Optimize This! 2016 International HEEDS User Conference
was held at the Dearborn Inn Marriott (20301 Oakwood Blvd, Dearborn, MI 48124).
|Tuesday, October 11
||Meet & Greet Welcome Reception
|Wednesday, October 12
||REGISTRATION & BREAKFAST in Exhibitor Hall
||Opening Remarks - Ron Averill, Co-Founder
||HEEDS: Past, Present, Future - Bob Ryan, CEO
||What's New in HEEDS MDO - Ranny Sidhu, VP of Product Development
||BREAK in Exhibitor Hall
||Visualizing Many-Objective Optimal Solutions for an Informed Decision-Making
Dr. Kalyanmoy Deb, NSF Beacon Center at Michigan State University
||Using HEEDS MDO for Aircraft Engine Design Optimization
Douglas Zhu, Honeywell Aerospace
||Hyperloop Propulsion System Linear Motor: Optimization using HEEDS + JMAG
Dr. James Dorris, Hyperloop One
||LUNCH in Exhibitor Hall
||Multi-Objective Optimization of a Differential Pinion Shaft
Dr. TC Kim, Toyota Technical Center (TEMA)
|Multi-Objective Optimization of Flow Diverter Geometry Towards Patient-Specific Treatment of Intracranial Aneurysms
Laszlo Daroczy, Otto-von-Guericke-Universität Magdeburg
||Optimization of a Bumper for Performance, Mass and Cost
Abhinand Chelikani, Magna Cosma
|Development and Automated Design Exploration of a Novel DLN Hydrogen Combustion Technology for Gas Turbine Applications
Dipl.-Ing. Anis Haj Ayed, B&B-AGEMA GmbH
||Multi-Disciplinary Optimization of Automotive Chassis Components Using HEEDS
Joel Albrektsson, CAE Value (CEVT & Beta CAE)
|From Design Space Exploration to Conceptual System Performance
Stephen Smith, Electrolux
||BREAK in Exhibitor Hall
||Optimizing Multimatic’s DSSV Adaptive Dampers
Lars Ogilvie, Multimatic Inc.
|How Japanese Manufacturers Use HEEDS to Create Innovative Designs and Novel Design Processes
Dr. Taiki Matsumura, CD-adapco Japan
||Efficient Truck Frame Optimization Using ACP OpDesign and HEEDS
Dr. Akbar Farahani, ETA, Inc. & Alexandros Kaloudis, BETA CAE Systems SA
|Using HEEDS MDO to Loosen the Required Manufacturing Tolerances of a U-Shaped FMC SBMS2 Seal, Without Sacrificing Performance
William Thomas & John Greenwood, FMC Technologies
||Exploring Engine Performance and Combustion Using a Combined 1D/3D CFD Simulation Approach
Marc Zellat, CD-adapco & Karl Oberhumer, Red Cedar Technology
|Optimization of a Septum in BD FlowSmart™ Insulin Infusion Device
Nicole Wiley, BD
||Finding a Competitive Edge in C-class Sailing (Little America’s Cup)
Steve Clark, International Chairman, C-Class Catamarans & Robert Schartow, VP Business Development FlexSys, Inc.
|Design Exploration of a Static Air Mixer for a Commercial Airliner
Aaron Godfrey, CD-adapco (A Siemens Business)
||Conference Wrap Up - Bob Ryan
||COCKTAIL HOUR in Exhibitor Hall
||Board Buses to Henry Ford Museum - pick up at Dearborn Ballroom entrance
||DINNER & LIVE ENTERTAINMENT at the Henry Ford Museum
||Buses return to Dearborn Inn
Optimize This! 2016 Presentation Abstracts
Development and Automated Design Exploration of a Novel DLN Hydrogen Combustion Technology for Gas Turbine Applications by Dipl.-Ing. Anis Haj Ayed, B&B-AGEMA GmbH
Combined with the use of renewable energy sources for its production, Hydrogen represents a possible alternative gas turbine fuel for future low emission power generation. Due its different physical properties compared to other fuels such as natural gas, well established gas turbine combustion systems cannot be directly applied for Dry Low NOx (DLN) Hydrogen combustion. This makes the development of new combustion technologies an essential and challenging task for the future of hydrogen fueled gas turbines.
