Innovation becomes more complex and multidisciplinary, and consequently more challenging and expensive. One way to remedy this, is by using simulation technology, facilitating design iterations and reducing the number of failed experiments.
Powerful Google developer tools for immediate impact! (2023-24 C)
Simulation technology, speed up your iterative process (by Jan Buytaert)
1. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
1
Template presentation Innovation Day 2016CONFIDENTIAL
Jan Buytaert
Consultant PhysicsLab
jan.buytaert@verhaert.com
Christophe Van Bavinchove
Coordinator PhysicsLab
christophe.vanbavinchove@verhaert.com
SIMULATION TECHNOLOGY:
SPEED UP YOUR ITERATIVE PROCESS
TRACK 2: TECHNOLOGY TO ACCELERATE
2. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
2
PhysicsLab – Systems Engineering
Christophe Van Bavinchove
Head of PhysicsLab
Jan Buytaert
Senior Systems Engineer
Consultant PhysicsLab
3. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
3
1
2
3
4
CONTENT
Why use simulation technology?
What is simulation technology?
How to use simulation technology?
Simulation technology examples
4. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
4
WHY USE
SIMULATION TECHNOLOGY?
CONFIDENTIAL
Problem statement & illustrations
4
5. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
5
WHY USE SIMULATION TECHNOLOGY?
• Traditionally design and failure predictions are carried out by
• hand calculations
• experimental testing
• design trials
• As organizations strive to produce products
• that are better than the state-of-the-art
• and better than their competitors
• and to do so in a shorter time span
they need sophisticated tools
and methodologies to assist them.
• One such tool is computer simulation software
6. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
6
THESIS of this TALK:
• Innovation
• becomes more complex and multidisciplinary,
• and consequently more challenging and expensive.
• One way to remedy this, is by using simulation technology
• facilitating design iterations
• reducing the number of (failed) experiments
• reducing the number of (failed) prototypes
WHY USE SIMULATION TECHNOLOGY?
7. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
7
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
8. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
8
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
• Process
1. Establish the concept and the channel design constraints
2. Perform benchmark tests to fine-tune simulation parameters
3. Optimize microfluidic channel design based on simulations
4. Verify simulation results by performing tests on prototype device
5. Make final design
Confluence concept
Designspace
Simulations
Prototypes & experiments
Design choice
Time
1
2
3
4
5
Simulation parameters
9. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
9
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
10. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
10
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
3. Optimize microfluidic channel design based on simulations
11. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
11
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
Engineer Jef Aernouts
12. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
12
WHY USE SIMULATION TECHNOLOGY?
sim
breadboard
• Case 1: Microfluidic channel design for sample dilution
13. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
13
WHY USE SIMULATION TECHNOLOGY?
• Case 1: Microfluidic channel design for sample dilution
14. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
14
WHY USE SIMULATION TECHNOLOGY?
• For design space exploration
• Virtually try-out new concepts/designs
• Sweep a range of design parameters
• For risk limitation
• Verify upfront the process performance
• Understanding robustness/failure of your design
• For design verification
• Supports physical verification tests which can be reduced in number
• Allows extrapolation of test results to non-testable cases
• For problem solving
• Understanding existing product failure/requirements/constraints
• Optimizing an existing design by low cost design iterations
PRODUCT
DEVELOPMENT
early stage
intermediate
before release
after release
15. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
15
WHY USE SIMULATION TECHNOLOGY?
• Risk limitation & design verification
• by analyzing design performance upfront
• Example
• PCB air fan cooling
• Multi-physics model (CFD & Heat transfer)
Engineer Jan Buytaert
16. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
16
WHY USE SIMULATION TECHNOLOGY?
• Design verification
• of a physically non-testable case
• Example
• Cooling of a reaction vessel
• Multi-physics model (CFD & Heat transfer)
Engineer Jan Buytaert & Wouter Vleugels
17. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
17
WHY USE SIMULATION TECHNOLOGY?
