evolution, revolution, & next generation of engineering ......jan 22, 2016  · •performance...

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Evolution, Revolution, & the Next New Generation of Engineering Simulation Dr. Rodney L. Dreisbach Independent Consultant: Engineering Analysis & Simulation Retired: Senior Technical Fellow Computational Structures Technology The Boeing Company Potomac, Maryland --- January 20-22, 2016 1 R. L. Dreisbach

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Page 1: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

Evolution, Revolution, & the Next New Generation of Engineering Simulation

Dr. Rodney L. Dreisbach Independent Consultant: Engineering Analysis & Simulation Retired: Senior Technical Fellow Computational Structures Technology The Boeing Company

Potomac, Maryland --- January 20-22, 2016

1 R. L. Dreisbach

Page 2: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Potomac, Maryland --- January 20-22, 2016

PRELUDE Premise

• The first generation of CAx is nearing an end! • NOW, “ A New First Generation of CAx” is beginning. • We need to define collectively, a unified vision and roles to

enable the CAx revolution in the coming decades. • We must rethink the industry!

Each Attendee: Actions for Me and My Organization • Does my CAx vision support the foregoing premise? • What are the top priorities in advancing my vision? • Am I able to support a common, unified vision? • How and when shall I support a unified vision proactively?

2

Page 3: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach 3

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

Page 4: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

1920s1

21st Century: Virtual Single Design Office

1960’s: Introduction of Computers

1970’s: More Powerful Computing

1920’s: Single Design Office

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Page 5: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The Boeing Company - First Home (circa 1916) -

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Page 6: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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1920’s: Single Design Office

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Page 7: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

• Use the computer for specific engineering analysis technologies

• Make the software/hardware work

• Independent organizations

• Independent databases

1960’s: Introduction of Computers

Power Plant Group Stress Group

Production

Micro Film

Balsa Wood

Weight Group

Loft Group

Stress Group

Power Plant Group

Wing Group

Weight Group

Production Group

7

Page 8: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

The Finite Element Method is First Choice for Internal Loads Analysis

Timeframe Airplane Extent of Application

1950’s 707 None

1960’s 727, 737, 747

Verification only (after drawing release)

Early 1970’s

747SP Drawing release of selected components

Late 1970’s 757, 767 Configuration development thru airplane certification of most primary structure

1990’s to Present

777, 737X, 787,…

Configuration development thru certification for all primary structure

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Page 9: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

The 747 Wing-Body Interaction Analysis Presented a Large Computing Problem

9

Wing-Body Interaction analysis

Page 10: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

The 747 Wing-Body Interaction Analysis Presented a Large Computing Problem

B

A

Substructuring Entered the Scene!

B

A

D

C

Landing gear beamPressure deck

Torque box

Keel beam

Substructure Nodes Elements Equations A 1,009 2,897 1003 B 1,014 2,728 1017 C 1,060 3,546 X6000 D 894 2,526 X5000

A

B

CD

Substructure Nodes Elements Equations

A 1,009 2,897 1,003

B 1,014 2,728 1,017

C 1,060 3,546 ~ 6,000

D 894 2,526 ~ 5,000 Substructuring was born! A

B

C

l

B

A

Substructuring Entered the Scene!

B

A

D

C

Landing gear beamPressure deck

Torque box

Keel beam

Substructure Nodes Elements Equations A 1,009 2,897 1003 B 1,014 2,728 1017 C 1,060 3,546 X6000 D 894 2,526 X5000

A

B

CD

10

Page 11: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Early CAD digital design technique!

Yeah, it’s a bit awkward . . . But Mike said I should make this drawing ON the computer!

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Page 12: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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• Faster and larger computers are best!

• Robust software

• Focused on the design cycle

• Interfaced specialized applications

• Collocated teams

• Interfaced databases

1970’s: More Powerful Computing

CRAY

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Page 13: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

• Automated concurrent engineering

• Integrated digital design/analysis/simulation processes

• Integrated cross-functional product teams

• Virtual collocation; geographically-distributed collaborative teaming

• Simulation of product lifecycle (conception to retirement)

21st Century: Product Lifecycle Simulation

Advanced Techniques •Clusters •Grids •Knowledge Management •Massively-Parallel •Warehousing • •

13

Clients

Clients

Data & Compute

Servers

Page 14: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

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Page 15: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Major Factors Associated with a Competitive Business Advantage

Technology • Math & Physics • Engineering • Computing hardware & software • Data management • etc.

