Corporation Can You A˜ ord NOT To Do Simulation Based Design Shorter designDesign cycles Optimization and multiple Sponsored Report/ Intel® iterations are within reach via simulation Corporation and professional workstations.

ou’ve heard all the talk about simulation-based design. You’ve listened to colleagues—maybe even some of your Ycompetitors—wax on about how doing robust simula- tion studies early on in the design cycle leads to more and better product ideas while also optimizing use of materials. In fact, you’re sold on the need to embrace advanced analysis, but you just don’t see how it’s feasible given the complexity and high cost of the simulation software — not to mention, the high- powered workstation gear. It’s time to put those preconceptions aside and look at the reality of just how accessible and affordable both high- Image courtesy of ANSYS, Inc. powered workstations and advanced analysis software have become. Today, any design and engineering professional can opment process, they can also ensure design robustness and easily trade up a mid- or even high-end desktop computer ultimate product integrity, Aberdeen analysts say. for an Intel Xeon-based workstation that fits within the Putting an affordable simulation-based design engine within parameters of the average budget. In fact, a dual processor close reach will also empower engineers to embrace new kinds Intel Xeon-based workstation with up to 24 cores is far more of innovation workflows. For example, such a setup would allow affordable than ever before and it can deliver the desktop for the iteration of more ideas and testing of coarse-grain mod- computing power necessary for running the robust parametric els on the local workstation, utilizing the more expensive local design studies and advanced analysis so crucial to modern-day or scalable cloud-based HPC resources more cost-effectively product development. for higher fidelity modeling of the optimized model at a critical point in the design cycle. In addition, a research project con- The Right-Sized System ducted by Sandia National Laboratories showcases how the new Why is it so important to invest in a system that is right-sized wave of affordable Intel Xeon-based workstations and HPC for parametric design studies and analysis? As business pressures clusters can be used to enable stochastic modeling, enabling continue to mount, studies show companies taking a simula- simulations to be used not just for single-point predictions, but tion-driven design approach are far more likely to be leaders in also for automated determination of system performance im- their markets. Not only can simulation-based design replace or provements throughout a product life cycle. reduce physical prototyping as a cost-saving measure, the ap- Before closing the door on simulation-based design proach can also inspire a completely new style of experimen- because it’s too costly or complex, consider how the world tation designed to spark innovation and spur development of of high-powered computing has changed. Thanks to the ac- best-in-class products, experts say. cessibility of affordable analysis software Consider research from Aberdeen Group. The firm found and workstations based on Intel Xeon that the top 20% best-in-class companies pursuing a robust processors, professional-grade simula- design approach, including widespread use of simulation, were tion capabilities are well within reach of more likely to meet product launch dates, hit product revenue, engineering organizations, both large cost, and quality targets, and reduce development cycles. Not and small. To find out more about Intel’s only do Intel Xeon processor-based workstations and HPC Xeon-based workstation products, go to clusters help drive significant time and cost out of the devel- www.intel.com/workstation

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DE_1213_Intel_Advertorial.indd 17 11/14/13 10:41 AM Engineering on the Edge Future Focus

Bionic Man Shows Off Army Looking for a Few Team Wins Solar Challenge Advanced Prosthetics Good Helicopter Designs The U.S. Army has signed technology investment agreements with Bell and Lockheed Martin, Boeing and Sikorsky, Karem Aircraft and AVX Aviation to develop prototypes for next-generation light- and medium-sized helicopters. The four teams will compete for the Delft University of Technology in The business as part of the Joint Multi-Role Netherlands won the 2013 World Solar (JMR) Technology Demonstrator Phase 1 Challenge, making a 1,864-mile trip across program. Two prototypes will be chosen the Australian outback in about 33 hours, to be built by 2018, with full deployment with an average speed of about 56 mph. A “bionic man” developed at the University by 2030. The Nuna7 vehicle’s shell was made of Zurich paid a visit to the U.S. capital using DSM’s Daron resins, optimized for in October, displaying some of the most use with TeXtreme carbon fiber. The team advanced prosthetics technology available. used DSM’s Somos stereolithography The international team that built the materials for prototyping. Nuon also used robot has recreated more than 50% of a lightweight version of Semprius’ high- the human body — including limbs and concentration solar photovoltaic modules a complete circulatory system — in the (NCPV) to power the vehicle. The modules remote-controlled humanoid contraption. were less than 2.75 in. thick, and were Shadow Robot Co. spearheaded the able to deliver about 13.6 watts per lb. assembly using donated components, MORE ➜ including a Touch Bionics i-limb prosthetic deskeng.com/edge/?p=5688 hand, a device also worn by Bertolt Meyer, The helicopters must be able to Ph.D., who designed the robot. The bionic travel at 265 mph (double current man includes 200 processors and nearly speeds); be able to hover at altitudes ‘Jumping’ Water Droplets 1 million sensors, along with 26 individual of 6,000 ft.; and must be quieter than Could Produce Electricity motors and 70 circuit boards. current models. Researchers at MIT have stumbled across MORE ➜ deskeng.com/edge/?p=5714 MORE ➜ deskeng.com/edge/?p=5669 a potential source of energy: condensation in the air. While investigating how water droplets interact with superhydrophobic Ship Uses Internal surfaces, they discovered that the repelled droplets produce a net positive electrical Waves for Stability charge as they jump from the surface. esigners and researchers at These jumping droplets enhance the DMarintek (a division of SINTEF) are efficiency of heat transfer on condensers, testing a ship design that can generate potentially improving power plant efficiency. waves inside its own hull to stabilize the By applying a charge to a nearby metal vessel while docked next to an oil rig. plate, the droplets can be pulled away from The Offshore Accommodation Vessel has water tanks in its hull formed into the surface, reducing the likelihood of their the shape of a U. Air valves control the direction of the water as it moves in the being pushed back onto the condenser. tanks. By counteracting the motion of the external waves with artificially generated The findings also suggest that power could internal waves, the designers believe they can reduce the motion of the ship. The be generated via condensation in the ship will also have azimuth thrusters that will be used to hold the ship’s position air. By placing two water-repellent metal next to the rig. The crew will be able to move from the vessel to the drilling rig via plates outside, energy could theoretically a telescoping 182-ft. gangway. Ship owner Østensjø contracted design company be produced by the water droplets jumping SALT to develop the ship. Hoppe Marine came up with the internal wave system, from one to the other. which has been modeled and tested by Marintek. MORE ➜ deskeng.com/edge/?p=5656 MORE ➜ ddeskeng.com/edge/?p=5636

➜ For more coverage of the future of engineering technology, visit deskeng.com/edge

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de1213_Edge_Albright.indd 18 11/14/13 4:16 PM 13th LS-DYNA®U.S. & International Users Conference June 8th -10th, 2014 Dearborn, MI Welcome and Call for Papers Livermore Software Technology Corporation (LSTC) and DYNAmore Germany are pleased to bring engineers, professors, students, consultants, industry leaders and interested parties together at the 13th International LS-DYNA® Users Conference to be held at the Adoba Hotel (formerly the Hyatt Regency) Dearborn, MI. Important Dates: Abstract Deadline: Nov 30, 2013 Email Your Abstract to: [email protected] Noti cation: No later than Dec 15, 2013 Paper Deadline: Mar 5, 2014. Papers are being reviewed upon receipt, with immediate notifi ction of acceptance.

The presenter of each accepted paper will receive free admission to the conference, provided that the presenter registers for a room at the Adoba Hotel under the LSTC Conference registration. Application Areas Being Accepted for Paper Submission: • Aerospace • Electromagnetics • Nuclear Applications • Automotive Crashworthiness • Heat Transfer • Occupant Safety • Ballistic and Penetration • Impace and Drop Testing • Seismic Engineering • Biomechanics • Manufacturying Processes • Ship Building • Civil Engineering • Metal Forming • Transportation • Compressible Fluid Dynamics • Modeling Techniques • Virtual Proving Ground Upcoming International Users Conferences

10th LS-DYNA® European & International Users Conference June 16-17, 2015 Wurzburg, Germany

For More Information on Call for Papers, Sponsorships and Exhibits [email protected]

LivermoreSoftwareTech.indd 1 11/14/13 10:43 AM Rapid Ready Tech Making Digital Designs Physical

Microsoft Prepares HP Indicates Plans to Enter AM Market by 2014 AM for Internet of Things ith the rapid growth of additive manufacturing (AM), Microsoft Research is just as interested Wit’s easy to forget the market is still relatively small in the Internet of Things (IoT) as when compared to big business. Even the largest AM other tech companies, and has been manufacturers, 3D Systems and Stratasys, aren’t large when quietly working on ways to include the compared to giants of industry like Apple or GE. technology in a number of objects via a At the Canalys Channels Forum in Bangkok, HP CEO Meg variety of different sensor types. Most Whitman announced the company’s intention to build 3D of this research uses radio frequency printers, entering the market in 2014. identification (RFID) chips for tracking “We are excited about 3D printing,” said Whitman. “We want to lead this business. purposes, but new research has HP Labs is looking at it. 3D printing is in its infancy. It is a big opportunity and we are all developed a method of using terahertz over it. We will have something by the middle of next year.” (THz) imaging to read specially designed Whitman added that HP’s main concerns with the technology at its current state structures within objects built with are build speeds and the cost associated with buying a top-of-the-line AM system. additive manufacturing (AM). She also insisted that when HP launches a product, it will be something new. That The system is called InfraStructs, likely means HP won’t be partnering with existing manufacturers the way it did with and is the brainchild of Karl Willis, Ph.D., Stratasys in the past. from Carnegie Mellon University, and MORE ➜ rapidreadytech.com/?p=5647 Andrew Wilson, Ph.D., from Microsoft. The basic premise of InfraStructs is to use the capability of AM to build complex Arburg Unveils Lockheed Martin Steps internal geometries to self-embed three- dimensional codes into objects that freeformer System Up Digital Manufacturing have been wholly or partially built using Arburg represents Lockheed Martin envisions a “digital a 3D printer. These codes are then read one of the first tapestry” of production in which every by a THz scanning device and used for established step of the process of creating new everything from simple identification to businesses to wade goods is a single strand. Its tool of actual programming code that allows into the additive choice is model-based engineering objects to connect with outside systems. manufacturing (MBE), an integrated toolset that (AM) fray with its updates and maintains digital data MORE ➜ rapidreadytech.com/?p=5356 freeformer 3D from start to finish. printer. Lockheed Martin’s Collaborative Latest DLP Systems: the Arburg’s AM Human Immersive Laboratory (CHIL) is a process is based on plastic, but differs part of the MBE. CHIL is a virtual reality ULTRA 3SP and 3SP HD from the material extrusion printers that (VR) design and simulation laboratory EnvisionTEC’s Digital have become generally available. In that can be used to optimize designs Light Processing place of plastic filament, the freeformer and help ensure a finished product will (DLP) uses a vat of uses plastic beads, which are melted meet optimal specifications. The VR photocurable resin inside the system. The melted plastic lab can also identify potential problems and a DLP projector to is forced out the nozzle in the form in the flow of production before they produce a 3D object. of plastic droplets, which build up become an issue. The object is built in an object over time. According to the On the AM front, the company chunks, called voxels, company, its process doesn’t require has stepped away from traditional which means no strata support materials, and uses less manufacturing techniques for the lines. EnvisionTEC’s materials overall. construction of parts with complex latest offerings using DLP are the ULTRA Another difference is the printhead. internal geometries, or that must be 3SP and 3SP HD. Instead of the nozzle moving over the built from expensive materials, such The main difference between the two surface of the build area, the build area as titanium. AM not only reduces the products is resolution. The 3SP offers 100µ, moves around the nozzle utilizing 5-axis production time of these items, but while the 3SP HD is capable of up to 50µ. movement to complete a build. offers substantial savings. MORE ➜ rapidreadytech.com/?p=5427 MORE ➜ rapidreadytech.com/?p=5604 MORE ➜ rapidreadytech.com/?p=5595

➜ For more coverage of rapid technologies, visit RapidReadyTech.com

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de1213_RapidReady_.indd 20 11/14/13 10:44 AM by Anthony J. Lockwood Editor’s Picks

Each week, Tony Lockwood combs through dozens of new products to bring you the ones he thinks will help you do your job better, smarter and faster. Here are Lockwood’s most recent musings about the products that have really grabbed his attention.

Maple IDE Reduces Development Time New development environment can manage projects in Maple language. Maplesoft’s Maple technical computing and extensions. With the recent introduction and documentation environment is one of of Maple IDE, making your own Maple code the handful of engineering, scientific, and sounds like it just got a lot easier research tool suites that resides on a different Maple IDE is a new integrated develop- plane than the rest. Part of the reason for this ment environment for the Maple program- is its great depth and breadth, and part of it is ming language. So, what does Maple IDE because you can access the Maple language have in it for you? and develop your own algorithms, scripts, MORE ➜ deskeng.com/articles/aabman.htm

Altium, Desktop EDA Partner for ECAD, MCAD Integration Integration synchronizes capabilities between applications.

We’re living in an electro-mechanical world. working together to bring top-end ECAD and The mechanisms get their smarts from top-end MCAD together grabbed my attention. embedded electronics and the electronics The Altium and Desktop EDA announce- need the mechanism and hardware to have ment really is a two-part affair, but both a reason for being. Yet sometimes you’d think parts target greater productivity in the that ECAD and MCAD have nothing to do with ECAD and MCAD design environments by each other. This is why the announcement making them work together more tightly.

from Altium and Desktop EDA about their MORE ➜ deskeng.com/articles/aabmar.htm

HP Unveils New Z Workstations Also introduces new Z-series displays optimized for professional use. HP’s recent announcement of its new Z230 x 13.3 x 15.0 in. Both workstations pack a Workstation caught my eye because they say lot of punch: quad core Intel CPUs running flat out that it’s engineered for professional 3.20GHz Core i5 processors with 6MB use 24/7/365. of cache up to 3.60GHz Xeon processors The Z230 comes in traditional tower with 8MB of cache. They can house up to and small form factor (SFF) versions. The 32GB memory, and storage options will tower unit measures 15.7 x 6.7 x 17.4 in. take you well into terabyte territory.

(H x W x D) and the SFF comes in at 3.95 MORE ➜ deskeng.com/articles/aabmdw.htm

Simulate On-Demand Browser-based online platform provides access to on-demand computing for simulation. The SimScale Platform is an online, on- mechanics simulation capabilities include demand, and scalable system for engineer- laminar and turbulent modeling and mass ing simulation. Specific CAE (computer-aided transport within fluid flows. You can use engineering) tools target structural mechan- SimScale Platform’s thermodynamic analy- ics, fluid dynamics, and thermodynamics sis tools to conjugate heat flows or use its analyses. For structural mechanics, you can steady state and transient solvers with time- do things like modal/frequency analysis and dependent processes.

nonlinear and dynamic simulations. Fluid MORE ➜ deskeng.com/articles/aabmew.htm

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de1213_EditorsPicks.indd 21 11/14/13 10:45 AM Optimize Analysis /// PLM Winning the Hearts and Minds of Rocket Scientists ULA set out to consolidate analysis data and processes in Siemens PLM So˜ ware’s Teamcenter. BY KENNETH WONG United Launch Alliance’s engineering hen Michael Gass, president workfl ow is designed to minimize human and CEO of United Launch error via automation. W Alliance (ULA), sat down for an on-camera interview with Siemens Product Lifecycle Management (PLM) Software’s public relations department, he revealed something about engineers that might seem counterintuitive to many. “Engineers are not the most flex- ible people, especially when they have a process that works,” he observed. “In our culture, we kind of resist change … Any- time you introduce a new process, there’s a bit of resistance.” That culture is bound to test the mas- sive data-and-process consolidation ini- tiative at ULA. As the science of rocket building gets more sophisticated, the types of analysis and simulation possible to predict and perfect the rocket’s performance also related to “mass, moments of inertia, To keep product development from dif- grow. “What is necessary to [analyze a control dynamics, and angle of attack, ferent disciplines in sync, the staff re- rocket] evolved over time,” says Marc for example.” These are, he says, “non- sorted to labor-intensive data re-entry. Solomon, ULA’s PLM chief engineer geometric analysis parameters that affect “How we melded data was mea- and engineering systems architect. “We the basic plan of flight.” sured in meetings and meeting time,” kept saying, ‘Let’s go try this’ or ‘Let’s ULA’s ambitious plan is to bring Gass explains. “It was brute force to make sure this doesn’t happen.’ We’re hundreds of simulation tools — a mix get everyone to share information constantly learning. So we end up where of homegrown, commercial and hybrid and check through the data to verify we are today — hundreds of tools, and a codes — under a single environment. As an analysis translated to a physical de- chain of analysis in multiple steps, each its data-management hub, ULA chose sign. To have the most up-to-date data, one feeding into the next.” Siemens PLM Software’s Teamcenter. we relied on manual processes — and It wouldn’t surprise anyone that Solomon predicts that the team will obviously that led to errors.” ULA relies on digital simulation using “probably learn more about ourselves than The data syncing difficulty was made industry-accepted CAE software to ver- we do about Teamcenter” in the process. more complex by ULA’s use of multi- ify the integrity of its product concepts. disciplinary optimization (MDO), an ap- But what’s lesser known is its reliance on The Data Mound proach in which various simulation and non-geometric analysis. Solomon de- In the past, ULA had to cope with dis- analysis tasks undertaken by different scribes them as large-scale calculations connected systems and manual processes. departments must come together.

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de1213__ULA_Wong.indd 22 11/14/13 2:03 PM NEW VERSION

“Our designs are essentially larger than their parts,” explains Solomon. “In most cases, we’re analyzing a large chunk Data Analysis and Graphing Software of the system or the whole thing. It seems the rest of the world is focused on design management. That’s not enough for us. We must manage our design, but the world we work in demands a compre- hensive engineering approach.” Because ULA is one of a handful of companies building rockets, the com- pany had to develop in-house tools to tackle the tasks commercial software couldn’t address. “In the rocket world, there aren’t too many things you can buy off the shelf,” Solomon quips. “We use lots of commer- cial tools, tools we’ve developed in-house, and hybrid tools that have home-devel- oped extensions on commercial tools. A big part of our Teamcenter integration is looking at how to integrate our non- commercial software tools.”

Big Bang Not Recommended Like any large institution, ULA has built up the equivalent of muscle mem- ory in its processes over the years. To persuade its staff to abandon the fa- miliar routines, even for more efficient ones, wouldn’t be easy. “I knew it was going to be hard, and it continues to be hard from the social per- spective,” Solomon admits. If the current system isn’t broken, why fix it? “We also wanted to break the mold of being tied to our roots to go on to doing something new,” Gass says, add- ing that he also recognized change is not ULA’s forte. Thus, he hedged on an in- ◾ cremental deployment strategy: Instead Point-and-Click GUI plus Over 500,000 registered users Programming Capability worldwide in: of the all-at-once Big Bang approach, ◾ 2D, 3D, Contour, Statistical, ◾ 6,000+ Companies including which would have likely been disrup- Specialized Graphs 120+ Fortune Global 500 tive and resistance-prone, the company ◾ Import Data from 3rd Party Files ◾ 6,500+ Colleges & Universities launched a pilot program that would or Database ◾ 3,000+ Government Agencies serve as a template. ◾ Curve Fitting, Peak Analysis, Signal & Research Labs As its first priority, ULA singled Processing, Statistics out requirements and analytical sys- ◾ Batch Plotting and Analysis tems, the sectors that involve a high ◾ Publication-Quality Reports number of homegrown tools with dif- OVER 200 NEW fEatuRES & 20+ years serving the scientific ferent characters. ImpROVEmENtS IN ORIgIN 9.1! & engineering community “Every [launch] mission has its own www.OriginLab.com/91 series of analyses,” Gass says. “Not only (800) 969-7720 [email protected]

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de1213__ULA_Wong.indd 23 11/14/13 11:25 AM Optimize Analysis /// PLM

LEFT: ULA measures launch success by its analysis work, even more so than its design work. BELOW: ULA is integrating its simulation tools via Siemens PLM Software’s Teamcenter.

do we manufacture the rocket, but we also manufacture the mis- sion design, and our ability to predict and model the mission, ULA runs two distinct rocket product lines, dubbed Atlas V and deliver it to customers so they can use it, is critical.” and Delta IV. Each system, according to Solomon, has its own Gass had another reason for starting with analysis: Simula- rich history and enterprise knowledge. tion analysts comprised the biggest skeptics who believed they “In the process of integrating the two businesses, with lots of could do everything themselves. At the same time, he also rec- different ideas from each, we have to make sure we incorporate ognized they had the skills to embrace a project of this magni- everything we know about each, and not lose any knowledge,” tude. Getting early buy-in from this group, then, would set the he explains. With Teamcenter as its consolidated data and pro- tone for the rest of the enterprise. cess hub, he says, ULA hopes to retain its institutional wisdom. “We’re at the beginning stage. We’ve done all the home- ULA engineers are used to relying on a rigorous checklist of work. We’ve built the railroad tracks [for integration],” he says. questions to conduct their analyses. The data from the check- “So as we move from group to group, we don’t need to start lists will now be mapped into Teamcenter, so most handoffs are all over. We pick a solution of ours, figure out the manner in automated, with a series of dashboards that reveal hiccups. which we’d like to integrate it, capture that very quickly, and The most immediate benefit from the project so far, Solo- then move on to the next group. It’s important to do this on an mon observes, is a “reduction in overhead of documenting anal- incremental basis, because we cannot destabilize the business as ysis assumptions, processes and outputs. These tasks used to be we move [our tools] into Teamcenter.” repetitive manual data-entry tasks; today, they’re to be captured by the system.” As a consequence, Solomon points out, “some- Laying Down the Tracks for the Future one downstream should be able to follow a chain of analysis all When fully implemented, ULA’s Teamcenter deployment will the way back to the start, so he or she can confirm or challenge oversee a mix of intertwining analysis activities, spanning from the assumptions.” stability calculations in MathWorks MATLAB to structural Another advantage introduced by Teamcenter is easier analyses in Siemens’ NX CAE. The success of the implementa- change management in the analysis chain. tion might be difficult to quantify, but Solomon has a specific “[Engineering] assumptions cascade through one group to yardstick in mind: “We want to see radical improvement in our the next,” Solomon says. “If there’s a change, new assumptions ability to move information through the business.” move downstream. So whenever there’s a change injected into There is also the issue of the retiring workforce. ULA’s cur- the process, the groups have to reassess the assumptions.” rent simulation expertise is confined to a small group, a “special With manual data entry, there was always a risk that altered tribe.” Therefore, in Gass’ words, “the transfer of tribal knowl- assumptions might not properly be communicated to the rest edge to the next generation and [to] do so as fast as possible of the analysis tree. The automated process ensures changes are using tools that appeal to the next-generation’s skill set” has flagged with alerts, along with dashboards providing a transpar- taken on new urgency. ent view of how the change affects the rest of the operations.

