miguel aguilo, ted blacker, andre claudet, brett clark
TRANSCRIPT
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Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed
Martin Corporation, for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000.
Miguel Aguilo, Ted Blacker, Andre Claudet,
Brett Clark, Ryan Rickerson, Josh Robbins,
Louis Vaught, and Tom Voth (as told by Corbett Battaile)
Sandia National Laboratories
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Example: Lantern Bracket
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A Revolution in Design and Fabrication
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Affordable
Agile
Assured
Introduction to This Revolution
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Enormous Opportunity (with Challenges)
Profoundly New Design Flexibility
In-Situ Material Qualification
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Inverting Conventional Design Paradigms
Embedded Uncertainty Quantification
Powder Bed Metal Additive
Topology Optimization
with Material Locality
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Specify Form Verify Function Using
FEA
Design
Specify Design Domain
and Function
Use Topology Optimization (FEA) to
Determine Form that Meets Function
Optimized
Design (Form)
Inverting Conventional Design Paradigms
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Mechanic
al P
erf
orm
ance
Thermal Performance
Pareto Suite of Topologies
Feasible
Infeasible
Design by Performance Prioritization
Thermal
Response
Horizontal
Displacement
Vertical
Displacement
Input
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Inverting Manufacture
Complexity is Free Preferred
Minimal Waste
Mixed and Graded Materials
Fast Design To Manufacture
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Inverting Qualification
Point-Wise Material Variability
Design Must Adjust Accordingly
In-Situ Metrology to Validate
Cost (Compute) Is a Critical Issue
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Making Resource Requirements Reasonable
- Linear Statics
- 1.5M elements
- 1 Objective (Maximize Stiffness)
- 1 Loading Condition
1 High Fidelity FEM
≈ 12 Minutes on
4196 Processors
Optimization
X 2 Evaluations
Per Iteration
X 50 Iterations
X 100 Samples
Uncertainty
Quantification
12
Minutes 20
Hours 2000
Hours
12
Weeks!
CPU TIME:
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0
8
0 6
Physics-Based Reduced Order Modeling O
bje
ctive F
unction V
alu
e
Stiffness
p* = arg minz J(p)
s.t. g(p)=0; h(p)≥0 ψp* = arg minψp J(ψp)
s.t. g(ψp)=0; h(ψp)≥0
7/10
(pK)u=f
φT(ψp)Kϕu=ϕTf
(pK)u=f
1
ψp* = arg minψp J(ψp)
s.t. g(ψp)=0; h(ψp)≥0
φT(ψp)Kϕu=ϕTf
Create ROM
Create ROM
Until error > tolerance
(pK)u=f
Until error > tolerance
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Smart Sampling Techniques
Build SROM Given Available Resources (# FEM Runs That Can Be Performed)
Density of Z Voronoi Cells
{Z}2
{Z}1
{Z}3
9/10
{Z}i = {Shear Modulus (G), Bulk Modulus (B)}
1 ≤ i ≤ M, M = #Samples
p* = arg minp E[UT(pK(G,B))U]
s.t.
(pK(G,B))U – f = 0; V(p) ≤ V0
0
8
0 6
0
8
0 6
0
8
0 6
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Benefits of Surrogate-Based Optimization
- Linear Statics
- 1.5M elements
- 1 Objective (Maximize Stiffness)
- 1 Loading Condition
1 High Fidelity FEM
≈ 3 Minutes on
4196 Processors
Optimization
X 2 Evaluations
Per Iteration
X 50 Iterations
X 5 Samples
Uncertainty
Quantification
CPU TIME
5
Hours
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How Does This All Tie Together?
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Diverse Tools and Expertise Necessary
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DOORS,
Genesys,
SysML
AM Topology
Optimization
Project
Dakota QMU
Toolkit
CUBIT Geometry
& Meshing Tools SIERRA
Simulation
Tools (ICME)
SCULPT
Meshing
Technology
Sandia
Analysis
Workbench
Predictive
Perfomance
Margins (ICME)
Product
Definition &
Config. Control
Primary
Standards
Laboratory
Component
Designers
Advanced AM
Hardware &
Diagnostics (ICME)
Sandia
Analysis
Workbench
Predictive
Perfomance
Margins (ICME)
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Optimization in Action
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Entire Bracket-Mass Assembly
Bracket System to
be Optimized
Example: Bracket Redesign
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Rapid Design Response to Source Requirement Change
Example: Bracket Redesign
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Refinements on Design with Options on Mass Mounting
Tall Bracket Option
High Mass Mount
Tall Bracket Option
Low Mass Mount
Example: Bracket Redesign
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Careful
Crafting
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Moving Forward: PLATO Technology Plan
Expected Outcomes:
Modern Design/
Analysis Environment
Clean, Smooth,
Connected Shapes
Fast Convergence
Interactive Speed & Control
Robust designs
Directly Printable Output
Interface to CAD
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Inverting Conventional Design Paradigms
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• Disruptive Change for NW
• Disruptive Change for SNL
• Disruptive Change for the
World of Engineering
In-Situ Validation of Materials and Processes
Powder Bed Metal Additive
Topology Optimization
with Material Locality