The Next Revolutionin Global Manufacturing.

MSC.visualNastran enterprise

Virtual MManufacturing

"Industries throughout the world rely on MSC.Software asthe leading source for critical design software and servicesin demanding environments."

Frank Perna Jr. Chairman and Chief Executive Officer of MSC.Software

What is Virtual Manufacturing? 1

At the Core is Nonlinear Finite Element Analysis 2

The Return on Investment 3

Case Studies:Virtual manufacturing significantly reduces fuel costs for Boeing 5

Virtual manufacturing optimizes roll forming process 7

Deep drawing simulation reveals manufacturing defect 8

Rubber boot redesign lessens repair costs 9

Side impact analysis of a car door reduces injuries 10

Connecting rod forging process developed virtually 11

Virtual prototyping improves buckle performance 12

Improved stent design saves lives 13

Why Virtual Manufacturing Now? 14

The Key is Domain Decomposition 15

The Advanced Technology of MSC.Software 16

TTable of Contentsable of Contents

Virtual Manufacturing

Manufacturing is a dynamic, exciting, and criticalindustry. A rapidly shrinking world is changing atan increasingly frantic rate. Manufacturing systems and processes are being combined withsimulation technology, computer hardware, andoperating systems to reduce costs and increasecompany profitability.

Perhaps one of the most interesting and importantof these recent developments is called "VirtualManufacturing." Often termed "The NextRevolution in Global Manufacturing," virtual manufacturing involves the simulation of a productand the processes involved in its fabrication.Simulation technology enables companies tooptimize key factors directly affecting the profitabilityof their manufactured products. These includemanufacturability, final shape, residual stress levels, and product durability. They directly affectprofitability by reducing the cost of production, material usage, and warranty liabilities.

In addition, virtual manufacturing also reducesthe cost of tooling, eliminates the need for multiplephysical prototypes, and reduces material waste.This allows everyone to "get it right the firsttime." It provides manufacturers with the confidenceof knowing that they can deliver quality productsto market on time and within budget. Smallimprovements in manufacturing have dramaticand profound effects in terms of cost and quality.

Return on Investment calculations have shownthat small savings in material usage deliver enormous returns in a manufacturing environment.For example, an automotive customer found thateach ounce of material saved in a forged carengine component saved many hundreds ofthousands of dollars of material costs each year.He calculated the impact on customer satisfaction,from the extra power available to the engine, tothe reduced running costs of the final vehicle.These calculations are simple thanks to the largemanufacturing runs.

A Virtual Lab for Product Creation

Virtual manufacturing uses a computer to simulatea product's performance and the processesinvolved in its fabrication. Virtual manufacturingutilizes nonlinear finite element analysis technologies to provide detailed informationabout a product, which is then used for optimizationof factors such as manufacturability, final shape,residual stress, and life-cycle estimations.

At the core of virtual manufacturing lies nonlinearFEA technology. This technology has enabledcompanies to simulate fabrication and testing ina more realistic manner than ever before.

What is What is VVirirtual Manufacturing?tual Manufacturing?

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At the CorAt the Core is Nonlineare is Nonlinear Finite Element Finite Element AnalysisAnalysisFEA Analysis

Finite Element Analysis is a very powerful engineering design tool that enables engineersand designers to simulate structural behavior,make design changes, and see the effects ofthese changes.

The finite element method works by breaking the geometry of a real object down into a large number (1000's or 100,000's) of elements (e.g.cubes). These elements form the mesh and theconnecting points are the nodes. The behavior ofeach little element, which is regular in shape, isreadily predicted by set mathematical equations.The summation of the individual element behavior produces the expected behavior of the actual object.

The mesh contains the material and structuralproperties that define how the part reacts tocertain load conditions. In essence, FEA is anumerical method used to solve a variety ofengineering problems that involve stress analysis,heat transfer, electromagnetism, and fluid flow.

FEA is in effect a computer simulation of thewhole process in which a physical prototype isbuilt and tested, and then rebuilt and retesteduntil an acceptable design is created.