24 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213__ULA_Wong.indd 24 11/14/13 1:59 PM Sponsored Report /// MSI

“We tend to be overly cautious, because our mistakes are highly visible,” Solomon notes. “If we don’t truly understand a MSI Mobile Workstations – change’s impact, we might possibly — and certainly have in the past — redo the work we’ve done, just to be sure. If we under- Built for Engineers stand the changes, we save cycles by reducing — in classic Lean manufacturing terms — overproduction.” Multi-monitor capable mobile workstations ready for compute-intensive engineering. Hands-free Flight Even among devout fans of rocket science, there may be a s an engineer, you know common misconception that unmanned rockets launched that sometimes you into space are meticulously shepherded by a team at Mis- A have to take work home sion Control, perhaps using a sophisticated steering device or to the client. You dread it to drive them through asteroid fields like you might do in a because your home system and video game. But that is not the case, Solomon says. your business notebook are not “The launch vehicles are truly autonomous,” he explains. up for the job. Introducing the “When we designed them, we gave them structure, capability all-new MSI GT70 and GT60 and power. We also gave them autopilot. We tell them, ‘Your Mobile Workstations from MSI Computer Corp. With the job is to get from here to there. Whatever you may encoun- power and flexibility to serve as a multi-monitor desktop ter in space, your job is to get this [payload] to this point and workstation running compute-intensive engineering appli- drop it off without breaking it.’ At a certain point, we say cations, the GT70 and GT60 Mobile Workstations are built goodbye to them; they’re on their own. There’s nobody with and designed so that you can take your engineering worksta- a joystick driving them.” tion with you wherever you need to go. To be able to travel through space autonomously, the Based on the award-winning GT Series notebooks, the GT70 rocket’s internal infrastructure must facilitate automatic and GT60 next generation workstations are fueled by NVIDIA flight data assessment, with no manual intervention from Quadro K3100M and K2100M mobile graphics cards and Intel Mission Control. There’s a certain parallel to this hands-free Core i7-4700MQ processors. Fully certified and optimized for approach to be found in what ULA has set out to accomplish such industry-leading applications as Autodesk, SolidWorks, and with Teamcenter. Adobe, the GT70 and GT60 leverage NVIDIA Quadro tech- “We’re not research scientists tackling open-ended ques- nology empowering you to run design and rendering, structural tions. We’re trying to solve engineering problems within set analysis, or fluid analysis without any downtime or delays. schedules and costs,” Solomon concludes. “We want to let The GT70 and GT60’s Matrix Display technology lets our engineers be part of an integrated system that stays in you switch from a mobile workstation to a multi-monitor lockstep with the business, but we don’t want to tell them desktop workstation easily and efficiently. Matrix Display how to do analysis.” supports up to 3 external independent displays simultane- Gass echoed the sentiment while talking about the ously, enabling you to render 3D images, design, and check project at Siemens’ analyst event in September: “It’s all your reference files at the same time. about winning the hearts and minds of people. Introducing Engineers and designers looking for a mobile worksta- Teamcenter is more about people change management than tion with higher resolutions, sharper images, and an precisely about IT connectivity.” DE calibrated display will appreciate the 3K monitor versions of the GT60. The GT60’s maximum 2880 by 1620 display out- Kenneth Wong is Desktop Engineering’s resident blogger and put ensures that your designs are represented the way they senior editor. Email him at [email protected] or share your were meant to be. thoughts on this article at deskeng.com/facebook. Additional reporting The GT70 and GT60 Mobile Workstations are also designed by Desktop Engineering Contributing Editor Beth Stackpole. with exclusive networking optimizations – the Killer DoubleShot high-performance Ethernet and Wi-Fi networking solution from Qualcomm Atheros. Offering up to 5x better latency than similar INFO ➜ MathWorks: MathWorks.com solutions, Killer DoubleShot gives you the horsepower to handle ➜ Siemens PLM Software’s interview with ULA CEO multiple in-coming and out-going data streams at once. For su- Machael Gass: youtu.be/RUX6pSB941A perior bandwidth control, Killer DoubleShot’s Visual Bandwidth Control lets you see and manage your data streams in real-time. ➜ Siemens PLM Software: PLM.automation.siemens.com/en_us To learn more about the MSI GT70 and GT60 Mobile ➜ United Launch Alliance: ULALaunch.com Workstations for engineers, go to: For more information on this topic, visit deskeng.com. www.msimobile.com/workstation.

deskeng.com /// December 2013 DESKTOP ENGINEERING 25

de1213__ULA_Wong.indd 25 11/14/13 11:26 AM Optimize Change /// The Human Element Overcoming Corporate Culture to Make a Change

Looking to change things for the be˜ er? Don’t be surprised to fi nd all manner of obstacles in your path. BY MARK CLARKSON Image courtesy of iStock.com

About 15 years ago, we developed a product called and the road surfaces. You can get results within 10% to Virtual Proving Ground,” recalls Abe Keisoglou, president 15% of experimental results up front, without building a “of Engineering Technology Associates (ETA). “It was a million-dollar prototype. You save six to nine months in unique product, and we really thought that the auto in- your design cycle up front.” dustry would accept it.” Keisoglou and his team completed several successful Virtual Proving Ground, however, was not a success. projects with Ford, GM and Chrysler. Top management At the time, says Keisoglou, a rigid body kinematics was excited, each time enthusing “This is a great idea. program called Adams (now owned by MSC) was the Let’s do it!” predominant product in the auto industry for doing load So how, exactly, did Virtual Proving Ground fail? Top simulations. “A whole car was about 60 points,” he says. management. “It’s a very simple model to build, and runs very quickly.” “They didn’t want to make enemies of middle manage- But to create that model, you first had to build an ac- ment by forcing things down their throat,” Keisoglou ex- tual car. “You’d build a prototype,” says Keisoglou. “It plains. “So they would say, ‘You need to talk to so-and-so costs $1 million, and takes six to nine months. Then you middle manager. He needs to implement this himself, so instrument that car, and run through different road condi- he needs to feel comfortable with it.’ This middle man- tions at the proving grounds while you capture data on all ager’s career is based on a legacy of success with [Adams]. the loads. You take those loads and build an Adams model, They had a lot of money invested in the software and the and tune it to match the experimental data from the car. training. They would do everything possible to kill the Then you’ve got a model you can use to start making de- implementation of our new process. And politically, it sign changes for the car.” became impossible to break through and implement our “You can’t do any design for at least a year,” he adds. technology. This was almost across the board in the U.S. “So we came up with Virtual Proving Ground. You build auto industry.” a finite element (FE) model of the whole car — instead It’s not just management who’s resistant to change, of of having 60 points, you have millions of elements: ele- course. Bill Zavadil, senior vice president at IMAGINiT ments that describe the body, the suspension, the chassis Technologies, recalls a project with a major equipment

26 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_Culture_Clarkson.indd 26 11/14/13 11:49 AM manufacturer who had spent millions of dollars to migrate will happen when you change things? I can’t tell you how from CADAM to Autodesk. many companies we’ve walked into that have changed “Two years later, we walked into the place and the guys something in their product and now it didn’t work any- were still using CADAM,” he says. “It’s what they were more. They didn’t know what to do.” used to. They were getting the job done. One day, [the Veikos recalls one such company whose business was company] took that desktop away, and forced them to making foam mattresses. “They had a very old process that make the change. had developed over time,” he says. “It worked just fine, “You’re always going to have people who aren’t going and then something forced them to make a change and it to buy into change,” Zavadil continues. “But the company stopped working. The one guy who knew how to tweak didn’t try to understand where these guys were coming the thing was long gone and retired. All the company from. They didn’t explain the logic behind the change, did was make these mattresses, and they had no insight didn’t articulate the objectives behind it. That has to come into what was going on. They thought they knew how it from the top.” worked, but that wasn’t how it worked at all.”

Until Now, Everything Was Fine Segregation Sometimes, the problem lies in convincing management “Sometimes,” notes Rod Mach, president of TotalCAE, that potential problems even exist when everything seems “the company is segmented in a way that creates these to be going swimmingly. Companies often make the mis- islands of engineering. There’s a CAE group and an FEA take of assuming that, since they have created a process group. Or they’ll segment groups by product. That might that consistently produces good quality products, they look good on an org chart, but groups don’t speak to each understand how that process works. other and aren’t learning from each other. They each only Nicholas Veikos, Ph.D., president of CAE Associates, have a small pool of money. They can’t pool licensing or poses some key questions: “Do you really understand hardware or brains.” how your product works? Do you really understand what For example, Mach continues, he was consulting on a

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desktop publishing advert nov 2013.indd 1 deskeng.com /// December 2013 DESKTOP ENGINEERING06/11/2013 27 17:24

de1213_Culture_Clarkson.indd 27 11/14/13 11:50 AM Optimize Change /// The Human Element

project that several different groups within one company Be a Champion were trying to do independently: “They were all going to “There’s always resistance to change,” says Mach. “Al- the same vendors and getting quotes they couldn’t afford. ways. Even if the change is better, people naturally resist We said, ‘Did you know there are other people at your change.” company doing the same thing? Why don’t you all work Mach adds that for big companies especially, it’s not together and pool the money to get the tools you all need?’ usually one person’s decision to adopt something new. If They were all starving, whereas if they’d pooled their you can’t find a champion, somebody who’s really going money together, they could have gotten a steak dinner.” to lead, then it takes just one person to negate the idea for it to completely disappear. You Want What? “You need someone with enough political capital to Another big impediment, says Mach, is that management take a few bruises. Without that champion, without having views engineering technology the same way they view a someone who’s really invested and can make other peo- file print resource. They don’t understand why engineers ple believe in the change, it’s very different to get things need so many expensive resources: “Engineers just want changed internally,” he says. better toys. Why can’t they run on their laptops like ev- To get management buy-in, says CAE Associates’ Vei- erybody else does?” kos, you have to be able to quantify the benefits. “There’s “In most companies, IT will try to shoehorn you into no better way than some kind of pilot project,” he says. [hardware] they’ve already picked,” he “Find something that’s not going continues. “But these are scientific in- There’s always resistance to take the company down if it goes struments that take special skills and “ to change. Always. Even if wrong, so nobody gets nervous, and are solving special problems. Your IT the change is bette , people then go through the process. Develop department might not be your best naturally resist change. metrics for what success is, before you leader to decide what your engineers start, and then measure everything. At need to get their job done.” — Rod Mach, president” of the end of the day, you’ll have a very In addition, management may not TotalCAE good comparison: Here are the quan- always recognize expenses. “A lot of the tifiable benefits that you’ve achieved, focus at companies is on the spending side,” says Mach. how much money you saved in the design process, how “The ROI calculations often don’t consider labor and time much time you’ve saved. Many times, that’s sufficient to to market.” change the mindset.” Take simulation run times, for example. “People get ac- “You have to stick your neck out and be proactive,” agrees customed to engineers sitting around for a week waiting for ETA’s Abe Keisoglou. “You’ve got to take the lead. You have an answer,” says Mach. “They see the capital expenditure to take chances. Find out what the new technology is, and of getting a better resource in place — a cluster or what- how to bring it into the organization with the intent of help- have-you — as an immediate expense, but they don’t see the ing the company be more efficient and more profitable. value of getting the results faster, of the engineers not sit- “Be a visionary. If you see something that needs to be ting around waiting. If you’re paying 10 engineers $100,000 done, go out there and make it happen.” DE each, you’re paying $1 million to have those engineers idle in order to avoid a $100,000 capital expenditure.” Contributing Editor Mark Clarkson is DE’s expert in visu- To get management’s attention, says Mach, you need to alization, computer animation, and graphics. His newest book quantify the improvement. Maybe the engineer won’t be is Photoshop Elements by Example. Visit him on the web at sitting and waiting for results as often, but what are you MarkClarkson.com or send e-mail about this article to DE- going to do with the time that you freed up? What are the [email protected]. benefits? Because the costs — the software, the hardware, the process, the consultants — are all too visible. “Engineer-speak doesn’t always translate up the food INFO ➜ CAE Associates: CAEai.com chain to the people who sign the checks to fund these ➜ Dassault Systèmes CADAM: CADAM.com initiatives,” says Mach. “Don’t say, ‘I can do 1,000 runs.’ Say, ‘We can make our product X percent lighter than the ➜ Engineering Technology Associates: ETA.com competition if we have this tool,’ or ‘We’ll get the answer ➜ IMAGINiT Technologies: IMAGINiT.com 10 times faster, which will impact design and save money ➜ MSC Software: MSCSoftware.com/product/adams on testing.’ That seems to be a better understood metric.” That can be hard to do, he admits: “You’re setting ➜ TotalCAE: TotalCAE.com yourself up for more work.” For more information on this topic, visit deskeng.com.

28 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_Culture_Clarkson.indd 28 11/14/13 11:51 AM Special Sponsored Section Siemens PLM Software /// Optimization Leader Rocket Scientists Unite Simulation Data to Go Beyond Teamcenter Simulation Process Management from Siemens PLM So˜ ware gives United Launch Alliance truly integrated simulation data.

nited Launch Alliance (ULA) to speed launch timeframes is the leader in designing and and ensure quality. Ubuilding vehicles to launch criti- cal spacecraft for the U.S. Government, Teamcenter – a including the Department of Defense, powerful solution to a NASA, the Na tional Reconnaissance complex problem Office, and other commercial custom- Teamcenter Simulation Pro- ers. As the science of rocket building cess Management was devel- becomes more sophisticated, the need oped for exactly these types for more complex, comprehensive sim- of challenges that need to ulation models evolves. With this evo- integrate and leverage com- lution comes a need to unify and inte- plex simulation data from a grate data from a wide range of sources multitude of sources across the enterprise. try where mistakes are highly visible. and align it to mission objectives. Teamcenter Simulation Process Man- ULA management knew it needed agement provides data, workflow, and to demonstrate early advantages It IS rocket science process management across departments on a controlled scale to fuel adop- To achieve its goal of 100 percent mis- and functions to streamline collaboration. tion. Teamcenter Simulation Process sion success, ULA has come to rely on ULA, a longtime user of Siemens PLM Management enables exactly the in- a vast array of simulation solutions – Software’s NX CAE and Teamcenter cremental roll-out they wanted. ULA both off-the-shelf and custom – and products, saw the potential of extending could select a process to optimize, a chain of analysis in which one step its use of Teamcenter to address the simu- configure Teamcenter to address the feeds the next. This de mands labor lation data management challenge. challenge, and then move on to the intensive repetitive manual data man- next group. Although ULA is only agement. The result? An overwhelm- A rational implementation path beginning to implement this new ap- ing mountain of data. ULA needed a Engineers are an inherently conser- proach, the early results are already better way to harness simulation data vative group, especially in an indus- paying dividends.

About Siemens PLM Software Siemens PLM Software is a leading global provider of product life- cycle management (PLM) software and services with seven million licensed seats and more than 71,000 customers worldwide. Head- quartered in Plano, Texas, Siemens PLM Software works collabora- tively with companies to deliver open solutions to help them make smarter decisions that result in better products. For more informa- tion on Siemens PLM Software simulation products, please visit: www.siemens.com/plm/nxcae.

Contact Information: For more information visit: 5800 Granite Parkway, Suite 600, Plano TX 75024 www.siemens.com/plm/nxcae Phone: 1-800-498-5351 • Email: [email protected]

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Optimization_Siemens.indd 29 11/14/13 3:29 PM Special Sponsored Section Optimization Leader /// Altair Innovative Design Can Make Anything Lighter

Altair’s technologies and expertise change the way organizations design products.

ltair develops and imple- Over the last two decades, Altair ments intelligent simulation has pioneered simulation-driven de- A technologies that allow you sign to generate innovative design to significantly reduce the weight of solutions for its clients. This has re- your products, saving cost, fuel and sulted in products that exhibit mini- CO2 emissions, but how do we do it? mum weight and outstanding perfor- Instead of taking a product that’s mance in industry leading timescales. already been designed and just try to Altair’s software solutions enable shave off material, we take a different users to design high performance, approach, which we call ‘simulation- weight efficient structures, starting in a multi-disciplinary product design driven design’ where CAD and CAE the concept design phase. Designers cycle even for the most complex are deployed in parallel. and architects can use solidThinking structures. Using our optimization technolo- Inspire to generate and explore struc- But we’re not just another soft- gies our clients can define a design turally efficient concepts in a friendly ware developer. Altair began life as space, an area where the component and intuitive environment. a product design services company must fit in the structure, including data Moving to product engineers and and the knowledge of real world of any holes or access points required. analysts, HyperWorks offers opti- product development and under- Loads are applied to the design space mization solutions for both concept standing of manufacturing processes along with manufacturing constraints studies and design fine-tuning stages. and constraints has never been lost. and other variables, allowing our tech- OptiStruct, Altair’s award-winning Our team works across industries, al- nology to suggest the best possible ma- integrated analysis and optimization lowing us to use processes and tech- terial layout, which meets the predeter- tool, along with HyperStudy, Altair’s niques from one industry and apply mined performance targets. design exploration software, enable them to another.

About Altair A Culture of Innovation Our vision is to radically change the way organizations design products and make decisions, developing and applying simulation technology to synthesize and optimize designs, processes and decisions for improved business performance. Privately held, with offices in 20 countries, Altair provides Innovation Intelligence® to thousands of customers worldwide.

Contact Information: World Headquarters 1820 East Big Beaver Rd., Troy, MI 48083 For more information visit: Phone: (248) 614-2400 • Fax: (248) 614-2411 www.altair.com e-mail: [email protected]

30 DESKTOP ENGINEERING December 2013 /// deskeng.com

Optimization_Altair.indd 30 11/14/13 2:09 PM Special Sponsored Section Aras /// Optimization Leader

Replace Legacy PLM to Optimize and Accelerate Performance for Large-Scale Multi-CAD Management Independent Testing Verifi es Aras Next Generation PLM Outperforms Leading Legacy PLM and Loads CATIA 81% Faster.

f you’re looking to optimize perfor- acute when a business has complex pro- mance across the enterprise, there’s cesses and is using a legacy PLM system I no better place to focus than PLM for CAD data management, as the total starting with CAD file management. size of files and metadata continue to in- And if you are a CATIA user, you’ve crease exponentially. likely experienced the frustration of A recent independent report by T- slow performance when managing these Systems International documents the large, complex files on a daily basis. You actual, validated performance improve- are not alone. ments achieved when a legacy PLM sys- Performance is a very real chal- tem for managing CATIA was replaced lenge that global companies face with with Aras. legacy PLM systems. Organizations During a client project, a series of are frequently forced to spend valuable different real world assembly structures resources and time to improve PLM were identified, analyzed and used as performance, and are often unable to reference cases. The file size of the CAD achieve meaningful improvements. Per- data varied between 50 and 450 MB — formance issues become particularly depending on the volume and complex- ity of the CAD structure — including Global companies should test scenarios focused on the loading Read the full report at “ consider the performance procedure of large assembly structures www.aras.com/OPTIMIZE characteristics of Aras (with over 1000 CAD objects) into the BOOSTING PERFORMANCE USING “NEXT GENERATION” PLM FROM ARAS comparable or be˜ er than design mode of CATIA V5. by T-Systems International other PLM so° ware solu- Aras Innovator outperformed the legacy PLM system in every test. tions currently available on Aras’s speed ranged from 41% to the market, particularly for 81% faster, performing better on larger Aras loaded the assemblies quickly. large complex CAD data assemblies. On the two largest assem- What’s more, Aras achieved these results management workloads. bles, the legacy system failed to load the with 1/3 the IT hardware resources of T-Systems International” files even after several attempts while the legacy PLM system.

About Aras Aras provides powerful PLM technology to leading companies around the world. Only Aras offers a highly scalable, flexible and secure PLM platform with an open architecture designed specifically for tomorrow’s complex global product development environments. Discover your next PLM solution at www.aras.com

Contact Information: 300 Brickstone Square, Suite 700 For more information visit: Andover, MA 01810 www.aras.com Phone: 978-691-8940

deskeng.com /// December 2013 DESKTOP ENGINEERING 31

Optimization_Aras.indd 31 11/14/13 3:28 PM Special Sponsored Section Optimization Leader /// CAE Associates, Inc. Pervasive Simulation is the Key to Optimized Products CAE Associates helps companies succeed through automation of CAE processes. n today’s competitive business en- real-time. Also, to be truly predictive vironment, the traditional product of product behavior in the field, and to I development paradigm cannot pro- ensure that the optimal design is cho- duce designs with enough speed or ro- sen, hundreds, perhaps thousands of bustness to ensure market dominance. variations must be investigated. This sis software. The complexity of the Multiple iterations of design-build-test is not feasible without an integrated, project is not important; we remain are not acceptable from a time and cost automated process. To be successful, focused on the benefits to our clients. perspective. As a result, market leaders optimization first requires automation. Past projects include: in all major industries, having adopted For over 30 years, CAE Associates • Process to automatically predict fa- engineering simulation a long time ago, has been helping technology leaders tigue life in ball grid arrays. are at the next stage and employ simu- integrate automated, customized, FEA • Automated procedures to configure lation as an inherent part of all phases and CFD solutions into their process. and optimize medical stents. of the product development process. We work closely with clients to under- • CFD-based electric motor optimiza- From preliminary design through stand how they design products, make tion to minimize windage losses. manufacturing, simulation plays a key recommendations for how they can • Automated spline-coupling modeling role in how they develop better qual- most benefit from simulation at vari- system for gas turbine engines. ity, lower cost products and get them ous stages, and implement the resulting • Comprehensive customization pro- to market first. plan. The result is a streamlined simu- cess for optimization of air condition- The infusion of computer modeling lation workflow which can be leveraged ing compressors. and simulation throughout the design to produce an optimal design. All of these examples began with process cannot be successful without Automation and customization simulations that required many man- development of automated analysis projects at CAE Associates range from weeks or months to complete manually, methods which are scalable and persis- the development of simple scripts for and reduced the process to a few simple tent throughout. There is insufficient automating a repetitive task, to creat- mouse-clicks. We enabled our clients to time for manual creation and rework ing entire simulation processes, driven move from using simulation as a last re- of FEA and CFD models as the design from beginning to end with no user sort to the new paradigm of using it in progresses from concept to production. intervention, or even any knowledge a systematic, predictive fashion for the This must happen automatically and in of how to use the underlying analy- development of optimized products.