The DLN Micromix Combustion technology has been successfully developed to address this challenge. Thereby, a systematic design exploration has been performed using HEEDS and STAR-CCM+, allowing the identification of complex relationships between design parameters and their impact on the burner’s performance. The seamless coupling with CFD (STAR-CCM+) helped understanding complex physical interactions between aerodynamics, combustion, emission formation and heat transfer of different burner configurations within the explored design space. This numerical approach helped reducing development time and cost significantly, since experimental testing was reduced to validation campaigns, which have confirmed lowest NOx emissions and highest combustion stability of the developed pure Hydrogen Micromix burner, providing a mature key technology for the use of Hydrogen within the future low emission power generation.
Optimization of a Septum in BD FlowSmart™ Insulin Infusion Device by Nicole Wiley & Marcus Rademacher, BD
A finite element analysis (FEA) and optimization approach was utilized to develop a rubber septum for the BD FlowSmart™ Technology. The septum’s small geometry and tight tolerances made it challenging to develop experimentally. Through the automated optimization approach, over 100 viable septum designs were discovered that satisfied the design criteria of robust sealing and low cannula insertion force. The selected optimal geometry was successful in meeting the requirements when tested experimentally and the improved septum was implemented into the BD FlowSmart™ device.
Multi-Disciplinary Optimization of Automotive Chassis Components Using HEEDS by Joel Albrektsson, CAE Value ( in conjunction with CEVT & Beta CAE)
When designing automotive suspensions – as with vehicle development in general – numerous attributes in several disciplines must be considered. A small change in one area can have large and sometimes unintended effects on other characteristics. When exploring design changes and new concepts, the ability to predict their effects on all key performance metrics is crucial.
The purpose of this project was to demonstrate the value of performing multi-disciplinary optimization studies, compared to unilateral methods based on manual iterations and/or topology optimization.
A scalable framework for optimization of chassis components was developed using HEEDS MDO. A first case study was aimed at minimizing the mass of a twist beam rear axle while fulfilling strict requirements in terms of vehicle dynamics attributes. An automated simulation process interfacing with ANSA, MSC Nastran and MSC Adams/Car was created.
How Japanese Manufacturers Use HEEDS to Create Innovative Designs and Novel Design Processes by Dr. Taiki Matsumura, Ph.D, PMP; CD-adapco Japan (A Siemens Business)
It's been two years since CD-adapco Japan introduced HEEDS to Japanese manufactures. We have seen a significant growth in the market, and Japanese customer base covers various industries, such as automotive, energy, life-science, electronics, material, chemical process, etc. Taiki Matsumura, MDX team leader of CD-adapco Japan, will be showing how Japanese manufactures, including automotive OEMs, take advantage of unique features of HEEDS to establish novel design processes and create innovative designs.
Design Exploration of a Static Air Mixer for a Commercial Airliner by Aaron Godfrey, CD-adapco (A Siemens Business)
Modern commercial aircraft contain a complex and interrelated set of subsystems that must work together to ensure the performance of aircraft as a whole. An example of this is the use of bleed air from engine core flow to pressurize and heat the main cabin as well as supply hot air to the aircraft's anti-icing system. Prior to distribution this air is mixed with cold air from the engine bypass to achieve the appropriate temperature for these subsystems. Uniform and thorough mixing of the core and bypass air is critical to maintaining subsystem performance and is monitored via sensors. The current work is a parametric optimization of a proposed static mixer. The objectives are to maximize temperature uniformity at the sensor location while simultaneously minimizing the pressure drop associated with the mixer. CATIA was used for the parametric CAD while STAR-CCM+ and HEEDS are used to perform the simulation and design exploration respectively.
