Industrial Best Practice in Modelling and Simulation Gino Duffett gino.duffett@nafems.org 3rd STFC FEA Workshop 18 May 2017

Survey Project Financed by Coordinated by Partnered with NAFEMS coordinated sector Experts GE/Alstom, Dutton Simulation, Wilde Analysis, Simpleware, Organel, MMI Engineering, Cadfem-IDAC Project period: April 2015 – March 2016

Objective Enable new and struggling simulation users to learn from more experienced users Experienced users Good simulation knowledge New users What do I need to learn? Where can I learn it? Little simulation knowledge Is sector knowledge available? Is there knowledge in other sectors?

Additional Objective Identify future requirements so that experienced users can progress in using these tools and increase the benefits Improved users Improve and solve the key challenges Experienced users What do I need to learn? Where can I learn it? Good simulation knowledge Is sector knowledge available? Is there knowledge in other sectors? 4

Best Practice, Future needs Sector focus INDUSTRY… Best Practice, Future needs Energy Auto Built Env Health Aero Process Elect 5

Technical areas Primary topics… Material technologies Numerical methodologies for simulating the characteristics of a variety of materials including fluids, granular materials, laminar or other composites, as well as more traditional structural materials. Coupled & Multi-physics Multi-disciplinary coupled simulation or multi-physics simulation. Multi-scale The integration of detailed models of a wide range of scales (e.g. micro-macro, 1D-2D-3D, combine detailed with simplistic, etc.) Optimization Obtaining the best value using an automatic methodology employing mathematic and computational tools and methods. 6

Technical areas Secondary topics… High Performance Computing (HPC) Use of supercomputers, parallel computer hardware and software, cloud computing, etc. to improve simulation throughput and speed. Uncertainty Quantification (UQ) Concerns taking into account the numerous uncertainties affecting the behaviour of physical systems. Verification & Validation (V&V) The technologies of determining and quantifying the level of confidence of computer simulation predictions. Simulation Process & Data Management (SPDM) Technologies and methods to ensure that our knowledge, processes, tools and corporate culture are best placed to take advantage of simulation technology. 7

Industrial Best Practice Selected contact companies: Good simulation users Knowledgeable on simulation Discussion interviews with Experts: 79 personal interviews (32% of contacts) The first survey with this approach Previous studies… Often a few experts in a room (small) Generally email questionnaires (random)

Is knowledge a barrier? The barriers on using simulation are… Common result: all sectors and technical areas Built_Env Auto Elect Health Process Aero Energy Confirmed at presentation event: 33% software price, 27% engineer knowledge, 25% qualified engineering resource. 9

Training that would help The training that would help engineers is… Common result: all sectors and technical areas Built_Env Auto Elect Health Process Aero Energy 10

Best Practice Knowledge Development of engineers through a controlled system is very effective, combining in-house, professional and collegial/university education and training. Collaboration across disciplines and sharing end-goals enhances communication, integration, knowledge transfer and develops a learning culture. Know how to use many hardware and software capabilities. Energy Auto Aero Aero Process Energy Auto Aero 11

Best Practice Resources Work within and be aware of available resources. Develop a feel for what level of simulation is within your capability, and outsource more novel/complex work to sub-contractors. Partner with institutions that have the knowledge and resources to undertake advanced simulation. Built_Env Aero Health Process Health 12

Best Practice Methods Despite strong dependence on simulation, best practitioners always question the results. De-risk simulation by standardising methods for the most mature applications. Keep it simple. Use lowest level of simulation required to justify the design. A good understanding of the problem physics is necessary before simulation is started. Auto Auto Aero Built_Env Aero Elect Auto Built_Env Health Elect 13

Best Practice Decision making & Strategy Engineers/Technical specialists should be fully involved in the decision making process regarding simulation. Management must buy into simulation. All levels of the business from management downwards typically support and understand the use of simulation. Auto Health Process Elect Energy Auto Built_Env Aero Elect 14

Best Practice Material technologies Many companies rely on data obtained from academic institutes and commercial companies. Only well understood standard materials are employed in certain cases due to design standards constraints. Materials should be validated and approved before use. Be aware that for some organisations material technology is their IPR. Energy Built_Env Energy Aero Elect 15

Leading sectors Built_Env Auto Process Elect Aero Energy 16

Best Practice Multi-scale Simplistic calculations are quite often used at the initial phases followed by more complex calculations. 1D-2D-3D methods: speed of 1D calculations allows a lot of optimisation before a detailed 3D model is required. Accept lower simulation and calculation standards in earlier stages of the design cycle. Energy Health Auto Aero 17

Leading sectors Aero Auto Process Energy Elect 18

Best Practice Verification & Validation (V&V) Specific BP in different sectors due to different approaches. Rely on a certain level of verification done by the software vendors. Verify the engineers and users: carry out a considerable amount of internal training during new staff induction processes to ensure the quality of simulations performed. Auto Aero Elect 19

Leading sectors Auto Process Elect Energy Built_Env Health Aero 20

Expertise in Technical areas 21

Potential collaborations experienced users innovative materials, coupled & multi-physics, multi-scale optimization fluid behaviour and rheology, multi-scale V&V materials knowledge, composites, management of large data sets V&V V&V, SPDM 22

Conclusions Problematic Issues defined for all simulation sectors and users Engineer knowledge needs to improve in almost all areas. Cross-sector learning and collaboration is seen to have huge potential. Need to try and remove barriers to promote external use of national HPC centres. (possible issues for UK Government and Funding agencies attention) New users Experienced users Improved users Little simulation knowledge Good simulation knowledge Improve and solve the key challenges 23

Conclusions Best Practice and sector expertise defined to help - new users - experienced users review practices 14 general simulation Best Practices defined 24 technical area Best Practices defined New users Experienced users Improved users Little simulation knowledge Good simulation knowledge Improve and solve the key challenges 24

Conclusions Simulation issues and inter-sector collaboration defined for experienced users to progress Coupled and multi-physics simulations can provide more accuracy, use is increasing. Automatic processes and optimization can increase productivity. Better solutions and designs can be obtained if more emphasis is placed on UQ. SPDM will be essential in the future and increased use must be ensured. New users Experienced users Improved users Little simulation knowledge Good simulation knowledge Improve and solve the key challenges 25

Industrial Best Practice in Modelling and Simulation Gino Duffett gino.duffett@nafems.org 3rd STFC FEA Workshop 18 May 2017