About CAE Associates, Inc. As an engineering consulting firm founded in 1981, CAE Associates guides leading organizations through simulation solutions for structural, thermal and fluid design challenges. We offer straight advice and expert consulting to help both large and small companies maximize the value ASSOCI AT ES from engineering simulation. Our solutions are tailored to the unique ENGINEERING ADVANTAGE needs of each client, helping to quickly meet near-term requirements, while positioning for long-term success.

Contact Information: 1579 Straits Turnpike, Suite 2B, Middlebury, CT 06762 For more information visit: Phone: 203-758-2914 www.caeai.com Email: [email protected]

32 DESKTOP ENGINEERING December 2013 /// deskeng.com

Optimization_CAE.indd 32 11/14/13 12:04 PM Special Sponsored Section CD-adapco /// Optimization Leader Breaking Down the Barriers of Design Exploration and Optimization Bringing High Fidelity Engineering Simulation into the Design Loop

s organizations realize the value parallel optimization of design optimization studies algorithms are a practi- A to gain competitive advantage, cal must-have for auto- it is a natural desire to have the pro- mated design studies. cess driven by the most accurate simu- Historically this would lations possible. Otherwise there is a have meant purchasing significant risk that the design space many expensive soft- established will be a false “virtual de- ware licenses. sign space” that does not correspond But with the new to the “actual design space”, leading Power Token license to designs that do not meet expecta- system, engineers have tions when they are put to the test in full access to affordable license tokens CD-adapco employs an army of software the real world, thus the need to bring that provide the flexibility to minimize developers and physics modeling experts high fidelity CAE simulations into the the cost of their optimization process for from around the globe with a singular automated design loop. each individual project. purpose to make STAR-CCM+ the most Traditionally, however, there have accurate, robust, and efficient CAE soft- been several significant challenges that Accuracy, Robustness and ware on the market. have kept high-end CAE technology Efficiency from being implemented within design Accuracy, robustness and efficiency are State-of-the-art Optimization optimization: commercial licensing, ac- fundamental requirements for point Technology curacy, robustness, efficiency, and cou- evaluations in a design study. A simula- Finally, the simulation software must be pling with optimization technology. tion code must be valid for the entire coupled with design optimization tech- design space otherwise the optimization nology such as with STAR-CCM+ and Power Token Licensing algorithm will be lost. It is akin to the the SHERPA algorithm from Red Cedar One of the most common barriers to old adage “garbage in — garbage out.” Technology. The Optimate+ add-on for using high-fidelity CAE simulation is the An invalid design space, whether due STAR-CCM+ gives engineers direct ac- cost of traditional CAE licensing. The to code crashes or inaccuracy, will lead cess to the most powerful and effortless use of high performance computing and to an invalid design optimization result. optimization algorithm on the market.

About CD-adapco CD-adapco is the world’s largest independent CFD-focused CAE provider. Our singular purpose is to inspire innovation with our customers while reducing their costs through the application of engineering simulation. A key to achieving this purpose is pro- viding access to advanced physics models during conceptual and preliminary design phases, and innovative licensing models for design exploration and optimization.

60 Broadhollow Road, Melville For more information visit: NY 11747 USA www.cd-adapco.com Phone: (+1) 631 549 2300

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Optimization_Cd-adapco.indd 33 11/14/13 2:10 PM Special Sponsored Section Optimization Leader /// Collier Research Corporation Optimization of Sophisticated Materials Made Simpler HyperSizer V7 from Collier Research has been fundamentally reconfi gured for ease of use by the skilled non-expert.

omposite materials have ligence,” along with reached the engineering main- quick, detailed sizing C stream. They are in wide use that increases analysis in aerospace, windpower, transporta- speeds up to 1000X, al- tion and a variety of other industries. lows for design decisions In most of these settings, optimization to be made in real time traditionally has been the domain of throughout the design/ technical specialists. analysis workflow. A Hy- But now there is a sophisticated, perSizer optimization easy-to-use composites (and metal) typically yields weight optimization tool that simplifies the savings from 20-40%. process and can be trusted in the hands Automatically iter- of the general engineer. The V7 release ating in a continuous loop with finite Originally developed at NASA, of HyperSizer® structural sizing and element analysis (FEA) solvers, Hyper- HyperSizer was the first software al- analysis software has a new interface Sizer software can optimize millions lowed to be commercialized and ha and other enhanced usability features. of design candidates while visualizing seen ongoing use at the agency on These empower the engineers respon- composite details to the ply, even ele- high-profile, zero-failure-tolerance sible for primary design and analysis of ment, level. The tool defines laminate programs. It is also employed by lead- structures in their day-to-day work by zones and provides precise details about ing companies involved in commer- delivering consistent, reliable and ro- ply coverage and ply drops, improving cial aircraft, UAV, space launch, and bust solutions. manufacturability. Serving as an inde- wind energy projects. To identify optimal lightweight pendent and neutral hub for industry- With its new ease-of-use capabili- and fuel-efficient designs, HyperSizer accepted CAD, FEA, and composites ties, HyperSizer V7 puts the power of V7 self-configures for different load- software, HyperSizer automates project optimization within the reach of the ing scenarios, requiring less input data flow from early conceptual design everyday engineer—and every engi- from engineers. This added “intel- through final certification. neering organization.

About Collier Research Corporation One of the early leaders in product optimization software, Collier Research Corporation is the developer of the NASA-originated HyperSizer® structural sizing and design optimization tool for composites and metallic materials. Since 1996, our company provides the engineering community with robust and easy to use software for designing the lightest weight producible structure.

Contact Information: 760 Pilot House Dr. Suite A, Newport News, VA 23606 Phone: (757) 825-0000 For more information visit: Fax: (757) 282-5853 www.hypersizer.com [email protected]

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Optimization_Collier.indd 34 11/14/13 12:10 PM Special Sponsored Section Convergent Science, Inc. /// Optimization Leader Convergent Science Optimizes CFD by Automating the Meshing Process

Never make a mesh again.

s organizations sprint at a the addition of Adaptive Mesh breakneck pace toward product Refinement (AMR). AMR adds Ainnovation and improvement, increased meshing resolution they often run into a hurdle in their where and when it is needed CAE toolchain…Meshing. Meshing automatically. This new and in- can be one of the most time consuming novative approach uses a com- processes in the entire CAE procedure. pletely stationary orthogonal With inconsistencies between different Cartesian mesh. The ability meshes, diffusion due to mesh stretch- to simulate complex moving ing, and trying to guess where to put geometries is handled just as more mesh for increased accuracy, the easily as stationary geometries. list of meshing issues is long. Add to that a complicated or moving geometry Optimized Detailed Chemistry Optimized Designs and the complexity of the mesh can in- The automated meshing in CON- CONVERGE™ comes fully equipped crease exponentially. VERGE™ not only optimizes your with a genetic algorithm optimiza- CFD lifecycle, it also allows engineers tion model. To put it simply, CON- Optimized Meshing to accurately solve combustion analyses VERGE™ takes a “survival of the Convergent Science, Inc. has opti- with detailed chemistry. Solving detailed fittest” approach to design optimiza- mized the CFD lifecycle by remov- chemistry with CONVERGE™’s AMR tion and automatically initiates CON- ing the user defined meshing process technology will reduce runtimes and in- VERGE™ CFD simulations in search with CONVERGE™ CFD Software. crease accuracy by dynamically adding of an optimum product design. Utiliz- CONVERGE™ automates the entire mesh resolution at runtime when and ing this approach, the manual user in- meshing process at runtime. The mesh where it is needed, effectively optimizing teraction inherent in traditional design is re-created for each time step with the mesh for combustion during runtime. optimization is effectively removed.

About Convergent Science, Inc. Convergent Science, Inc. is a world leader in Computational Fluid Dynamics (CFD) software. Our flagship product, CONVERGE™, is CONVERGENT a CFD software package that is revolutionizing how fluid dynamics SCIENCE modeling is being used by engineers, researchers and designers. With CONVERGE™, traditional CFD bottlenecks (namely grid generation) have been removed from the modeling process, allowing users to spend more time analyzing their simulations and no time generating grids.

Contact Information: For more information visit: [email protected] www.convergecfd.com 830.625.5005

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Optimization_Convergent.indd 35 11/14/13 4:56 PM Special Sponsored Section Optimization Leader /// CPFD Optimize Refi nery and Chemical Plant Processes with Accurate CPFD Models Models help operators to improve plant reliability, reduce costs, and minimize emissions.

PFD Software is revolutioniz- even further, though units can be ing the design and operation limited by erosion and its impact on C of fluidized catalytic cracking mechanical reliability. Emissions (FCC) units, chemical-plant fluid- standards are increasing year-by- ized reactors, power plants, gasifiers, year and new ways of meeting these cyclones and other fluidized systems regulatory requirements cost effec- by providing a means to “see inside” tively are needed. reacting fluidized systems. CPFD’s solutions are built on their Com- Reactor Models Enable Solutions putational Particle Fluid Dynamics CPFD has become a leader in this (CPFD®) method, which is specifi- field by offering an enabling tech- cally designed for modeling reacting nology, Barracuda Virtual Reac- gas-particle systems. tor®, now available in a massively parallel version designed to run on Plant Operators Face low-cost GPU cards, giving every Challenges user the option of a “desk-side su- Refinery and CPI plant operators percomputer.” Barracuda VR helps face numerous challenges. Plants meet these important challenges range in age from a few years to de- by enabling process engineers and helping engineers right now to op- cades. Building new plants is dif- equipment designers to model even timize their processes while mini- ficult and expensive, so operators the most complex, 3D reacting flu- mizing capital expenditures, outage are looking to uprate and improve idized systems accurately, predicting time, and business risk. their existing plants wherever pos- both the hydrodynamic behavior and By providing both detailed mod- sible. Feedstock prices are volatile, the chemical kinetics. Models allow els and the software to run them, so feed flexibility improves profit- users to view their mixing, tempera- CPFD has become a leader in the ef- ability. Operating cycles have been ture distribution, conversion, oxygen fort to make refinery, chemical and extended to 5 years or more but op- usage, emissions, catalyst carryover, power plant processes both greener erators would like to extend them and more. The insights gained are and more profitable at the same time.

About CPFD Optimizing Fluidized Reactor Processes Worldwide CPFD Software provides models and modeling technology for the international fluidization industry across many applications with their unique Barracuda Virtual Reactor®, which can be used to optimize processes for economy, reliability, extended operating cycles, higher ® yields, and lower emissions. We help enable emerging processes that are critical to clean technology.

Contact Information: U.S. Corporate Headquarters For more information visit: 10899 Montgomery Blvd NE, Albuquerque NM 87111 USA www.cpfd-software.com/de T: 505-275-3849 | F: 505-275-3346 | E: [email protected]

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Optimization_CPFD.indd 36 11/14/13 2:18 PM Special Sponsored Section CST of America, Inc. /// Optimization Leader Optimization in Electromagnetic Design By integrating optimizers in its EM simulation tools, CST streamlines the development process.

he potential applications for embedded both local optimization in electrical en- and global optimization T gineering are plentiful. Tuning tools into the founda- filters and antennas, placing decou- tions of their software. pling capacitors, maximizing shield- Local optimizers are ing efficiency, improving connector suitable for problems performance, calculating useful input where the initial values signals, increasing manufacturing are reasonably close to the optimum, across a cluster means that these opti- yield; these are all tasks in which op- and offer quick performance at the mizations can be sped up significantly. timization is invaluable. risk of finding only a local optimum. CST offers Genetic, Particle Swarm CST knows that engineers want a pal- The local optimizers provided by CST and CMA-ES global optimizers, each ette of powerful, versatile optimization include Interpolated Quasi Newton, well suited for certain applications. tools at their disposal, but equally impor- Nelder-Mead Simplex Algorithm, and Because these tools are a funda- tantly, they want to be able to use these Trust Region Framework. The latter mental part of CST STUDIO SUITE, tools as part of their familiar workflow. can use sensitivity information — an they are compatible with all solver CST STUDIO SUITE®, CST’s estimation of how the structure will types and there is no need to set up flagship product, comprises a range of behave under small geometric changes complex links between simulation tool electromagnetic solver technologies, — to speed up the optimization pro- and optimizer. Geometries, material variously suitable for high-frequency, cess further. properties and waveforms can all be low-frequency, static, transient, Global optimizers on the other optimized according to goals drawn charged particle and multiphysics hand search the entire parameter from numerous different types of re- problems. To make it easier for de- space to find the optimum. This is a sult data, allowing engineers to design, signers to supplement the simula- somewhat slower process, although simulate and tune their devices in a tion process with optimization, CST the ability to distribute simulations single workspace.

About CST CST develops and markets high-performance software for the simu- lation of electromagnetic fields in all frequency bands. Our advanced simulation solutions help companies increase profitability and engineers to minimize costs by reducing the design risk and improving the overall performance of devices, especially for new or cutting-edge products.

CST – Computer Simulation CST of America, Inc. Technology AG HQ: US Headquarters: Darmstadt, Germany Framingham, MA 01701 For more information visit: For other locations in the Americas, Asia and Europe, please www.cst.com/optimization check the CST website at www.cst.com/Locations

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Optimization_CST_.indd 37 11/14/13 3:30 PM Special Sponsored Section Optimization Leader /// Dassault Systèmes SIMULIA The Quest for the ‘Best’ 3DEXPERIENCE is about optimizing a company’s business and products.

uickly creating the best design for performance, weight, cost Q and other mission-critical factors is increasingly important in launching market-winning products. Finding the best option requires a multidisciplinary approach with multiple trade-off studies. To reduce physical testing, companies are expanding the use of virtual testing and Image courtesy of GF Automotive design optimization technology. Dassault Systèmes, the world-leader sign optimization. Its SIMULIA realistic a defined optimization task. Innovative de- in developing 3D software applications, is simulation applications provide the most sign proposals can be optimized earlier in delivering on a long-term strategy to pro- complete, open and robust toolset avail- the design process, reducing the number vide the most powerful solutions for de- able on the market. of physical tests. The business value of these applica- The 3DEXPERIENCE plat- Leading Technology: tions is significant and will increase dra- “form is all about optimizing a SIMULIA Isight is used to integrate matically as capabilities within Dassault company’s business and the multiple cross-disciplinary models and Systèmes’ 3DEXPERIENCE platform. products it o˜ ers. Is it what applications together in a simulation pro- This will provide easier access to these customers want? Can we cess flow, automate their execution across powerful capabilities for users of CAD, produce it quickly? Is it right distributed compute resources, explore FEA, and CFD technologies—not only for a sustainable future? the resulting design space, and identify from Dassault Systèmes, but also from its These are the questions optimal designs based on user-defined software partners. This openness ensures industry must ask to harmo- parameters. that manufacturing companies can lever- SIMULIA Tosca is the leading tech- age their current design and engineering nize products, nature and nology for non-parametric structural and software investments. life. And these are the ques- fluid flow optimization. It delivers power- When applied as an integral part of the tions our 3DEXPERIENCE ful optimization technology for design of product development process, Dassault platform answers. lightweight, stiff, and durable parts and as- Systèmes’ optimization technology will Bernard Charlès, President and” semblies. With Tosca, product designs are further enable companies to accelerate CEO, Dassault Systèmes. created solely on a given design space and and achieve their quest for the best.

About Dassault Systèmes SIMULIA As an integral part of the Dassault Systèmes 3DEXPERIENCE platform, SIMULIA applications, including Abaqus, fe-safe, Isight, Tosca and Simulation Lifecycle Management, enable users to lever- age physics-based simulation and high-performance computing to accelerate the evaluation and optimization of product performance, reliability and safety—before committing to costly and time-con- suming physical prototypes.

Contact Information: 166 Valley St. For more information visit: Providence, RI 02909 www.3ds.com/simulia Phone: +1 401-276-4400

38 DESKTOP ENGINEERING December 2013 /// deskeng.com

Optimization_SIMULIA.indd 38 11/14/13 3:20 PM Special Sponsored Section ETA /// Optimization Leader Following Nature’s Lead for Ultimate Design Efficien Optimization-led Engineering Service Enables Over 40% Mass Reduction.

he shapes and configurations of ponent, sub-system and/or full- nature are wildly complicated, system level in a wide variety of T non-intuitive and completely industries. amazing. The shapes and forms found in ACP is a performance-driven nature in the structure of a tree, a human product design development engine skeleton, insects and animals are truly based on design optimization and incor- the most efficient designs imaginable. By porates the use of multiple CAD, CAE mimicking the flawless balance between and CAO tools in a systematic approach structure and strength of nature’s most to find the optimal design solution. This efficient shapes, ETA engineers incorpo- methodology provides solutions, which rials; facilitates significant mass reduc- rate similar balance to product structural address the conflicting challenges facing tion (40% or more) for the final design, design for any complex structure, such as the modern product development envi- while realizing and even exceeding per- automobiles, aircraft and other systems. ronment. It achieves this by synchroniz- formance requirements. The Accelerated Concept to Product® ing the individual facets of the product The ACP Process has been applied (ACP) Process is a holistic cost reduc- development process, resulting in an to many structural systems in its entirety, tion methodology which enables the overall cost reduction (material, manu- including World Auto Steel’s FutureSteel- structure of a product, such as the vehi- facturing, tools and design time), in de- Vehicle (FSV) Program, which was com- cle’s body-in-white, to mimic “Nature’s velopment costs and time to market. pleted last year. During the final phase of Way”. Doing so creates the ultimate Material selection and utilization, program, FSV achieved 39% mass reduc- design efficiency, where structure, stiff- product performance, manufacturing tion and the new mass target was achieved ness and strength are perfectly balanced requirements and assembly processes in the design. The program incorporated for the intended multidisciplinary func- are all considered as early as possible in weight reduction, from vehicle baseline to tion. As a Product Design Engineering the design cycle. The resulting design detailing the steel body structure concepts Consultant, ETA provides this service offers a robust and highly efficient so- for the vehicles to meet aggressive mass to companies looking to improve ef- lution; which when combined with the targets of 177.6 kg, while meeting 2015- ficiency and performance at the com- strength and design flexibility of mate- 2020 performance objectives.

ETA ETA is committed to the delivery of processes, tools and services of consistently high quality and to continual improvement. ETA strives to be innovative and excels at providing new technology and multi-disciplinary expertise by developing new processes to help reduce cost and increase quality.

Contact Information: Email: [email protected] 1133 E. Maple Rd, Suite 200 For more information visit: Troy, MI 48083 USA www.eta.com +1.248.729-3010

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Optimization_ETA.indd 39 11/14/13 2:19 PM Special Sponsored Section Optimization Leader /// ESTECO Modularity to Master Complexity ESTECO technology evolves to a new paradigm, extending modeFRONTIER capabilities to a collaborative and fl exible environment.

ith an accelerating pace of ing problems, and once again nature EES combines the advanced capabili- request for innovation and provides the inspiration to resolve ties of the optimization platform mo- W steady increase in competi- the complexity of modern products deFRONTIER 4.5 with SOMO, the tion, companies today face product manufacturing. new distributed execution framework, complexity as the next challenge. In nature, organisms’ complexity for managing collaborative design pro- Time to market and effective life grows with the natural selection, and cesses. The solution empowers design cycle management are the drivers to so does the modularity and specializa- teams with a sharing platform for mod- leverage for higher levels of profit- tion of biological systems and units, els, workflows, simulations, optimiza- ability, inducing, however, a further which in turn increases the organism’s tions and results analisys. EES, inspired increase in complexity. All along the efficiency and chances of survival. Take by modularity, is capable of efficiently value chain, from concept design to the human brain as an example: dealing handling all stages of the product de- manufacturing and maintenance, spe- with an immense number of complex sign process, with the SOMO frame- cialists from different disciplines are tasks, the brain has different modules work. Domain experts, optimization summoned to make critical decisions specialized in individual cognitive and integration specialists and decision with paramount impact on product functions, but highly interconnected makers join forces and build advanced quality. And quality, with speed of de- and collaborative, allowing the human multidisciplinary optimization (MDO) cision, often determines the market being to achieve sophisticated tasks. frameworks and workflows, reaching a success of a product. With this in mind ESTECO better control over the design of com- Engineers and designers need to has developed the software package plex systems. Just like the brain drives master such complexity, and technol- ESTECO Enterprise Suite (EES) the body, EES drives product develop- ogy comes in aid. Software companies extending its established mode- ment by enabling engineers to under- have often looked to nature to get in- FRONTIER desktop paradigm to a stand the complexity behind it and turn spiration for solutions to engineer- web-based collaborative environment. it into innovation.

About ESTECO ESTECO is a pioneer in numerical optimization solutions, specialized in the research and development of engineering software. Perfecting engineering and reducing complexity in the design process is our vision. Our aim is to decrease the tedium and increase creativity by develop- ing and maintaining cutting-edge software for integration, optimization and advanced data analysis.

