EXAM Q

SimAutoInd | WS 2014/2015 | Friedrich-Alexander-University Erlangen-Nuremberg

Challenges for Simulation in the Automotive

Industry (SimAutoInd)

Questions for Exams WS 2014/2015


Visit to BMW Factory in Munich

• Attendees

• Max. 30 students (first come first serve – according to the registration in the list of attendees)

• Date

• Friday 30.1.2015, 15:00

• We will meet at BMW Welt Munich, Information Counter North, 14:30 at latest

• Logistics:

• Latest start of tours is 15:30, tour takes max. 2.5 hours

• Meet at BMW Welt Information Counter North 30 minutes prior to tour start

• Payment happens at information counter, Stefan invites you

• Please organize travel yourself

• If you want to participate, please make a cross in the list of attendees

• If further information is to be distributed and we do not meet in the lecture in time, StudOn will

be used

• (Please name a „group leader“ – he/she should please send an e-mail to

[email protected] ) (not in WS 2014)

mailto:[email protected]


Exam

• We will have a written exam

• Duration 60 minutes

• 07.04.2015

• If you have a conflict with this date, please send

an e-mail to [email protected]

• I will upload the list of potential questions

to StudOn

mailto:[email protected]


Evaluation of Lecture


Evaluation of Lecture

• TANs available

• Please evaluate the lecture –

www.tf.fau.de/studium/evaluation

• Deadline: 17.1.2015

http://www.tf.fau.de/studium/evaluation


Questions for Exams

• State of the Art and Challenges for Simulation from an Industrial Point of View (1)

• Please give reasons for using simulation

• Test of functional behaviour, etc.

• Why can physical test alone not do the job?

• General motivation (cost, many different load conditions, etc.)

• Enables insights which physical test cannot deliver – e.g. transparent real time view of interior components (remember Audi movie)

• Product development trends (amount of product lines and variants, etc.)

• Simulation in development of Audi A6/A8

• List and briefly explain some of the most important simulation disciplines und subdisciplines in automotive hat development (“Funktionsauslegung Aufbau”)

• In A8 movie, underlined items were shown in A6 movie as well (A6 movie not shown in WS2013/2014:

• Crash (side, front, etc.)

• NVH (comfort (vibrations etc.), acoustics)

• Durability (misuse - pit hole example)

• Fluid dynamics (external aerodynamics CW and CA value, aeroacoustics, air conditioning)

• In A6 movie only:

• Running gear (Fahrwerk)

• dynamic stiffness

• ESP

• Adaptive light

• Which other examples of „virtual testing“ (i.e. simulation) do you remember from the automotive industries (seeslide 3 of the introductory slide set for „State of the Art and Challenges for Simulation from an Industrial Point of View”)

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Questions for Exams

• State of the Art and Challenges for Simulation from an Industrial Point of

View (2)

• When was BMW founded, what was its initial product?

• When did BMW enter the automotive market?

• Which car brands make up the BMW Group today?

• How many car series make up the BMW automobile range today?

• How many cars did BMW sell in 2013 and which revenues did BMW achieve in

2013?

• Briefly describe the CAE compute capacity of BMW: how many cores? (about

24,000; in lecture it was mentioned that next year it will be about 43,000) In

which locations? What is the preferred platform for CAE? (see BMW slide

handout page 20)

• What is CAD, CAE, CAT?

• Why is a multidisciplinary way of working important? Explain potential conflicts

for example regarding the front vehicle functional design (Weight, Stiffness,

Crashworthiness, Vibration of Hoods, Aerodynamics, Pedestrian Protection)

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comp aided testing

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Questions for Exams

• State of the Art and Challenges for Simulation from an Industrial Point of View (3)

• What is „CAE-Bench“ at BMW?

• Explain the overall “simulation process integrated into CAE-Bench” at BMW

based on a printout of the corresponding slide

• List and explain some benefits of CAE-Bench for BMW

• System integration – explain with your own words why it is important to

integrate CAD, CAE, CAT and TI (Bill of Material) (keywords: integrated

workflows, controlled, efficient communication)

• Explain why integrating data and processes across distributed locations and suppliers is important and which challenges arise from this

• See slide with title “Development Networks“ and subtitle „More efficiency of processes in development networks” and use your own know-how fromthe press and other sources

• List and briefly summarize the challenges for simulation in the automotive industries which were discussed in this lecture

• Challenges from industrial point of view, FEM, Parallel FEM, Materials, Future Trends in Structural Analysis, SDM, IT Challenges

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Questions for Exams

• Introduction to the FEM (1)

• Overview (section 1)

• Give a brief description of the FEM (section 1.1)

• Application Areas of FEM (section 1.2)

• List some typical FE analysis types, explain them and give an example for each

• Linear static analysis, linear dynamic analysis (normal modes and acoustics), nonlinear analysis

• Brief description of design optimization as application area of FEM (example: topology optimization)

• Brief description of stochastic analysis as application area of FEM

• What does CFD mean?