• Problem solving
• by design optimization
• Example
• Beer bottle interlayer
• Structural model
Engineer Wouter Vleugels & Jan Buytaert
18. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
18
WHY USE SIMULATION TECHNOLOGY?
• Problem solving
• by design vs cost optimization
• Example
• Beer appliance door
• Structural model
Engineer Tom Beeldens
19. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
21
WHY USE SIMULATION TECHNOLOGY?
• Benefits of numerical analysis
• Detailed understanding of product performance
• Design space exploration
• Optimization of performance
• Optimization of amount of material/weight economically
• Reducing testing costs
• Reduction of failure risks
• Reduction of incremental development risks
• Reduction of time to market
• Improved product quality
20. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
22
WHAT IS
SIMULATION TECHNOLOGY?
CONFIDENTIAL
The finite-element method
22
21. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
23
WHAT IS SIMULATION TECHNOLOGY?
• Simulation
• The imitation of the operation of a real-world process or system over time.
• Requires that a model be developed (containing geometry + loads).
• Simulation technology
• Physical model versus …
• … abstract mathematical model
• Computer simulation technology
• Software tool
22. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
24
WHAT IS SIMULATION TECHNOLOGY?
• Finite-element analysis (FEA)
• the practical application of the finite-element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.
23. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
25
WHAT IS SIMULATION TECHNOLOGY?
• Finite-element analysis (FEA)
• the practical application of the finite element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.
24. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
26
WHAT IS SIMULATION TECHNOLOGY?
• FEM simulation software tools consist of
• pre-processing (meshing, boundary conditions)
• solvers (actual calculations)
• post-processing (results, visualization)
• Nowadays
• all-in-one integrated (yet expensive) FEM software is available
• hardware has become powerful (and affordable)
25. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
27
What is simulation technology?
26. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
28
WHAT IS SIMULATION TECHNOLOGY?
• FEM modeling software resembles the cockpit of a space shuttle …
• A enormous amount of knobs and dials and controls ~ options
of which most aren’t used
though they all have a function and reason for being there
• One can fly on automatic pilot
however when deviating from the routine,
expert flying is needed
• You do not take a space shuttle
when a balloon flight can do the job
• Expensive way of traveling
so make it worth the effort
• Trained pilots reduce the chance of failure
27. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
29
WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
28. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
30
WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Michael Burm
29. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
31
WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
30. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
32
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times
31. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
33
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times
mesh
32. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
34
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
symmetry & boundary conditions
33. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
35
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
symmetry & boundary conditions
34. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
37
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible
35. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
38
WHAT IS SIMULATION TECHNOLOGY?
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible (too many variables, degrees of freedom, equations)
• Approximate solution
• Calculation time …
• Convergence to a solution …
• Post-processing and interpretation of the results
36. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
39
• Case 2: BIB handle failure analysis and remedy
WHAT IS SIMULATION TECHNOLOGY?
stress safety factor Engineer Jan Buytaert
37. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
40
WHAT IS SIMULATION TECHNOLOGY?
symmetry & boundary conditions
• Case 2: BIB handle failure analysis and remedy
Engineer Jan Buytaert & Tobe Wauters
38. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
41
WHAT IS SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Jan Buytaert
safety factor
stress
39. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
42
HOW TO
USE SIMULATION TECHNOLOGY?
CONFIDENTIAL
Insights
42
40. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
43
HOW TO USE SIMULATION TECHNOLOGY?
• Challenges
• Optimal meshing of the geometry
• Breaking down a problem into subsystems for simulation
• The art of idealization (stripping away of unnecessary complexity)
• Applying realistic boundary conditions
• Interpreting the results correctly
41. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
44
HOW TO USE SIMULATION TECHNOLOGY?
• How to go about these challenges
• A critical mass of experts/expertise
• Knowledge of the physics
• Knowledge of the modeling and the modeling tool
• Understanding of the extent to which modeling decisions impact accuracy
• Understanding of the consequences on resources and time by modeling decisions
42. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
45
HOW TO USE SIMULATION TECHNOLOGY?
