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”
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
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XY Plot 1
Curve Info
FmSetup1 : LastAdaptiveGap='0.001in'
FmSetup1 : LastAdaptiveGap='0.002in'
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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…
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
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