Blue Collar Computing Overview

Blue Collar Computing OSC Approach to Industrial OutreachIDC HPC User Forum, Beijing

Ashok Krishnamurthy Interim Co-Executive Directorashok@osc.edu

October 30, 201011OSC Contributions to Ohio Academic and Industrial ResearchProviding HPC resources and research support to higher educationEmpowers over $85 million per year in research grants to the PIs that use OSC resourcesRepresents a return on investment on state dollars of 17:1Making Ohio industry more competitive through the use of modeling and simulationTraining the future workforceNew academic and certificate programs

Our duty is to empowerour clients, partner strategically to develop new research and business opportunities, andleadOhio's knowledge economy

3Providing Stable Computational Infrastructure Glenn IBM 1350 SystemAMD Opteron processors9,500+ cores24 TBytes memory75+ teraflopsBlend of 4, 8 & 16 core nodesLarge processor countLarge memory SMP jobsCsuri GPU Environment16 nVidia C1060 cards installed on BALE18 nVidia Quadro Plex 2200 S4 units installed on GlennMass Storage ~1 PBytes disk 80 TBytes tape NFS, PVFS, iSCSI

3In FY09, OSC executed jobs for 750 researchers that consumed 27.5 million computational hours, which would have taken 3,139 years to run on stand-alone computers4OSC Supports Variety of Research ApplicationsComputational Fluid DynamicsFLUENT (serial and parallel)Flow 3DOpenFOAM (serial and parallel)Structural MechanicsLS-DYNA (parallel)ABAQUS (serial and parallel)ANSYSAltair HyperworksMesh Generation/Pre-processingAltair HypermeshGambitGridProBiosciencesAmberBioperlBLASTOSC staff members maintain more than 30 software applications and provide access to more than 70 different software packages44Center staff maintain more than 30 software applications, and we provide access to more than 70 different software packages, Open source, OSC created, or licensed through OSC's Statewide Software License Distribution

A recent survey showed that 87 percent of our user community responded positively when asked about their satisfaction with our software.

OSCs Industrial Outreach ProgramBlue Collar Computing

556Ohios Emerging Areas of ExcellencePremise:

Council on Competitiveness case studies demonstrate how key U.S. industries applied computational science to gain a competitive edge over global competitorsNumerous other national studies reinforce link between computation and competitivenessFuture Ohio competitiveness is linked to application of computation to solve design, engineering, and research challenges through modeling, experimentation, and analysis.66OSCs Industrial Outreach Program OSC introduced Blue Collar Computing concept at SC2004 invited talk in Pittsburgh Blue Collar Computing (BCC) provides industrial clients with supercomputing resources, training, and expertise to enhance their competitivenessInvited Talk: Towards a High Performance Computing Economy: Blue Collar ComputingPublic and private sector researchers partner to:Accelerate product developmentPromote process improvement Solve challenging scientific and industrial / business problemsBCC Impacts Time, Quality and Cost of Product & Service Development

720Number of UsersNumber of Applications1464MISSINGMIDDLEEntry Level HPCUsersWorld Class/Leadership ComputingNodes1,00010,000+Leading HPC Users (Heroes)Industry Competitiveness Transformation ChallengeNational Labs, University HPC Centers & Commercial HPC ServicesExperienced Industry HPC Users Filling the Expertise GapNeverEverUsersAdapted from OSC GraphicsCouncil and USC ISI ProprietaryMoving Users Forward89Two classes of industrial clients:Experienced HPC users who need access to larger systems for specific tasks (peaking facility)E.g., Goodyear, P&G, Ohio auto makerNovice - and some experienced HPC users is to develop industry-specific portals in collaboration with industry-focused organizationsEWI, PolymerOhio

Blue Collar Computing Clients9999OSC Portal PhilosophyDevelop portal based HPC access to areas of strategic interest: BCC and biomedical sciencesTargeted (applications with limited functionality provided to non-HPC people)Comprehensive (data, software and cycles in one click)Lightweight (no client resources except web browser) BCC Portal Philosophy web appliancesIntegrated applications that engage user