Clearly, testing physical prototypes can be costly and time consuming when compared with running a computer simulation. However, FEA is not meant to replace prototype testing, merely to complement it. Testing is a means of validating the computer model. In certain cases it is impossible to accurately model a complex real life situation. Thankfully, with the constant improvements in today's finite element software, such situations are becoming more and more infrequent.

Nonlinear FEA Analysis

Nonlinear FEA uses an incremental solution procedure to step through the analysis. In contrastto linear FEA, where a solution is achieved inone step, nonlinear FEA may require hundreds,even thousands of steps. There are three majortypes of nonlinearites:

· Material - plasticity, creep, viscoelasticity· Geometric - large deformations, large

strains, snap-through buckling· Boundary - contact, friction, gaps,

follower force

A nonlinear analysis can include any combinationof these. In the case studies to follow, you willencounter examples including all of these solution types.

FEA ApplicationsIn theory, there are no limits to the types of applications that FEA can be used for. FEAwas born and nurtured in the automotive andaerospace industries but has since spread toencompass all other sectors of industry, frommedical instruments and car design to plasticmouldings and watch springs. If it can be designed,it can be modeled using FEA technology.

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In this section, we present some of the costs and benefits to consider when incorporating virtual manufacturing into your product lifecycle management.

Return

MSC.Software customers around the world have seen their profits rise and costs decreasedramatically in just months. Our technology hashelped increase efficiency from small projects tolarge and complex manufacturing processes.

Fewer prototypes

The more trials you can simulate in a virtualenvironment, the less physical prototypes youneed to perfect your design. This means youspend more time up front in engineering anddesign, and less resources running physical trials. Virtual prototyping is cheaper than building physical models and optimizing your design bytrial-and-error. It is not a complete replacementfor physical testing, but it can minimize the effortand enable the resulting physical tests to bemore successful.

Less material waste

If you build fewer physical models, you wasteless material in the form of prototypes as well asthe tooling used to create them.

Reduced cost of tooling

Again, it follows that if you build fewer prototypes,then you develop fewer tools, which are typicallyvery expensive. Furthermore, by modeling thetools, you can reduce the tool wear, thus increasing tool life.

Confidence in manufacturing process

Even if the tools are properly designed, the controlof the tools may affect the quality of the part produced. Virtual manufacturing allows you to simulate the part, the tools, and their control. This simulation can let you optimize your toolcontrol before building prototypes, again letting

you "get it right the first time."

Improved quality

We have repeatedly seen our customersimprove their part quality by utilizing virtual manufacturing techniques. There are numerousexamples throughout this paper, and almost allof them result in a part with quality produced atlower cost than previously attained through traditional prototyping techniques.

Reduced time to market

Time to market is becoming increasingly criticalin an age where information can be transmittedand shared readily. Although virtual manufacturingmay translate into spending more resources inthe design and engineering phases, the resultingproduct will need much less rework downstream.This saves enormously in unforeseen redesignand reengineering efforts.

Lower overall manufacturing cost

The bottom line is that our customers have hadsuccess incorporating virtual manufacturing techniques into their processes, and none havegone back to the traditional product design cycle. We are confident that you will also sharein this success.

Costs

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Hardware

The good news is that entry costs to acquiring aplatform to run your simulations is continuouslydecreasing. Desktop Workstations, readily availablefrom a number of vendors, now have plenty ofpower to drive these types of nonlinear analyses.With MSC.Marc's Domain Decompositionmethod (explained in more detail later on), morepower requirements simply translate into moreCPUs. For example, you can string fourWorkstations together over a network and runproblems that are four times as large.

If having the hardware in-house is not practical,you may consider running your simulation onMSC.Software Simulation Center, whereMSC.Software hosts the software and hardware.The only requirement is a client computer that canconnect over the Internet.

Software

When buying an MSC.Software product, you arebuying years of expertise and development fromengineers around the world. There is a coststructure to fit any size budget, so you canchoose to license the software for any amount oftime, whether it is years or as short as a day.The choice is yours.