Processes • Sharing knowledge • Reusing knowledge • Best practices • etc.

People • Tacit knowledge • Collaboration • Cultures • Global • etc.

Business • Customer knowledge • Market intelligence • Strategic goals • etc.

Simulation Plays a Key Role in Each Group 15

Page 16: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Data

Information

Knowledge

Innovation

Competitive

Advantage

Hig

h-Le

vera

ge

Bus

ines

s O

ppor

tuni

ties

Knowledge is the Key to Competitive Advantage Through Innovation

Wisdom

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Page 17: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Characteristics of Innovation --- the Interaction of the Four Groups

• Innovation – Feeds off of the knowledge of a company

– Is based on sharing knowledge across different domain groups and organizational boundaries

– Is generally associated with the development of new products and services

– Is generally the result of a series of incremental improvements

– Results from well-managed, disciplined business processes---it is not accidental!

“Invention is 1% inspiration versus 99% perspiration” --- Thomas Edison

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Page 18: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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How to Think like Leonardo da Vinci* --- Seven da Vincian Principles

• Curiosita: An insatiably curious approach to life and an unrelenting quest for continuous learning

• Dimonstrazione: Tests knowledge through experience, persistence, and willing to learn from mistakes

• Sensazione: Continually refines the senses, especially sight, as a means to enliven experience

• Sfumato (literally "Going up in smoke"): Willing to embrace ambiguity, paradox, and uncertainty

• Arte/Scienza: Develops a balance between art and science, imagination and logic. "Whole-Brain" thinking

• Corporalita: Cultivates grace, ambidexterity, fitness, and poise • Connessione: Recognizes and appreciates the interconnectedness of all

things and phenomena - systems thinking * Book by Michael J. Gelb

Not Bad For A Man Who Was Born In 1452!

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Page 19: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Innovation & Competitive Advantage

• People, Processes and Technology define the foundation for creativity and innovation

– Technology makes it feasible

– People and their Processes make it successful!

• Balancing and aligning these elements with the Business Strategy results in a Competitive Business Advantage

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Page 20: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Simulation Roles & Their Elements

Simulation Plays a Key Role in Each Group

Technology • Math & Physics • Engineering • Computing hardware & software • Data management • etc.

Processes • Sharing knowledge • Reusing knowledge • Best practices • etc.

People • Tacit knowledge • Collaboration • Cultures • Global • etc.

Business • Customer knowledge • Market intelligence • Strategic goals • etc.

Where the Elements of Simulation include: • Modeling • Visualization • Analysis & Optimization • Knowledge Lifecycle Management

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Page 21: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

21

Page 22: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Simulation and Test Correlation

Functional

Requirements

Logical

Physical

System

Subsystems

Components

Voice of Customer

High Fidelity

Low Fidelity

Customer Experience

System Acceptance

Integration Test

Subsystem test

Simulation Drives Decisions Throughout the Product Lifecycle

FEOB Conceptual Preliminary Detailed Validation

(Test) Manufacture In Use

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Page 23: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Continued Progress in Design Paradigm Change

Traditional Engineering:

• Limited functional integration during PD

• Iteration is slow and results in significant schedule delays and cost overruns

• Manufacturing, assembly, and certification criteria are brought into development at detailed design

• Rapid Iteration >>> Concurrent Engineering

• Multidisciplinary simulation

• Robust design architecture for rapid trade capability and risk assessment

• Manufacturing and certification criteria included to optimize design for weight, cost, and rate

• Promote standards such as MoSSEC

Evolving

Verify & Validate

System Requirements

Preliminary Design

Detailed Design

Manufacturing Trials

Assembly & Tooling

Operations & Support

Implementation

Time

Integration & Test

Configuration Definition

Configuration Definition

Fabrication Simulation

Certification&

Qualification Criteria

Materials Definition and

Simulation

Performance Model Cost/Weight/Rate/Risk

Multidisciplinary Simulation Framework Assembly &

Tooling

Integrated System Requirements

Structural Design & Analysis

Increased Focus on Concurrent Engineering Up Front

Production Plan and

Optimization

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Page 24: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Model-Based Engineering

1st Generation 2nd Generation 3rd Generation

• 2D Drawing Based Design

• Paper Based Master

• Multidiscipline Collaboration via Engineering Bullpen

• Functional Management Organization

• Performance Driven Design Requirements

• 3D Wireframe Design

• Electronic Drafting

• Data Stored by Discipline

• Introduction of CAD /CAM

• First-Generation Integrated Product Team Development Approach

• Performance & Cost Based Requirements

• 3D Solids Design

• Model Based Design

• Model Based Work Instructions

• Introduction of PDM

• Full IPT Implementation including Suppliers

• CAIV Philosophy to Requirements

1990’s 1970’s 2000’s Paper Drawings Electronic Drawings Electronic Engineering

Model Based Development (MBD) or Model Based Engineering (MBE) is a paradigm shift for Systems/Software design, in much the same way that CAD was for hardware design.