Exploring Engine Performance and Combustion Using a Combined 1D/3D CFD Simulation Approach by Marc Zellat, CD-adapco & Karl Oberhumer, Red Cedar Technology
Nowadays, 1D-CFD codes like GT-Power are manipulated daily by engineers to design and improve gas engine components. The whole engine system is designed this way, but needs at least two important input quantities: valve discharges coefficients and combustion parameters.
Doing a full engine in full three-dimensional analysis is very expensive and time consuming. Hence, the combination of a 1D with 3D-CFD approaches would be a best compromise, enabling engineers to bypass the timely and expensive experimental testing to provide discharge coefficients and combustion parameters.
To drive the innovation using CAE in 1D and 3D, HEEDS utilizes a modern process which simply consists of the definition of objectives and constraints, allowing an automatic search in the variables space of both codes thanks to automatic data exchange via direct interfaces to the CAE tools, called ‘portals.’
In this work, we present an example of engine design exploration in which piston geometry and ports are optimized for full load operating condition on a generic SI-GDI engine with realistic geometries. Using this example, we will show how information between 1D and 3D-CFD are exchanged. In particular, we will show how we can achieve the best thermodynamic efficiency from the combustion history.
Bridging the Gap between CAD to CAE by David Selliman, CoreTechnologie
In this global market, Multi-CAD (Computer Aided Design) environments have become a standard. Companies are looking for interoperability that goes beyond the need for CAD translations in a Boundary Representation (B-Rep) of 3D models. Specially, for pre-processing data for CAE (Computer Aided Engineering) analysis for, but not limited to Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), Thermal, Mechanical System Simulation or Durability testing in 3D space. The need to merging faces, de-featuring filets while removing small details and holes, and mid-face creation is a must. Furthermore, the optimal solution is automating the creation of a solid 3D model using model clean up tools for gaps, impressions, or free edges.
From Design Space Exploration to Conceptual System Performance by Stephen Smith, Electrolux
The evolution of HEEDS deployment throughout a design space exploration project aimed at producing a step change in performance will be discussed. As the project evolved from a very high conceptual level project toward moving in the direction of a more concrete design, HEEDS usage evolved from early design space sweeps, to modeling system level performance with particular emphasis on performance degradation. Novel approaches to looping a design system’s performance utilizing the newly introduced looping features of the spring 2016 release of HEEDS MDO, were utilized to provide transient system level performance insights and design direction. The new capability provided an easy-to-use and streamlined process that allowed HEEDS to be utilized to not only define the design space, but also to perform advanced investigations of system level performance, resulting in the enhancement of design capabilities and allowing for new insight which has had large implications for the final design direction on the given program.
Efficient Truck Frame Optimization Using ACP OpDesign and HEEDS by Dr. Akbar Farahani, Dr. Morteza Kiani & Divesh Mittal, ETA, Inc.; Alexandros Kaloudis, BETA CAE Systems SA
Today's product design and development engineers are facing numerous multi-disciplinary challenges. Many product design and development challenges often contradict each other. For example, the need to reduce cost and weight conflicts with the need to improve quality and performance for medium and heavy trucks.
Product design and development industries have strived for an optimization design driven software tool that can assist them overcome their engineering and manufacturing challenges.
ETA and BETA CAE have developed a seamless optimization product design process and tool, called ACP OpDesign. It is an integrated, automated system using ANSA and μETA andcoupling it with HEEDS to simplify optimization workflow management.
ACP OpDesign enhances optimization, handling topology, geometry, material, shape and gauge optimization within a single environment and provides a gateway to all commercial optimization and solvers. It is a process for product efficiency for cost and mass reduction, while improving a product’s level of performance. The systematic method creates balance between structure and strength, synchronizing the individual facets of the product development process.
