CONFIDENTIAL Template presentation Innovation Day 2016

Jan Buytaert Christophe Van Bavinchove

Consultant PhysicsLab Coordinator PhysicsLab
jan.buytaert@verhaert.com christophe.vanbavinchove@verhaert.com

TRACK 2: TECHNOLOGY TO ACCELERATE

SIMULATION TECHNOLOGY:
SPEED UP YOUR ITERATIVE PROCESS

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
2

PhysicsLab – Systems Engineering

Christophe Van Bavinchove

Head of PhysicsLab

Jan Buytaert
Senior Systems Engineer
Consultant PhysicsLab

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
3

CONTENT

1 Why use simulation technology?

2 What is simulation technology?
3 How to use simulation technology?
4 Simulation technology examples

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
4

WHY USE
SIMULATION TECHNOLOGY?
Problem statement & illustrations

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
5

WHY USE SIMULATION TECHNOLOGY?

• Traditionally design and failure predictions are carried out by

• hand calculations
• experimental testing

• design trials

• As organizations strive to produce products

• that are better than the state-of-the-art
• and better than their competitors
• and to do so in a shorter time span

they need sophisticated tools

and methodologies to assist them.
• One such tool is computer simulation software

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
6

WHY USE SIMULATION TECHNOLOGY?

THESIS of this TALK:

• Innovation
• becomes more complex and multidisciplinary,
• and consequently more challenging and expensive.

• One way to remedy this, is by using simulation technology

• facilitating design iterations
• reducing the number of (failed) experiments
• reducing the number of (failed) prototypes
2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
7

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
8

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

• Process
1. Establish the concept and the channel design constraints
2. Perform benchmark tests to fine-tune simulation parameters
3. Optimize microfluidic channel design based on simulations
4. Verify simulation results by performing tests on prototype device
5. Make final design

1 Confluence concept
2 Simulation parameters
Design space

3 Simulations
4 Prototypes & experiments
5 Design choice

Time
2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
9

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
10

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

3. Optimize microfluidic channel design based on simulations

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
11

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

Engineer Jef Aernouts

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
12

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

sim
breadboard

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
13

WHY USE SIMULATION TECHNOLOGY?

• Case 1: Microfluidic channel design for sample dilution

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
14

WHY USE SIMULATION TECHNOLOGY?

PRODUCT
• For design space exploration DEVELOPMENT

• Virtually try-out new concepts/designs

early stage
• Sweep a range of design parameters

• For risk limitation

• Verify upfront the process performance intermediate
• Understanding robustness/failure of your design

• For design verification

• Supports physical verification tests which can be reduced in number before release

• Allows extrapolation of test results to non-testable cases

• For problem solving

after release
• Understanding existing product failure/requirements/constraints
• Optimizing an existing design by low cost design iterations

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
15

WHY USE SIMULATION TECHNOLOGY?

• Risk limitation & design verification

• by analyzing design performance upfront

• Example
• PCB air fan cooling
• Multi-physics model (CFD & Heat transfer)

Engineer Jan Buytaert

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
16

WHY USE SIMULATION TECHNOLOGY?

• Design verification
• of a physically non-testable case

• Example
• Cooling of a reaction vessel
• Multi-physics model (CFD & Heat transfer)

Engineer Jan Buytaert & Wouter Vleugels

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
17

WHY USE SIMULATION TECHNOLOGY?

• Problem solving
• by design optimization

• Example
• Beer bottle interlayer
• Structural model

Engineer Wouter Vleugels & Jan Buytaert

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
18

WHY USE SIMULATION TECHNOLOGY?

• Problem solving
• by design vs cost optimization

• Example
• Beer appliance door
• Structural model

Engineer Tom Beeldens

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
21

WHY USE SIMULATION TECHNOLOGY?

• Benefits of numerical analysis

• Detailed understanding of product performance
• Design space exploration

• Optimization of performance
• Optimization of amount of material/weight economically
• Reducing testing costs

• Reduction of failure risks

• Reduction of incremental development risks
• Reduction of time to market
• Improved product quality

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
22

WHAT IS
SIMULATION TECHNOLOGY?
The finite-element method

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
23

WHAT IS SIMULATION TECHNOLOGY?

• Simulation
• The imitation of the operation of a real-world process or system over time.
• Requires that a model be developed (containing geometry + loads).

• Simulation technology
• Physical model versus …
• … abstract mathematical model

• Computer simulation technology

• Software tool

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
24

WHAT IS SIMULATION TECHNOLOGY?

• Finite-element analysis (FEA)

• the practical application of the finite-element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
25

WHAT IS SIMULATION TECHNOLOGY?

• Finite-element analysis (FEA)

• the practical application of the finite element method (FEM)
• used by scientist and engineers
• to mathematically model
and numerically solve
very complex
structural, fluid,
and multi-physics problems.

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
26

WHAT IS SIMULATION TECHNOLOGY?

• FEM simulation software tools consist of

• pre-processing (meshing, boundary conditions)
• solvers (actual calculations)
• post-processing (results, visualization)
• Nowadays
• all-in-one integrated (yet expensive) FEM software is available
• hardware has become powerful (and affordable)

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
27

What is simulation technology?

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
28

WHAT IS SIMULATION TECHNOLOGY?