Training

Most engineering groups will want to developtheir own in-house expertise. The MSC Instituteof Technology offers training courses that giveyou the quickest path to get up to speed.Training costs typically decrease over time asyour group gains in expertise.

Expertise

Certain, more difficult problems may require outside expertise. The MSC.Software ConsultingServices delivers fast, accurate analyses, anddeep engineering insight.

As a part of MSC.Software, they can solve yourproblems with the latest leading-edge softwareand hardware tools months before they areavailable to others. In addition, they can drawupon the MSC.Software staff of developers,application engineers, and world-renownedexperts to provide solutions that no one elsecan. The costs associated with outside consultingcan vary considerably, and are dependent onthe difficulty of the problem encountered.

Support

Support costs can be in the form of additionalmanuals, training materials, attending conferences,etc. You will find it very beneficial to become apart of the MSC.Software community and utilizemany of the support resources offered, and toshare experiences with other users. Much of the support available, especially from theMSC.Software web site, is free.(www.mscsoftware.com)

Otto Fuchs’ Success

German forger Otto Fuchs’ discovered that theuse of state-of-the-art simulation software couldnot only reduce tool and die iterations, but literallyeliminate them. Using MSC.SuperForge, theyhave reduced the number of new die iterationsfrom three to one for certain parts. This savesprecious resources and time on expensivepresses. In a recent Forging Magazine interview,Otto Fuchs’ head of design, Jorg Ihne, explained:

"In three weeks we can do the simulation forthree different geometries of a complex part, optimizing the final geometry. And by using thesame die design for production, developmenttime can be reduced by a factor of three times,because the die doesn't have to be changedthree times and doesn't have to be setup on theforging machine three times." *

* Forging Magazine; July/Aug. 2000, page 51

Virtual manufacturing significantly reduces fuel costs for Boeing

Problem

During the metal-forming process of aircraft skinpanels, the work piece undergoes large deformations and accumulates considerable plastic strain. Upon release of the work piece, thepart recovers the elastic energy stored in it. Thiscauses the deformed part to deviate from thedesired shape. Historically, empirical methodswere used to determine this spring-back effectafter forming the panel. In the modern era, suchmethods are impractical and cost prohibitive,especially because of the large number of variousparts in a modern airplane. A new stretch formblock shape must be designed with the inherentspringback accounted for. Without optimized dieshapes, the quality of the part suffers, leading toassembly problems that are compensated for bytrimming and shims to attain a proper fit. Suchdifficulties can extend production schedulesunpredictably. The final installed aircraft skinscan become wavy, resulting in reduced fueleconomy over the life of the aircraft.

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Solution

By using the nonlinear finite element (FEA) software, MSC.Marc, to simulate the metal-form-ing process, the spring-back can be accurately predicted before the real die is built. The materialoften used is aluminum, which is elastic-plasticwith large deformation in the plastic region.There is material, geometric, and boundary nonlinearity involved. The software must be ableto accurately predict this spring back effect. Tooptimize the die shape, a trial-and-error procedureis required. Instead of implementing the trial-and-error procedure on the real model, FEA is usedto find the optimal die shape. Using MSC.Marc's automated contact applied to 3-D bodiesrequired no exotic programming by the end userto converge on a solution, making it a very practical tool for this virtual manufacturing simulation. Once a Stretch Form Block shapewas designed, a robotics model of the stretchpress was undertaken to determine the optimalcontrol of the sheet-forming process. Once therobotics model was optimized in the virtual environment, the data was sent to the controlleron the stretch press. Thus the operator, whenforming the part, directly used the FEA information.

By developing the tooling dies and the manufacturing controls in a virtual manner, therisk associated with part manufacture andassembly was reduced.

Shimming was minimized and waviness wasreduced resulting in exceptional skin quality.

High quality skins allowed production schedules to be met more easily, and theresulting aircraft would see improved fueleconomy over its lifetime.