Contact Information: ESTECO North America 1221 Brickell Ave. Suite 900 Miami, FL 33131 U.S.A. For more information visit: ESTECO SpA www.esteco.com AREA Science Park, Padriciano 99, 34149 TRIEST ITALY

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Optimization_ESTECO.indd 40 11/14/13 3:31 PM Special Sponsored Section HBM-nCode /// Optimization Leader Reduce Product Development Time with nCode Achieve new standards through fi nite element based analysis.

dvanced technologies developed prior to physical proto- over the past decade have enabled typing will increase. Aautomotive engineers to design products to meet current and future fuel Flexible, Powerful, economy standards. As new fuel economy Up-front Design standards have been set, automakers must Up-front design tools now meet a federal Corporate Average such as nCode Design- Fuel Economy (CAFE) of 54.5 mpg by Life™ enables engi- 2025. This means that engineers are now neers to gain insight faced with one of the biggest engineering into new material per- challenges in decades, a 5 percent increase formance and reduce in fuel economy per year. These new fuel product development economy demands require automakers to time. With this CAE- reshape their engineering process without based tool, fatigue and compromising the reliability and durabil- durability may be cal- ity of their designs. culated from FEA re- New materials such as ultra-high- sults, identifying critical strength steels are being used in body locations and calculating fatigue lives for are being used to improve simulation structures, as are aluminum and magne- both metals and composites. DesignLife throughput. The largest computa- sium alloys for structural components. users also benefit from advanced tech- tional problems can be broken down The use of lightweight material such nology for virtual shaker testing simula- and solved many times quicker, but as composites also presents significant tion, welds, vibration, crack growth, and hardware is not the only requirement. benefits for some automotive compo- thermo-mechanical fatigue analysis. DesignLife can take advantage of exist- nents. As these new materials and in- ing hardware scalability by distributing creasingly radical solutions are required Rapidly Improve Designs fatigue analysis tasks to open up the in more engineering applications, the As finite element models increase in possibility of more robust, up-front de- need to simulate and optimize designs size and fidelity, HPC environments sign through simulation.

About HBM-nCode With over 30 years of expertise in durability and data analysis solu- tions, nCode enables customers to understand product performance, accelerate product development and improve design. The power and scalability of nCode software is a direct result of its expertise and in-depth experience in a broad range of industries.

Sales, Training, and Support HBM-nCode sales and support is available through local offices in For more information visit: Europe, North America and Asia. www.ncode.com Contact: [email protected] to reach an office near you.

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Optimization_HBM-nCode.indd 41 11/14/13 12:18 PM Special Sponsored Section Optimization Leader /// IronCAD Minimize Risks in the Transition From 2D to 3D Design Using innovative new technology, designers can safely transition to 3D by reducing training and learning times while leveraging 2D in the Design and Communication Processes.

esigning in 3D can improve Here’s how we mini- design accuracy, efficiency, mize the risks in transi- D and make it easier to col- tioning from 2D to 3D laborate through manufacturing pro- design: cesses. However, most people famil- iar with 2D are reluctant to make this Quickly Learn move and here’s why: Due to IronCAD’s • It requires a commitment to unique drag & drop cata- learning 3D. logs, push & pull handle • Designers fear rules and restric- design, patented TriBall tions imposed on them from 3D. positioning tool, and its • Compatibility with their legacy 2D flexible design environ- data needs to be maintained. ment, you can quickly become pro- Leverage and Use Legacy 2D • Communication with both 2D and ductive in 3D. In addition, the inte- The integrated, DWG compatible, 2D en- 3D is still required. gration of a familiar 2D mechanical vironment allows you to maintain and reuse IronCAD’s Design Solutions design interface avoids learning a your legacy 2D data in 3D Design. Thus, minimizes these risks by providing a new 2D. it preserves your previous investment. flexible and easy to use 3D design so- lution allowing you to become profi- Design the Way You Want in 3D Collaboration cient in 3D within a matter of days. IronCAD’s innovative design tech- Easily import and edit 3D data from Its integrated 2D Mechanical design nology allows you to design in 3D all major CAD formats. Automatically environment enables reuse of legacy freely with or without design rules. update changes in the 2D through the 2D data and allows design modifica- Consequently, you can make both associative 2D/3D. Share the updated tions to be updated and easily shared planned and unexpected changes at 2D and 3D design data throughout the in both 3D and 2D formats. any stage of the design. collaboration process.

About IronCAD IronCAD is a leading provider of 3D Design Productivity Solutions that deliver the highest levels of customer satisfaction and produc- tivity. Individual components of this solution can be used standalone, IronCAD complementary within an existing design environment, or can be used together to collaborate effectively throughout the enterprise to extend productivity.

Contact Information: IronCAD Corporate Headquarters 2000 RiverEdge Parkway Suite 745 For more information visit: Atlanta, GA 30328 www.ironcad.com T: 800-339-7304 | E: [email protected]

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Optimization_IronCAD.indd 42 11/14/13 3:31 PM Special Sponsored Section Noesis Solutions /// Optimization Leader Top Brands Secure Competitive Edge Optimus from Noesis Solutions helps manufacturers design benchmark products.

remium manufacturers rely on At the latest Optimus World Confer- high quality and clear differentia- ence, Audi, BMW, Snecma, Thales Ale- P tion to ensure new products excel nia Space, Tyco Electronics, Volkswagen, in today’s competitive market. They must among others, presented how they use do this in a lean environment with intense Optimus to stay ahead of competition. pressure to reduce time to market and de- velopment costs. Noesis Solutions’ flag- Combining faster development with ship software Optimus empowers compa- superior design performance? nies to explore the design space and adopt On average, Optimus users achieve an ‘Engineer by Objective’ development 10% or more design performance im- technical support team enable tailor- strategy. This enables them to design provements and over 30% design time ing, when needed, to match the user’s benchmark products ‘right first time’. reduction. Optimus frees users from design process, software, and IT. repetitive manual model changes and Ease and speed of use are often cited as A solution for today’s lean staffed data processing, while efficiently iden- major factors in the adoption of Optimus, engineering design teams tifying design space regions contain- along with capabilities including: Optimus today helps numerous leading ing leading candidate designs. These • Process integration and automation companies in engineering-intense indus- designs meet a combination of objec- • Integration with the vast majority tries worldwide tives set by multiple (often competing) of CAE and mathematical model- • Automate simulation processes performance targets as well as design ing software • Increase simulation throughput constraints imposed by manufacturing • Design of experiments (DOE) • Simplify the decision process realities, stringent regulatory and stan- • Surrogate modeling (or response • Consolidate corporate simulation dardization requirements. surface modeling) knowledge Implementation is key, and Opti- • Single and multiple objective optimization • Deliver optimized, robust product mus’ unique customization capability • Statistical data mining and analysis designs coupled with an exceptionally skilled • Robust design

About Noesis Solutions Noesis Solutions is a simulation innovation partner to manu- facturers in engineering-intense industries. Its process inte- gration and design optimization (PIDO) software Optimus helps manufacturers resolve their toughest multi-disciplinary engineering challenges. Optimus automates the traditional ‘trial-and-error’ simulation based design process, and with powerful optimization algorithms efficiently directs simula- tions toward the best designs.

North America: Europe: For more information visit: 35 E. Main Street, Suite 300 Gaston Geenslaan 11B4 www.noesissolutions.com Carmel, IN 46032 3001 Leuven, Belgium

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Optimization_Noesis_.indd 43 11/14/13 2:20 PM Special Sponsored Section Optimization Leader /// Professional Systems Associates Are Your Business Processes Helping or Hurting You? In order to gain eÿ ciencies through product lifecycle management, your business processes must be defi ned.

usiness processes play a major tronic workflow role in how efficiently and ef- enabled forms in- B fectively products can be engi- side CMPRO pro- neered, manufactured, delivered, and vide a framework maintained. According to CMII for to document busi- Business Process Infrastructure, “Deficient ness processes. requirements are a by-product of defi- Once the pro- cient processes.”[1] cesses are defined, In order to gain efficiency through you can use the product lifecycle management, your CMPRO Process business processes must be well de- Workflow Engine fined and continuously maintained as (PWE) to help your business evolves. CMPRO is the flush out the details • What are the requirements? product lifecycle management soft- and make sure all of the steps are clearly • Are there fields that need to be updated ware with a Process Workflow Engine established. Some items to consider are: automatically based on other values? (PWE) that helps you optimize your • What is going on at each point in • Are there things that need to be done business processes. the process? before we move forward in the process? • Who is responsible for this? CMPRO empowers businesses to con- How does CMPRO Help • Who has the ability to authorize activity trol processes by offering polls, check- Organizations Optimize Processes? and assure that the work is completed? lists, and discussions that can be added CMPRO helps organizations optimize The CMPRO PWE also allows you to to each step of the process based on the productivity by providing a vehicle to identify the kind of information that needs business requirements. record internal processes. Often times, to be captured at each point in a process. Source [1]: Guess, V. C. (2006). CMII for people go through daily activities • Who supplies this information? Business Process Infrastructure. Pheonix, AZ: without defined processes. The elec- • Where does it come from? CMII Research Institute.

About Professional Systems Associates

Gain Control Over Processes and Product Information Professional Systems Associates, Inc. helps organizations gain con- trol over their processes and product information. PSA believes in creating long-term relationships with its customers by constantly adapting CMPRO to their needs and providing exceptional support.

Contact Information: 1308 Florida Avenue For more information visit: Panama City, FL 32401 www.psasys.com Phone: 1-800-373-3453

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Optimization_PSA.indd 44 11/14/13 2:21 PM Special Sponsored Section Proto Labs /// Optimization Leader A Company Bred for Speed Proto Labs accelerates innovation with its quick-turn manufacturing services for prototypes. roto Labs, through its Firstcut Through a sub- CNC Machining and Proto- tractive manufactur- P mold Injection Molding ser- ing process, First- vices, manufactures custom parts for cut uses three-axis designers and engineers around the milling from up to world. Its proprietary software and six sides to machine automated manufacturing processes low volumes of parts allow for quick-turn prototyping and from about 40 avail- fast low- to mid-volume production of able plastic and real plastic and metal parts in days. metal materials in- Product designers and engineers cluding ABS, Nylon, upload a 3D CAD model online and PC, Delrin, PEEK, receive an interactive quote with free Ultem®, aluminum, design analysis, full pricing informa- magnesium, steel, in a fraction of the time and cost in tion and quick-turn options, generally stainless steel and more. The result is comparison to traditional mold manu- within hours. The manufacturability functional parts made from real mate- facturers, to produce custom parts for analysis and quote feedback helps cus- rials for prototype testing, jigs, fixtures all industries. tomers potentially eliminate problems, or one-off projects. By providing timely design feedback like sink or internal undercuts. The For customers that need low-vol- on 3D CAD models followed by quick- free design analysis can aid designers ume production or bridge tooling, turn production of prototypes, modi- early in the prototyping process and Protomold can injection mold up to fications can be made fast and often. help them get real parts faster. Once 10,000+ parts from hundreds of dif- It’s iterative product development that a part design is ready and a quote ap- ferent stocked resins in three weeks allows designers and engineers to opti- proved, production begins and parts or less. The injection-molding service mize their own processes and ultimately are shipped in one to 15 business days. machines aluminum or steel molds, get their product to market faster.

About Proto Labs At Proto Labs, speed and innovation are the cornerstones of our success. We are committed to being a solution for getting things done quickly and a catalyst for great ideas for our shareholders, customers and each other. We are responsible for our performance, our results and our future.

Contact Information: 5540 Pioneer Creek Dr. For more information visit: Maple Plain, MN 55359 www.protolabs.com 877.479.3680

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Optimization_Proto_Labs.indd 45 11/14/13 12:21 PM Special Sponsored Section Optimization Leader /// Red Cedar Technology Discover Be˜ er Designs, Faster Drive Product Innovation through Simulation and Optimization.

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46 DESKTOP ENGINEERING December 2013 /// deskeng.com

Optimization_RedCedar.indd 46 11/14/13 12:08 PM Special Sponsored Section RTT /// Optimization Leader Optimizing a Product’s Lifecycle from End-to-End RTT’s integrated approach to visualization enables companies to maximize their workfl ows and reduce time-to-market.

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Optimization_Tormach.indd 48 11/14/13 12:24 PM Case Study /// Optimize CFD Extreme Hydrofoiling, Powered by Simulation ANSYS CFD analysis so˜ ware helped Emirates Team New Zealand bring new spe ed to the world’s oldest trophy event. BY PAMELA J. WATERMAN

f the America’s Cup races make Wing sail and mast structure being you envision the (so-called) 12- mounted between the dual hulls of the I meter craft that rode the waves ETNZ trimaran America’s Cup 2013 boat. A from 1958 to 1987, or even the glori- central pivot structure allows added control ous J-boats of the 1930s, you need a in a manner similar to the ailerons of an radical mind-shift to appreciate the aircraft wing. Images courtesy of ANSYS. current look and feel. Lift, drag and thrust — the vocabulary of aircraft, not boats — most aptly describe the performance of the 2013 America’s Cup racers. Yet for Emirates Team New Zealand (ETNZ), ANSYS computational fluid dynamics (CFD) simulation software handled the transition with grace and speed. The sailing competition, begun in 1851, has seen periodic rule changes that push each new generation to sail faster than before. The latest rules gave way to increased spirit of which is “as long as it fits inside the box, it can race.” All speed and spectator excitement at this past September’s un- designs were catamaran-based; hulls became 72 ft. long by 48 ft. precedented series of 19 races over two-and-a-half weeks. wide, and the massive wing sails rose to 134 ft. tall. For all its copious details, the updated Class Rule, known as From Wind Tunnels to Workstations the AC72, contained a loophole permitting the use of movable, ETNZ’s experience with ANSYS goes way back, with the team shaped “daggerboards” or foils that protrude into the water from initially using FLUENT CFD software in 1998 and then ex- each hull. Such a feature effectively converts a catamaran into a panding to tap ANSYS CFD software for the boat design of both hydrofoil — elevating the hull out of the water so that the craft the 2007 and 2010 cup races. “flies” on upwind and downwind parts of the racing route. Sup- The 2007 boats were a more traditional yacht design; the ported only by the foils and rudders, and without the drag of 2010 Volvo Cup (America’s Cup Challenger face-off) trimaran water on the hulls, it achieved speeds approaching 51 mph. boats were a completely different design, notes Gilles Eggen- With the design crew free to capitalize on the maximum air- spieler, Ph.D., ANSYS senior fluids product line manager: “And flow past its sails, both foil and wing design became critical design now the 2013 versions are yet a third.” elements for successful tacking, foiling or rounding of racecourse The trimarans and “hard” (non-fabric) wing sails that first de- marks. From the moment this was acknowledged, ETNZ knew buted in the 2010 America’s Cup races had hardly been hauled their catchphrase would be “controlled flying.” out of the water when the rules were being modified yet again to set the tone for the 2013 competition. Past rules had been Design Versatility with ANSYS formula-based — resulting, for example, in the 12-meter boats, The 38-member ETNZ started working on the design of a where 12 meters is the maximum value of a formula that com- scaled-down prototype boat in October 2010, in preparation for bines such design specifications as load, waterline length and area the July 2013 Louis Vuitton Cup Challenger elimination series. of the sails. This time, the committee opted for a Box Rule, the “The first six months of the project were totally simula-

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de1213_ANSYScup_Waterman.indd 49 11/14/13 12:31 PM Optimize CFD /// Case Study

tion-driven and all our initial concepts were evaluated through ANSYS CFD simulation of ANSYS CFD,” recalls Steve Collie, Ph.D., ETNZ design team ETNZ’s Cup 2013 boat sailing member for aerodynamic CFD (sail design). “At that stage, we downwind, showing wind built small 33-ft. catamarans — the largest prototype allowed pressure on the structure. under the rules — through which we tested concepts. By October 2011, we launched two identical scale wings for these test yachts, very similar in shape and design to the full-scale AC72 wings we ended up with.” “Wings” are the best way to describe the curved, carbon-fiber- ribbed 3D sail-structures that are skinned with conformal, nearly plastic sheeting. Think of an airplane wing turned vertical and pivoting about a mast, with the added sophistication of a full- length controllable aileron. To evaluate hundreds of variables determining the possible wing shape, the design team looked at a wide range of wind con- ditions. Critical to boat speed is minimizing the drag of the air ANSYS CFD simulation of ETNZ coming off the headsail (the more-traditional fabric sail in the for- America’s Cup 2013 boat sailing ward section) as well as from the mast. In addition, when the craft into upwind conditions; colors is sailing at a large angle to the wind, stalling is a real possibility. indicate wind pressure on the Modeling all the variations of wing geometry vs. operational con- structure. Analyses must take ditions presented a big challenge in itself, yet Collie knew that into account the effects of the this would still only include part of the problem. airfl ow coming off the front “There is no point in analyzing the wing by itself,” he notes, (head) sail as well as from the “as its aerodynamic performance is dramatically influenced by mast. Accurate turbulence the headsail and the hulls, crossbeams and fairings. With ANSYS, modeling is critical. we’ve modeled the aerodynamics of the yacht, in its entirety, through a massive range of situations that we call the aeromet- rics. This involves up to 750 different simulations per design of the wing and sails.” ANSYS CFD software was up to the task of evaluating design improvements with short turnarounds, generally two to three weeks. Inputs included trim parameters for the wing and sails and apparent wind angle. For each iteration, the meshing was 100% Diagram of primary structural automated — which was absolutely key to getting fast results. elements important for ANSYS “After a matrix of new geometries is transferred to the cluster, CFD simulation and optimization a Perl script would automatically mesh, solve and post-process of ETNZ boat design. the results,” Collie says. “The output was a text file describing the Rules and the Need for Speed tarting with the 1907 race, America’s Cup rules were developed to ensure both safety and compet- S itive racing. They governed boat size and shape, plus the materials and approaches allowed in support of perfecting a design. They have actually been revised for every one of the 34 Cup races, with just two exceptions. From the moment the U.S. entered a catamaran model (not expressly forbidden), the face of the race changed dramatically. From the trimarans of the 2010 competition to the “flying boats” of this past September’s race, it’s clear that engineering-based ingenuity, including soft- ware simulation such as powered by ANSYS CFD analy- ses, will continue to help Cup sailors rule the waves. — PJW

50 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_ANSYScup_Waterman.indd 50 11/14/13 12:34 PM Case Study /// Optimize CFD

ENTERPRISE SUITE View of the “hard” wing, 134-ft.-tall sail of the ETNZ trimaran boat from the 2013 America’s Cup race, fully simulated with ANSYS CFD simulation software prior to building. The wing is split in two vertical sections, each of which can be trimmed on the fl y. Note steps to right for scale.

relevant forces and moments for each point of the matrix. Images were also automatically generated.” Simulations showed when the flow was attached to the wing, and where there was a great deal of interaction with the headsail and the hull, notes Nick Hutchins, ETNZ CFD engineer (wing design). “ANSYS is easy software to use quickly,” he adds. “It’s easy to get good, reliable answers, and from an aerodynamics per- spective, the really key technical thing we’re looking for is good turbulence modeling.” With the earlier, 33-ft. simulated design concepts proven on the water (netting ETNZ the single Cup challenger slot), the design team had the confidence to use 100% simulation for the full 72-ft. craft design. Simulations began Aug. 5, and the boat was built within a month. Further hardware modifications were made in just two days based on additional performance testing, and the craft was ready for racing on Sept. 7. ETNZ Technical Director Nick Holroyd sums up the power AUTOMATE of simulation: “In 16 years, we’ve seen the transition from physi- cal testing, where almost everything we did was done in the wind INTEGRATE tunnel or the towing tank, through to this Cup cycle, where we’ve finally managed to get to 100% numerical analysis and digital prototyping. The productivity gains and the extra insight it’s of- RUN fering us are extremely valuable.” In spite of this year’s Cup being won by Oracle Team USA in a come from behind victory (see “The Winning Edge,” page 53) that was ultimately based on a combination of many factors in addition to boat design, ETNZ say they will stay the course on using ANSYS CFD analysis in the future. DE DECIDE

Contributing Editor Pamela Waterman, DE’s simulation expert, is an electrical engineer and freelance technical writer based in Arizona. OPTIMIZE You can send her e-mail to [email protected].

INFO ➜ ANSYS: ANSYS.com ➜ Emirates Team New Zealand: Emirates-team-new-zealand. americascup.com www.esteco.com For more information on this topic, visit deskeng.com.