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Page 25: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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• Provides a common modeling and simulation environment • Requirements, functional, logical, and physical inter-relationships • 3D CAx parametric, cross-discipline functions • Virtual design, build, test, and certify • Multi-physics modeling & simulation • Common meta-model • Knowledge capture

What?

Model-Based Engineering

Why? • Allows for Rapid Prototyping and Architecture Optimization • Leads to Early Integration and Requirements Validation • Creates a Truly Representative Simulation of the Product • Supports Model-Based Requirements to Suppliers • Increased Overall Fidelity of the Simulations • Reduced Development Time and Cost

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Page 26: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Decision Support

Results

Process Management

Scenarios

Data Management

Models

Collaboration

Simulation Management in a Collaborative Engineering Environment

26

Page 27: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The EU CRESCENDO Project and its Multiple Platforms for Collaboration

Standard specification of BDA Functions supporting collaboration across companies

Specialised BDA Engineering Methods for M&S => Functions/Tools supporting different company roles

Enterprise Collaboration Functions

Model Store Functions

Quality Lab Functions

Simulation Factory Functions

Modelling & Simulation Tools

Generic BDA Platform Specification

Company A : OEM Company B: Partner Company C: Supplier

Collaboration Standard • Connect & control global processes • To be formalised as “SE” DEX mapped to AP233 & AP239/PLCS

Technical Standard(s) enabling exchange of detailed data e.g., AP209, AP242, neutral & vendor formats, ...

e.g. e.g. e.g.

Multiple BDA Platforms Deployed 27

Page 28: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The NAFEMS/INCOSE Systems Modeling and Simulation Working Group (SMSWG)

Objective: NAFEMS and INCOSE agreed to a mutually beneficial strategy to develop a collaborative relationship that would benefit both the organizations and their members (kick-off agreement on August 18, 2011)

Mission:

• Develop a vendor-neutral, end-user driven consortium

• Promote advancement of the technology and practices associated with co-simulation of systems engineering and engineering analysis

• Act as the governing body of standards in this space

• Drive strategic direction for technology development in this space

Includes education, communication, promotion of standards, and developing requirements having general benefits to the simulation and analysis communities.

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Page 29: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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MBE Example: Mechatronics Simulation

Coupling of disciplines: Mechanical, Electronics, Controls and Software

Control Systems

Software

Mechanical Systems

Mechanical

CAD

Digital Control

Systems

Electro-

Mechanics

Control

Electronics

Electronic Systems

Mechatronics

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Page 30: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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“Intuitive Simulation” Real Time Comprehension

--- versus ---

“Realistic Simulation” Batch Computation Synthesis

The Opportunity Realistic Simulation in Real Time!

What did we just see???

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Page 31: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Conceptual System Development Virtual Test & Validation

Process for Developing Multibody Systems

Hybrid MBD/FEM

Static Analysis

Animation in Context

Product Development

Product Development and Solution Method Relationship

MBS Modeling Complexity & Solution Time Required

Rea

l-Tim

e An

imat

ion

Rea

listic

Phy

sics

Mod

elin

g

Spatial Integration

Detailed FEM Kinematic Analysis

Swept Volume

Inverse Dynamic Analysis

Dynamic Analysis

Hydraulics/Controls

Inverse Kinematic Analysis

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Page 32: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Airplane Flap Design: An Art & a Science!

Kinematic synthesis determines the configuration and size of the mechanical elements that direct power flow in a mechanism.

A flap mechanism is a mechanical system that transforms a power source into a desired application of forces and movement.

“Mechanism design is the process of determining how to put 10 lbs of mechanism in a 2 lb bag”

To put it more succinctly...