• List and describe three examples of problems addressed with CFD

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Questions for Exams


• FEM Theory (section 2)

• List and briefly describe the 7 basic steps of the FEM (section 2)

• We assume a threedimensional linear elastic body which is supported and

constrained and subject to loads. Explain the meaning of the term „displacements“.

• Give the text definition of strain; and an intuitive definition for a tensile rod.

• We assume a tensile rod which extends along the y-axis:

• Under which condition are all terms in 0 except ?

• Derive the relationship between and .

1P

2P

)( 11 Pff )( 22 Pff y

z

lx

A )( 22 Puu )( 11 Puu

T

zxyzxyzyx ),,,,,( y

yuy

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• Define the term stress

• Give the unit of stress in both US and SI unit systems

• What is an elasticity law?

• Give the formula for Hooke‘s law and explain for which which materials it applies.

Give an example for a material where Hooke‘s law applies. Does it always apply for

this material?

• Describe the meaning of Young‘s modulus. Give its value for steel in the US unit

system. Based on this value, derive its value in the SI unit system, assuming

1lb=0,4535924kg.

• Definition of stress-strain curve

• Plot a stress-strain curve for steel and explain the major regions of this curve.

Explain the meaning of „yield point“ and give the approx. strain value for steel at the

yield point (about 0.2%). Derive the corresponding stress value using Hooke‘s law.

• Explain the meaning of the Poisson ratio for linear elastic materials.

• Based on the formulas and ,explain the meaning of the

values 0 and 0.5 of the Poisson ratio. Give examples of materials with these values

for the Poisson ratio.

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• The potential energy of a threedimensional constrained linear elastic body under

load is given as

• Explain the meaning of p, q, f, u

• Explain the meaning of each of the four terms which consitute the potential energy

• What is the main idea of the principle of „minimum“ potential energy?

m

i

i

T

i

S

T

V

T

V

T PuPfdSuqdVupdV1

)()(2

1

x

z y

q

p P

u

if


Questions for Exams



• For the rod along the y-axis, give a linear function for , which fulfills

and

• Derive an expression for the potential energy of the rod based on

using this linear function, and express it in matrix vector writing

• We assume a structure of two rods along the y-axis. Both are made of steel, are 10

cm long, the lower rod has a constant cross sectional area of 3cm2, the upper rod

2cm2. The lower rod is fixed at the bottom, a load of 4,000N is applied to the upper

rod. For Young‘s modulus, you can use a value which is convenient for the

calculation.

• Compute the element stiffness matrices and element load vectors for both rods

• Assemble these matrices and vectors into a global stiffness matrix and load vector

• Write down the resulting system of linear equations

• Eliminate the unknown for the constrained grid point

• Solve the system of linear equations, i.e. compute the values for the unknowns

• Calculate the values for strains and stresses in both rods.

• We have shown in the lecture that for the FEM the potential energy can by

expressed as . Proof for three unknowns that the following is true for

yu 1)0( uu y

2)( ulu y

ufuKu TT 2

1

fKuuuu

graduuu

0)()(:),,(

321

321

2121 , and , ffuu

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Questions for Exams


• FEM practice (section 3)

• A Nastran input deck template for the rod example is given, but

misses a few entries. Fill in the missing entries.

• Describe the typical contents of a Nastran log file, f04 file, f06 file

• What is Nastran DMAP?

• Pre- and postprocessing (section 4)

• Why is a FE preprocessor required? (slide 63)

• List and briefly describe the major preprocessing steps for linear static

analysis (slide 63)

• For which purpose will an engineer use a FE postprocessor? (slide 64)

• List and briefly describe the major postprocessing steps for linear

static analysis (slide 64)


Questions for Exams


• Role of linear algebra for FEM (section 5)

• What are the typical characteristics of a system of linear

equations arising from a linear statics analysis? (sparse vs.

dense, (un)symmetric, number of right hand sides, etc.)