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Simulation & Analysis /// Composites Options for Composites Analysis and Simulation

Find your comfort zone with today’s softwa e tools. BY PAMELA J. WATERMAN Expand Your Industry Exposure

iber-reinforced technology is seeing extensive use for its low weight-to-strength ratios—as well as other Modal analyses (left) of carbon-fiber sounding board Fbenefits. But working with composites is rarely a for a dulcimer musical instrument (right), are performed with Article Reprints! 1-2-3 process. If ever there was a need for close coopera- with NEi Nastran software by consultants at ALLRed & tion among designers, structural analysts and manufactur- Associates. Image courtesy of ALLRed & Associates. ing engineers, this is the time, and optimization plays a key role across the board. With dozens of software packages are high compared to ‘traditional materials,’” explains addressing these challenges, DE takes a look at what’s new, Markku Palantera, general manager at Componeering. what’s critical and what challenges remain. “Therefore, the superior performance of the end product must be achieved by careful design, which eventually in- Composites: Why now? volves software.” The term composite covers material compositions ranging /// Composites from glass-filled liquid resins to “fabric” Simulationsheets with em- Defining & Your AnalysisRole bedded carbon fibers. (See “The Life of Composite Materi- Componeering, which markets ESAComp, is one of a num- als,” DE May 2007.) Just that difference helps explain the ber of companies focused on composites-specific software. variety of software packages targeted to the field. How these firms can help you depends partly on your spe- Depending on the exact formulation, composite materials cific project, partly on your existing CAD and CAE soft- Printed reprints, as well as locked and unlocked PDFs display such positive attributes as easy formability, strength ware, and partly just on your preferred approach to workingSeamless workfl ws be- with light weight, excellent long-term weathering and resis- with these materials. tween VISTAGY’s FiberSIM tance to corrosion and chemicals. These advantages, in turn, Not surprisingly, opinions run strong and deep insoftware this and MSC.Soft- may make it easier to integrate multiple parts. Plus, proper- corner of the design world. Dr. John Klintworth, Simulayt’sware’s SimXpert move a ties such as good thermal stability and high thermal conduc- founder and managing director, points out the major sourcedesign from preliminary siz- tivity are increasingly useful in special applications. for differences in perspective is whether you operateing in to a final part validation. However, achieving these desirable properties is a chal- CAD environment or an analysis environment. The parallel process helps lenge at every step—from initial design to hand-done or “Any conventional [finite element analysis, or FEA]designers and analysts automated part creation. package cannot do design and manufacture, and cannotoptimize the part based “The material and manufacturing costs of composites even create a decent composites model,” he continues.on weight, performance, are available. Reprints are personalized with your design specifications, and manufacturing costs. 1 DESKTOP ENGINEERING May 2011 /// deskeng.com Image courtesy of VISTAGY.

ing the export plybook with flat patterns of the plies to be manu- are deeply embedded in CATIA V5, Abaqus/CAE, SolidWorks factured. All partners involved in this process can exchange data. and Femap, and allow users to define plys on individual finite ele- In addition, as a pre- and post-processor, Laminate Tools in- ments, reflecting the actual manufacturing process. company name and logo for better branding. terfaces with standard CAD and FEA applications to produce As an example of its power, you could define a part with 200 composite-specific results. It also offers an embedded interface plies, then with the push of a button automatically generate 2,000 with Solidworks, Nastran and ANSYS, as well as with Anaglyph’s laminate properties—a task impossible to do by hand. hand layup ply-placement software, PlyMatch. STRAND7 is a general-purpose FEA package with an op- Multi-layered Challenges tional laminated composite module tightly integrated with the A metal is a metal, but composites are a whole ’nother ballgame. rest of the system. Users can easily combine traditional plate/shell As Firehole Composites’ Shrader puts it, “The biggest software composite elements with 1D prismatic beam elements, as well challenge in working with composites is simultaneously captur- as 3D brick elements. The company notes that its price/perfor- ing all of the physics involved, while also maintaining reasonable mance ratio in the FEA software arena is particularly appealing computational time and resources.” for small organizations because it supports the full spectrum of You definitely need specialized tools to achieve this balance. design concept evaluation, detailed analysis and the production The good news is, as users realize there’s a good return on invest- of layup schedules. ment in specifying these materials, the software developers are Simulayt’s solutions for the composites field have been in right there, expanding their support. DE continuous development for 20 years. As the developer of Layup Technology, which incorporates advanced fiber simulation and Contributing Editor Pamela Waterman, DE’s simulation expert, is ply modeling capabilities, the company is positioned to offer soft- an electrical engineer and freelance technical writer based in Arizona. ware tools running in both CAD and CAE systems. The products You can send her e-mail to [email protected]. Contact Jeanne DuVal

Reprinted from May 2011 Desktop Engineering with adaptations. Copyright© by Level 5 Communications, Inc., 1283 Main St., Dublin, NH 03444, All Rights Reserved. For more information on this topic, please visit deskeng.com. 603.563.1631 x274 • [email protected]

6 DESKTOP ENGINEERING May 2011 /// deskeng.com

52 DESKTOP ENGINEERING December 2013 /// deskeng.com

1213_DE_Spotlight.indd 52 11/14/13 11:37 AM Case Study /// Optimize CFD The Winning Edge STAR-CCM+ CFD So˜ ware helps guide Oracle Team USA Hydrofoil to victory. BY DE EDITORS

racle Team USA won the 2013 Cup by combining ele- ments of its winning 2010 trimaran design with insight O gained from simulations done in CD-adapco’s STAR- CCM+ computational fluid dynamics (CFD) analysis software. Mario Caponnetto, Oracle Team USA’s design executive for wing sail design and head of CFD analyses, points out that, from the beginning, the 34th America’s Cup competitors worked with extreme parameters — the brand-new AC72 class rule defining a CFD-simulated airfl ow across structure and crew. Analysis high-performance, 72-ft. catamaran running under a semi-rigid done with CD-adapco STAR CCM+ software. (Image wing sail. From a performance optimization point of view, every courtesy Oracle Team USA and CD-adapco) part of a high-speed catamaran boat (below or above the water) is equally important. But the 131-ft.-tall wing sail was a particular to increase the load on the lowest flap, pushing the safety mar- challenge: “Although water is 800 times denser than air, there is a gin. Increased aerodynamic efficiency — plus reduced overall lot more yacht surface moving in the wind than in the sea, espe- hydrodynamic drag — was the positive result. cially for a foiling AC72 catamaran,” Caponnetto explains. The second improvement produced a faster maneuver when Knowing that aerodynamic drag would be critical to operat- making the upwind transition between low-speed (hull in the ing speed (expected to reach more than 53mph), the team applied water) sailing to high-speed (hydrofoiling) mode. According STAR-CCM+ from the beginning to evaluate and optimize hy- to Caponnetto, the stern “wasn’t producing enough lift, so we drodynamic and aerodynamic performance. Caponnetto’s ana- decided to modify it with a device we have CFD-tested many lysts used Reynolds-averaged Navier-Stokes (RANS) equations times. A small fixed wedge glued below the transom greatly in- to obtain time-averaged behavior during turbulent flow; they also creased the local pressure and lift with only minor drag.” applied large eddy simulations (LES) to some detailed areas. Third, the design team worked with the cavitation module “Most of the simulations were pure CFD analysis, steady or of STAR-CCM+ through the final race day, confident enough unsteady, with multiple degrees of freedom and fluids, capturing in the CFD simulation results to physically modify the rudder/ the air/water interface and cavitation effects,” he says. “Some- elevator junction, reducing cavitation over these appendages and times we had to test each candidate geometry for hundreds of increasing the top speed for the first leg of each race. different combinations of speed and trim.” Oracle Team USA also investigated fluid-structure interac- The only way to avoid mistakes in comparing so many tiny tions (FSI) on the appendages and the wing sail by using the differences among shapes was to maintain the consistency of the STAR CCM+ built-in finite volume stress solver as well as mesh and the physical model as much as possible. The STAR- performing co-simulation with Dassault Systèmes SIMULIA CCM+ solution was to automate the simulation process. Abaqus finite element analysis software. During the previous America’s Cup, the team used structured Caponnetto was in on the ground floor betting on CFD vs. meshes for most of the computations, Caponnetto explains. This physical experiments for boat design. “Now I can say for the first time, they switched to automatically trimmed, polyhedral cells. time all fluid dynamic design during America’s Cup has been car- ried out with the use of CFD only,” he says. “Some of the insights CFD on the Fly we obtained were unthinkable even 10 years ago, such as the Anyone watching the 2013 America’s Cup races saw the drama modification of boat features during the last week of races. It is unfold as Oracle Team USA worked to come back at the 1-8 fascinating to think what will happen in the future.” DE point in the event. Caponnetto describes three ways that CFD calculations were involved even then, supporting decisions for INFO ➜ CD-adapco: CD-adapco.com critical modifications to the boat’s structure and operation. The first step involved reducing the safety margin when ➜ Dassault Systèmes: 3ds.com trimming the wing sail; simulations convinced the sailing crew ➜ Oracle Team USA: Oracle-team-usa.americascup.com

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de1213_American_Cup_Companion_Waterman.indd 53 11/14/13 12:36 PM Optimize Data /// Finite Element Analysis Big Data: DON’T PANIC Fight the data explosion with smart FEA. BY TONY ABBEY

Editor’s Note: Tony Abbey teaches live NAFEMS FEA classes in the US, Europe and Asia. He also teaches NAFEMS e-learning classes globally. Contact [email protected] for details.

any simulation technologies have been restricted until now by the granularity of the solution that M can be employed. For example, in computational fluid dynamics (CFD), desired accuracy has been compro- mised by the physical size of the mesh and the time steps achievable. To capture phenomena such as chaotic vortex patterns in highly turbulent flow demands a very high level of fidelity. Computing power has been a limiting factor in achieving the Not to spoil it for you, but the ultimate answer to the extreme level of simulation required in this case. It may be Great Question of Life, the Universe and Everything is 42, several years before sufficiently powerful computing is avail- according to Douglas Adams’ Hitchhiker’s Guide to the able to achieve the required granularity for the average user. Galaxy. The answer is a great illustration of the need to The important point is that the baseline we are seeking is an frame the right questions to get the answers you need from accurate high-fidelity representation of the physics involved. the deluge of engineering data. Image courtesy of Del Rey. Other simulation areas in a similar position are combus- tion technology and climate modeling. Indeed, it could be argued that climate modeling is so chaotic that there will computing resource. However, this discussion relates to the never be adequate fidelity in the simulation process. Many more mundane, but vital categories of analysis that most of claim that weather forecasting will always be at least one day us are involved with from day-to-day. out of date! Over the past five years, I’ve watched with great interest Structural analysis at a macro level, however, is not usually as basic structural finite element analysis (FEA) has moved that chaotic. We are able to predict the response of com- to an ever-greater element count for quite simple models. ponents to many loading phenomena very accurately with a Much of this is premature, given the state of FEA pre- and modest mesh density. In other words, we’ve reached the ideal post-processing technology. My fundamental questions are: point where we have sufficient model fidelity easily achiev- What is driving analysts to this “big data” trend, and how can able with average computing resource. we avoid it until we are really ready for it? Most static, dynamic and mildly nonlinear analyses fall into this category. If we move beyond this into impact, low Making Big Data cycle fatigue and micro-mechanical response of composites, There is an enormous excitement in many areas over the then we have not reached that required fidelity using typical concept and promise of big data. Many feel that there is a

54 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_Green_Abbey.indd 54 11/14/13 4:17 PM virtual explosion of big data about to hit us. The essence 3. Increasing the granularity of research or simulation of the paradigm is that dramatically increasing the fidel- data will improve the modeling by allowing greater ac- ity, scope and interchangeability of data will allow higher curacy and better targeting. This includes anything from levels of productivity and competitiveness in industry as FEA to consumer marketing. we understand better what that data is telling us. 4. Replacing and/or supporting human decision-making Mainstream examples of data captured at ever-faster by automated risk engines will improve product perfor- rates include: mance, as is done in financial and insurance circles now. • Indirect and direct tracking of human opinions, habits 5. New business or operational models will emerge, such as and responses on the Internet; assessing driver insurance risk by monitoring actual behavior. • GPS information linked to activities on smartphones Now some of these sound downright scary, but with a and other mobile devices; and bit of imagination we can see many of these points reso- • Sensor information fed to the central computer on nating in a design, analysis and production environment. modern cars. I will talk about some FEA areas where I think we can see The McKinsey Global Institute (MGI) paper1 on big real benefits. data predicts that we will all be immersed its creation and influence over the next few years. The researchers cite five The Caveat main areas where industries will benefit: For this explosion of data to mean anything, of course, we 1. Creating exhaustive data sets will mean that all data is need technologies that can actually deal with its volume readily available and less time will be wasted in searching and interpretation. How and where do we store it? How for it. The data will be more naturally integrated between do we retrieve it, and how do we figure out what it is tell- R&D and manufacturing, for example. ing us? 2. Increased experimentation and variability in simulation The MGI paper has a very important section on this. models, combined with efficient data mining, will allow It emphasizes that disciplines such as ours that consist of increases in product performance. a large amount of legacy data and disparate systems will

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de1213_Green_Abbey.indd 55 11/14/13 12:42 PM Optimize Data /// Finite Element Analysis

need the development of new and innovative systems to will be involved with Big Data, and whose skills will be deal with big data. increasingly needed: That really is the basis of my argument: I feel we are • Deep Analytical nowhere near having these types of systems in place in • Big Data Savvy a general sense. There is a strong growth in the areas • Supporting Technology of simulation data management (SDM) and simulation After looking carefully at the MGI data matrix that process data management (SPDM), and that is bringing supports this, I came to the conclusion that most of us big benefits. However, that is not the full story, as it is fit into the appropriate “Big Data Savvy” occupation de- essentially managing the data flow. What is missing is the scribed there as “engineer.” That requires us to have some technology to be able to interpret what that data means knowledge of data technology, but the vital ingredient is — or as the MGI paper puts it, the ability to “integrate, the ability to “define key questions data can answer.” If analyze, visualize and consume the growing torrent of you remember The Hitchhikers Guide to the Galaxy, the an- big data.” swer to the Question of the Universe is given2: Without additional interpretation of the results, what “All right,” said Deep Thought. “The Answer to the Great Question...” is the point of increasing the fidelity of an FEA mesh? We “Yes..!” converge to an accurate stress solution at a very specific “Of Life, the Universe and Everything...” said Deep Thought. mesh density; beyond that, we are just wasting comput- “Yes...!” ing power and our own time. If the increased fidelity can “Is...” said Deep Thought, and paused. actually tell us something more useful, that’s great. But we “Yes...!” don’t have tools to enable that as yet. I will discuss later “Is...” what these tools might be. “Yes...!!!...?” “Forty-two,” said Deep Thought, with infinite majesty and calm. Our Future Role with Big Data The quote really sums it up well — how to pose the The MGI paper defines three categories of people who right question and not to just accept a deluge of data as being the “answer.” Terabytes Terrify me and Let’s Go Green At an FEA conference two years ago, I first heard of the Petabytes Petrify me! term petabyte in relation to data size. It means 1,000 tera- o get a handle on the size of data we are discuss- bytes. That was the volume of data being considered for a ing, the amount of data stored in the US Library fairly average analysis. Tof Congress is sometimes used as a yardstick. As I don’t actually know of a post-processor that can han- of 2007 it was estimated there are 10 Terabytes of data dle output of that quantity. So we have a disconnect — in the written works collection. The current storage of careless meshing or idealization will generate huge num- all US Academic research libraries runs at 2 Petabytes. bers of elements (the solvers are now reaching the stage Storing all the words ever spoken in the world is com- where they can generate huge volumes of result data with monly assessed at 5 Exabytes. There is no warranty on average computing resource). However, we can’t handle the accuracy of the numbers, but they are indicative! that amount of data; in many cases, it adds nothing to our Data Definitions: understanding of the results. • One Megabyte is 1,000 Kilobytes Let’s keep our model size down. Don’t fill up the com- • One Gigabyte is 1,000 Megabytes puting resource just because it’s there. Think of the chal- • One Terabyte is 1,000 Gigabytes lenge as a green element footprint instead of a green car- • One Petabyte is 1,000 Terabytes bon footprint! • One Exabyte is 1,000 Petabytes If we keep model size modest for “normal” analyses, it To remind ourselves: opens up the possibility of running more analyses rather • The old 3 ½ inch floppy held about 1 Megabyte than bigger analyses. This means we can follow a couple • A CD-ROM holds 500 to 700 Megabytes of interesting paths: • A DVD holds 4.7 to 9.4 Gigabytes • Optimization: Modern optimization techniques • A Blu-Ray disc can hold 50 Gigabytes have an inexhaustible appetite for numbers of analyses. A 4 Terabyte External Hard drive has a low-end To be most efficient and effective, genetic algorithm, ar- street price of $200. You can pay much more for faster tificial intelligence (AI) and design of experiment (DOE) data transfer rate, but it clearly shows the trend in data methods really need analysis counts in the thousands. storage for the average user. Software that is capable of spawning FEA analysis vari-

56 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_Green_Abbey.indd 56 11/14/13 12:43 PM ants, retrieving the data and presenting it in a meaningful ships and aircraft with solid elements, rather than shells way is quite mature. The best visualization tools enable and beams. This will be an enormous extrapolation of the engineer to try to understand why a particular con- data, and will require a total rethink of how we store, ma- figuration has evolved, and what the key drivers are. This nipulate and interrogate structural analysis results. The enables a direct relationship to be made to practical de- challenge will be to have a process that will add to our sign insights. This is the best example I see today of the understanding of structural load paths and stress patterns use of big data in FEA. in complex structures. The danger will be in producing • Stochastics: The very term of stochastics scares vast quantities of data that defy interrogation as to which most engineers, including me until a few years ago. But structural responses are critical and why. This will require all it basically means is throwing some variability into the software developers to push the innovation aspects dis- modeling. Much traditional focus is on variations in mate- cussed in the MGI paper to the max. DE rial properties, etc. I am more interested, however, in the idea of automatically generating a range of mesh densities, Tony Abbey is a consultant analyst with his own company, boundary conditions and loading conditions to see how FETraining. He also works as training manager for NA- robust a particular solution is. I think this has tremendous FEMS, responsible for developing and implementing training potential in supplementing, to some extent, the skill and classes, including a wide range of e-learning classes. Send e- experience needed in FEA. The ability to assess risk of mail about this article to [email protected]. inaccurate analyses dovetails very nicely with some of the risk assessment models described in the MGI paper. The References data mining tools to explore this type of analysis results 1 The McKinsey Global Institute 2011. Big data: The next frontier are quite mature, and this is where I see a place for ex- for innovation, competition, and productivity. James Manyika, panding big data in FEA right now. Michael Chui, Brad Brown, et al. At some point in the history of idealization, it will 2 The Hitchhiker’s Guide to the Galaxy. Douglas Adams. 1979. become common to model fabricated structures such as Harmony Publishing.

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de1213_Green_Abbey.indd 57 11/14/13 12:44 PM Optimize Workfl w /// CAD to CAE The Cleanup Headache CAD geometry cleanup stirs workfl w questions in quest to quell CAD-to-CAE issues. By Kenneth W ong

AD and CAE have existed in parallel for decades. Even if there were wrinkles in C their data exchange before, by now the combined will of the software developers and users has solved the most severe issues, right? Wrong, according to H. Clark Briggs, Ph.D., from ATA Engineering Inc. ATA supplies design analysis and testing services to major manufac- turers. Briggs, vice president of aerospace and defense business development, estimates his staff spends between 30% and 50% of the project time repairing their clients’ geometry. Indrakanti Chakravarthy, Siemens PLM Software’s director of simulation marketing for the Americas, has a higher estimate: “Up to 70% of an analyst’s time is spent searching for data and preparing a model for analysis.” But what’s the cure: simulation-led design or adopting a standardized design toolset for both CAD and CAE? With Altair’s software, you can automatically single out Design-led vs. Analysis-driven Workflow the minor features that fall within a range to decide “The current workflow is so bad. While it’s very common, it’s whether they should be disregarded in the simulation. horribly wasteful — and I fought for the last 20 years for com- Image courtesy of Altair. panies to realize it,” Briggs laments. “I spend most of my pro- cess consulting time trying to get organizations to realize it.” In the current product development roadmap, simula- tures too small to make a difference in simulation. Today, the tion and analysis experts typically receive 3D geometry con- rise of computer-driven optimization adds a new twist. structed in mechanical design programs by design engineers, Analysis involves subjecting a 3D digital replica of your often in a finalized, fully detailed form. Because the typical product to simulated loads and stresses to predict how it design department is less knowledgeable about digital simu- would perform under real-world usage. A typical analysis lation, CAE software users often have to repair or refine the might be something like simulating the drop of a cellphone 3D model before they can run a simulation. at a specific height and angle to determine whether it can Some advocate reversing the process: Let simulation and withstand such an accident. analysis define the initial design’s shape. Briggs, however, is By comparison, topology optimization, a more recent more cautious. He recommends a workflow in which “the practice made possible by increased computing power, uses evolving design is regularly and actively shaped by inputs de- sophisticated algorithms to seek the best possible shape or rived from performance analyses.” He also recommends work- parameters for a product. For example, it might be used to ing in a toolset that accommodates both design and analysis identify the leanest airplane wing based on manufacturing — in ATA’s case, NX — to reduce data exchange headaches. material properties and anticipated loads. In the past, a team of experts would have reviewed the results Analyze or Optimize? from digital simulations to determine how to refine the original Previously, the CAE software users’ prep work primarily design. With optimization, the computer steps in to do the lion’s consisted of identifying and (in most cases) removing fea- share of the job human experts once did. The algorithm-driven

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de1213_Automation_Wong.indd 58 11/14/13 4:36 PM With Phoenix Integration, users can iteratively run Automating the data exchange between CAD to CAE is analyses and then automatically upload results into part of Phoenix Integration’s service offerings. Shown PHX AnalysisLibrary for data capture. Image courtesy of here is the analysis view in PHX ModelCenter. Image Phoenix Integration. courtesy of Phoenix Integration.

method can also provide designers and engineers with uncon- face-wrapping, a method that’s quickly becoming the stan- ventional solutions seldom explored if executed manually. dard approach in dealing with pesky features. Another is the “The key in developing the geometry parameters for automatic detection of features. optimization is to control the design space,” notes David CD-adapco’s Vaughn says, “The feature that we pio- Vaughn, simulation software maker CD-adapco’s vice presi- neered for that purpose is surface wrapping.” The tool lets dent of worldwide marketing. CAE users shrink-wrap imperfect CAD geometry to prevent For instance, if you plan to run an optimization study on holes, gaps and overlapped surfaces from compromising the the best possible shape for an airfoil, he says, the key is to limit analysis. “The benefit of that is, you can use the most com- the shape parameterization to feasible airfoil shapes. If you put plex CAD model you’ve got for optimization and can still a bunch of non-uniform rational basis spline (NURBS) con- mesh it very quickly — and it’s automated,” he adds. trol points into the mix, you’ll end up with possibly hundreds Siemens’ Shankar points out that NX also has a surface- of variables. That’s overdesigning for optimization, Vaughn wrapping tool. “For example, if you’re trying to study the says, “because the objective is to minimize the number of sim- cooling under the hood of a car, you’ll need to specify the ulations required to get to the optimal answer.” flow volume,” he says, referring to the enclosed space under S. Ravi Shankar, Ph.D., Siemens PLM Software’s global the hood with the mechanical components excluded. “We director of simulation product marketing, agrees: “If you have tools that let you create that volume based on the solid start out with geometry that’s too detailed, if you were to models you have. In the past, that volume could only be de- mesh that without any simplification, if would be a large fined in the preset global resolution. In NX 9, you now have mesh model. Then each iteration would take much longer.” the option to specify a finer resolution in certain regions to Considering the number of variations the computer capture necessary detail.” would need to generate before arriving at the answer, the Altair HyperWorks CAE suite takes a similar approach computing time could increase exponentially, Shankar adds. with its shrink-wrap feature, described as a way “to generate an enclosed volume or solid mesh, and is typically used to ap- Defeaturing Makes Way for Shrink-wrapping proximate and simplify an existing model.” With the option Several direct-editing programs also serve the CAD-to-CAE to specify whether you want a loose or tight wrapping, you data exchange. Without the restrictions and learning curve can speedily create the general shape of the geometry with of history-based CAD, these programs were able to capture the desired mesh resolution. a portion of the analysts looking for an easy way to edit 3D Another alternative comes from Altair’s SimLab (acquired geometry. (Editor’s Note: For more, read “Direct Modelers as by Altair in 2010). Ulrich Gollwitzer, Altair’s marketing man- FEA Pre-Processors,” Part I & II, April and May 2012.) But the ager for modeling and visualization products, notes that Sim- CAE vendors soon struck back, by introducing their own Lab “reads native geometry, along with the CAD parameters. geometry cleanup functions and tools. It specializes in solid-meshing technology —for example, “I’m sure [direct modelers] help,” says Simone Bonino, powertrain and [computational fluid dynamics, or CFD] appli- Altair’s marketing director for HyperWorks. “But the ques- cations. The software can automatically recognize parametric tion is, do you really need another tool between CAD and features. But in SimLab, instead of simplifying the geometry, CAE? Now, you can skip that step.” you identify regions and set local or global mesh parameters.” One of the shortcuts is known as shrink-wrapping or sur- Once the software has identified features that are problem-