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Page 33: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

33

Page 34: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The Aerospace Industry Building-Block Test Approach

Airplane and Major Components Validate analyses & verify product

performance; optimize via large-scale

optimization tools

Details and Subcomponents Develop design values; optimize

manually or automatically

Materials and Processes Develop material properties

via theory, experiment, &

empirical methods

Component tests

Sub-component tests

Structural elements tests

Allowables development

Material specification development

Material screening and selection

Full- scale tests

Tier 1

Tier 3

Tier 2

The test plan

integrates all levels!

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Page 35: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Computational Materials

Material Models

Process and Manufacturing Simulation for Quality Aspects

of Full Size Parts

Tolerances & Assembly Simulation

Processing and Quality Simulation

Advanced computational structural mechanics

Constituent Design

Material System & Forms

Vehicle

Process Development

Scale Up Assembly

Multiscale Modeling & Simulation --- Structures Example

Quantum & Molecular Mechanics

Simulation, Manufacturing & Testing Integrate all Levels of Product Creation

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Page 36: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Current – Notional Material Development and Certification Cycle

Material Properties ~4 yrs

Material Development & Producibility ~9 yrs

~ 18 Years

Material Performance Frozen

Product Design Cycle Begins

• Trial & Error

• Disconnected from Requirements

Design Value Devel ~3 yrs

Analysis Validation ~4 yrs

New Product Development Cycle ~5-9 yrs

It can take longer to develop an all-new structural material than it takes to

develop a new airplane – So designers have to rely on last-generation materials.

Material Development & Certification Timeliness

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Page 37: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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When you compress most materials, you squash their atoms or molecules up against each other, shortening the bonds between them. But a new kind ultra-compressible material acts like a set of gears and springs that shrink in size. Researchers from the Molecular Materials Group at the University of Sydney have created a series of new materials that deform using a kind of torsional mechanism. The material’s made up from two different metallic molecules—one lanthanide-based (LnN6) and the other iron-based (FeC6)—which are connected by cyanide bridges. When exposed to pressure, they collapse in on themselves. The LnN6 units acting like torsion springs are synchronised by rigid Fe(CN)6 units acting like gears. The LnN6 twists away from its original trigonal prismatic geometry becoming octahedral. These LnN6 units act as torsional centres that coil dramatically under pressure and enable extreme compressibility in combination with chemical and thermal stability for the first time. The material compresses by around 20 percent in volume at 1GPa (~145,000 psi)

Example Material Simulation: --- An Ultra-Compressible Material ---

Page 38: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

38

Page 39: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Ongoing Efforts Related to the Internet of Things • Cognitive Computing

• Dialog with Humans (cyber-physical) • Interpret Large Unstructured Data Sets • Learn & Help Make Decisions

• Digital Intelligence Embedded in Software • Interpreted Analytical Results Based on Math and Physics

• Extreme Computing (smartphones now have more processing power than the 1960’s supercomputers)

• On-Demand Computing (e.g., exaflop clouds) • Desktop Supercomputers • Quantum Computing (in 5 to 25 years)

• Exploitation of International Standards • FMI, OPM, Model-Based Engineering • ISO, OSLC, etc.

• Connecting Software Internally via Biomimetic Programming • Synchronous (Concurrent) Simulations & Co-Simulations • Appifications & Vertical Applications: “ … designers and engineers using computer

programs for design or analysis are cautioned that they are responsible for all technical assumptions inherent in the programs they use and they are responsible for the application of these programs to their design.” … ASME VIII Div2 2010

• Microsoft’s “HoloLens” for cross-team collaboration? Overlay virtual reality on real surroundings…

• •

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Page 40: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Ongoing Efforts Related to the Internet of Things (Concluded)

• Democratization • Expert Knowledge Capture & Reuse • Usability • Accessibility • Interoperability Across Engineering Domains • Next-Generation Computing Architectures

• Simulation Governance • Verification & Validation • Uncertainty Quantification • Risk Management • Simulation Deployment • Simulation Process & Data Management • International Standards

• Business Challenges • ROI • Licensing Models • Communication • Influence of SMEs • Vendor & End-User Collaboration (Alliances?)

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Page 41: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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Meeting the Demand for CAx Expertise

Great strides are underway to “appify” focused processes especially for the novice users; however, much is still needed to guide the expert analysts! • Examples of non-interpretable error messages from commercial software

Example 1:

Example 2:

(11th World Congress on Structural and Multidisciplinary Optimisation; 07th -12th, June 2015, Sydney Australia)

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Page 42: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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An optimization problem may involve one or more items from the 1st column, and one or more items from the top row.