• A small finite element model is given with elements and grid

points, some grid points are fixed. Please show the pattern of

nonzero terms in the corresponding stiffness matrix and load

vector

• Describe why matrices become denser with higher dimensional

elements

• Shown for 2D and 3D example with 12 grid points each in the

lecture, in the exam also demonstrate this with a 1D example with

12 grid points (just take a tensile rod with 11 elements)

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Questions for Exams

• Parallel FEM (1)

• Motivation for parallel FEM (section 1)

• Describe reasons why parallel FEM is required

• Larger models

• Roughly describe how resource requirements grow with model size

(e.g. crankshaft link, compare in particular link02 and link04)

• Describe reasons for growing model sizes (automatic mesh

generators, usage of meshes across different analysis types, digital

mock-up of FE models)

• (Topology) optimization

• Stochastics

• Assume a single finite element analysis would require 4 hours.

How long would a serial topology optimization and a serial

stochastic analysis need? Explain your assumptions to get to your

result.

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Questions for Exams

• Parallel FEM (2)• Introduction to parallel computing (section 2)

• Plot a diagram for an SMP architecture. List its advantages and disadvantages, and give an example of a corresponding parallel computer used in industry today

• Plot a diagram for a DMP architecture. List its advantages and disadvantages, and give an example of a corresponding parallel computer used in industry today

• Is the memory the only resource shared/distributed in an SMP/DMP computer? Explain your answer

• What is the main principle behind shared memory parallel programming and distributed memory parallel programming? (see slide 22)

• The following situation is given in an SMP architecture with two processors. Which value(s) will/could be printed for x? Explain your answers.

• Explain the main ideas of shared memory parallel programming (shared memory, threads, fork-join, etc.)

• What is the advantage/disadvantage of using directives specified by the programmer vs. letting the compiler do an automatic parallelization?

integer x

x=0

x=x+1 x=x+1

write (*,*) x

proc. 1 proc. 2

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Questions for Exams


• Introduction to parallel computing (section 2)

• What is OpenMP? What does it deliver to the programmer?

• Standard directives, library routines and environment variables

• Explain an OpenMP program listing which is shown to you

during the exam, for example a program which creates a

number of threads equal to the number of processors and

prints the ID of each thread. The OpenMP program may

contain some open gaps/errors, fill in the gaps/correct the

errors.

• Explain the advantages/disadvantages of shared memory

parallel programming

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• Introduction to parallel computing (section 2)

• Explain the main principles of distributed parallel programming

• Explain the abbreviations SPMD and MPMD and explain the differences between both models

• Explain message passing and data parallel programming

• Which advantages could you imagine for data parallel programming?

• What is MPI? What does it deliver to the programmer?

• Standardized constants and library routines

• Explain an MPI program listing which is shown to you during the exam. The MPI program may contain some open gaps/errors, fill in the gaps/correct the errors.

• What do the routines MPI_BCAST and MPI_ALLREDUCE do?

• Explain the advantages/disadvantages of distributed memory parallel programming

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Questions for Exams

• Parallel FEM (5)• Parallel performance metrics

• Define and explain speedup and parallel efficiency

• For a FEM example, a table with elapsed times for a serial, 4- and 8-processor parallel runs is given. Compute speedups and efficiencies on 4 and 8 processors

• Define linear and superlinear speedup

• Is superlinear speedup possible? If yes, give an example

• Amdahl‘s law• Define and explain Amdahl‘s law

• Let‘s assume a parallelized FEM code. The serial elapsed execution time for a certain FE model is T. The code has not been completely parallelized, in any parallel execution the serial fraction of the run time is 0<<1.

• Give an expression for the parallel run time on p processors dependent on , T and p, assuming linear speedup in the parallel code parts

• Based on this answer, write down the expression for Amdahl’s speedup

• Compute the limes for Amdahl’s speedup for

• Explain the meaning of Amdahl’s law with your own words

• Which main types of performance monitoring tools exist (hardware and software), what are the pros and cons

• Explain what an „a posteriori trace tool“ does and what it is used for, give an example for such a tool

• Intel Trace Analyzer and Collector

p

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Questions for Exams


• Parallelization approaches (section 3)

• List the five potential parallelization approach categories

which we discussed in the lecture

• Shared or distributed memory parallelization

• Embarrassingly parallel or not

• Module (kernel) oriented or complete parallelization

• GPGPU

• Data distribution (=partitioning): algebraic or geometric

• Explain one of the five approaches in more details

• What does „embarrassingly parallel“ mean? Give one

example for an FEM analysis which is embarrassingly

parallel, and one which is not

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Questions for Exams

• Parallel FEM (7)• Parallelization approaches (section 3)

• In a linear statics FEM analysis, let us assume that n is thenumber of different load vectors, and c the number of different constraint sets. The following two situations are given

• a) n>1, c=1

• b) n=1, c>1

Write down the linear equation systems to be solved for a) withn=4, and for b) with c=4

Which of these two situations is embarrassingly parallel? Explain your answer.