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de1213_Automation_Wong.indd 59 11/14/13 12:48 PM Optimize Workfl w /// CAD to CAE

In Altair’s software, you have to option to shrink-wrap a complex model. The dialog box lets you choose a tight wrap or a loose wrap. Image courtesy of Altair. prone in simulation, SimLab offers you the choice to disregard tomer, we try to explain to them about these geometry-related them, or treat them a certain way during meshing. If you have issues and guide them toward simulation-driven design.” gone through this process, you can save the treatment as a tem- ATA’s Briggs says he’s a “big fan of putting the whole or- plate, so SimLab knows how to address future CAD geometry ganization on a homogenous toolset. I guarantee that you’ll that involves the same type of features — for instance, using a make one-and-a-half or two times’ improvement in produc- specific mesh pattern for holes in-between certain ranges. tivity and in reducing technical errors.” Gollwitzer asserts that Altair is preaching simulation-led What’s Important? Who’s Asking? design. “If you start out with optimization, it might even give As president and CEO of the multi-disciplinary optimization you a completely new idea of how your structure should look specialist Phoenix Integration, Scott Woyak, Ph.D., has seen like,” he adds. “Then you’re not just replicating similar de- both sides of the design-simulation division. Phoenix Integra- sign patterns over and over again.” tion’s expertise is workflow automation, including the common Gollwitzer suggests that it would be “smart to establish a CAD-to-simulation workflow. Sometimes the project involves workflow where the designers hand over the geometry at the custom application programming interface (API) development. level of details sufficient for an analysis. Once simulation has “We’ve seen some customers who develop their own sys- proven that the design works, designers can add additional tem to clean up CAD geometry for optimization,” Woyak details to that design. It would take a little bit of education.” says. “Some use specialized tools like Sculptor [from Optimal Either way, the design process is iterative, so CAD to Solutions Software].” CAE or CAE to CAD will always require communication Sculptor lets you deform and adjust your mesh models and collaboration. DE in optimization runs. It uses what the company describes as “Arbitrary Shape Deformation (ASD) technology and can be Kenneth Wong is Desktop Engineering’s resident blogger and linked to existing fluid-flow (CFD) and/or structural (FEA) senior editor. Email him at [email protected] or share your analysis tools to accelerate CAE design optimization efforts.” thoughts on this article at deskeng.com/facebook. The key to eliminating the wrinkles in CAD-to-simula- tion is to figure out “the best way to construct your geometry so you won’t encounter problems in simulation when you try INFO ➜ Altair HyperWorks: AltairHyperWorks.com to solve,” says Woyak. ➜ ATA Engineering: ATA-E.com The discussion, therefore, raises a question: Is it fair to put the burden on the designer? ➜ CD-adapco: CD-adapco.com ➜ Optimal Solutions Software: GoSculptor.com Reshuffling the Order ➜ Phoenix Integration: Phoenix-Int.com “People are beginning to realize that, to lower cost and shorten cycles, they’ve got to use simulation more, earlier in ➜ Siemens NX CAE: Siemens.com/plm/nxcae the process,” Woyak observes. “When we work with a cus- For more information on this topic, visit deskeng.com.

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de1213_Automation_Wong.indd 60 11/14/13 12:49 PM Multiphysics /// Optimize Simulation Pulling Double Duty COMSOL Multiphysics˜So° ware o˛ ers simulation and modeling for Sharp Corp.’s research and product development. BY JIM ROMEO

ptimizing digital engineering design and optimizing finite attributes of components is the goal of many O global technology companies, particularly at the re- search and development stages. Today’s electronic products contain many sophisticated components including processors, communication chips, analog and passive components, light and power sources, as well as displays, imagers and micro-electro- mechanical systems (MEMS). Such component technologies require complex scientific and engineering demands. Simulation and modeling software becomes an asset to the intellectual prowess of researchers as they seek the most accu- rate prediction of the performance and reliability in a very com- petitive environment. Such is the case for researchers in Sharp Corp.’s R&D laboratories. According to Valerio Marra, Ph.D., technical marketing manager for COMSOL, Sharp found that COMSOL Multi- physics software was very helpful to its research efforts. As the model grew, Sharp became more familiar with various applica- tions that COMSOL offered in its software. “You can start with structural mechanics,” says Marra, “and LCD: Structure of LCD pixel as drawn in ECAD software. then add heat transfer and other physics in order to accurately Images courtesy of Sharp Corp. represent, thanks to multiphysics, the behavior of your appli- cations. Sharp took advantage of the fact that they can let the model grow accordingly to their simulation needs.” Once one department learned the software, regardless of the has about 100 employees engaged in the R&D of electronic physics used, they were able to train colleagues of other depart- hardware and devices. Chris Brown, Ph.D., is SLE’s research ments in its use and applications. He explains that Sharp was manager for the Health and Medical Devices Group. According attracted to COMSOL’s “real-world accuracy” simulation ap- to Brown, the multidisciplinary trend is quite compatible with proach, meaning they got better and better as they built simula- changes in the type of R&D done in the lab. tions and models — and at a certain point, they reduced testing “Ten years ago, our main research themes were based on im- significantly and kept optimizing the designs with the software. proving component technologies — in particular, displays and optoelectronic devices such as semiconductor lasers,” he says. Diverse Technology Development “Activities tended to be driven by depth of knowledge in just Sharp’s global R&D presence includes laboratories in Japan, one technical specialty, such as optics or electronic circuit design. which is the global headquarters for R&D, as well as in Ox- More recently, though, there has been a shift in focus to systems ford, England; Camas, WA; and Shanghai, China. The mission or products as a whole, such as health systems and energy sys- of each laboratory is to develop technology that can be used tems. By their nature, these activities are broader, and the research in Sharp products, and while each lab works on roughly the is driven by understanding how all the parts fit together,” same research themes — displays, health, energy and lighting — SLE uses COMSOL Multiphysics in a number of projects each has its own unique capability to tailor activities to support across the lab, for purposes ranging from early-stage research Sharp’s regional businesses. to product development in areas such as light-emitting diode Sharp Laboratories of Europe (SLE), located in Oxford, (LED) devices, displays, labs-on-a-chip, and energy systems.

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de1213_COMSOL_Sharp_Romeo.indd 61 11/14/13 12:54 PM Optimize Simulation /// Multiphysics

1 2

FIG. 1: Imported LCD pixel geometry in COMSOL. FIG. 2: COMSOL mesh of thin-fi lm high aspect ratio structures.

LED and LCD Development Healthcare Product Development SLE’s use of COMSOL has grown over the last five years, In the healthcare market, Sharp sought to develop palm-sized having begun in LED research and expanded to˜other themes diagnostic tools for doctors, nurses and other healthcare profes- by way of internal recommendations. SLE supports Sharp’s sionals to allow blood testing in a matter of minutes, compared LED business by providing technical analysis and design mod- with the hours or days it ordinarily takes. Sharp used COMSOL ifications to improve the performance of LED devices. Multiphysics to investigate the interactions between the fluid One example is optimization of LED electrode designs layer and the electronics. for improved wall-plug efficiency. A major issue with LED “We have modeled fluid flow at the input ports of the array, devices is that high operating temperatures can cause a enabling us to design fluid-input structures to get the droplets reduction in efficiency in the conversion of electricity to onto the array in the right place with minimum fluid-input vol- light. The relationship between optical efficiency and tem- umes,” says Brown. “This modeling ability gives us a more ac- perature in an LED is not linear; any hot spots in the LED curate starting point for experimental work, hence reducing the chip will disproportionately reduce the efficiency of the number of design iterations required, which in turn helps us to entire device. reduce R&D prototyping time and cost compared with simple Sharp’s goal was to create a uniform temperature distri- hand calculations.” bution. This is accomplished by designing the LED’s elec- The software also allowed them to model interactions be- trodes so that no hot spots appeared. The resulting uniform tween the droplets or particles in the fluid, and the electronic temperature distribution also tends to maximize heat dis- sensors in the array. “In this case, we were interested in inves- sipation from the LED and lower average temperature. tigating impedance changes as droplets or particles in the fluid COMSOL software also helps support Sharp’s displays pass between a pair of electrodes,” Brown says. “The simulation business. Sharp’s objective is to improve image quality while output is a range of likely impedance values, and this can be reducing liquid-crystal display (LCD) power consumption used as the basis of a specification for designing sensor circuits in Sharp products, such as smartphones and TVs. A detailed to detect the presence of the droplets or particles.” understanding of the electrical and optical performance of the LCD displays — particularly the electrical characteris- Compatibility and Versatility tics of the LCD pixels — goes a long way toward achieving COMSOL is compatible with other software tools that Sharp these goals.˜ uses, such as CAD programs, Brown notes. The versatility of Overall, Sharp’s design and simulation environment for the software fit nicely in its portfolio, strengthening its overall electronic circuit design uses the AC/DC Module found toolkit for cutting edge research. in the COMSOL product suite to extract the parasitic re- According to Brown, Sharp attempted the use of parasitic sistances and capacitances of the electrical wiring inside extraction tools from several traditional ECAD software pack- the LCD. Specifically, it capitalizes on the meshing capa- ages,˜but none were able to successfully cope with the large as- bilities available in COMSOL Multiphysics to achieve the pect ratio of the thin-film, large-area structures used in LCDs. desired accuracy. For Sharp, the COMSOL software provided the first opportu-

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de1213_COMSOL_Sharp_Romeo.indd 62 11/14/13 1:15 PM Multiphysics /// Optimize Simulation

3 4

FIG. 3: Structure of an LED chip. FIG. 4: COMSOL simulation output of an LED structure showing surface electric potential.

nity to enable versatility and degree of control over the meshing thermal transfer in the solid components.” procedure. Ultimately, it allowed them to thoroughly explore Besides providing technical support for existing products, such structures. SLE is also engaged in creating business opportunities for Brown also says the software’s ECAD Import Module Sharp to enter new markets. Specifically, in the health care lets researchers transfer layout designs from ECAD software arena, SLE led to the development of so-called lab-on-a-chip quickly and without error — enabling them to explore the ef- systems. This demonstrated how COMSOL’s value to Sharp fects of design modifications to a degree not possible otherwise. in one application gave way to similar value in another: Sharp That’s because the only alternative is to hand-calculate the ca- was able to leverage manufacturing expertise with the thin-film pacitances between wires using simple linear design equations. transistors traditionally used in the LCD market. The shape of the wiring in the LCD makes this quite compli- For Sharp, COMSOL software parallels the same rigor- cated, however. In the past, SLE’s researchers made a number ous approach it uses in R&D explorations. Given the diverse of simplifications when using this method. “Hand calculations range of projects for which COMSOL Multiphysics is used, of capacitance are correct to a first order, but aren’t really of any each research group has its own license and add-on products. use when trying to optimize or improve designs,” Brown says. A member of the research staff in each group is˜responsible for the˜maintenance of that group’s license. Cross-pollination and Knowledge Transfer Ten research staff members across the lab are now trained The software’s versatility was key for Sharp, as they used their in its use. Projects and teams are structured to enable flex- models and simulations in multiple applications across their ibility for several researchers across the lab to use the software R&D efforts. The key advantage of this “cross-pollination” is simultaneously. As team usage of COMSOL grew, they began that a technical solution can be transferred from one application to dedicate a stand-alone workstation within each group just or market area to another, developing solutions that would be for COMSOL. otherwise hard to find. “The multidisciplinary nature of our research activities For example, Sharp used COMSOL for its development of at SLE will continue in the future,” Brown says. “As such, new energy storage systems and sustainable heating and cool- we expect COMSOL Multiphysics to continue to play an ing. An important R&D target is to optimize the performance important role, both as a research tool and as a product of heat exchanger components so as to achieve high heat-trans- development tool.” DE fer efficiency and minimize system size and weight. This work has involved both the optimization of existing heat exchange Jim Romeo is a freelance writer based in Chesapeake, VA. Send components and the design of new ones. e-mail about this article to [email protected]. “We have simulated the fluid dynamics of cooling fluids in air-conditioning systems and achieved an efficiency improve- INFO ➜ COMSOL Multiphysics: COMSOL.com ment of 30 percent with a new system,” Brown reports. “We use COMSOL because this is inherently a multiphysics problem, ➜ Sharp Corp.: Sharp-World.com given the need to link the gas and liquid flows in the system to For more information on this topic, visit deskeng.com.

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de1213_COMSOL_Sharp_Romeo.indd 63 11/14/13 1:16 PM Optimize Workfl w /// Collaboration Making Optimization a Shared Experience Enterprise Suite allows teams to build the advanced multidisciplinary optimization workfl ws that are critical to complex system design. By Beth St ackp ole

o longer an oddity or curious interloper, wind turbines The Power of the Web are settling in as a familiar part of both urban and rural Key to the pair’s power is a complete redesign that extends the N landscapes. Yet beneath their simple and majestic stature modeFRONTIER desktop paradigm to a Web-based collab- belies a design complexity that tests even the most technically orative environment. The new approach means that multiple astute engineering organizations. users, with different competencies and located at different sites, Just ask Airworks, a contractor for advanced projects in the can more easily participate in the MDO process. They can share space and defense industries, which is refining a long-term strat- models and optimization strategies via a shared repository that egy for wind energy with a pilot project for wind turbine rotor can be accessed anywhere, anytime, with only a Web browser. blade design. To ensure a proper concept for a certified rotor “Today, all companies are working in scenarios where differ- blade, the Airworks team needs to balance a variety of multidis- ent people work together; there are few instances of single en- ciplinary optimizations (MDOs) — for example, creating models gineers doing all the work on their own from design to detailed that couple aero-structural blade properties with wind flows and modeling,” notes Matteo Nicolich, ESTECO’s product manager possible failure scenarios — in addition to performing stability for SOMO. “Rather, you have different groups with different ex- analysis and evaluating materials and manufacturing time costs. pertise working together, and they need a tool to integrate the On top of the sheer complexity of the blade design, there is different levels of knowledge in the same environment. The Web the collaborative nature of the engineering process. It’s made all provides the classic answer for this type of framework.” the more challenging given that Airworks’ aerodynamics, load Consider a scenario where an aerodynamics specialist and a and mold design experts are based in Rome, and the system-level structural expert need to collaborate on the same design, but are architecture, structure, manufacturing and project management located in different venues. They’re performing their individual domain experts reside more than 400 miles away in Trieste, Italy. modeling and optimization routines using siloed tools and with “When a wind energy project launches, we always have prob- very disconnected workflows. Traditionally, these two would have lems,” admits Stefano Picinich, Airworks’ founder and manag- to manually trade their different model files to work together — ing director. “Normally, we move three or four key people from raising the risk of one party being saddled with incomplete data if Rome to Trieste for a couple of months to enable a smooth de- a particular type of simulation or MDO changed along the way. sign start, but this took engineers away from routine support, Moreover, domain experts unfamiliar with how to create specific which was far more costly.” design of experiments (DOE) or optimization strategies in mode- The solution to both the design complexity and collaboration FRONTIER were shut out of the workflow, unable to contribute problem arrived in the form of Enterprise Suite, a new platform models to the greater cause or to reuse other experts’ MDO work from ESTECO, which aims to simplify some of the challenges because it was not easily accessible. around MDO and multi-objective optimization. With Enterprise Suite’s Web-based approach, however, Launched mid-year, Enterprise Suite combines the advanced project experts can participate in MDOs without knowing the capabilities of the modeFRONTIER 4.5 multi-objective and details of that other discipline, and without the skills to create MDO platform, with SOMO, ESTECO’s new framework for the integration and workflows. Moreover, by storing specialists’ distributed execution and collaboration. The duo is designed to optimization and design space exploration strategies in a single, give engineering groups better control over the design of com- structured database, companies protect their intellectual property, plex systems by helping them more effectively organize and man- nurture a shared knowledgebase, and promote MDO reuse. age critical simulation data — all while allowing a dispersed and While the ability to share optimization plans is intriguing, varied team of domain experts and optimization and integration SOMO’s potential to facilitate collaboration and help multidisci- specialists to join forces to build advanced MDO workflows. plinary engineering teams easily create and modify optimization

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de1213_ESTECO_Beth.indd 64 11/14/13 1:04 PM workflows is its strongest selling point, according to Marc Halpern, Ph.D., research vice president at Gartner. Workflow is generally dif- ficult to change in typical product data management (PDM), product lifecycle management (PLM), and service lifecycle management (SLM) offerings, Halpern says, so SOMO’s “flexibility of workflow and col- SOMO’s Dashboard page lets users find in ormation laboration functionality will be key to its acceptance.” about their work, as well as direct links to the most recent resources. Images courtesy of ESTECO. Freedom to Innovate Enterprise Suite also delivers innovations in the areas of distributed execution and post-processing analysis capabilities. With simulation and optimization continually hungry for additional compute power, ESTECO designed SOMO to support high-performance computing (HPC) systems and cloud environments so engineering groups can eas- ily add more horsepower when needed. In addition, SOMO will automatically execute simulations and optimizations across a number of nodes in a distributed fashion. It’s a process that is transparent to the user, thereby reducing the burden on IT, Nicolich says. Users can select where they want their task to be executed based on their role and privileges, or the software will auto- Users can organize their work and data inside matically queue up and distribute jobs based on the requirements of the the SOMO shared repository using projects and software, as well as the availability of computing resources. workspaces. Users associate projects with one or On the post-processing front, Enterprise Suite is stocked with an more workspaces to control how project resources array of tools, including new data visualization capabilities and statistical are shared among other users. analysis reports to help domain experts and other engineering collabo- rators make sense of the DOE and optimization findings. Because the Web-based system supports HTML5, users can access the charts and report capabilities on an array of devices, from laptops to tablets. While Airworks is still getting its feet wet with Enterprise Suite’s new capabilities, Picinich says the Web-based interfaces align perfectly with the firm’s working style and is likely to make the collaboration process a lot easier. More to the point, though, he sees Enterprise Suite opening doors to new design innovations, whether related to wind tur- bine blade design or in Airworks’ other core areas of focus. “The platform gives our people the freedom to think about how to improve the product, rather than occupy their minds with issues that With SOMO, users can create a DOE or optimization have more to do with logistics like relocating from one office to another plan for a given project, while having direct visibility or checking an FTP for new data,” he explains. to the most meaningful information from the Nevertheless, even the best engineering tools can’t cover for a lack generated session. of design expertise and well-defined goals, he cautions. “Sharing opti- mization data, accessing HPC resources, and having a smarter, faster platform doesn’t mean people can relax on the engineering side,” he says. “Tools only provide a link between your expertise and your ideas for the product you design.” DE

Beth Stackpole is a contributing editor to DE. You can reach her at [email protected].

INFO ➜ Airworks Engineering: Air-Works.eu ➜ ESTECO s.p.a.: ESTECO.com Visualization and analytical post-processing tools ➜ Gartner: Gartner.com like this scatter bubble chart help users glean an understanding of complex datasets. For more information on this topic, visit deskeng.com.