Return on investment

Correcting the stretch form block prior to its fabrication, and optimizing the forming processreduced approximately a third to half the totalmanufacturing cost per part. As much as 100 lbsof shims were eliminated from the cab sectionand installation time was shortened several days.

“Virtual Manufacturing savedBoeing more than 2 million dollarsa year for the 737 program alone.The improved skin quality afterfinal installation minimized wavinessand increased fuel economy of theplane over its lifetime.”

-Darrell Wade, Boeing

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VVirirtual manufacturing optimizes rtual manufacturing optimizes roll forming proll forming processocessProblem

Cold formed roll profiles are important structuralelements in almost any area of engineering. Thisincludes automotive, and construction, where alarge variety of open or closed section barshaped profiles are used. In the continuous rollforming process, flat sheet metal is formed bydriving pairs of contoured rolls into a finishedprofile through several stages without anyintended reduction in sheet thickness. The finalprofile shape can be influenced by longitudinalstrains causing sheet edge waviness and bowing. Also, residual stresses in the profile produce spring-back, and can deform the finalprofile shape. In order to speed up tool design,virtual manufacturing based techniques arerequired to aid in planning of the pass sequencedevelopment, calculation of the spring-backangle, and estimation of the strip edge elongation.

Solution

The planning for a new part begins with a definitionof the finished section, the design of the passsequences, and the sizing of the different rolls inthe CAD system. In this analysis, the CAD datawas fed into the MSC.Marc FEA solver, and thesimulation was run. The results were analyzed todetermine the deviations in shape and dimensionsof the finished section. The longitudinal strains ofthe sheet edge revealed the quality of the rollforming process. Some of the characteristics thatwere checked included, dimensional tolerances,angular tolerances, longitudinal bow, twist sheetedge waviness, and profile end deformation.After optimizing the manufacturing process in thisvirtual environment, the manufacturer was ableto manufacture the tools and run a test in themill. This analysis avoids high costs derived fromimproperly designed tools needing adjustmentand rework in the mill to fit a new profile.*

* Prof. Dr. Schmoeckel, -Ing. D.; Sitzmann, B. Institute forProduction Technology and Forming Machines TechnicalUniversity Darmstadt, Germany. Integration of the FE-simulation in a planning for roll forming

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Deep drawing simulation rDeep drawing simulation reveals manufacturing defecteveals manufacturing defect

Solution

The edge wrinkles can be observed in the shadowof the last image. This potentially costly mistakewas avoided prior to committing resources totooling. To achieve an accurate analysis,MSC.Marc was able to simulate the contact andfriction between the sheet and die, and to calculatethe plastic deformation of the work piece. Thepunch velocity and other parameters were optimized to avoid tearing and to monitor thefinal thickness distribution leading to a high quality part. The virtual lighting capabilities ofMSC.Marc Mentat facilitated visualization of thewrinkles while postprocessing the FEA results.

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Problem

Deep drawing is a process to manufacture highquality stamped metal products. During theprocess, an initially flat sheet is clampedbetween the die and the blank holder after whicha punch moves down to deform the clampedblank into the desired shape. The shape of thepart depends on the geometry of the tools, thematerial behavior of the blank, and the processparameters. FEA can provide detailed insightinto tool design and manufacturing parameters.After simulating Deep Drawing of an s-shapedrail, wrinkles were discovered along the edge.

