ANSYS Workbench and

DesignXplorer

© 2011 ANSYS, Inc. May 14, 20121

Gilles Eggenspieler

Senior Product Manager

Agenda

• The path to robust design

• A closer look at what DX offers

• Some examples

© 2011 ANSYS, Inc. May 14, 20122

The Path to Robust DesignRobust Design

“What if”

Design Exploration

•DOE, Response Surfaces,

Optimization

•Algorithms

•Published API

Robust Design

•Six Sigma Analysis

•Probabilistic Algorithms

•Adjoint solver methods

Robust Design is an

ANSYS Advantage

© 2011 ANSYS, Inc. May 14, 20123

Single Physics

Solution

•Accuracy, robustness, speed…

Multiphysics

Solution

•Integration Platform

“What if”

Study

•Parametric Platform

•DOE, Response Surfaces, Correlation, Sensitivity, Unified reporting, etc.

Single Physics/Multi Physics

Single physics is the

entry point to

Simulation

Multi-Physics enables

real virtual prototyping

Fluid Pressure

Distribution

© 2011 ANSYS, Inc. May 14, 20124

Deformation

of the Stator ?

Electromagnetic Force Density with Thermal-Stress and Electromagnetic Force load

2 way coupled with a

transient structural solution

Stress ?

“What If?”

© 2011 ANSYS, Inc. May 14, 20125

� Parametric CAD Connections

� Pervasive Parameters

� Persistent Updates

� Managed State, Update Mechanisms

� Remote Solve Manager (RSM)

� …

Needed for "What If?"

Parametric Persistence is

an ANSYS Advantage!

Interactively adjust the

parameter values and “Update”

Design Exploration

Design Exploration is an ANSYS Advantage

© 2011 ANSYS, Inc. May 14, 20126

Optimization

Optimal Candidates

© 2011 ANSYS, Inc. May 14, 20127

Structural Analysis with Fatigue module

Turbine Turbine blade root designblade root design

Input Parameters:

Initial

Result

ds_xtilt

Life

Minimum

Fatigue life optimizationFatigue life optimization

© 2011 ANSYS, Inc. May 14, 20128

DOE; Central

Composite Difference

Algorithm

3 input parameters =>

15 design points

Response Surface

based on 15 DOE

runs

Goal Driven Optimization

using MOGA algorithm

Optimized

Candidate

ds_xtilt

ds_ytilt

ds_rootrad

Output Parameter:

Minimum Life

Exhaust manifold designExhaust manifold design

Parametric Geometry

Pressure & Flow

Velocity

Thermal

Deformation

Stress

Six Sigma AnalysisSix Sigma Analysis

© 2011 ANSYS, Inc. May 14, 20129

�Input Parameters

�Outlet Diameter of the

manifold

�Thickness at inlet

�External Temperature

�Engine RPM

All samples reports

max deformation

below 1.5 mm �Response Parameters

�Max Flow Temperature

�Max Deformation

�Max Von-Mises stress

Uncertainty

of input

parameters

Maximum Displacement should not exceed 1.5 mm

Response Surface showing

the effect of engine speed

and thickness at outlet on

the maximum deformation

Six Sigma AnalysisSix Sigma Analysis

Robust Design Tools at ANSYS

• ANSYS DesignXplorer

– Unified Workbench solution

• ANSYS Fluent

– Built-in Mesh Morphing and

shape Optimization (MMO) tools

• Being hooked up to DX for 14.5

– Adjoint solver

Baseline Design

© 2011 ANSYS, Inc. May 14, 201210

– Adjoint solver

Optimized DesignHigh sensitivity – changes to

shape have a big effect on drag

Low sensitivity

High sensitivity – Shape on

Downforce

R14R14

Robust Design Tools at ANSYS

• ANSYS DesignXplorer

– Unified Workbench solution

• ANSOFT Optimetrics

– Produce “families of curves”

– Simultaneous solve with DSO

packs

– Access to EBU AdjointAnsoft Corporation Maxwell3DDesign1XY Plot 1Ansoft Corporation Maxwell3DDesign1XY Plot 1

© 2011 ANSYS, Inc. May 14, 201211

– Access to EBU Adjoint

• And more

0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00 900.00 1000.00ampturns [A]

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

Fm

[new

ton

]

XY Plot 1

Curve Info

FmSetup1 : LastAdaptiveGap='0.001in'

FmSetup1 : LastAdaptiveGap='0.002in'

FmSetup1 : LastAdaptiveGap='0.003in'

FmSetup1 : LastAdaptiveGap='0.004in'

FmSetup1 : LastAdaptiveGap='0.005in'

FmSetup1 : LastAdaptiveGap='0.006in'

0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00 900.00 1000.00ampturns [A]

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

Fm

[new

ton

]

XY Plot 1

Curve Info

FmSetup1 : LastAdaptiveGap='0.001in'

FmSetup1 : LastAdaptiveGap='0.002in'

FmSetup1 : LastAdaptiveGap='0.003in'

FmSetup1 : LastAdaptiveGap='0.004in'

FmSetup1 : LastAdaptiveGap='0.005in'

FmSetup1 : LastAdaptiveGap='0.006in'

ANSYS DesignXplorerIntegral with Workbench

• Parametric multiphysics

modeling with automated

updates

• Bi-directional CAD, RSM,

scripting, reporting and

more...

Integral with Workbench

• Parametric multiphysics

modeling with automated

updates

• Bi-directional CAD, RSM,

scripting, reporting and

more...

© 2011 ANSYS, Inc. May 14, 201212

more...more...

