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www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Structural Optimization Using the New RBF Morph ANSYS ACT Extension
Structural Optimization Using the New RBF Morph ANSYS ACT Extension
Prof. Marco Evangelos BiancoliniUniversity of Rome Tor Vergata
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Company Introduction• RBF Morph Software
Line• ACT Extension• Industrial Applications
OutlineOutline
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph is a pioneer and world-leading provider of numerical morphing techniques and solutions conceived to efficiently handle shape optimization studies concerning most challenging industrial applications.We are an independent software-house and vendor. Our main product is RBF Morph™, that is a unique morpher that combines a very accurate control of the geometrical parameters with an extremely fast mesh smoothing properly designed to be integrated in advanced computational optimization procedures.
The RBF Morph tool is currently available in the market as an add-on of the CFD commercial code ANSYS® Fluent®, as a stand alone product and as an ANSYS ACT Extension.
Company IntroductionCompany Introduction
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
The RBF Morph tool had its inception in 2008 as on-demand solution for a Formula 1 top team. The need was a novel technology able to change the shape of large CFD numerical models as fast as possible. The final result had been so good that the technology was packaged in a commercial software product and launched onto the market.At present, Dr. Marco Evangelos Biancolini is the unique owner of the RBF Morph technology and, as Director, avails himself of the collaboration of several experts for the deliver of products and services.
Company IntroductionCompany Introduction
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Morphing-based numerical tools and services RBF Morph Milestones
2008: tool implementation for Formula 1 top team consultancy activity
2009: founded in Italy 2009: Software Partner of ANSYS 2009: at EASC RBF Morph won the Most Advanced
Approach Award Most Innovative Approach using Simulation Methods
2011: strategic partnership with Tor Vergata University (Rome)
2012: OEM partner of ANSYS 2013: beneficiary of an FP7 AAT Project RBF4AERO 2013: at ASWC RBF Morph awarded for the Best use
of HPC 2013: Partner of Enginsoft 2014: beneficiary of FP7 Project RIBES 2014: beneficiary of FP7 Fortissimo
Company IntroductionCompany Introduction
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Knowledge GalaxyKnowledge Galaxy
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph software lineRBF Morph software line
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Mesh Morphing with RBFMesh Morphing with RBF
• A system of Radial Basis Functions is used to fit a solution for the mesh movement/Morphing, from a list of source points and their displacements.
• The RBF problem definition does not depend on the mesh• Radial Basis Function interpolation is used to derive the
displacement in any location in the space, each component of the displacement is interpolated:
• RBF are recognized as on of the best mathematical tool for mesh morphing. The main issue is about performances required for the solution of large dataset.
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www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
One pt at center and border (80 pts)One pt at center and border (80 pts)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Effect on surface (gs-r)Effect on surface (gs-r)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Effect on surface (cp-c4)Effect on surface (cp-c4)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Control of volume mesh (1166 pts)Control of volume mesh (1166 pts)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Morphing the volume meshMorphing the volume mesh
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• HPC RBF general purposes library (state of the art algorithms, parallel, GPU). This is the numerical kernel of our software. Millions of RBF centers can be fitted in a short time.
• Awarded mesh morphing software available as an add-on for ANSYS Fluent CFD solver
• Stand alone morphing software + smoothing commands for different mesh formats
• ANSYS Mechanical ACT module (Released in May 2015!).
RBF Morph software lineRBF Morph software line
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Add on fully integrated within Fluent (GUI, TUI & solving stage), Workbench and Adjoint Solver
• Mesh-independent RBF fit used for surface mesh morphing and volume mesh smoothing
• Parallel calculation allows to morph large size models (many millions of cells) in a short time
• Management of every kind of mesh element type (tetrahedral, hexahedral, polyhedral, etc.)