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Partnership with Edison Welding InstituteEWI-OSC WeldPredictorSecure websiteEasy access to advanced weld modeling toolsArc welding proceduresSingle and multi-pass welding simulationOutputTemperatureHardnessResidual stressDistortion

https://eweldpredictor.ewi.org/UsersWeb browser

WeldPredictor Development HistoryWeldPredictor has been in development stage over past 4 years:2007 - Prototype launch2008 - Bug fixes2009 - Weld bead enhancement and accuracy improvement2010 - Deployment Significant effort and funding were invested during the developmentEWI project team members including S. Babu, S. Khurana, W. Zhang, W. Gan, J. Xu, H. Kim, and Y. YangOSC project team members including N. Ludban, L. Yang, and D. Hudak

WeldPredictor Was Recognized InternationallyAbout 550 engineers worldwide have used EWI WeldPredictorEWI won the 2009 International Institute of Welding Sossenheimer Award for this innovative modeling softwareA WeldPredictor paper was published in the Journal of Welding in the World, Volume 53, Issue 1/2, January/February 2009WeldPredictor was presented in a number of international conference: PVP2008, IABC2009, AeroMat2009, and GDIS2010WeldPredictor Portal ImpactWeldPredictor allows industrial companies to access advanced weld modeling technology in their product design and manufacturing process improvement. This technology used to be accessed by few research companies. WeldPredictor is free to EWI members which significantly increases the ability of EWI members to use computer simulation to determine weld parametersWeldPredictor changes industrial engineers thinking to solve a problem. They start thinking to apply modeling in problem solving. EWI WeldPredictor Portal ImpactPreviouslyWeldPredictorExpertise NeededPh.D.B.S.Analysis Setup12 hours1 hourProject duration6 months1 month14141414Login page

15Weld Geometry Selection16

Status Page

17E-Weld Predictor Example Output

18Polymer Portal being developed in collaboration with PolymerOhioThe Polymer Portal will offer: Computational resources and software for modeling/simulationExpertise in polymer science and engineeringTrainingDatabases with relevant material propertiesAdvanced instrumentation Business intelligence and strategyOffering Moldex3D and Ximex for industry and education trainingWeb front endPylons JSONTomcatmySQLJUnitApacheAntPython and Java

19Software components supporting the OSC PortalsPartership with PolymerOhio PolymerOhio-OSC PolymerPortal1919Polymer Portal Computational Application: Prediction of Nanofiber Composite ProcessingProblem: Carbon nanofibers are added to compound before mixing and extrusion to improve material properties. The mixing breaks up the nanofibers, and this affects the final material propertiesSolution: Use multi-physics modeling and simulation to identify optimum processing routes for nanotechnology based fiber composites20

Nanofiber Design Portal21

Training(4 Courses)

Projects(6 Projects)

App Access(5 Apps)

ProductivityAudits(24 Audits)Outreach to Industry(50 Visits)Case studies provide MEP model to:Illustrate MS&A value to production and profitabilityAssist companies in application selectionDevelop training for high value-added MS&A appsEngage companies in employee training for MS&AProvide broad access to low-cost, productivity-enhancing appsMEP Advanced Modeling and SimulationFunded by NIST MEP for PolymerOhio and OSCGoals:Raise awareness of MS&A in Polymer industry and MEP systemMake cost-effective computational methods available to SMEs~$700K for 1st year

23Light Weight Material in Vehicles Computational Analysis

NASTRAN, MSC Genesis, Vanderplaats R&D Genoa, Alpha STAR Glenn, OSC HPC cluster Upgrade in Summer, 2009 Total: 9,500 cores, 75 TF, 24 TB RAM23

Damage Growth at 12000 lb

Fracture at 13000 lb

Volume of control arm before optimization: 106.9 in^3Volume of control arm after optimization: 132 in^3

Metallic and Hybrid Composite DesignFailure Mechanism contributionOptimized ShapeOptimized Control Arm with minimum weight, & comparable steel stiffness