• How to go about these challenges
• A critical mass of experts/expertise
• A structured workflow (and report)
Analysis intake
Analysis specifications
Geometry creation
Mesh grid generation
Model set-up
Solution process
Solution verification
Solution validation
Post-processing
Report writing
43. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
46
HOW TO USE SIMULATION TECHNOLOGY?
• How trustworthy are simulation results?
Solution validation
Analysis validation is carried out
to determine that the analysis
solution represents the physical
system it was designed to
simulate. Validation is actually
evaluation and can be done by:
• Hand calculations
• Physical testing
It should be remembered that test
data contains experimental errors,
and hand calculations contain
assumptions as well.
Analysis intake
Analysis specifications
Geometry creation
Mesh grid generation
Model set-up
Solution process
Solution verification
Solution validation
Post-processing
Report writing
44. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
47
HOW TO USE SIMULATION TECHNOLOGY?
"Nobody trusts a computer simulation except the guy who did it,
and everybody trusts experimental data except the guy who did it.
Why not combine the two and get results
everybody can mistrust a little."
- T. Kordyban -
• How trustworthy are simulation results?
45. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
48
HOW TO USE SIMULATION TECHNOLOGY?
• Case 2: BIB handle failure analysis and remedy
Engineer Michael Burm & Jan Buytaert
5G
46. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
49
HOW TO USE SIMULATION TECHNOLOGY?
• Conclusions
Simulation technology serves agility in innovation
• Speed-up your innovative process
• Model and load case variations can be readily made
• At a reduced testing cost
• Concretize your product/process
• Facilitated design space exploration
and the converge towards a chosen design
• Simulations and physical testing both have value
• User-centric development
• Specification/discussion load cases
• Robustness/safety factor for use cases
Gate: Go/No-Go
Gate: Go/No-Go
47. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
50
EXAMPLES
SIMULATION TECHNOLOGY
CONFIDENTIAL
From beer to Darwin’s evolutionary theory
50
48. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
51
SIMULATION TECHNOLOGY EXAMPLES
• Example
Chimney with different flows inside
• Multi-physics model
• Particle tracing
• CFD
Engineer Jochem Grieten & Wouter Vleugels
49. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
52
SIMULATION TECHNOLOGY EXAMPLES
• Example
Gravitational oil drain
• CFD model
• Design optimization
• Design verification
Engineer Wouter Vleugels
50. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
53
SIMULATION TECHNOLOGY EXAMPLES
• Example
Biomechanical structural analysis of bird beak evolution
• Structural model
• Mechanical stress, fracture risk and beak evolution
• Conceptual understanding
Joris Soons & Jana Goyens & Joris Dirckx
52. 2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
55
Innovation Day is an initiative of Masters in Innovation,
the umbrella brand of the Verhaert Group which aims
to connect, train and accelerate professional innovators.
Kruibeke
Belgium
Hogenakkerhoekstraat 21
B-9150 Kruibeke
T +32 3 250 19 00
E info@verhaert.com
www.verhaert.com
Nivelles
Belgium
Noordwijk
Netherlands
Av. Robert Schuman 102
B-1400 Nivelles
T +32 67 47 57 10
E info@lambda-x.com
www.lambda-x.com
Kapteynstraat 1
2201 BB Noordwijk
T +31 71 760 05 50
E info@verhaert.com
connect.verhaert.com
INDUSTRY
TECHXFER
MEDICAL
AEROSPACE
TECHXFER
FMCGCONNECT
TECHXFER
FMCGCONNECT
MEDICAL
Aveiro
Portugal
Av. Dr. Lourenço
Peixinho 96D 4o
3800-159 Aveiro
T +351 234 604 088
E info@load-interactive.com
www.load-interactive.com
CONNECT
Gentbrugge
Belgium
Bruiloftstraat 55-57
B-9050 Gentbrugge
T +32 9 330 27 90
E info@moebiusdesign.be
www.moebiusdesign.com
ON SITE CONSULTANCY