RubberRubber boot rboot redesign lessens redesign lessens repairepair costs costs

Solution

A stress analysis of the design was performedusing MSC.Marc to gain some understanding ofthe mode of failure. After an accurate model ofthe existing seal was created, changes weremade to the design in an effort to reduce the criticalstresses. A modified design resulted which wasthen built and tested. The actual behavior of thenew seal agreed with the predicted behavior and product cycle-life was increased to anacceptable level.*

* Swanson, Douglas J. Gates Rubber Company. Designand analysis of an elastomeric constant velocity joint seal

Problem

An existing constant velocity joint seal designexhibited unsatisfactory life-cycle performancewhen it was modified to a split seal configurationfor ease of installation. The purpose of the seal,which is used on front- and four-wheel drive vehicles, is to keep grease in the joint and keepdirt and moisture out. The original equipmentversions of the boot were one piece and wereinstalled over the CV joint at assembly. However,when failure of a part occurs due to wear,fatigue, or road hazards, it usually cannot bereplaced without first removing the entire CVjoint and associated axle. This results in a repairbill that is 90% labor and 10% parts. By providinga boot with a seam which could be mountedover an installed joint, the consumer would besaved much of the installation costs. It wasexpected that introducing a seam into the existingboot design would lower the life expectancy ofthe boot. The original replacement design had alife expectancy of about 70,000 miles, and if alife of 30% to 50% of this value could beachieved with the split design, that would beacceptable. The logic behind this was that whilethe customer who used the split boot wouldhave to replace it more often, he could do so ata much lower cost.

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Problem

In car accidents, side impacts result in numerousinjuries because the side structure of the car,including the occupant compartment, is crushed.During design, the strength of the door should bestressed for passenger safety. It is a commonbelief that improvements in the strength of thedoor itself is quite effective for passenger safety,particularly in collisions from the oblique direction,or with fixed objects. In this research, MSC.Marcwas used for static compression analysis anddynamic impact analysis to understand the crashworthiness of the door. Experiments were alsoperformed for comparison purposes. In addition,the effectiveness of the door-beams, which wereinstalled within the doors, were analyzed.

Solution

The doors used for this experiment were thefront doors of four door sedans. The door panels,hinges, locks, and other necessary mechanismswere used, while the windows and door trimswere removed. Hinges and latches were constrained. For static compression and dynamicimpact, the loading device was applied laterallyon the center of the door.

Experimental results of a door in the body showdifferent characteristics from the results of a dooralone, mainly because the door contacts with thecenter pillar and side sill; therefore, the force onthe door is distributed rather than concentratedon the latch.

However, the latch part still receives most of theforce. In fact, experimental results of the doorwithin the car body showed cracks in the latchpart, just like the results with the door alone. Theimportance of the strength of the latch part shouldbe stressed for the strength of the door itself.

From the static compression analysis anddynamic impact analysis of a door, as well as the experiments, it was found that the strength of the door hinge and door latch strongly affectedthe crush resistance of a door itself. In the experiments, it was found that once crack propagation occurred in the latch, the force drastically decreased. It was also necessary toconsider reinforcing the latch even when a doorhas a door-beam. It was also found that byattaching a door-beam, absorption of the deformation energy increased and deformation of the door decreased upon impact.*

* Mizuno, K.; Toyofuku, Y.; Irie, H.; Tateishi, M.; Maeda, K.Analysis of impacted car door

Side impact analysis of a carSide impact analysis of a car doordoor rreduces injurieseduces injuries

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Connecting rConnecting rod forging prod forging process developed virocess developed virtuallytuallyProblem

In the field of hot forging technology, developmentsof new forming processes are difficult due to thelarge number of parameters constituting theprocess. In developing a process, the design engineer has to consider both the technical andeconomical limits in order to obtain competitiveforgings. Forming a connecting rod requires several single forming processes resulting in aprecision forming operation. During this multi-stepprocess, there is the risk of gap formation. Gapscontain the danger of material flowing into themmaking the forging useless. The timing of thetool and the force closing the gap influences itsformation. If the force is too low, the gap canopen again during the forming operation. Otherprocess goals include reducing the number offorging steps, minimizing tool abrasion, reducingthe contribution of flash material, and ensuringthe stability of the forming process with a minimum of rejects.

