CD-adapco
Better Designs, Faster
Bill Jester, Ph.D., Director STAR-CCM+ Platform Development
PLM Components Innovation Conference, October 2016
Restricted © Siemens AG 2016
Realize innovation.
.
Agenda
Who is CD-adapco?
What does interoperability mean to us?
What progress have we made?
Where do we go from here?
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Agenda
Who is CD-adapco?
What does interoperability mean to us?
What progress have we made?
Where do we go from here?
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Who is CD-adapco?
• 35 years of developing multi-disciplinary simulation software
• Flagship software, STAR-CCM+, used across dozens of
engineering disciplines
• Team of 900+ dedicated to helping customers innovate and
improve their designs
• Now a part of Siemens PLM Organization – excited for the
future!
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Agenda
Who is CD-adapco?
What does interoperability mean to us?
How far have we come?
Where do we go from here?
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What does interoperability mean to us?
Flexible co-simulation
with peer tools
High fidelity, efficient
CAD data exchange
Accurate and insightful
results analysis
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Three challenges in design/simulation interoperability
You often don’t simulate
what you manufacture.
• Fluid extraction
• Artificial wind tunnels
• Farfield boundaries
Simulation requires a high
level of spatial detail and
tight tolerances.
• Part imprinting
• Geometry clean up
• Removing manufacturing
gaps/overlaps
Simulation (historically)
required vastly different
expertise from design.
• Mesh generation
• High performance
computing
• Numerical analysis
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Agenda
Who is CD-adapco?
What does interoperability mean to us?
What progress have we made?
Where do we go from here?
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What progress have we made?
Isolation
Design and
simulation are
disjoint with basic
data exchange
Integration
Design and
simulation are
loosely coupled
through component
integration and
process automation
Interoperation
Design and simulation
are tightly coupled
through an intelligent,
collaborative process
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Isolated Design/Simulation
Circa 2001
• Simulation and design often done by different teams, even
different companies
• Simulation software was disjoint and manually intensive
• Multi-physics simulation was well understood in some
domains but not yet widely accepted
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Isolated Design/Simulation
IGES, STEP, STL
Interpretation of results
Design Engineer
• Create CAD
• Prepare CAD
for simulation
• Save CAD to
neutral format
Simulation
Engineer
• Repair CAD
• Mesh and solve
• Analyze results
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Isolated Design/Simulation
Cost of isolation
• Turnaround time from updated design to results could be weeks to months.
• Simulation required a dedicated team often with consulting support
• Results were not always well understood or easily communicated back to designers
Image courtesy of Daimler
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Integrated Design/Simulation
Circa 2007
• Introduction of the integrated STAR-CCM+ simulation pipeline
• Basic, one-directional interoperability through CAD import and
CAD-embedding
• Simulation-driven design creation and modification through
internal CAD
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Integrated Design/Simulation
The STAR-CCM+ Simulation Pipeline
Volume
Extraction
Surface
Cleanup
Surface
Preparation
Surface
Meshing
Volume
Meshing
Mesh
Generation
Solution
Post
Processing
Solver
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Integrated Design/Simulation
CAD-Embedded simulation through CAD Clients
Geometry +
Simulation
setup
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Integrated Design/Simulation
Simulation-driven design through embedded CAD modeler
External
translators
CAD
HOOPS Exchange
Parametric
definition
Scripted geometry
creation
3D-CAD Modeler
Create or
modify
geometry
Extract
fluid
Defeature
Imprint
Parasolid
DCM
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Integrated Design/Simulation
The value of integration
• Turnaround time significantly reduced – design modification now possible
• Less isolation between designers and simulation engineers
• Simulation pipeline opened the door to fully automatic “vertical” applications
• Batch automation through Java for custom workflows
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Interoperating Design/Simulation
Present Day
• Bidirectional communication between CAD and Simulation
• PLM Integration
• Design space exploration
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Interoperating Design/Simulation
Bidirectional communication between CAD and Simulation
Updated Geometry
Geometry and
Parameters
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Parameter Change
Siemens PLM Software
Interoperating Design/Simulation
PLM Integration through JTOpen
Geometry
Attributes
Assembly Structure
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Interoperating Design/Simulation
Design Space Exploration
• Evolve from running a single simulation
or manual “what if?” to fully automated
exploration of multi-dimensional design
spaces.
Analyze Design
Space
Quantify Results
Run Simulation
Update Design
Parameters
Modify Design
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Interoperating Design/Simulation
Baseline Design
Optimization Process
Improved Design
• 50% lower mass
• 10% better cooling
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Kawasaki Heavy Industry (KHI) and B&B-AGEMA
Improving gas turbine blade cooling effectiveness
Higher-efficiency GT through improved cooling effectiveness
cooling holes
cooling air jets
• Improved cooling effectiveness 200%
• Physically tested nekomimi technology,
proved it feasible, and patented
• Reduced risk of shutdowns and
unplanned maintenance costs
Parametric 3-D CAD model
of blade cooling holes
(cat ears = “nekomimi”)
+
CFD / CHT prediction of
temperatures, cooling effectiveness
=
Many better designs
for cooling effectiveness
“STAR-CCM+ is the best commercial CFD tool to perform fast, accurate
simulations of conjugate heat transfer (CHT). Together with STAR-CCM+ and
NX, HEEDS helps us discover better designs faster.”
– Dr.-Ing. Karsten Kusterer, General Director, B&B-AGEMA
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Agenda
Who is CD-adapco?
What does interoperability mean to us?
What progress have we made?
Where do we go from here?
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Where do we go from here?
“Digital Twin”
• Multi-disciplinary simulation and lifecycle management as part
of the Simcenter portfolio
• Deeper understanding of why a design is better, not just which
is better
• Connection of simulation results back to real life through
effective visual communication
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Solutions Part of Siemens Simcenter™ Portfolio
BUILD
TEST
ASSESS
EXPLORE
Covering the Full Range of Methods
1D
CFD
3D
Controls
Test
Multidiscipline and Multiphysics
Acoustics
Safety
Stress
Durability
Vibration
Motion
Fluid
Thermal
Particles
Reactions
Structure
Electromagnetics
Electrochemistry
Rheology
STAR-CCM+
Data and Process Management
Complete traceability within the PLM system
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Results Exploration with Data Focus
What is going on physically in the wake?
Why is the modified design better than the baseline?
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Connection to the Real World
How do we connect simulation results back to real life
through compelling visuals?
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Summary
What is the role of an engineer in an
increasingly automated, intelligent, and
interoperating simulation environment?
Innovation
Interoperation
Integration
Isolation
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CD-adapco
Better Designs, Faster
Bill Jester, Ph.D., Director STAR-CCM+ Platform Development
PLM Components Innovation Conference, October 2016
Restricted © Siemens AG 2016
Realize innovation.