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de1213_ESTECO_Beth.indd 65 11/14/13 1:05 PM Optimize Design /// Cyber-physical Systems The Coming Impact of CPS on Design What does the future hold for design methodology in the face of technology? By Ran dy Frank

he convergence of design meth- odologies has been an ongoing T work-in-progress for decades. In 1969, Tetsuro Mori of Yaskawa coined the term mechatronics for combining the aspects of mechanical and electronic design. It evolved to include computing, as well. Today, with technology terms such as the Internet of Things (IoT), cloud computing and others, cyber- physical systems (CPSs) seek to define the next-generation approach for the design of complex systems. Differentiating themselves from pre- vious design approaches, CPS designs are coordinated, distributed and con- nected. Their goals include the ability to far exceed the systems of today in ca- Fig . 1: The CPS concept map embraces control systems, cyber pability, adaptability, resiliency, safety, security and advanced design methodologies, including validation and security and usability. The key to their verification. Image courtesy of CyberPhysicalSystems.org. success is connectivity between the cyber-world of computing and communica- tions with the physical world. in 2011 as a forward-looking project under the Germany Potential application areas for CPS include a smart government’s “High-Tech Strategy” initiative. A Work- electric grid, smart transportation, smart buildings, smart ing Group was initiated later that year to draft compre- medical technologies, and essentially any of the smart- hensive strategic recommendations for implementing prefixed, next-generation physical systems — including Industry 4.0, which is based on the use of cyber-physical smart manufacturing and smart factories. (See Fig. 1.) systems to accomplish its goals. In his keynote presentation at NIWeek 2013 in Au- Industry 4.0 gust, James Truchard, Ph.D., president, CEO and co- Smarter factories with increased automation that include founder of National Instruments, discussed CPS, In- intelligent monitoring and autonomous decision-making dustry 4.0 and the transformation of tools. He provided processes will require new business models. Recogniz- greater insight into CPS’ impact on the design process ing that the areas of production and logistics are prime in an exclusive interview with DE. candidates for optimization, Industry 4.0 was conceived Truchard acknowledges the continuous nature of im-

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de1213_NI_Profile_Frank.indd 66 11/14/13 1:18 PM Fig . 2: A concise view of CPS shows three Cs for ubiquitous information. Image courtesy of National Instruments

proved design methodologies, and the relationship of CPS to well-accepted approaches such as mechatronics, model- based design and other recent design methodologies. “Every now and then, another piece of the puzzle comes together,” he says. “When you step back a few steps and look at the whole process, things have just changed.” National Instruments recognized the value of CPS more than seven years ago. The iPhone, for example, shows how the right graphical user interface (GUI), several sensing technologies and the resulting mea- surements can significantly change consumer products. Truchard says he sees the same thing occurring in indus- trial systems for large-scale physical problems. “For the first time in history, you can have advanced measurements in the same platform you have advanced control,” he explains. “That’s one aspect of the whole. Then you have this ubiquitous capability that combines measure- ments — it combines control, it combines advanced analysis — all being done in real-time, with the ability to interface the computing world to the physical world.” In fact, machine-to-machine (M2M) communications and control, the IoT, cloud computing and just about everything “smart” can all fall under the CPS design um- brella, he points out. “And there is one more sort of consolidating perspec- tive on it, and that’s the ubiquitous nature of information or data being converted into information, top to bottom in the decision process,” adds Truchard. (See Fig. 2.) Because of CPS, Truchard notes, people are using data in ways that were not previously imagined. One example is the Dresden light rail system in Germany. With seven years of data collection and consolidation, researchers at

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de1213_NI_Profile_Frank.indd 67 11/14/13 1:18 PM Optimize Design /// Cyber-physical Systems

FIG. 4: National Instruments’ LabVIEW and other hardware provide solutions for different application systems, including CPS. Image courtesy of National FIG. 3: Transitioning from prototype to high volume. Instruments. Image courtesy of National Instruments.

the university published 19 papers demonstrating several things on their own are isolated facts, but when you pull ideas they were able to implement to improve the effi- them together in an aggregated way, they change your ciency of the system, from effective use of electricity to ability to understand use-related information.” vehicle maintenance. With CPS in mind, NI has implemented advance- “Another piece of the puzzle is what we call ‘big ana- ments in its tools and software to provide a unified log data,’” says Truchard. “You have this data that is a platform for designing, prototyping and deploying ap- variable — accessible across the network, across the ac- plications. Graphical system design allows designers to tivities and whatever dimension you want to go. These integrate real-world signals sooner in the design process,

FIG. 5: E3.eCheck provides a circuit test showing an active lamp, current fl ow, voltage and current. Image courtesy of Zuken.

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de1213_NI_Profile_Frank.indd 68 11/14/13 1:19 PM for earlier error detection and reuse code for maximum gies. Truchard says he also wants to educate and prepare efficiency. By taking advantage of the latest advances in designers for the future of engineering. computing technology, this approach can optimize sys- “You have all these things that are combining, and tem performance more quickly than traditional design the key is to be a player, to be a part of that ecosystem methodologies, Truchard says. (See Fig. 3.) in a way that your information and your [technology] — “What makes that possible for us is we combine the in our case, measurements and systems that are being processing, distributed processing and the [field-pro- built with our technology — can integrate into this big- grammable gate array] FPGA that lets us go the last ger picture … with things like the cloud included,” he mile for the high speed that’s needed in some cases, so concludes. DE it becomes a software problem in that space,” he contin- ues. While sensor integration is still a physical system problem, he says, other design aspects would become a Randy Frank is a contributor to DE. Send e-mail about software problem where re-use of work plays a critical this article to [email protected] role. (See Fig. 4.)

Additional Tools INFO ➜ Cyber-physical Systems: CyberPhysicalSystems.org Other companies have recognized the importance of CPS thinking, but may not use that terminology. Zuken, ➜ Industry 4.0: BMBF.de/en/19955.php a software and services company, has tackled design com- ➜ National Instruments: NI.com plexity system cost reduction with E3.eCheck. As part ➜ Practical Software and Systems Measurement: PSMSC.com of its E3 series of electrical and fluid CAD software, E3.eCheck identifies errors at the development stage. ➜ Zuken: Zuken.com/en Running in real-time, the software automatically ensures For more information on this topic, visit deskeng.com. the functional accuracy of a schematic and verifies that wires and fuses are within acceptable tolerances. “E3.eCheck represents an advancement in the tools available for electrical engineering of harnesses and con- trol systems,” says Steve Chidester, head of international marketing at Zuken. “The days of prototyping and then documenting afterward are on their way out. Today, it is important to engineer products from concept through manufacturing. E3.eCheck not only makes design analy- sis faster and more accurate, but it also identifies design flaws early — saving time and cost by eliminating proto- type iterations.” (See Fig. 5.)

Evolving Design Methodology While many of the enhanced capabilities from CPS are reality, some of the pieces are still falling into place. “There are some components that depend on some new standards that are coming out,” says Truchard. “One is [Practical Software and Systems Measurement, or PSM] time-synchronized networks, for example, that we’re ac- tive in committee form, driving the components that are needed to make this happen.” The time-synchronized aspect is required to take CPS to the next level. One of the primary goals of the PSM project is to transition the issue-drive measurement pro- cess into everyday practice. With its role in measurement technology, NI has interest in both of these areas. To deliver on the vision of cyber-physical systems, NI is involved in driving the standards and developing tools needed so that users can implement the latest technolo-

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de1213_NI_Profile_Frank.indd 69 11/14/13 1:19 PM Optimize Computing /// Virtualization Speed Up Engineering IT Virtualization promises a solution to the budget constraints and challenges associated with deploying new engineering computing hardware. Frank J. Ohlh orst

irtualization has been the buzzword in IT circles for several years now. After all, what’s not to like? Simply V put, virtualization allows IT managers to more effi- ciently use their existing resources, maximizing CPU utiliza- tion and abstracting compute, storage and infrastructure from the physical realm while easing management at the same time. However, there are those looking to extend the promise of virtualization, and pushing the envelope, at least when it comes to high performance computing (HPC), remote computing and the maximizing of simulation resources.

Virtual, High-Powered Machines Vendors and developers have come to the realization that vir- tual representations of HPC systems can be deployed rapidly and offer remote access, without the need for HPC resources The NVIDIA GRID Visual Computing Appliance (VCA) allows located at the customer’s site. That has created a boon for high users to create virtual machines called workspaces, which performance virtualization, where expensive HPC systems can NVIDIA says are effectively dedicated high-performance, be remotely accessed and custom configured for a short pe- GPU-based systems. riod of time, making it much more affordable, yet still offering needed compute resources on demand. and others may push the on-sight ideology. Yet, different solu- Ultimately, virtualization promises to lower the entry point tions are designed to handle different problems, so the first step into HPC utilization, bringing the technology to a vast array of on the path to virtualization is to ask what problem needs to be businesses, which previously did not have the financial resources solved. That fragments the market into three distinct segments, to invest in the needed hardware. Nowhere in engineering each with its own capabilities, needs and solutions. will that benefit be realized more than in advanced simulation chores, where grids of systems were often required to perform 1 Access HPC on Demand tasks in a timely manner. Take for example companies that need part time access to HPC However, the benefits offered by virtualization do not end offerings. Those companies will be looking for a pay-as-you-go with remote HPC, several other use cases prove the technology offering that minimizes costs, yet scales up to meet demands of offers value for engineering and design firms, where stretching individual projects. Those businesses are best served by cloud/ the performance of systems and doing more with less are the hosted offerings that can offer remote access in to virtualized orders of the day. Virtualization can be used to maximize CPU infrastructures/compute farms/storage subsystems and so on. utilization by running several virtual machines on a single high The needs of those businesses may be met by service ven- performance system. In effect, doing more with less, while uti- dors, such as RackSpace, Amazon, Peer1, and others. For exam- lizing those normally discarded CPU cycles. ple, RackSpace offers an HPC Cluster in a Cloud Environment, An entire market segment has become devoted to virtualiza- which incorporates a technology called Open MPI (Message tion, with dozens of vendors offering hundreds of products and Passing Interface) that supports the threading of HPC appli- services designed to bring the technology to most any business. cations across a cluster. RackSpace allows their customers to However, that cornucopia of virtualization variety creates an- self-provision HPC clusters for remote access using multiple other problem: What technology to use? Virtualized Rackspace Cloud Servers. Each vendor will tout its own virtualization platforms and Amazon and Peer1 offer similar ideologies, where the vir- subsequent ecosystems — some will leverage the service/hosted tualization layer becomes basically a transport layer to con- model, while others will associate virtualization with the cloud, nect physical servers to virtual machines for HPC processing.

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de1213_Virtualization_Ohlhorst.indd 70 11/14/13 4:19 PM However, there are some other vendors that take a different 3 Boost Performance approach, aiming to ease the burden on customers by handling The third virtualization scenario often found in the engineer- the provisioning and maintenance of Virtualized HPC offers. ing space focuses on performance and not so much remote Cases in Point include companies such as NIMBIX and IBM’s access or cloud enablement. Here, engineering firms are using SoftLayer, which offer private cloud types of virtualized HPC virtualization (both hardware and software) solutions to maxi- clusters. Those vendors offer solutions that are somewhat pre- mize performance and minimize wasted CPU cycles. configured and fully managed, allowing customers to focus on One major player is NVIDIA, with its Grid Series of add- compute jobs and not ancillary issues. on boards that are designed to allow virtualized systems to offload graphics processing to a dedicated GPU, improving 2 Maximize Computing ROI performance, responsiveness and usability of virtualized sys- For many businesses, virtualization is about maximizing the tems working with intensive graphics. Ideally, a GRID board value of what they already have — in other words, increasing can use a single high performance workstation as a host for the return on investment on systems already purchased. virtual machines, allowing several users to share the process- One way to do this is by extending the reach of internal ing power of that system, while not experiencing drops in HPC resources out to remote workers and satellite offices. By graphics performance. combining web access with virtual machines, those businesses The key driver of virtualization seems to be the need to can deliver a full HPC environment to a distant engineer, with- centralize HPC, making it easier to manage, scale and provi- out having to invest in additional hardware. That scenario also sion based upon project needs and not assumptions. That has extends to mobile workers as well, where a user can access an led to the adoption of high-end virtualization systems, which HPC virtual machine on a tablet, notebook computer or even operate by accumulating and assigning multiple cores to a a smartphone — eliminating the need to bring expensive (and single machine. The single virtual system aggregated from cumbersome) hardware out into the field. multiple physical machines proves to be a powerful manage- Those scenarios are typically powered by leading technol- ment tool that helps the IT department increase its efficiency, ogy vendors such as VMware, Citrix, Microsoft and Parallels, as well as the efficiency of engineering computing. DE who offer virtualization platforms that abstract the hardware from the virtual machine. However, most adopters are finding Frank Ohlhorst is chief analyst and freelance writer at Ohlhorst.net. that those basic platforms are not enough and have to assemble Send e-mail about this article to [email protected]. ecosystems that support VDI (Virtual Desktop Infrastructures). Vendors in that space include LiquidWareLabs, a company that provides pre-assessment, deployment and management INFO ➜ Amazon: aws.amazon.com tools for VDI implementations. Other vendors include LU- ➜ Citrix: citrix.com CIDLOGiX, Syncron, Quest, Ericom and Moka5. However, ➜ Dell: dell.com remote VDI capabilities doesn’t end with just software vendors, Ericom: ericom.com there are others offering a hybrid solution, which pairs a client ➜ device with VDI software. PanoLogic offers its “zero client,” a ➜ IBM’s SoftLayer: softlayer.com small Ethernet attached device that presents a virtual machine ➜ LiquidWareLabs: liquidwarelabs.com to users — no local CPU needed. The device simply attaches ➜ Microsoft: Microsoft.com the desktop peripherals to the remote virtual machine via an Ethernet connection. ➜ Moka5: moka5.com Dell’s recent acquisition of Wyse Technologies brings an- ➜ nComputing: ncomputing.com other solution to play, a terminal device that works much in the ➜ NIMBIX: nimbix.net same way as Pano’s offering. nComputing is yet another vendor offering a combination of virtualization and remote desktop ac- ➜ NVIDIA: nvidia.com cess — the company offers a multiuser card that is installed into ➜ Parallels: parallels.com a PC and then uses Ethernet to deliver the experience to a small ➜ Peer1: peer1.com client device that powers a terminal setup. ➜ RackSpace: Rackspace.com Other technologies also are available that do a good job of en- abling remote access to virtual systems. Take for example Teradici, ➜ LUCIDLOGiX: lucidlogix.com a company that offers a card that plugs into a host system and ➜ PanoLogic: panologic.com then delivers the host’s capabilities to a remote, dumb terminal ➜ Teradici: teradici.com — while not exactly a virtualization product, it does abstract the user’s desktop from a high performance system, allowing those ➜ VMware: vmware.com HPC systems to be accessed remotely. For more information on this topic, visit deskeng.com.

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de1213_Virtualization_Ohlhorst.indd 71 11/14/13 1:32 PM Optimize Computing /// Ultrabook Review Yes It Can The new Lenovo ThinkPad Helix ultrabook is nimble enough to run mainstream CAD applications. By David Cohn

ith the advent of Windows 8, most PC manufacturers released tablets and W convertible systems combining touchscreens with small, often detach- able keyboards. One new category of systems is the ultrabook. Based on a specification developed by Intel, ultrabooks represent a new class of high-end subnotebooks designed to feature reduced bulk without compromising performance and battery life. Ultrabooks use low-power Intel Core processors and solid-state drives (SSDs). The big question for DE read- ers, however, is whether these new ultrabooks are ca- pable of running mainstream CAD software. We finally got a chance to find out firsthand when we received the new Lenovo ThinkPad Helix. INFO ➜ Lenovo: Lenovo.com/thinkstation The machine consists of two distinct components: Lenovo ThinkPad Helix an 11.6-in. tablet and a keyboard dock featuring an 83- • Price: $1,609 as tested ($1,477 base price) key full-sized, spill-resistant keyboard. On its own, the • Size: 11.66x8.90x0.77-in. (DxWxH) notebook 11.7x7.3x0.5-in. (WxDxH) tablet weighs just 1.8 lbs., • Weight: 3.7 lbs. as tested, plus 0.25 lb. for power supply and cords and features a bright (400 nits) full HD 1920x1080 dis- • CPU: 1.8GHz Intel Core i5-3337U dual-core w/3MB cache play with a screen protected by Corning Gorilla glass. • Memory: 4GB DDR3 at 1,333MHz When inserted into the keyboard dock, the Helix resem- • Graphics: integrated Intel HD Graphics 4000 bles a small, 3.7-lb. laptop measuring just 11.66x8.9x0.77 • Display: 11.6 in. full HD (1,920x1,080) IPS (400 nits) in. You can also insert the tablet into the keyboard dock • Hard disk: 180GB SSD (128GB and 256GB also available) with the screen facing away from the keyboard for use as • Audio: Dolby Home Theater 4.0 with 3.5mm combo audio jack a stand — or even fold the entire system flat. • Network: integrated Intel Centrino Advanced-N 6235 Wi-Fi, Lenovo offers a choice of either the 1.8GHz Intel Gigabit Ethernet via supplied USB dongle, Ericsson C5621 TFF Core i5-3337U CPU, which came in our evaluation unit, (with GPS), Bluetooth, NFC and optional 3G broadband or the nearly identical Core i5-3427U processor, which • Other: one USB 2.0, mini DisplayPort, and SIM card in tablet; has a slightly faster maximum turbo frequency, faster two USB 3.0 and mini DisplayPort in keyboard dock built-in graphics and adds Intel Clear Video, vPro and • Keyboard: integrated 83-key keyboard Trusted Execution technologies. The i5-3427U proces- • Pointing device: 10-point multitouch, ThinkPad digitizer pen, sor adds $80 to the overall system price. Both processors fi e-button Clickpa are designed specifically for ultrabooks and feature two • Warranty: one year

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de1213_Review_Lenovo_Cohn.indd 72 11/14/13 1:38 PM CPU cores for a total of four threads, a 3MB cache, and the fan, which is sometimes audible, the tablet does get support for up to 32GB of memory, although Lenovo a bit warm — around 86˚F. The digitizer pen has both only offers the Helix with 4GB of RAM. a tip sensor and a side-mounted button; it enables you to input text in a natural manner as well as take notes, Lots of Flexibility annotate PDF files, and draw when used in conjunction On its own, the Helix tablet is considerably bigger and with compatible software. a half-pound heavier than an Apple iPad. But its dimen- A combo audio jack, volume controls and a screen sions result in an industry-standard 16:9 display, com- rotation lock button are located on the left edge. Along pared to the iPad’s 4:3 ratio. The Helix powers on via a the bottom edge are a power connector, emergency reset button on the upper-right edge. A digitizer pen fits into hole, keyboard dock connector, subscriber identity module a storage slot in the upper-left edge, and a fan louver (SIM) card tray, mini DisplayPort connector, and a single extends along a portion of the upper edge. In spite of USB 2.0 port. A 2 megapixel 1080p front-facing camera

Lenovo ThinkPad Helix Eurocom Panther 4.0 Lenovo ThinkPad W530 HP EliteBook 8560w Mobile ultrabook mobile workstation mobile workstation mobile workstation (1.8GHz Intel Core (3.1GHz Intel Xeon (2.90GHz Intel Core i7- (2.30GHz Intel Core Workstations i5-3337U dual-core CPU, E5-2867W 8-core CPU, 3920XM quad-core CPU, i7-2820QM quad-core Intel HD Graphics 4000, NVIDIA Quadro K5000M, NVIDIA Quadro K2000M, CPU, NVIDIA Quadro Compared 4GB RAM) 16GB RAM) 16GB RAM) 2000M, 16GB RAM)

Price as tested $1,609 $6,800 $2,592 $4,063 Date tested 9/10/13 4/20/13 12/29/12 5/1/12 Operating System Windows 8 Windows 7 Windows 7 Windows 7 SPECview 11 higher catia-03 n/a 65.87 34.82 27.49 ensight-04 1.33 61.01 18.40 18.46 lightwave-01 8.68 65.85 62.75 48.21 maya-03 8.78 102.18 62.04 58.12 proe-5 1.00 13.82 15.58 9.77 sw-02 4.90 55.06 39.48 35.85 tcvis-02 1.37 59.28 30.63 23.12 snx-01 0.82 64.62 25.14 19.85 SPECapc SolidWorks 2013 Higher Graphics Composite n/a 2.26 2.06 n/a RealView Graphics Composite n/a 2.42 2.18 n/a Shadows Composite n/a 2.42 2.18 n/a Ambient Occlusion Composite n/a 5.14 3.76 n/a Shaded Mode Composite n/a 2.41 2.13 n/a Shaded With Edges Mode Composite n/a 2.12 2.00 n/a RealView Disabled Composite n/a 1.72 1.65 n/a CPU Composite n/a 3.72 3.59 n/a Autodesk Render Test Lower Time Seconds 244.16 57.33 62.00 89.83 Battery Test Higher Time Hours:min 6:18 1:14 6:09 2:37 Numbers in blue indicate best recorded results. Numbers in red indicate worst recorded results. Results are shown separately for the ultrabook and mobile workstation classes.

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de1213_Review_Lenovo_Cohn.indd 73 11/14/13 1:38 PM Optimize Computing /// Ultrabook Review

and Windows button are centered above and below the i5 CPU, its graphics performance on the SPECviewperf screen, respectively. There are also stereo speakers located benchmark pales in comparison to systems equipped at either corner below the screen, as well as a built-in mi- with discrete graphics. Indeed, the Helix was incapable crophone and an ambient light sensor. of even completing the Computer Aided Three-dimen- On the rear of the tablet, an illuminated dot in the sional Interactive Application (CATIA) portion of the ThinkPad logo glows red to indicate when the tablet SPECviewperf test. is powered on and in use, and blinks to indicate other Similarly, we were unable to run the SPECapc Solid- modes. There is also a 5 megapixel 1080p HD webcam Works benchmark because the Intel HD Graphics 4000 with auto focus and a built-in flash. It’s capable of shoot- does not support the SolidWorks RealView feature, ing video at 30 frames per second, as well as Motion which is an integral part of the test. But the Lenovo JPEG. ThinkPad Helix ran SolidWorks 2013 just fine — and The standard tablet houses a 128GB SSD, but Lenovo we had no problem working with parts and assemblies. included a 180GB drive in our evaluation unit, which We also ran our standard AutoCAD rendering test. added $100 to the price. A 256GB drive (a $200 option) Again, because this test is multi-threaded and is meant is also available. to illustrate the benefits of multiple, fast CPU cores, the In addition to adding an excellent keyboard, the key- results were the slowest we’ve recorded in years — av- board dock acts like a port replicator and holds the tablet eraging slightly more than four minutes. But we doubt upright to provide a typing experience similar to that of a anyone would rely on a system like this for rendering notebook computer. A gesture-sensitive 4x2.5-in. touch- unless they were out in the field and had no other choice. pad is centered below the keyboard, while a TrackPoint The Lenovo ThinkPad Helix performed fine when doing pointing stick is nestled above the B key. Again, a red actual work in AutoCAD. LED within the ThinkPad logo in the lower-right corner Prices for the Lenovo ThinkPad Helix start at $1,477. of the palm rest functions as a system status indicator, Although the base configuration comes with Windows 8 with a blinking or constant light indicating the current 64-bit, our evaluation unit came with Windows 8 Pro 64, system status. On the rear of the keyboard dock are a pair which added an additional $50 to the price. Other than of USB 3.0 connectors, a mini DisplayPort connector, a that and the bigger hard drive, our review unit was pretty power connector and an emergency reset hole. basic. You can have Lenovo preload Microsoft Office and One of the most interesting features of the Lenovo various other software, and add a mini DisplayPort/VGA ThinkPad Helix is that both the tablet and keyboard monitor cable to connect to an external monitor. We dock include batteries. The tablet itself comes with a hooked the Helix up to an external monitor using a mini three-cell battery that Lenovo claims to provide up to DisplayPort cable we already had on hand. six hours of battery life, while the keyboard dock has its Lenovo backs the Helix with a one-year depot/express own four-cell battery. According to Lenovo, the combi- warranty. The company also gives you a number of cus- nation provides up to 10 hours of use. On our own bat- tom tools, including Lenovo Quick Launch, which adds tery run-down test, however, the system ran for just six a Start button that can be used in lieu of the standard hours before warning that our charge was down to 5%. Windows 8 interface, as well as Evernote, Skype and a The system shut down completely 18 minutes later. number of other preloaded applications. With built-in Wi-Fi, Bluetooth, near field computing, and optional 3G Performance Better Than Benchmarks mobile broadband, the Lenovo ThinkPad Helix is a great So now the big question: Can you run mainstream CAD system for engineering executives on the go. It’s certainly applications on this ultrabook? We are happy to report not a replacement for a high-end mobile workstation, but that the answer is yes! We installed AutoCAD, Solid- at just 3.7 lbs. and with a price of $1,609 as tested, the Works and a host of other applications — as well as all of Lenovo ThinkPad Helix may be just right when you need our standard benchmarks — and put the Lenovo Think- to travel light and still get some work done. DE Pad Helix through the exact same paces as any other workstation. While the Helix certainly didn’t set any re- cords, and we do not recommend it for daily production, David Cohn is the technical publishing manager at 4D you can definitely load it up and take it with you for Technologies. He also does consulting and technical writing extended trips away from the office. from his home in Bellingham, WA, and has been benchmark- In fact, our benchmark results do not really reflect ing PCs since 1984. He’s a contributing editor to Desktop our actual experiences using CAD applications on this Engineering and the author of more than a dozen books. You diminutive device. Because the Helix relies entirely on can contact him via email at [email protected] or visit his the Intel HD Graphics 4000 integrated into the Core website at www.dscohn.com.