Solution

Experimental testing is one method of forgingprocess development, but usually requires muchtime and money, especially during developmentof new processes. Time and costs of developingthe forging process for the connecting rod wasreduced with the help of the forging simulationpackages, MSC.SuperForge andMSC.SuperForm. These codes made it possibleto vary many process parameters in a "virtual"way. The result was new process knowledge,which never would appear in such evident formduring physical testing. These virtual tools allowed tuning of theforging process to avoid potential trouble areas,like gap formation, before the manufacturing ofthe tools took place.*

* Altmann, Hans Christoph. Institute for IntegratedProduction Ltd, Hanover, Germany; Slagter, Wim J.MSC.Software (E.D.C.) B.V., Gouda, The Netherlands.Quality of simulation packages for flashless hot forgingoperations

ProblemIn designing a snap buckle, several objectivesmust be addressed including load required toopen and close, fatigue life of the clasp, acousticprofile, weight, and cost. For this design, thefatigue life was a critical component to providemaximum customer satisfaction. In many consumer products, the prevention of failure isimportant to minimize warranty costs. By adjustingthe geometry in the design phase, one caninsure that the product is both reliable and hasthe correct “feel” to the user.

Solution

The snap buckle was designed in MSC.Patran,and analyzed using MSC.Marc. The analysisincluded large deflection with sliding contact plusfriction, which MSC.Marc can easily handle withits automatic load stepping algorithm and ease of defining the contact bodies. The product'sperformance was measured by monitoring themaximum strains in the plastic, the insertionforce required, as well as other variables, allwithin the virtual environment. These resultsused in conjunction with MSC.Fatigue may beused to predict the product life cycle. This virtual prototyping application demonstrates how a consumer product can be optimized and testedbefore being manufactured and subjected tophysical testing.

VVirirtual prtual prototyping imprototyping improves buckle performanceoves buckle performance

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ImprImproved stent design saves lives oved stent design saves lives Problem

A stent is a cylindrical device used in arteriesand veins to maintain patency of the vessel foracceptable levels of blood flow to specificorgans. Their widespread use in cardiovascularsurgical procedures is hindered by 20%-30%failure rates within the first year. Stent designprofoundly influences the post-procedural hemodynamic and solid mechanical environmentof the stented artery by introducing non-physiologicflow patterns and elevated vessel strain. Thisalteration in the mechanical environment isknown to be an important factor in the long-termperformance of stented vessels. Because oftheir critical function, it is vital that the stentdesign be thoroughly validated by methods such as FEA. Finite element modeling highlightsany design or process problems well in advance.

Solution

The finite element models used in this studyrelied upon simple linear elastic, isotropic beamand shell elements. Researchers at Wake ForestUniversity School of Medicine are designingstents using MSC.Patran for the pre-and postprocessing. MSC.Marc Mentat can also be used.MSC.Marc is used as the analysis code becauseof its capability of handling nonlinear and largedeformation material behavior.

Clinical evidence showed an abrupt compliancemismatch existing at the junction between thestent ends and the host arterial wall disturbingboth the vascular hemodynamics and the naturalwall stress distribution. These alterations causedby the stent were greatly reduced by smoothingthe compliance mismatch between the stent andthe host vessel. MSC.Patran was used to evaluate the solid mechanical stress created byexisting commercially available stents. It wasfound that stresses were five to ten timesgreater than the arterial wall stress under normal physiologic pressure. A compliance matchingstent (CMS) was created using these findingsand was manufactured and tested. Preliminaryresults show the CMS is effective in reducing theunwanted tissue growth associated with the failure of conventional stents. It is expected thatthese results will lead to improved stent designsthat will ultimately improve the quality of life forpatients receiving them.*

* Berry, Joel. Wake Forest University. Finite elementanalysis is used to design cardiovascular stents

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Why Why VVirirtual Manufacturing Now?tual Manufacturing Now?

Why virtual manufacturing now? Perhaps thebest answer to this question is that the verynature of simulation is the search for more information. Every simulation acts as the vantage point from which one can better viewthe possibilities and then ask the next question.That question generally requires a finer simulation,or more of them, and as soon as that is available,someone will ask for the "optimum" solution.