• FEM modeling software resembles the cockpit of a space shuttle …

• A enormous amount of knobs and dials and controls ~ options
of which most aren’t used
though they all have a function and reason for being there
• One can fly on automatic pilot
however when deviating from the routine,
expert flying is needed
• You do not take a space shuttle
when a balloon flight can do the job
• Expensive way of traveling
so make it worth the effort
• Trained pilots reduce the chance of failure

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
29

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
30

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

2.3 Simulation technology, speed up your iterative process Engineer Michael Burm
CONFIDENTIAL
31

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
32

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry

• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
33

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry

• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times

mesh

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
34

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation

symmetry & boundary conditions

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
35

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation

symmetry & boundary conditions

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
37

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
38

WHAT IS SIMULATION TECHNOLOGY?

• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible (too many variables, degrees of freedom, equations)
• Approximate solution
• Calculation time …
• Convergence to a solution …

• Post-processing and interpretation of the results

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
39

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

stress safety factor Engineer Jan Buytaert

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
40

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

symmetry & boundary conditions

Engineer Jan Buytaert & Tobe Wauters

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
41

WHAT IS SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

safety factor

stress

Engineer Jan Buytaert

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
42

HOW TO
USE SIMULATION TECHNOLOGY?
Insights

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
43

HOW TO USE SIMULATION TECHNOLOGY?

• Challenges
• Optimal meshing of the geometry
• Breaking down a problem into subsystems for simulation
• The art of idealization (stripping away of unnecessary complexity)
• Applying realistic boundary conditions
• Interpreting the results correctly

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
44

HOW TO USE SIMULATION TECHNOLOGY?

• How to go about these challenges

• A critical mass of experts/expertise
• Knowledge of the physics
• Knowledge of the modeling and the modeling tool
• Understanding of the extent to which modeling decisions impact accuracy
• Understanding of the consequences on resources and time by modeling decisions

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
45

HOW TO USE SIMULATION TECHNOLOGY?

• How to go about these challenges Analysis intake

• A critical mass of experts/expertise

Analysis specifications
• A structured workflow (and report)
Geometry creation

Mesh grid generation

Model set-up

Solution process

Solution verification

Solution validation

Post-processing

Report writing

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
46

HOW TO USE SIMULATION TECHNOLOGY?

• How trustworthy are simulation results? Analysis intake

Analysis specifications
Solution validation
Geometry creation

Analysis validation is carried out Mesh grid generation

to determine that the analysis
solution represents the physical Model set-up
system it was designed to
simulate. Validation is actually Solution process
evaluation and can be done by:
• Hand calculations Solution verification

• Physical testing
It should be remembered that test Solution validation

data contains experimental errors, Post-processing

and hand calculations contain
assumptions as well. Report writing

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
47

HOW TO USE SIMULATION TECHNOLOGY?

• How trustworthy are simulation results?

"Nobody trusts a computer simulation except the guy who did it,
and everybody trusts experimental data except the guy who did it.
Why not combine the two and get results
everybody can mistrust a little."
- T. Kordyban -

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
48

HOW TO USE SIMULATION TECHNOLOGY?

• Case 2: BIB handle failure analysis and remedy

Engineer Michael Burm & Jan Buytaert
5G

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
49

HOW TO USE SIMULATION TECHNOLOGY?

• Conclusions
Simulation technology serves agility in innovation
• Speed-up your innovative process
• Model and load case variations can be readily made
• At a reduced testing cost
• Concretize your product/process
Gate: Go/No-Go
• Facilitated design space exploration
Gate: Go/No-Go
and the converge towards a chosen design
• Simulations and physical testing both have value
• User-centric development
• Specification/discussion load cases
• Robustness/safety factor for use cases

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
50

EXAMPLES
SIMULATION TECHNOLOGY
From beer to Darwin’s evolutionary theory

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
51

SIMULATION TECHNOLOGY EXAMPLES

• Example
Chimney with different flows inside
• Multi-physics model
• Particle tracing
• CFD

Engineer Jochem Grieten & Wouter Vleugels

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
52

SIMULATION TECHNOLOGY EXAMPLES

• Example
Gravitational oil drain
• CFD model
• Design optimization
• Design verification

Engineer Wouter Vleugels

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
53

SIMULATION TECHNOLOGY EXAMPLES

• Example
Biomechanical structural analysis of bird beak evolution
• Structural model
• Mechanical stress, fracture risk and beak evolution
• Conceptual understanding

Joris Soons & Jana Goyens & Joris Dirckx

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
54

QUESTIONS?

2.3 Simulation technology, speed up your iterative process

CONFIDENTIAL
55

Innovation Day is an initiative of Masters in Innovation,

the umbrella brand of the Verhaert Group which aims
to connect, train and accelerate professional innovators.

Kruibeke Gentbrugge Nivelles Noordwijk Aveiro

Belgium Belgium Belgium Netherlands Portugal
Hogenakkerhoekstraat 21 Bruiloftstraat 55-57 Av. Robert Schuman 102 Kapteynstraat 1 Av. Dr. Lourenço
B-9150 Kruibeke B-9050 Gentbrugge B-1400 Nivelles 2201 BB Noordwijk Peixinho 96D 4o
T +32 3 250 19 00 T +32 9 330 27 90 T +32 67 47 57 10 T +31 71 760 05 50 3800-159 Aveiro
E info@verhaert.com E info@moebiusdesign.be E info@lambda-x.com E info@verhaert.com T +351 234 604 088
E info@load-interactive.com
www.verhaert.com www.moebiusdesign.com www.lambda-x.com connect.verhaert.com
www.load-interactive.com

CONNECT FMCG ON SITE CONSULTANCY AEROSPACE CONNECT FMCG CONNECT

INDUSTRY MEDICAL MEDICAL TECHXFER
TECHXFER TECHXFER

2.3 Simulation technology, speed up your iterative process