74 DESKTOP ENGINEERING December 2013 /// deskeng.com

de1213_Review_Lenovo_Cohn.indd 74 11/14/13 1:38 PM 3D Printing /// Optimize Design to Manufacture Additive Manufacturing’s New Design Paradigm 3D printing allows companies to rethink previously impossible to manufacture designs, optimize their products, and support new business models. BY JAMIE J. GOOCH

n September, a small part that will make a big splash in the world of manufacturing was successfully tested. It’s a I new fuel nozzle being developed by GE Aviation for the next-generation LEAP jet engines, which are scheduled to be in production by 2015. GE says the fuel nozzle is 25% lighter and as much as five times more durable than the cur- rent nozzle. It is being 3D printed in one piece, as opposed to the 20 parts that comprise the current model. Those num- bers are impressive, and illustrate the weight and process op- timization benefits of additive manufacturing (AM), but they are not the most remarkable part of GE’s announcement. The number that has everyone taking notice is 85,500. That’s how many of the new 3D printed fuel nozzles GE Aviation will produce in order to install 19 of the parts in the 4,500 LEAP jet engines that have already been ordered. GE calls itself the largest user of additive technologies for metallic parts, and it has one of the largest fleets of 3D printers that it regularly uses for prototyping and tooling. While it’s no longer unusual to use 3D printing to simplify the production of complicated parts, or to optimize specialized parts for weight CFM INTERNATIONAL, a joint venture between Snecma and strength, the volume of fuel nozzles GE plans to make via (Safran) and GE, initiated testing of the fi rst full LEAP engine its direct laser melting process is unprecedented. In fact, it’s so in September. The engine includes 19 3D printed fuel nozzles. far forward that it’s not feasible yet. GE’s Business Development Leader for Additive Manu- Consistent Quality facturing, Greg Morris, recently told Bloomberg.com that ex- However, Singh seems more concerned with quality. “Mak- isting additive manufacturing (AM) systems aren’t efficient ing sure every part is made consistently is a top concern mov- enough to economically meet the demand, so GE is banking ing forward,” he says. “More and more parts are going to pass on the development of new, more efficient 3D printers. Morris though additive manufacturing machines, and they all will should know the existing technologies’ limitations. GE Avia- need to be qualified. That’s a big challenge.” tion acquired the 3D printing company he founded, Morris The infrastructure needed to produce parts in high volume: Technologies, and its sister company, Rapid Quality Manufac- materials for speciÿ c applications, a published materials data- turing, in November 2012. base of characteristics, rapid part inspection systems, better “Throughput is an issue,” admits Prabhjot Singh, manager, post processing, better design tools, and a supply chain for all Additive Manufacturing Lab, GE Global Research. The $27 of the above, isn’t yet mature. million lab acts as a central research and development hub fo- “We have a very strong materials and manufacturing cused on developing new AM processes for all of GE. “We’re not group,” Singh says. “It is helping us bring in new technol- talking one-offs, we’re talking hundreds of thousands of parts.” ogy and mature it to our needs. The engineering teams we

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de1213_Prototyping_Gooch.indd 75 11/14/13 4:14 PM Optimize Design to Manufacture /// Additive Manufacturing

While augmented manufacturing brings design engineers one step closer to the manufacturing process, creating end-use parts via 3D printers the way GE is doing — what Reis calls alternative manufacturing — further breaks down the walls between design and build. With business units in power and water, oil and gas, energy management, aviation, health care, transportation, and home appliances that dwarf many competitors in their own right, GE is in the rare position of being able to advance alter- native manufacturing in many industries. The way it does so will no doubt serve as a template for other companies looking to use 3D printing to speed design and development. During the GE webcast, Furstoss called AM part of the next industrial revolution that “represents a convergence of design and materials and manufacturing. It’s a new way of thinking about man- ufacturing as being as important as any product. That process is the product. That materials and manufacturing and design can meet.” Such a meeting could shift the design engineer from the front of the design-to-manufacture process to its center. If the process is the product, then the engineer will be designing for REDEYE ON DEMAND by Stratasys is a “factory of the manufacture in a way that makes an immediate impact on a com- future” that quietly creates parts using 150 AM systems.

work with keep us real, and they help us develop the right MakerBot Academy Launched kinds of technology.” he US has been the leader in additive manu- In a recent webcast titled “The Future of Manufacturing,” GE facturing (AM) ever since 3D Systems’ founder Global Research’s Technical Director, Manufacturing & Materials T Chuck Hull patented stereolithography and Technologies, Christine Furstoss, echoed Singh’s concerns. Scott Crump designed Stratasys’ first 3D printer, but “We’re just learning what gives the materials the types of that may be changing. Both the UK and China have properties it’s achieving,” she said. “What are the things we can invested serious amounts of money into the technol- do in the equipment to make sure we make a material strong ogy, and the EU, with the European Space Agency as enough and tough enough? How do we make sure we do that a partner, isn’t far behind. The US does have its own every time for every part?” investments in place, such as America Makes, the While GE has been able to develop that quality control process National Additive Manufacturing Innovation Institute, for its new fuel nozzles, it needs to grow exponentially to advance but the race is tight. other end uses for AM technology. MakerBot is hoping to help keep the US at the forefront of AM with its MakerBot Academy program. Expanding the Reach of Additive Manufacturing It represents a partnership between donorschoose. Thus far, professional 3D printing technology has largely fo- org, Autodesk, America Makes, and, of course, cused on rapid prototyping and what Stratasys’ CEO David MakerBot (now a owned by Stratasys). Reis calls augmented manufacturing, which refers to using 3D Businesses and individuals who would like to printers to create tools, jigs and templates to support tradi- assist with the MakerBot Academy program can visit tional manufacturing processing. The design cycle optimi- donorschoose.org and offer financial support for the zation opportunities for prototyping are obvious: a physical program. Teachers can then register on the site to model can be used to advance a concept, sell executives on a receive a MakerBot Academy bundle. Each MakerBot design change, or cut down on costlier physical testing. Academy bundle includes a MakerBot Replicator 2, “People are less aware of the augmented part of additive three spools of PLA filament, and a full year of the manufacturing,” Reis says. “It’s a huge opportunity for Stratasys MakerBot MakerCare Service and Protection Plan. and a huge opportunity for our customers. All of them are using MakerBot will also assist teachers in the develop- tools today in a traditional way, which is long, expensive, not ef- ment of ongoing 3D printing curriculum for classroom ÿ cient. Here (with 3D printing) we have tools that can go into activities, and draw upon Autodesk’s software and production the next morning. There are hundreds of thousands of educator curriculum as well. production facilities who can use this technology today.” — John Newman

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de1213_Prototyping_Gooch.indd 76 11/14/13 4:14 PM 3D Printing /// Optimize Design to Manufacture

pany’s output. In some instances, the time to market would be tal, president and chief executive office , 3D Systems during GE’s measured in hours, not days, weeks or months. webcast. “We see a clear opportunity for mashups between additive An example of this was presented at Stratasys’ Manufactur- and subtractive in a single manufacturing box as a way to expand the ing the Future Summit in October by Bryan Dods, an executive degrees of freedom and flexibility in manufacturing.” in Manufacturing Engineering & Technology at GE Power & GE Power & Water’s Dods is equally optimistic. Water. Dods’ customers include large power plants that could “3D printing is giving us functionality we can’t get other- stand to lose $1 million each day that they’re offline due to a faulty wise,” he said. “It changes the business model by allowing the part. If a 3D printed part could be designed and manufactured to company to make what it can design.” DE get them up and running quickly, it would change the traditional design to manufacture cycle for that service industry. Jamie Gooch is managing editor of Desktop Engineering. Send e-mail about this article to [email protected]. Challenges are Opportunities GE’s investment in AM bodes well for advancing the tech- nology, but there’s still a long way to go. Despite the chal- INFO ➜ 3D Systems: 3dsystems.com lenges of new materials and quality controls, there seem to ➜ America Makes/NAMII: americamakes.us be nearly endless possibilities on the horizon. ➜ GE: ge.com/stories/additive-manufacturing “There are areas of opportunities — where we need to develop ➜ Makerbot Industries: makerbot.com multi-material functionality, where we need to develop conductivity, we need to be able to embed intelligence functionality and sensing ➜ Stratasys: stratasys.com — where a great deal of development is required,” said Avi Reichen- For more information on this topic, visit rapidreadytech.com. Advertising Index

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de1213_Prototyping_Gooch.indd 77 11/14/13 4:15 PM Fast Apps Engineering Case Studies

Optimization Improves Style Without Adding Costs Evenflo redesigns a car seat release handle using solidThinking Inspire. If you have kids, you’ve probably heard of struggle of structure vs. design vs. cost. Evenflo Company, Inc. You may have even The pair decided to use Inspire to redesign trusted your most precious cargo to one a car seat handle for an existing product. of the Ohio-based company’s infant car The handle secures the car seat shell to seats, or stopped junior from falling down a seat base or a stroller. The intent of the the stairs with one of the company’s baby redesign was to improve the styling and gates. The 93-year-old company’s product maintain ease without increasing costs rela- offerings span a range of infant and juvenile tive to the current part. categories. Its products have to be structur- ally sound, but also aesthetically appealing Getting a Handle on Optimization to compete for consumer attention. The To use Inspire, the team needed two company is always looking for ways to things: a package space and a set of static result also enabled less measurable ben- improve both without increasing costs. loads for the release handle. As this was a efits. The engineering design team was able “Safety is the key consideration in replacement part, the package space was to see load paths for the design in Inspire the design process. Ease of use is also easy to create with a simplified version of before exporting to Pro/E. The results also important, but costs must be controlled,” the current part in PTC’s Pro/ENGINEER. provided a place to start a conversation said Andy Davis, senior design engineer, “Brian and I talked about the block of with the industrial design team to ensure Evenflo CAE. material to optimize,” Davis says. “It was the delivery of style and function. With solidThinking Inspire shape and very easy to modify the model slightly to “The industrial designers were pretty topology optimization software, Davis found get it into inspire and still keep all of the excited about Inspire as well,” Pleiman said. he could investigate structurally efficient CAD geometry that could not change.” “The team we have here likes it when form concepts that his industrial design col- The crash and abuse loads that the han- meets function, and this plays into that.” leagues could use to make aesthetically dle may see during its life are dynamic. Once the design direction was finalized, pleasing designs. Even better, it allowed This means equivalent static loads need- the part was matured in Pro/E and a Evenflo to reduce material costs. ed to be developed for Inspire. Generating 3D printed rapid prototype was built for In 2008, Altair acquired solidThinking, approximate loads involved using previ- stroller and sled testing. allowing it to expand Inspire’s capabilities. ous data, making some assumptions and “This was a successful project for us. Inspire is included in Altair’s HyperWorks using a few rules of thumb. After styling the part, we were still able suite, which Evenflo was already using. “From some of the finite element analy- to achieve a 25% improvement,” said “Inspire software is included in our licens- sis we have done — we are dealing with Pleiman. “The quick results we were ing, and Altair pointed out it might be some- a lot of dynamic loads from drop testing able to get from Inspire assisted the co- thing we would be interested in,” Davis said. and crash testing, for example — so we development of the new part between ID “Since it was already included in the licens- have grown accustomed to approximating (industrial design) and engineering.” ing and had the potential to reduce material static loads for dynamic situations,” Davis “solidThinking Inspire shows the mate- usage, we started trying it out.” said. “Between myself and Brian, we had rial that cannot be removed from a Davis was intrigued by the organic a good understanding of the load sce- design. This helps you understand your shapes that Inspire suggests when using narios that this part would see.” design earlier and it can be used as optimizing design topology. The design would still be developed in CAD a common language between depart- “For us, making consumer products, and validated using the standard corporate ments,” added Davis. interesting shapes resonate with our cus- procedures so that a high degree of accu- Evenflo has since asked Altair for Inspire tomers,” he said. “We don’t make boxy racy wasn’t essential for idea generation. training session with a larger group of engi- square shapes. If we could optimize the Inspire also made it easy to evaluate differ- neers. Now that Evenflo understands the material and make it an interesting shape ent loading conditions and view their effect capabilities of Inspire, Davis said they are for the customer, it would be a win-win.” through the concept designs generated. looking for any place where it might provide Davis showed the software to Brian material reduction and better aesthetics Pleiman, senior project engineer in the Positive Results without reducing quality. Child Restraint team at Evenflo, who saw The initial Inspire results showed potential Source: Interviews with end users and infor- it as a potential solution for the perennial for a 30% mass and material reduction. The mation provided by Altair’s solidThinking.

➜ For the complete application stories, visit deskeng.com/fastapps

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1213_FastApps.indd 78 11/14/13 3:41 PM Driving for Design Success — and Cleaner Air Scania redesigns truck engine components, helping reach Euro 6 emissions goals, using SIMULIA Tosca Structure.

As the European Union adapts to Euro structures have helped Scania build light- 6 — legislation that sets the highest- er-weight vehicles that consume less fuel ever pollution regulations on trucks and produce fewer emissions, helping the and buses — global commercial vehicle company meet the Euro 6 standards that maker Scania is finding new ways to have applied to all new trucks registered Image courtesy of Scania. meet the challenge. in Europe since Jan. 1, 2013. Over the 20 years since Euro 1 was insti- tuted, the Swedish-based company has had Seamless Integration industry-standard solvers, Tosca Structure an ongoing program to develop vehicles Scania’s engineers work in a mixed CAE allows for easy integration into any existing and engines with a host of innovative environment, using a variety of design CAE environment. This lets engineers work technical solutions that have radically cut tools. For optimization, they use Tosca in their accustomed IT environment with emissions. For additional design refinement Structure from FE-DESIGN — since May their existing FEA models. of powertrain and drivetrain components, 2013, part of the Dassault Systèmes Scania’s primary FEA solver is Abaqus, however, it has added the optimization soft- 3DEXPERIENCE technology portfolio also from SIMULIA. Using Tosca ware Tosca Structure to its CAE toolkit. under the SIMULIA brand. Structure along with their own FEA mod- The software creates design concepts SIMULIA Tosca Structure is a flexible, mod- els and knowledge base enables the early in the product development process ular software system for non-parametric engineers to exploit the full potential of to show the potential to reduce material structural optimization of topology, shape optimization ... weight while maintaining, or even improv- and bead design using finite element anal- ing, rigidity and durability. Such optimized ysis (FEA). With its open interfaces to FEA MORE ➜ deskeng.com/articles/aabmzs.htm

Pushing the Pedal to Its Mettle Mechatronic simulation enables PSA Peugeot Citroën to enhance fuel efficiency and reliability of powertrain components.

Car manufacturers face multiple challenges Powertrain systems are becoming standards. It also facilitates appropriate when designing powertrain architectures. increasingly complex, and include a powertrain cooling and passenger thermal They must reconcile numerous (and some- growing number of actuators, sensors, comfort by controlling cooling fluid tempera- times contradictory) requirements to reach hybrid traction systems, and electric ture and flow rate in the air heater. the desired level of product quality, pollut- and electronic components — requiring In addition, effective powertrain ther- ant emissions, passenger comfort, fun-to- controls and protection strategies to mal management maintains an optimal drive performance, reliability and safety. limit component damage. Developing operating temperature for the engine and And they must do all of this while striving to powertrain thermal management strate- gearbox, promoting component reliability be profitable, shorten the product develop- gies is a major issue for original equip- and fuel efficiency. The thermal manage- ment cycle and reduce time-to-market. ment manufacturers (OEMs), and these ment system can adapt to vehicle usage strategies are taking more systems into under a variety of conditions, and set account than ever before, including the temperature thresholds to further help internal combustion engine, gearbox, car protect powertrain components. interior, electric powertrain battery and electronic controls units. Broad Appeal Powertrain thermal management optimi- PSA Peugeot Citroën addresses pow- zation enables car manufacturers to reduce ertrain thermal management by using fuel consumption (for example, via warm-up simulation throughout the powertrain phase acceleration) and carbon dioxide component and system design process. (CO2) emissions. Therefore, it allows the OEMs to meet stringent international MORE ➜ deskeng.com/articles/aabmzx.htm

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deskeng.com /// December 2013 DESKTOP ENGINEERING 79

1213_FastApps.indd 79 11/14/13 3:42 PM Fast Apps Engineering Case Studies

Becoming Empowered by PLM With Omnify Empower PLM, security provider Genetec integrates PLM software with ERP and engineering tools for better integration and data quality.

Based in Montreal, Genetec is a pioneer capabilities had to be implemented via in the physical security and public safety customization of the software. The time industry, and a global provider of IP video spent by software designers to custom- surveillance, access control and license ize the tool to meet their needs was plate recognition (LPR) solutions to mar- extensive and counterproductive. kets such as transportation, education, It was becoming important for Genetec retail, gaming, government and more. to have the ability to catch product doc- ability to interface with its enterprise Genetec had previously implemented umentation problems early on, prior to resource planning (ERP) system (MS an open-source product lifecycle man- manufacturing, and to have a complete Dynamics) — all at a price that made agement (PLM) system to replace the history of the changes for accountabil- sense for the organization. use of spreadsheets for managing prod- ity. Genetec needed a PLM system that After researching the market, the team uct information. Although the team did delivered robust, out-of-the-box func- decided on Omnify Software. realize some improvements in their pro- tionality including electronic manage- “Ultimately, we were impressed by how cesses, they needed to find a new PLM ment of part data, engineering changes, easy the software seemed to configure, solution to meet their requirements in an BOMs, and product documentation that and by how many functionalities this electronic manufacturing environment. did not require customization to imple- software offered out-of-the-box,” says They found with the open-source solution ment. It also needed a system that Danny Roy, hardware development man- that minimum functionalities such as offered easy integration with its exist- ager for Genetec. reference designators, redlining, bill of ing engineering design tools (Altium material (BOM) compare, and importing Designer and SolidWorks) and the MORE ➜ deskeng.com/articles/aabmzr.htm

From Mud Stream to Value Stream Viatran’s redesign for manufacture and assembly implementation benchmarks competition, reduces part count, and re-imagines a pressure transmitter design with total cost of ownership in mind.

Sensitive, yet tough. That’s the job humidity, temperature extremes — and ing functional improvements to which description of the hammer-union pres- the routine shock of hammer blows during customers would respond, along with sure transmitter used in oil and gas well installation — the unit plays a pivotal role increased assembly efficiency and cost- servicing applications like cementing, in communicating with down-hole mea- effectiveness. fracturing and acidizing. This fine-tuned surement-while-drilling (MWD) tools to help sensor must accurately (and repeatedly) ensure safety and efficiency in the produc- Begin with Benchmarking measure the hydraulic and pressure tion environment. The unit’s reliable perfor- A company-wide philosophy of continuous characteristics of drilling fluid in the harsh mance is critical to the integrity of hammer- improvement has led Dynisco to empha- environments found in the secondary oil wing union fittings, used in thousands of size the role of early design evaluation and gas recovery industry. energy installations around the globe. in its product development process. Withstanding mud, corrosion, vibration, The Viatran business unit of Dynisco, a Knowing the value of applying Design for Roper Industries company, has offered Manufacture and Assembly (DFMA) from model 510 Hammer Union pressure Boothroyd Dewhurst — with benchmark- transmitter as an industry staple for ing, Lean, and Total Cost of Ownership years. With a number of competitors (TCO) methodologies — Viatran engineers vying for position in the supplier arena, teamed with Dynisco’s Value/Analysis/ Dynisco decided to take a renewed look Value Engineering (VAVE) group to launch at its core product to ensure that its lead the redesign project. would hold. The company launched a redesign project with the goal of provid- MORE ➜ deskeng.com/articles/aabmzw.htm

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80 DESKTOP ENGINEERING December 2013 /// deskeng.com

1213_FastApps.indd 80 11/14/13 3:43 PM Aras.indd 1 11/14/13 10:47 AM A STRONG CASE FOR COMPLEX DESIGN. The Mojo 3D Printer knocks out complex parts with ease. There’s only one desktop 3D printer on the market that arrives equipped with everything designers and engineers need to start 3D printing complex geometries. The Mojo is powered by genuine FDM® to build spot-on, functional concept models and rapid prototypes in ABSplus thermoplastic. Take it for a spin and we think you’ll agree – the competition better get a move on.

Only $185/month

See if your printer can make the case. Visit stratasys.com/case to download a free STL fi le of the cell phone case (pictured).

Leasing only available in the United States. Additional options, © 2013 Stratasys, Inc shipping, applicable taxes and/or duties not included.

Stratasys_Mojo.indd 1 11/14/13 10:47 AM

Creative: Susan Schmidt Stratasys_“Mojo Phone Case” Trim: 7.825 x 10.75 66437 Live: 7.375 x 10.25 Account: Michael Jensen Publication: Desktop Engineering Bleed: 8.125 x 11 Production: Tina Anderson 4 Color Proofreader: