© 2011 ANSYS, Inc. 8/29/111

Design Exploration and Robust Design

Judd KaiserProduct Manager,ANSYS Workbench Platform

© 2011 ANSYS, Inc. 8/29/112

Agenda• What is Robust Design?• At ANSYS• Workbench Principles• DesignXplorer• ANSYS Vision

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What is Robust Design?

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The Path to Robust Design

Single Physics Solution• Accuracy, robustness, speed…

Multiphysics Solution• Integration Platform

“What if” Study• Parametric Platform

Design Exploration• DOE, Response Surfaces, Correlation, Sensitivity, etc.

Optimization• Algorithms

Robust Design

• Probabilistic Algorithms

• Adjoint solver methods

Increasing understanding,

innovation, R

OI Doesn’t account

for physics interactions

Doesn’t provide direction for

design improvement

?

??

Solutions compared, but

design is not well understood and no optimum is

found

Provides design understanding,

but optimization is not

automated

Solutions may be too sensitive

to input variability

Input distribution

Output distribution

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ANSYS Vision

ANSYS Has a very clear vision for Simulation Driven Product Development!• Best-in-class solvers combined for multiphysics• Ease of use, knowledge capture, integration platform…• Parametric, persistent, automated• Design exploration & robust design!

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Design Exploration and Robust Design at ANSYS

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Optimization tools at ANSYS• ANSYS DesignXplorer

– Unified Workbench solution

• ANSYS Fluent – Has built-in morphing

and optimization tools– Has an adjoint solver

• ANSOFT Optimetrics• ANSYS MAPDL

– DX VT• And more

Baseline Design

Optimized Design

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ANSYS DesignXplorerIntegral with Workbench• Parametric multiphysics modeling with automated updates• Bi-directional CAD, RSM, scripting, reporting and more...

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Optimization PartnersANSYS simulation software has

been effectively used to drive innovation in concert with optimization partners

• MATLAB (Mathworks)• ModeFrontier (Esteco)• OptiSLang (Dynardo)• RBF-Morph• Sculptor (Optimal)• Sigma Technology (IOSO)• TOSCA (FE-DESIGN)• Qfin (Qfinsoft)• and more…

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Workbench Principles

(It’s built for SDPD)

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ANSYS Workbench Schematic Workflow

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Workbench

Integrates ANSYS tools and solvers

Parametric, persistent and scriptable environment

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DesignXplorer in Workbench(It’s built for SDPD)

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ANSYS DesignXplorer

DesignXplorer is everything under this Parameter bar…• Low cost & easy to use!• It drives Workbench • Improves the ROI!

DX

CAD Connections & DM ANSYS Workbench

Solvers

EKM &

HPC

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ANSYS DesignXplorer Design of Experiments

With little more effort than for a single run, you can use

DesignXplorer to create a DOE and run many variations.

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Correlation Matrix

Understand how your parameters are correlated/influenced by other

parameters!

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Sensitivity

Understand which

parameters your design is most

sensitive to!

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Response Surface

Understand the sensitivities of the output parameters

(results) wrt the input parameters.

3D Response

2D Slices Response

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Goal-Driven Optimization

Use an optimization algorithm or screening to understand tradeoffs or discover optimal design

candidates!

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Robustness EvaluationInput parameters have variation!

Output parameters vary also!

How will your performance vary with your design

tolerances?

Make sure your design is robust!

Six Sigma, TQM

How many parts will likely

fail?

Which inputs require the

greatest control?

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ANSYS DesignXplorerInitial vs. Optimized Design

Output Initial Design Optimized

Tt Ratio 1.116 1.126

pt Ratio 1.674 1.709

η [%] 71.65 76.25

Power [MW] 1.208 1.268

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DesignXplorer Vision

(It’s built for SDPD)

Disclaimer: plans for future releases are preliminary, and subject to change.

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Engineers face numerous obstacles that prevent them from using optimization fully

Our plans are largely based on removing those obstacles so our customers can get more out of simulation

Remove the Road Blocks

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

Design not Suitable

Understanding Results

Other

Algorithms

Faith in Results

Baseline Model

Parameter Information

Integration Issues

Resouces

Parametric Model

Too Much Time

Main obstacles to Optimization

Linked in Survey, Q1 2011

Do you use optimization software?

Matlab16%

18.6%41.9%

21.8%

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Many ways to reduce the time requirements

• Speedup of individual components– Geometry import, meshing, solve, etc.

• Speedup between design points– “DOE Sorting” at 14.0 – Mesh morphing

• Reduce the number of design points required

– Improved Sparse Grid DOE at 14.0– New Auto-Kriging at 14.0– New KMOGA adaptive optimization

coming at 14.5– Researching ways to use Adjoint

information or ROM to dramatically reduce the number of solves required

• HPC to distribute the solve– New distributed design point solve

with RSM at 14.0

Running all those design points takes too long!

Dynamic convergen

ce feedback

Resolution w/

fewer points

R14

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Removing RoadblocksEasier to build a parametric model

– “Pervasive Parameters” across WB• Manufacturable values, R14• Extend discrete parameters, R15

– Material selection, Booleans, string parameters, etc.

• System Level Modeling, ROM, RS Systems, etc.

Easier to connect various tools together

– Workbench + External Connection + SDK

– ANSYS ICEM CFD Meshing at R14.5– Extend the External Connection

Easier access to resources– Hardware

• Cloud computing– Software Licensing

• Simultaneous Design Point (SDP) packs, R14.5

R14

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~1/3rd of Engineers would prefer to use their own algorithms for Optimization

Algorithms R15

• Opening up our Optimization Platform (R15)– Matlab optimization toolbox– API for customized optimization algorithms– Flexible process with custom cost functions

and convergence criteria• This flexibility will be in addition to our “out of

the box” functionality designed to please the other 2/3rds.

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• New Charts– Added 2D slices, local

sensitivity curves and convergence plots; R14

– Significant enhancements planned

Charting & Reporting

R14

R14

• Unified Reporting– Auto-generate project level

reports, R14– Strategic theme for R15

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Strategic Theme• Already available

– Six Sigma analysis– Sensitivity / Determination

• Research and future development – Probabilistic optimization– Adjoint methods

Robust Design

R12

High sensitivity – changes to shape have a big effect on drag

Low sensitivity

High sensitivity – Shape on Downforce

R14

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The Path to Robust Design

Single Physics

Multiphysics

“What if” Study

Design Exploration

Optimization

Robust Design

• Build on the solid foundation of Workbench as a platform for parametric simulation

• Develop DX as an optimization platform

• Build up to probabilistic optimization

© 2011 ANSYS, Inc. 8/29/1130

Thank You

Join Simon’s DesignXplorer user group on Linked-In

Search Groups for “DesignXplorer” to join.

Judd.Kaiser@ANSYS.com 734-213-1266

Simon.Pereira@ANSYS.com 734-812-6528