Realistic Structural Optimization of Multi-Physics Problems

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Page 43: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The Internet of Things-----Physical and Digital!

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Page 44: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The Internet of Things-----Physical and Digital!

A Hyperloop Tube??? LA to San Francisco in 35 minutes!

An Autonomous Car???

Can Similar Technologies be Applied to Engineering Simulation???

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Page 45: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

45

Page 46: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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• CRESCENDO: Collaborative and Robust Engineering using Simulation Capability Enabling Next Design Optimisation – 59 partners

– Thermal Aircraft – Power-plant integration

• TOICA: Thermal Overall Integrated Concept Aircraft – 30 partners – Dynamic Aircraft Thermal Architectures; functional, physical, zonal, logical…

• CONGA: Configuration Optimisation of Next Generation Aircraft – 7 partners

– Set Based Design

• HORIZON 2020: 2014 to 2020; 80 B€ gross budget – thousands of projects

– Science, Industrial Leadership, Societal Challenges, …

Example European Union Collaboration Projects

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Page 47: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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COLLABORATIVE ROBUST ENGINEERING using SIMULATION CAPABILITY ENABLING NEXT DESIGN OPTIMISATION

CRESCENDO project key facts:

FP7 2nd Call Integrated Project 234344 May 2009 to October 2012 55 M€ gross budget 59 partners from 13 countries 5000+ person months effort 17 test cases More than 50 publications + 5 theses

CRESCENDO Forum:

~330 registered 50 presentation sessions 30 marketplace stands + 70 posters Handbook

European focus ... Global outreach

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Page 48: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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The CRESCENDO Consortium

18 Aeronautic Industry

partners

9 Research Centre

partners

12 Academic partners

20 Solutions & Services

partners

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Page 49: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

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High Level Objectives:

10% reduction development life cycle duration and cost

50% reduction in rework

20% reduction in cost of physical testing

CRESCENDO’s Ambition

Initiate a step change in

the way that Modelling & Simulation activities are carried out,

by multi-disciplinary teams working as part of a

collaborative enterprise, in order to develop

new aeronautical products in a more cost and time efficient manner

Impact on Aeronautics:

Halve time to market with advanced ... processes, methods and tools

Increase integration of supply chain into the network.

Maintain steady and continuous fall in travel charges ...

Managing the evolution of the Behavioural Digital Aircraft (BDA) dataset from concept to certification is key to achieving maturity at entry into service

CRESCENDO takes up the challenge!

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External Leverage Opportunities – Partners & Collaborators –

Academia

Government Vendors

Suppliers

Professional

Organizations

Technology

Processes

People

Business

Industry CAx End-Users

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R. L. Dreisbach

CAx-IF & CAE vendors PDES, Inc., ProSTEP iViP, AFNeT (AP209 ed2 development)

MoSSEC

Use cases, requirements, and methods oriented to capture of analysis metadata and pedigree

NAFEMS engineering methods WGs

User requirements oriented around analysis methods

End Users

Use cases, requirements, and sample data

ISO (ISO 10303 STEP, ISO 14721 OAIS)

Publish International standards

NIST

User requirements oriented around simulation data management artifacts

NAFEMS Simulation Data

Management WG

Development of Data models and standard representations

Software capabilities and recommended practices

Testing support (compliance) syntax, structure, semantics; validate recommended practices, Promote the standards

LOTAR EAS WG (NAS / EN 9300-6xx)

Requirements

Requirements

Education

Published standards

Data model, standards

Identifies needed enhancements

Use cases & Requirements

Software capabilities & recommended practices

Candidate capabilities

Compliance testing results

Promote standards

Develop standards for engineering analysis and simulation LOTAR

Use cases & Requirements

Collaborative Development Space for EAS LOTAR Consumers, Providers, and Artifacts

Sept 2015 Draft 3

ASD-STAN (LOTAR EN 9300-xx)

AIA (LOTAR NAS 9300-xx)

Published standards

Use cases & Requirements

Publish standards

Requirements

Output

Development

Legend

Other Activities 51

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R. L. Dreisbach

Evolution of the Engineering Design Process

Innovation and Competitive Advantage

Collaborative Model-Based Engineering

Manufacturing, Testing, and Simulation Synergy

The Internet of Things: Physical & Digital

Collaboration Options via Consortia

Opportunities for Enabling the CAx Revolution

Outline

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Opportunities for Enabling the CAx Revolution

• Promote the concepts and processes for user organizations to instill “Engineering Simulation Governance” firmly as an essential strategic business goal; a prerequisite for competiveness (leadership, competencies/skills, reliable standard processes)

• Focus on optimizing the product itself and not the different math models of the product (e.g., strength optimization of the geometry, topology or topography of the product vs the “modeled” structural gages).