• Support of the CAD re-design of the morphed surfaces
• Multi fit makes the Fluent case truly parametric (only 1 mesh is stored)
• Precision: exact nodal movement and exact feature preservation (RBF are better than FFD)
Fluent add-onFluent add-on
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• RBF solutions are fully compatible and exchangeable between add-on and standalone versions
• Support for STL and CGNS file formats. Selected morphed surfaces can be exported in STL format and back to CAD is possible via STEP files
• Add-on-like interface
• Solver independent processcurrently supports manymesh formats
• Functions scriptable via tcl
• Global supported bi-harmonicfunctions and C0, C2, C4
compact supported functionsavailable
RBF Morph Stand AloneRBF Morph Stand Alone
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Deeply integrated in ANSYS Mechanical: same look & feel, same interaction logic
• Nested in the usual Mechanical tree as an added object, shares its scoping tools for geometrical and mesh elements selections
• Written in python and xml, uses external RBF Morph core libraries
• Child hierarchical logic for complex morphings (two steps, three steps, …, n steps setups)
ACT module for MechanicalACT module for Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
ACT Extension for MechanicalACT Extension for Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Why FEM mesh morphing?Why FEM mesh morphing?
• It allows to have parametric shape mesh that preserves the original topology. Remeshing noise is avoided.
• It allows to update the shape of a validated FEM model without rebuilding a new mesh.
• New shapes can be investigated even if the underlying CAD geometry is missing.
• The mesh can be updated to measured shapes (i.e. accounting for manufacturing tolerances)
• It’s usually faster than remeshing (short time required to morph, quick set-up of shape variations)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Why RBF morphing?Why RBF morphing?
• RBF Morph is a best in class product crafted to deal with challenging CFD application (huge meshes)
• 7 years of experience on industrial applications of Radial Basis Functions (RBF)
• RBF are recognized as one of the best mesh morphing tool available in the industrial and scientific community
• A new vision (we have started the new project from scratch) to put in the hands of ANSYS Mechanical Users the fastest and easiest mesh morphing tool
• Satisfy the needs of many users asking for such a kind of technology available in ANSYS Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Video number 1Video number 1
https://youtu.be/KxZzq0F3mQ8
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• The evaluation of RBF at a point has a cost of order n.
• The fit has a cost of order n3 for a direct fit (full populated matrix); this limit to ~10.000 the number of source points that can be used in a practical problem.
• Using an iterative solver (with a good pre-conditioner) the fit has a cost of order n2; the number of points can be increased up to ~70.000.
• With parallelization and fast RBF methods (OpenMP GPU) we are able to scale up to very large problems
Accelerating the solverAccelerating the solver
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Size: 160.000 nodes
CPU: 497 s
CPU OMP: 53 s
K2000: 55 s
K40: 34 s
Registered TimeConrod testcaseRegistered TimeConrod testcase
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Fully embedded in ANSYS Mechanical with same “look & feel”
• Integration in the tree and founded on the working principles of ANSYS Workbench
• Based on the ACT (Application Customization Toolkit) extension concept
• Geometrical and mesh scoping to set-up the mesh morphing problem
• Parametric
• RBF fast solver (including parallel and GPU support)
ACT extension specsACT extension specs
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Easy to use, flexible and expressive.
• Powered by multi-step RBF technology (which effectiveness has been extensively proven in RBF Morph)
• RBF fitting and mesh morphing happen as a unique HPC process at each shape update. This allows the maximum flexibility with respect to parameterization
• RBF component set-up data stored and persistent with the ANSYS Mechanical project.
• Advanced interaction with DM to enable CAD resynchronization after morphing
ACT extension specsACT extension specs
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Hierarchical multi-step RBF approach
• Each morphing target can be controlled using the superposition of a local modifier and an RBF field generated by its sources (if any)
• Source points are extracted using the motion of all the children
• If the child is a leaf its movement is known otherwise it becomes a target and has to be solved descending the tree
ACT extension specsACT extension specs
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsTranslation
Available ModificationsTranslation
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsTranslation
Available ModificationsTranslation
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsScaling
Available ModificationsScaling
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsScaling
Available ModificationsScaling
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsRotation
Available ModificationsRotation
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsRotation
Available ModificationsRotation
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsSurface offset
Available ModificationsSurface offset
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsSurface offset
Available ModificationsSurface offset
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsCurve offset
Available ModificationsCurve offset
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsCurve offset
Available ModificationsCurve offset
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsSurface targeting
Available ModificationsSurface targeting
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsSurface targeting
Available ModificationsSurface targeting
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsSurface targeting
Available ModificationsSurface targeting
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsCurve targeting
Available ModificationsCurve targeting
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Available ModificationsCurve targeting
Available ModificationsCurve targeting
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Simple example of working logic behind the
RBF Morph ACT extension
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Morphed mesh!