The primary limitation today in reaching this optimum solution is problem size. The needs ofcompanies for faster solutions, for better andbetter simulations, for more refined and accuratesimulations, and now for virtual manufacturingsimulations leads to the unquenchable demandfor more computational power. The computerindustry is delivering on that demand.

Computer Industry Maturing

In the past, simulations such as these were limited to the largest of companies possessingthe largest of computers. That is no longer thecase. Today, all of our analysis and graphicalproducts operate on workstations that are readilyavailable from a number of manufacturers runningany of the popular operating systems.

Increasingly, the single most important factor indetermining which computer you choose is simply "How fast do you want your answers?"

Parallel Processing

Parallel Processing involves combining theresources of many CPU's or entire machinesand applying them to the solution of a single virtual manufacturing simulation.

The appeal of parallel processing is that it offersa means of simultaneously capitalizing on thegrowth of chip performance and the potentialperformance benefits of multiple chips.

At the moment, there are two fundamental problems associated with parallel processing: thefirst is that most existing algorithms can deriveonly limited benefits from the use of multipleCPUs; the second is Amdahl's Law, which loosely states that you can't parallelize a portionof an algorithm and make a significant impact onthe total clock time.

The solution to these two problems is toredesign the algorithm to provide scalable performance across multiple CPUs for allaspects of the problem. At MSC.Marc, we sawthe coming requirement for such a capabilityyears ago when we started the parallel processingproject. It has been a long road with occasionaldead ends, but we are very pleased with theresults of the research.

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MSC.Marc DDM Software

Pioneered by MSC.Marc, the DomainDecomposition Method or DDM, involves dividing up the virtual manufacturing simulationinto pieces, and feeding each piece separately to its own CPU. As the simulation progresses,some steps of the simulation allow all the CPUsto work by themselves. In other steps, all of theCPUs have to come to an agreement aboutresults before continuing. This inter-domain communication between CPUs is done with message-passing interface or MPI.

The challenge was to provide scalability for thebroadest possible range of nonlinear simulationsfor a sizable number of CPUs. The result is ourimplementation of Domain Decomposition. Thiswas a substantial challenge but now we are ableto provide scalable performance for virtually allof the linear and nonlinear analysis capabilitiesof MSC.Marc as well as our Vertical products.This includes capabilities such as large deformation,plasticity, viscoplastic effects, thermal effects,and automated 3-D contact.

In designing this system, we had to allow for many different architectures vying for ascendancy, with differences in the number ofprocessors, the allocation of memory, softwareinfrastructure, types of processors, and themethods of communication.

From the hardware point of view, the objectivewas to provide as much parallelism as possibleand to do so while minimizing inter-domain communications.

From the software point of view, the objectiveswere to provide an analysis product that wasfully integrated with our GUI including model definition, analysis and results viewing withrobustness similar to that of a single processorversion, and which required minimal additionaluser experience.

Overall, the objective was to permit the user to define the model without worrying about parallel considerations.

The concept of Domain Decomposition isstraightforward. There is a mapping between thefinite element model and the hardware. Eachdomain is handled by an individual CPU whilethe interaction between domains is handledusing message passing between processors.

The Key is Domain Decomposition The Key is Domain Decomposition

Analysis using 4 CPUs

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MPI MPI MPI

The simulation is defined and theanalysis is ready to begin. The user isasked one additional question: Howmany CPUs are to be involved in thecalculation? The GUI will then subdividethe model into as many domains asthere are CPUs, either interactively orautomatically. Then the analysis issubmitted and monitored automatically.When done, the user can view theresults in any domain or the entiremodel graphically.

MSC.Software offers a variety of products andservices to help you build your VirtualManufacturing facility. From advanced FEA tools,to experts and consultants, a total solution,enabling you to get started today leveraging thelatest in virtual manufacturing technology.

