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![Page 1: RADIOSS Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations](https://reader034.fdocuments.in/reader034/viewer/2022052301/554a177eb4c905825d8b4f93/html5/thumbnails/1.jpg)
7th European Altair Technology ConferenceMunich / June 24-26, 2014
Radioss Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations
Aleksandar Bach (Ford Research and Advanced Engineering Europe)Hüseyin Cakir
Vincent Dampure (Altair Engineering GmbH)
![Page 2: RADIOSS Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations](https://reader034.fdocuments.in/reader034/viewer/2022052301/554a177eb4c905825d8b4f93/html5/thumbnails/2.jpg)
7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
� Motivation
� Radioss Multi-Domain Approach
� Validation + Examples
� Summary
2
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Motivation: Standard vs. refined Mesh 3
���� Accurate prediction with refined mesh only
Discplacement [mm]
Imp
ac
tor
Fo
rce
CAE_STANDARD
CAE_REFINED
TEST
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Motivation 4
� Accurate prediction of crash events requires increased model complexity
o Local mesh refinement (shell / solid elements)
o Advanced material models incl. failure criteria
� Increase of model size + reduction of explicit time step
���� Increase of total CPU time beyond acceptable range of industrial applications
Objectives of RADIOSS Multi-Domain approach
Improve CPU time efficiency by maintaining the accuracy (compared to standard Mono-Domain approach)
test
CAE
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
� Motivation
� Radioss Multi-Domain Approach
� Validation + Examples
� Summary
5
![Page 6: RADIOSS Multi-Domain – Innovative Simulation Technique for CPU Time efficient Prediction of Material Failure in Full Vehicle Crash Simulations](https://reader034.fdocuments.in/reader034/viewer/2022052301/554a177eb4c905825d8b4f93/html5/thumbnails/6.jpg)
7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
What is Multi-Domain 6
� Split global model into physically equivalent “sub-domains”
� Each domain using its own time step (tF » tS)
� Force and momentum transfers between domains will be calculated by a separate program (RAD2RAD)
RAD2RAD
full domain (tF) sub-domain (tS)
full fullexplicit time step t
tF: full domain
tS: sub-domain
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Pre-Processing / Model Set-up 7
� User-friendly environment � single input file format (since Radioss V11.0.201)
- Define parts to be treated as sub-domain
- Define additional engine file per sub-domain
- Define cross contact between full domain and sub-domain
� Possible links between domains
- Common nodes
- Kinematic condition (/INTER/TYPE2: non-conforming meshes, beam2shell or solid2shell connections)
- General contact (/INTER/TYPE7, 11, 18, 24, …)
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Multi-Domain will be efficient if … 8
Minimize communication between domains
� Size of sub-domain is less than 30% of full domain (nodes/elements)
� Time step ratio between full domain and sub-domain ≥ 3
� Keep cross contact between full and sub-domain as small as possible
Minimize size of cross contact
� Use only segments of full domain which are potentially impacting parts of sub-domain (manual work)
� Development of automated contact optimization urgently needed (development ongoing)
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Parallelization of Multi-Domain Architecture 9
� No benefit of previous Multi-Domain release with more CPUs
� Due to parallelization of RAD2RAD process the performance of current Multi-Domain release was significantly improved
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Contents
� Motivation
� Radioss Multi-Domain Approach
� Validation + Examples
� Summary
10
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Method Development / Validation Procedure 11
COUPON
LEVELCOMPONENT
LEVEL
FULL VEHICLE
LEVEL
SYSTEMATIC VALIDATION PROCEDURE
� New CAE methodologies have to be checked by systematic
validation procedure in order to guarantee accuracy and robustness
of application for further industrial use
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Coupon Level 12
source: Research project FOSTA/AVIF Nr. P 806/06/2009 / A262 / S24 / 10162/08
Frauenhofer (IWM)
material properties
tensile test / 22MnB5 sample
� Metallurgical notch is significantly impacting
the crash performance
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Coupon Level / Multi-Domain vs. Mono-Domain 13
test data by Frauenhofer (IWM)
CAE Model
CAE vs. Test
� CAE correlates well with
test data
� No differences between
Multi-Domain and Mono-
Domain simulation
sub-domainfull domain
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Component Level 14
3PB of 22MnB5 beam
� Geometrical notch is significantly impacting the crash performance
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Component Level 15
CAE vs. Test
� Coarse mesh is not able to predict material failure correctly
� Fine mesh correlates perfectly with test data
� No differences between Multi-Domain and Mono-Domain simulation
coarse mesh (7mm)
fine mesh (1mm)
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level 16
full domain sub-domain with detailed SW
model (incl. HAZ)
side impact / run with 48 CPUs full vehicle crash model
number of elements ~ 2 millions
element ratio: sub-domain / full domain ~ 4%
time step ratio: full domain / sub-domain 2
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / Multi-Domain vs. Mono-Domain
time time
en
erg
ies
intr
usio
n
17
global energies intrusion (@ B-pillar lower)
� The results are comparable for the Multi-Domain and
Mono-Domain simulation
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / Run Time 18
„Multi-Domain #1sub-domain in global contact
side impact Mono-Domain Multi-Domain #1global contact
Multi-Domain #2cross contact
run time [h] ~ 27 ~ 100 ~ 15
Multi-Domain #2sub-domain in cross contact
slow-down 3.7 speed-up
1.8� For efficiency reasons it is
essential to optimize the contact between the sub-domain and full domain
� Automated routine urgently required (development ongoing)
major
improvement
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Example: Full Vehicle Level / Further CPU Benchmarks 19
case number of
elements
element ratiosub- / full domain
time step ratiofull / sub-domain
Speed-upMulti-/Mono
0.5 m 4% 4 3
1.2 m 2% 3 4
2.3 m 5% 4.4 / 10 3 / 4
0.35 m 20% 5 2
1.5 m 5% 7 6
� CPU speed-up highly depending on modeling conditions
(ratio of elements and time step, size of cross contact)
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7th European ATC / Munich / June 24-26, 2014A. Bach, H. Cakir (Ford), V. Dampure (Altair)
Summary 20
� The Multi-Domain simulation approach is very important for Ford
� Multi-Domain is available and in use on Ford high performance computing cluster, improvements regardinguser friendliness and performance were achieved
� Benchmarks on full vehicle level are showing promising potential of CPU time reduction at increased computing accuracy
Next Steps
� Optimization of cross contact
� Automated mesh refinement of critical parts and part replacement in full vehicle model