In this project ACP-Concept was used along with topology optimization (GENESIS/LS-TaSc) to develop the frame skeleton and Low Fidelity Design Concept model. ACP-3G (Geometry, Grade and Gage) drives the flow of ANSA, META and HEEDS into an automated process to setup optimization variables more simply, design and size the BIW sections (Geometry and Material of Choice) in a multidisciplinary environment, taking advantage of the optimization capabilities of HEEDS.
Using multiple CAE tools; HEEDS, LS-DYNA, ANSA and μETA, application-specific tools, solver technology and optimization solutions; CAE, design and manufacturing are all synchronized to find the optimal design solution.
This presenter will discuss how the process will guide the user from initial truck concept design, then step by step to a final detailed design using optimization tools to drive the process. This process allows the optimal, most efficient design to emerge in the end.
Using HEEDS MDO to Loosen the Required Manufacturing Tolerances of a U-Shaped FMC SBMS2 Seal, Without Sacrificing Performance by William Thomas & John Greenwood, FMC Technologies
In the oil and gas industry, metallic seals are often used to prevent the movement of fluid in the annular regions between concentric bodies. These seals may have a cross section in a "U" or "H" shape with bumps on the "legs" that provide the sealing surface. These seals must be designed with a sufficiently low installation load while at the same time must maintain adequate contact force on both sides of the seal during operation. Machining tolerances create the possibility of both a most-rigid and least-rigid version of a given nominal seal design, and the sealing criteria must be maintained for both scenarios. Tight machining tolerances allow for a less complicated design process with fewer iterations but are very expensive. HEEDS is used to optimize the geometry of a U-shaped FMC SBMS2 seal to allow for looser tolerances and to minimize the annular width while maintaining installation and sealing design criteria.
Using HEEDS MDO for Aircraft Engine Design Optimization by Douglas Zhu and Jeffrey Borlik, Honeywell Aerospace
Honeywell Aerospace started to use HEEDS MDO for aircraft engine design optimization in October 2015. Various applications have been run with HEEDS. They can be categorized into several cases: (1) Full engine performance optimization for preliminary design; (2) Design optimization for detailed engine component analysis; (3) Correlation and calibration of analysis algorithms against test data; (4) Tool integration and process automation.
The full engine performance studies run zero-dimensional or one-dimensional engine performance analysis codes. There are typically many variables and constraints and a single or multiple objectives. The codes generally run very fast so the optimization can afford to take a large number of evaluations. The detailed component analysis combines one-dimensional codes, for constructing turbine or fan blade geometry and creating initial and boundary conditions, and three-dimensional analysis codes, for detailed flow, stress and vibration analysis. Another category of optimization is the adjustment of parameters to minimize the differences between analysis results and test data. HEEDS is also used for tool integration and process automation to automatically pass the parameters and files from one code to another, to reduce manual time and minimize human errors. The automatic process can be later be used for future design explorations – optimization, DOE, or evaluation of multiple cases.
The presentation will include examples to discuss these use cases, and our successes and challenges.
Hyperloop Propulsion System Linear Motor: Optimization using HEEDS + JMAG by Dr. James Dorris, Hyperloop One
Hyperloop is a high-speed ground transportation system capable of speeds in excess of 700 mph, with extremely low operating costs. The system creates a low pressure environment for reduced drag losses, and utilizes a high power electromagnetic linear motor for propulsion. The motor design has been performed using JMAG and the optimization tool HEEDS to arrive at a motor design that is highly cost-effective at the system level. Optimization using HEEDS has also been deployed in the modeling of HyperPod dynamics during operation. Analyses and development activities will be presented showing how HEEDS has been deployed to help design the next mode of transportation.
Optimization of a Bumper for Performance, Mass and Cost by Abhinand Chelikani, Magna Cosma
The bumper beam system attached on the front and rear end of the BIW, is a component that is used for absorbing energy in low and high speed events. As efforts towards light weight solutions increase, Aluminum bumper assemblies based on extrusions are becoming main stream for weight benefits that Aluminum represent and its ease of manufacturing. Aluminum extrusions can be produced in varying cross sections and gages along with the swapping of various alloys. IIHS and FMVSS low speed impacts requirements drive the design of a bumper beam and accounts for 60% to 70% of the mass of the bumper assembly. So, it is important to identify bumper beam designs that represent the lowest mass and cost. The crush cans dominate the high speed performance and have not been include in the study.