MSC.Marc and MSC.Marc Mentat

MSC.Marc allows the user to perform a widevariety of structural, fluid, and coupled analysesusing the finite element method. These proceduresprovide solutions for simple to complex linearand nonlinear engineering problems. Analystscan graphically access all features via MSC.MarcMentat or the MSC.Patran interfaces. Alsoincluded in MSC.Marc is the parallel processingof large problems using Domain Decomposition.

MSC.SuperForm

MSC.SuperForm provides solutions to manufacturing problems including Hot and Cold (Open or Closed) Forging, Extrusion, Axialand Ring Rolling, Blanking, Cogging, Clading,Thick Sheet Bending, and Cutting. MSC.SuperFormuses the finite element method with a wealth ofmaterial and process models to support your tooldesign requirements.

MSC.Nastran

MSC.Nastran is the premier computer aidedengineering (CAE) tool that major manufacturersworldwide rely on for their critical engineeringcomputing needs to produce safe, reliable, fasterand optimized designs.

MSC.Dytran

MSC.Dytran is an advanced finite element program capable of simulating many commonforming processes, including the forming of complex sheet metal parts such as automobilehoods, fenders, and side panels, as well as forming of household and industrial containerslike plastic bottles.

MSC.Patran

MSC.Patran provides a complete software environment for companies performing simulationof mechanical products. MSC.Patran enables theuser to conceptualize, develop and test a productusing computer-based simulation prior to makingmanufacturing and material commitments. Majormanufacturers around the world use MSC.Patranas the basis for their product improvementprocess, reducing or eliminating costly physicalprototyping and testing.

MSC.SuperForge

MSC.SuperForge provides a fast and easy to usetool for forging engineers to analyze industrialforging processes. Using MSC.SuperForge inevery day forging practice allows for the reductionof shop floor trials by optimizing the forgingprocess, using more economical and faster computer simulations. As a result, product development time is shortened and product quality is increased.

Backed by MSC.Software

MSC.Software is the established informationtechnology software and services provider helping companies worldwide develop betterproducts faster. MSC.Software’s software andservices are used to enhance and automate theproduct design and manufacturing process. Theability to model and test software prototypes hascost effectively enabled manufacturers to designand build everything from sophisticated aircraftand automobiles to electronic products.

MSC.Software markets products and servicesinternationally to aerospace, automotive, biomedical,construction, consumer products, electronics,energy, manufacturing industries and universities.For additional information about MSC.Software,please visit us at www.mscsoftware.com.

The The Advanced Advanced TTechnology of MSC.Softwarechnology of MSC.Softwaree

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MSC.Software provides the industry's most comprehensive support system with over 50 officesworldwide to provide local and centralized support.Investing in MSC.Software gives you access toextensive client support through comprehensive documentation, direct technical expertise, and customized training classes.

To find your local MSC.Software office orto learn more about our company and our products, please contact:

Corporate:MSC.Software Corporation2 MacArthur PlaceSanta Ana, California 92707 USA

+1 714 540.8900Fax: +1 714 784.4056

Information Center:1 800 642.7437 ext. 2500 (U.S. only)1 978 453.5310 ext. 2500 (International)

Worldwide Web - www.mscsoftware.comOn-line Purchases - www.engineering-e.comOn-line Simulation - www.simulationcenter.com

Europe:MSC.Software GmbHAm Moosfeld 1381829 Munich, Germany

+49 89 43 19 87 0Fax: +49 89 43 61 71 6

Asia-Pacific:MSC Japan Ltd.Entsuji-Gadelius Bldg.2-39, Akasaka 5-chomeMinato-ku, Tokyo 107-0052 Japan

+81 3 3505 0266Fax: +81 3 3505 0914

MSC, Marc and Patran are registered trademarks of MSC.Software Corporation. Nastran is aregistered trademark of NASA.MSC.Nastran, MSC.Patran, MSC.Dytran, MSC.MarcMentat, MSC.SuperForm, MSC.SuperForge, MSC.Fatigue, are trademarks of MSC.SoftwareCorporation. All other trademarks are the property of their registered owners. All specificationsare subject to change without notice.

©2001 MSC.Software Corporation