Optimization Partners

ANSYS simulation software has been

effectively used in concert with many

optimization partners

•MATLAB (Mathworks)

•ModeFrontier (Esteco)

•OptiSLang (Dynardo)

•eArtius

© 2011 ANSYS, Inc. May 14, 201213

•eArtius

•Optimus (Noesis)

•RBF-Morph

•Sculptor (Optimal)

•Sigma Technology (IOSO)

•TOSCA (FE-DESIGN)

•iSight (Dassault)

•Qfin (Qfinsoft)

•and more…

DesignXplorer in Workbench(It’s built for SDPD)

© 2011 ANSYS, Inc. May 14, 201214

ANSYS DesignXplorer

DesignXplorer is everything

under this Parameter bar…

• Low cost & easy to use!

• It drives Workbench

DesignXplorer is everything

under this Parameter bar…

• Low cost & easy to use!

• It drives Workbench ANSYS

© 2011 ANSYS, Inc. May 14, 201215

• Improves the ROI!• Improves the ROI!

DX

ANSYS Workbench

Solvers

Design of Experiments

© 2011 ANSYS, Inc. May 14, 201216

With little more effort than for

a single run, you can use

DesignXplorer to create a DOE

and run many variations.

With little more effort than for

a single run, you can use

DesignXplorer to create a DOE

and run many variations.

Correlation Matrix

Understand how your parameters are

correlated/influenced by other parameters!

Understand how your parameters are

correlated/influenced by other parameters!

© 2011 ANSYS, Inc. May 14, 201217

Sensitivity

Understand which

parameters your

design is most

sensitive to!

Understand which

parameters your

design is most

sensitive to!

© 2011 ANSYS, Inc. May 14, 201218

Response Surface

Understand the

sensitivities of the output

parameters (results) wrt

the input parameters.

Understand the

sensitivities of the output

parameters (results) wrt

the input parameters.3D Response

2D Slices Response

© 2011 ANSYS, Inc. May 14, 201219

Goal-Driven Optimization

© 2011 ANSYS, Inc. May 14, 201220

Use an optimization algorithm

or screening to understand

tradeoffs or discover optimal

design candidates!

Use an optimization algorithm

or screening to understand

tradeoffs or discover optimal

design candidates!

Robustness Evaluation

Input parameters have variation! Make sure your

design is robust!

Six Sigma, TQM

Make sure your

design is robust!

Six Sigma, TQM

© 2011 ANSYS, Inc. May 14, 201221

Output

parameters

vary also!

Understand how

your performance

will vary with your

design tolerances?

Understand how

your performance

will vary with your

design tolerances?

Predict how

many parts

will likely fail?

Predict how

many parts

will likely fail?

Understand

which inputs

require the

greatest control?

Understand

which inputs

require the

greatest control?

ANSYS DesignXplorerInitial vs. Optimized Design

Output Initial Design Optimized

Tt Ratio 1.116 1.126

pt Ratio 1.674 1.709

© 2011 ANSYS, Inc. May 14, 201222

η [%] 71.65 76.25

Power [MW] 1.208 1.268

Engineers can easily

appreciate the value of

understanding.

Engineers can easily

appreciate the value of

understanding.

Green Technology!!!

© 2011 ANSYS, Inc. May 14, 201223

Power Plant 1000 MW

Efficiency 50 %

Increase of 1% +20 MW

=Electricity for 120 000 Inhabitants

Robust Design saves Money and makes Greener products!

Robust Design saves Money and makes Greener products!

Industry Testimonials

“This technology makes it possible to quickly evaluate hundreds of

designs in batch processes to explore the complete design space

so that we know we have the best possible design.”

“The ease of using simulation tools has helped to

transform our organization from a test-centric

culture to an analysis-centric culture.”

Bob Tickel, Director of Analysis at Cummins

© 2011 ANSYS, Inc. May 14, 201224

“Over the course of the design process, Dyson’s engineers steadily improved the

performance of the fan to the point that the final design has an amplification ratio of 15

to one, a 2.5-fold improvement over the six-to-one ratio of the original concept design.

The team investigated 200 different design iterations using simulation, which was 10

times the number that would have been possible had physical prototyping been the

primary design tool. Physical testing was used to validate the final design, and the

results correlated well with the simulation analysis.”

R. Mason, Research, Design and Development Manager, DYSON

so that we know we have the best possible design.”

Stresses Ken Karbon, Staff Engineer, General Motors

Some quick examples

© 2011 ANSYS, Inc. May 14, 201225

Structural Analysis with Fatigue module

Turbine Turbine blade root designblade root design

Input Parameters:

Initial

Result

ds_xtilt

Life

Minimum

Fatigue life optimizationFatigue life optimization

© 2011 ANSYS, Inc. May 14, 201226

DOE; Central

Composite Difference

Algorithm

3 input parameters =>

15 design points

Response Surface

based on 15 DOE

runs

Goal Driven Optimization

using MOGA algorithm

Optimized

Candidate

ds_ytilt

ds_rootrad

Output Parameter:

Minimum Life

P3

P2

P1

Slit Die

Slit Die

• Need uniform outflow

• Minimize pressure drop

Flo

w U

nif

orm

ity

Go

od

© 2011 ANSYS, Inc. May 14, 201227

BAD

GOOD

Pre

ssure

Dro

p

Flo

w U

nif

orm

ity

Go

od

Ba

d

Combustor

Combustor

−3 parameters

−Minimize pressure loss

−Minimize mach numberInlet

Outlet

Outlet

Outlet

Dump Gap

Diffuser

Length

Exit Height

© 2011 ANSYS, Inc. May 14, 201228

Sensitivity