Hybrid Control ArmDamage Initiation at 8000 lb24Development Costs Design LandscapeStageProbability defect(Physical)Probability defect(HPC analysis)Cost to fixConcept-N/A*$40,000PoC-N/A*$240,000Engineering50%5%$445,000Qualification7.5%0.25%$450,000Deployment0.375%0.0125%$450,000***HPC-based analysis not applicable, existing desktop based analysis sufficient**Cost assumed to be for new unit design and qualification, installation costs ignoredEstimated savings using HPC analysis: $233,0002525

Partnership with Center for Automotive ResearchPHEV Battery Simulation

26Goal: Achieve a better understanding of the characteristics and behavior of lithium-ion automotive batteries arranged in parallelConfiguration required to achieve performance and range for Plug-in Hybrid Electric Vehicles (PHEVs)Understanding the behavior of individual cells will lead to improved voltage equalization through better battery management systems.Successfully conducted 6 million distributed Monte Carlo calculations thru OSCs Remote MATLAB ServicesFunding: OSU Center for Automotive Research

27PHEV Battery Simulations

Partnership with Fireline TCON/Youngstown State Material DesignCollaboratorsFireline TCON Inc. (FTi)Produces ceramic/metallic composite materials originally used for molten metal handling, melt treatment and castingsDOE Tests estimated that thermal management could save over .55 trillion BTU per year for the aluminum industryYSU Center for Excellence in Advanced MaterialsExperimental analysis and modeling of composite materialsCollaboration began with $2.1M grant from Ohio Third Frontier Program in 2008Software Application Discovery Implementation (SADI) - program funded by three NSF EAGER awards, one granted to OSC28

OSCs Workforce Development ProgramRalph Regula School of Computational Science

2929Education: Building a workforce competent in computational scienceTeacher professional development programs; workshops for middle and high school studentsModel of disease transmission in human populationMiddle and high school students and teachersCause and effect relationships and simple modeling principlesPLTW training course for teachers; course given to studentsModeling simple physics phenomena: statics, gravity, pendulumOhio PLTW students and teachersApplying models to engineering and architecture fieldsCertificate programUndergraduate minor programOSC training programUsing commercial computational package or service to test strength of new container designCurrent workforceCollege graduatesUnderstand use of modeling for business and researchCertificate and graduate programs; OSC training coursesApplying protein folding simulations to discover candidates for new drugsEngineers/scientists in university and businessExpert in ApplicationsProgramsExampleAudienceLevel3030The Ralph Regula School of Computational Science is a statewide, virtual school focused on computational science. It is a collaborative effort of the Ohio Board of Regents, Ohio Supercomputer Center, Ohio Learning Network and Ohio's colleges and universities. The school acts as a coordinating entity for a variety of computational science education activities aimed at making education in computational science available to students across Ohio, as well as to workers seeking continuing education about this technology. More information is available at www.rrscs.org;.

30Certificate Program to Meet Employer NeedsCertificate programsFocus on skills needed by employersStackable certificates starting with basic skills and working up to advanced skillsLevel 1 CertificatesMeet competencies of undergraduate minorWill require mathematics review for displaced workersPossible certificates:Modeling and Simulation Parallel computingVisualization Programming and algorithms for computational scientistsLevel 2 CertificatesMore specialized, focused on specific computational expertise

3131Industry reps on advisory boardRRSCS Industry Certificate Program UnderwayFirst of several stackable certificates in place at Sinclair Community CollegePlans to extend to Columbus State CC Expect an advanced certificate in polymer manufacturing later this yearWorking with PolymerOhio and Moldex3DWorking with the National Association of Manufacturers on a second advanced certificate program in metal stamping32Challenges: Lessons Learned in Industry EngagementHigh Performance Computing can be a force for improving economic competitiveness (the step taken before economic development)Choose the right partners they will help you reach the community and help you understand requirementsCommercial software and licensing is a HUGE bottleneckEngage with your state economic development agency earlyWorkforce development is very importantClearly understand your cost to provide industrial support

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Questions?

ashok@osc.edu(614) 292-9524sgordon@osc.edu (614) 292-4132

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