In this paper, an optimization process using HEEDS is proposed to identify an optimum design that meets performance and represent the lowest mass for IIHS low speed impact. The objective of the simulation is to identify the mass vs. cost balance using the Sherpa multi objective technique to aid in the decision making of proposing designs and material selections that are cost sensitive or mass sensitive or a good balance of both.
The inputs variables chosen for the optimization are shape, gage and material alloys. The shape variables have been created in Ansa and the gage and material variable have been identified in HEEDS, using the LS Dyna portal. The optimization problem has been constrained to meet the system stroke and back of the beam targets set by the program. In order to apply constraints, outputs have been extracted from the LS dyna analysis using the LS Dyna portal in HEEDS.
The bumper example illustrated in this paper explains the integrated process of running the optimization problem in HEEDS using Sherpa to develop a Pareto front of mass vs. cost to identify efficient designs and material selection that represent a balance of mass and cost. This study can also be used to understand the tradeoff between mass and performance.
Visualizing Many-Objective Optimal Solutions for an Informed Decision-Making by Dr. Kalyanmoy Deb, NSF Beacon Center at Michigan State University
Recent algorithmic developments for solving many-objective optimization problems involving 5 to 15 objectives have demonstrated their ability to find multiple trade-off solutions spanning over a multi-dimensional objective space. The next important task is to understand the trade-off well so that a single preferred solution can be chosen. Although many visualization techniques exist to represent many-dimensional data into two or three-dimensions, they have not been studied from the point of view multi-criterion decision analysis. In this talk, we review some of the existing visualization methods and propose some viable techniques for understanding and extracting key solutions from a many-objective Pareto-optimal data set.
Optimizing Multimatic’s DSSV Adaptive Dampers by Lars Ogilvie & Josh Morley, Multimatic Inc.
DSSV™ is an acronym for Dynamic Suspensions Spool Valve. The use of spool valves in dampers was pioneered by Multimatic in 2001 in order to deliver the highest level of damper predictability, accuracy and repeatability. Precise control of these performance characteristics help deliver the ultimate in wheel and vehicle control. The spool valve based technology was originally embraced by the motorsport community, and is now available in a range of road car and race car configurations.
The latest addition to Multimatic’s DSSV damper technology is an electric adaptive control valve allowing independent jounce and rebound settings to be modified in extremely fast steps. This presentation will illustrate examples of how HEEDS® MDO software was applied to optimize the behavior of this adaptive controller. The end result is the development of a toolset that allows Multimatic to optimize the damper’s characteristics to exceed vehicle level targets thru virtual development and component level verification.
Multi-Objective Optimization of Flow Diverter Geometry Towards Patient-Specific Treatment of Intracranial Aneurysms by Laszlo Daroczy, Philipp Berg, Gábor Janiga, and Dominique Thévenin,
It is estimated that 3-5% of the western population harbor an intracranial aneurysm, a permanent dilatation of the cerebral vasculature1, in most cases harmless. However, aneurysm rupture is in 40% lethal, while 66% of the survivors will suffer from permanent neurological deficit1. For the treatment of intracranial aneurysms endovascular techniques, such as stent deployments are increasingly recommended due to their minimally-invasive nature. To reduce the risk of complications during the intervention and to improve the treatment outcome for the patient, individualized treatment processes were proposed in the recent years.