• Allow the design data and parametric models across multidisciplines to have comparable fidelities during the same phase of a product creation.

• Exploit international standards for integrated data modeling, and for sharing simulation information and knowledge between independent models and disparate codes across the different engineering domains.

– Free exchange of accurate product-definition information is difficult; – Proprietary data formats are used, often in a federated data environment

with high costs to industry; – Many different data models needed for different functional analyses, using

different COTS and proprietary computer applications; – Evolution of technology is constrained by the closed and/or

proprietary nature of current computing systems & data models; – Product data redundancy is prevalent.

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(Continued)

• Use “smart” techniques for product-definition information representation, mapping & integration, supporting the continuous design evolution process, allowing design constraint representations across multidisciplines to be aligned dynamically.

• Integrate cognitive computing and predictive analytics into engineering simulation capabilities, whereby virtual product testing and certification can be performed through more realistic simulation.

• Introduce a common, logical single-source product information management system for simulating the lifecycle of systems, from product conceptual design through detailed design, manufacturing, testing, verification, and support.

• Promote horizontally-integrated “Plug & Play” application suites, allowing the tools to fit the business processes; Minimize the need for highly-trained experts in solving multidisciplined problems.

• Enhance concurrent and co-simulation solution capabilities for fully-coupled cross-functional problems associated with continuum mechanics throughout the product creation process; Solutions to multi-physics problems lack realism via overly-compromised, expansive assumptions (i.e., decoupling analysis fields).

• Enhance multi-scale modeling of materials and simulations from systems to sub-systems to components and back again.

Opportunities for Enabling the CAx Revolution

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(Concluded)

• Develop robust simulation methods and tools to capture accurately the 3-D physics of typical problems (e.g., aerodynamic turbulence & vortex breakdown, statistically-based, and data quality assessment metrics).

• Create integrated processes for designing reliability-based products by harnessing knowledge into non-deterministic analysis/optimization methods via embedded intelligence with uncertainty quantification and risk prediction.

• Form alliances to develop harmonized visions for engineering simulation across industry, academia, government, professional organizations, and CAx vendors.

Opportunities for Enabling the CAx Revolution

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Realistic simulation of problems at the speed of human thought should be our vision!

Sexy simulation environments will define the destiny of the CAx industry!

Need to implement “win-win” collaborative business scenarios for all.

• Develop engineering simulation environments for collaborative modeling, analysis/optimization, immersive man-machine interactions, common visualizers, and standards-based cognitive knowledge sharing systems for experiencing real-time multi-physical response simulations.

• Change our culture and enrich our pipeline of expertise in STEM (Science, Technology, Engineering, and Math) domains, beginning with preschoolers, through college, and beyond retirement; including skill/competency metrics, career growth training, communities of practice, etc.

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Our Mission!

Opportunities --- Engineering Simulation for Innovative Products---

Transform CAx As We Know It Today!

… We Should Accept It!! … Should We Accept It!

… into an Immersive Computing Environment … for Realistic Product Simulation of

Multi-Physical Phenomena at the Speed of Human Thought!

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CAx STASSE

STEROIDS A

ASSESS Smart Tools for Engineering Robust, Optimized & Innovative Design Simulations

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Build it Better, Faster, and Cheaper!

Manufacturability

Analysis & Optimization Cost

Customers Multi-Functional Operational Specs

Supportability Safety

Maintainability

and more

Strategic Direction: Revolutionizing the Future is Now!

--- An Immersive Design Environment ---

…through Realistic Digital Simulation of Multi-Physical Phenomena at the Speed of Human Thought! 57

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Potomac, Maryland --- January 20-22, 2016 Setting New Standards for the 21st Century

Exploiting Analysis & Simulation in Engineering

(EASE) … In Action!

Page 59: Evolution, Revolution, & Next Generation of Engineering ......Jan 22, 2016  · •Performance Driven Design Requirements •3D Wireframe Design •Electronic Drafting •Data Stored

Northwest Technical Excellence Knowledge Management Forum June 9, 20 08

BOEING PROPRIETARY - Distribution Limited to Boeing Personnel Only

Thank You!

R. L. Dreisbach 59