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Inspection of the morphing field using post processing tools of Mechanical.
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• Automatic sculpting using field data available in
the FEA solution.
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now
manually it will be automated.
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• CAD2CAD allows to use a new CAD as a morphing target for a whole part. Now
manually it will be automated.
RBF Morph ACT extensionfor Mechanical
RBF Morph ACT extensionfor Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Industrial ApplicationsIndustrial Applications
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph ACT extension for Mechanical: conrod
RBF Morph ACT extension for Mechanical: conrod
• Practical problem example: a connecting rod optimization.
• Geometry in Solidworks. Meshing, parameterization (RBF Morph) and structural analysis in Workbench. 161493 nodes mesh.
• The shape of the two lightening holes is varied, translating and resizing them
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph ACT extension for Mechanical: conrod
RBF Morph ACT extension for Mechanical: conrod
• Offset+rigid translation for the holes
• Null movement for other surfaces
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph ACT extension for Mechanical: conrod
RBF Morph ACT extension for Mechanical: conrod
• 2395 N traction load acting on big head
• Titanium Ti-6Al-4V (Grade 5)
• Cumulated damage map over the testing spectrum
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
RBF Morph ACT extension for Mechanical: conrod
RBF Morph ACT extension for Mechanical: conrod
Optimized 334.4g (-6.7%)
Original 358.7g
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
BGA Solder Joint studyBGA Solder Joint study
The objective here is to show how RBF Morph can be used in BGA Solder Joint Reliability simulations to show how geometric parameters can be morphed to itemize their effect on stress calculations
DIE
DIEUNDERFILL
MOLDCOMPOUND
SUBSTRATESOLDER BALLS
PCB
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
BGA Solder Joint studyBGA Solder Joint study
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
BGA Solder Joint studyBGA Solder Joint study
12 3
2
3
1
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
BGA Solder Joint studyBGA Solder Joint study
Baseline
Optimized (22% stress reduction)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
BGA Solder Joint studyBGA Solder Joint study
Baseline
Optimized (22% stress reduction)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Wheel Rim OptimizationWheel Rim Optimization
Load Scenario
representing TUV test
simulated using ANSYS Mechanical
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Wheel Rim OptimizationWheel Rim Optimization
Baseline 7.58kg
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Wheel Rim OptimizationWheel Rim Optimization
Optimized 6.98kg (-8%)
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
• The novel mesh morphing tool implemented in ANSYS Mechanical using ACT extension technology has been introduced
• Radial Basis Functions are used for multistep set-up
• The new software tailored for FEM benefits of past experience on RBF Morph ANSYS Fluent add-on (mainly CFD)
• Nevertheless we have restarted all the developments from scratch i.e. reusing knowledge and ideas (no cross compatibility between tools)
• Applications relevant for the automotive industry are demonstrated.
• The software has been released in May 2015
• How can we do better? Please do not hesitate to tell us your needs!
ConclusionsConclusions
www.rbf-morph.comRBF Morph, an ANSYS Inc. Partner
ASWC 2015
June 2015 - Detroit, MI, USA
Many thanks for your kind attention!
Prof. Marco Evangelos Biancolini
E-mail: [email protected]
Web: www.rbf-morph.com
Goo.gl/1svYd
Twitter.com/RBFMorph
linkedin.com/company/rbf-morph
youtube.com/user/RbfMorph