The current study represents a major step towards patient-specific treatment, as the multi-objective optimization of a flow-diverter geometry (densely braided stent) for a real patient geometry is executed in a completely automated manner. This is achieved by combining an in-house stent deployment software with CD-ADAPCO STAR-CCM+ for the robust mesh generation and fully resolved hemodynamic simulations. The complete automation and optimization process was implemented in HEEDS MDO. As MO-SHERPA is able to handle the objective functions independently, the complete Pareto front was retained. Thanks to the speed of this optimization method, relevant improvements have been identified among the considered configurations in only 6 generations. Altogether 110 flow simulations had to be executed, which was achieved in less than four days, making the approach compatible with clinical practice (except for urgent cases). This means that the optimization process could successfully support the decision-making process by providing the optimal set of configurations to the treating physician.
Multi-Objective Optimization of a Differential Pinion Shaft by Dr. TC Kim, Toyota Technical Center
In an automotive transmission, rotational mass reduction becomes more important in the improvement of fuel economy. However, difficulties in automated finite element modeling, non-linear analysis of gear contacts and bearing supports, and limitation of a single objective optimization are obstacles. In this presentation, an optimization process of a differential pinion shaft sub-system is presented. Multi-objectives of mass and gear root stress are minimized using HEEDS. The parametric FE model of a differential pinion shaft with two gear pairs and support bearings are created in Transmission3D. Dimensional parameters of the differential pinion shaft are optimized with several constraints from fatigue and bearing life.
An Innovative Approach to Drilling Riser Stack-Up Selection with DeepRiser and HEEDS MDO by Paul Bohan & John Thomson, Wood Group Kenny
DeepRiser is an integrated engineering application that has been developed to optimize and streamline the design and analysis of drilling riser systems. It is used extensively across the offshore drilling industry and combines an intuitive user interface, with powerful analytical capabilities, to provide a comprehensive engineering tool for the design and analysis of drilling riser systems.
While DeepRiser makes the process of setting up and analyzing riser stack-ups very efficient, it is still necessary to iterate on many different riser design scenarios to identify the best solution. To date, this has been a relatively manual process, assigned to an experienced riser engineer and could take between 5-10 days to complete. The objective for utilizing HEEDS was to determine if we could automate this process and still achieve the same or better levels of optimization as an experienced riser engineer.
The goal was to use DeepRiser together with HEEDS to discover riser designs that produce better performance under specific load conditions while keeping within a number of important design criteria. HEEDS can drive the DeepRiser software to run the analysis on the generated riser stack-ups and evaluate the performance of each to find improved designs.
This paper will give a detailed overview of a recent study undertaken using DeepRiser and HEEDS to design a specific riser stack-up that produces overall better operability, while satisfying a number of important design criteria. To add merit to this study, a real world riser model was used, with the approval of a major industry Drilling Contractor. The riser model had previously been optimized by Wood Group using a manual process. The non-optimized model was given to HEEDS as the base case, with a number of defined constraints such as maximum number of available joints, maintaining positive effective tension, depth ratings, etc. The results from the HEEDS optimized riser stack-up will be compared to the manual optimized stack-up and the potential benefits of using HEEDS with DeepRiser will be presented.
Finding a Competitive Edge in C-class Sailing (Little America’s Cup) by Steve Clark, International Chairman, C-Class Catamarans & Robert Schartow, VP Business Development FlexSys, Inc.
The C-Class Catamaran has been long been the incubator to advanced sailing technology. International teams are continually looking for new ways to achieve higher performance combined with durability and ease of use that can compete successfully over a seven day regatta. The rigid multi-element wing sails, now standard in the America's Cup were conceived, tested and developed in the C Class. Recent developments in hydrofoil sailing have somewhat eclipsed primacy of the wing, but there is still much to develop as there has been little change to the airfoil since the 1970’s when it was first conceived.
This paper investigates the adoption of aerospace variable geometry control surface technology developed by FlexSys Inc. This morphing technology enables to shape of the airfoil elements to be asymmetric and dynamically adjusted to maximize performance for the current conditions. Performance was evaluated using HEEDS in conjunction with STAR-CCM+ to compare potential morphing sail concepts to the standard rigid sail configuration.