The elapsed time of a serial FEM run is given, with a breakdown of time spent in the different main modules. Compute theestimated speedups on 4 and 8 processors for situation a) withn=8 and b) with c=16.

• List 2 advantages and 2 disadvantages for incompleteparallelization (i.e. module or kernel oriented) when comparedto complete parallelization

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Questions for Exams

• Parallel FEM (8)• Parallelization approaches (section 3)

• What does the abbreviation GPGPU stand for?

• Explain the principle how a GPU can accelerate an FEM program.

• An example for speedups using shared memory parallelism, distributedmemory parallelism, and GPU acceleration is given. The parallel computeron which this example was executed consists of 4 distributed nodes, eachof them contains 4 CPUs and 1 GPU. Mark in the following diagram, whichcomponents of the parallel computer were used in the runs in the speedupdiagram.

• Explain the difference between algebraic and geometric data distribution


Questions for Exams

• Parallel FEM (9)• Domain decomposition (section 4)

• Explain the basic idea of domain decomposition and give a high level overview of how this

works for parallelizing the FEM (section 4.1)

• Explain whether/how the 7 fundamental steps of the FEM have to be modified for parallel

FEM based on domain decomposition (section 4.2)

• Which 3 requirements should a good grid partitioning algorithm fulfill?

• The following FE model is given, and split into two domains.

• The element stiffness matrices are

For both domains, l=2.5cm, E=200MPa. For domain 1, A=2cm*cm, for 2 A=1.5cm*cm.

• Write down the local assembled stiffness matrices for domain 1 and domain 2

• Write down the global assembled stiffness matrix and mark the contributions from

both domains in a different way (e.g. different color, or underline the contributions

from domain 2)

Nf 000,108

grid 1 grid 2 grid 3 grid 4 grid 7grid 6grid 5grid 9 grid 8

rod 1 rod 2 rod 3 rod 4 rod 5 rod 6 rod 7 rod 8

domain 1 domain 2

11

11

l

AEK irod

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Questions for Exams

• Role of Materials in Simulation – from a manufacturing point of view (1)

• How are material properties fed into simulation?

• As constitutive relations which connect applied stresses or forces to strains or

deformations

• Give the text definition of stress

• Who introduced the concept of stress into the theory of elasticity?

• What is the difference between true stress (=Cauchy stress) and engineering stress

• True stress: area A would change, engineering stress uses original area A0

• Text definition of strain

• An upsetting process transforms the following material block from height h0 to

height h1. Calculate the values of strain and strain rate for the final state.

h0=100 mm

V0

h1=70 mm

V1

Initial state Final state

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Questions for Exams

• Role of Materials in Simulation – from a manufacturing

point of view (2)

• What is the advantage of using strain rate versus strain?

• List and briefly explain the main stages of the approach to

forming simulation

• Inputs: geometry and material parameters; tooling concept;

process parameters; simulation model; outputs: thickness

map, material strain rate, dimension accuracy

• Definition of yield point

• Explain a stress-strain curve of steel

• Show the locations of upper and lower yield stress,

uniform strain and strain at failure

• (Give orders of magnitude for uniform strain and

strain at failure in steel) (not in WS2014)

• Which part of the curve shows the elastic area, which

area describes the plastic behaviour?

• Which law describes the elastic part, which law

describes the plastic part?

• Which testing device is used to determine such

values?

• Tensile testing machine

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Plasticity and hardening (Hill's law)

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Questions for Exams

• Role of Materials in Simulation – from a manufacturing point of

view (3)

• Plot an approximate curve for yield stress over temperature

• Which manufacturing process exploits this? Forging

• What is an anisotropic material?

• Is stainless steel isotropic or anisotropic?

• The following anistropic coefficient is given.

• When selecting a material for a car body, which value is desirable for this

coefficient, |rα|=1, |rα |>1, or |rα |<1, and why?

• Why do we need rigid materials – for tools

• Manufacturing of heat exchanger – which manufacturing problems do we

want to avoid using simulation – e.g. rupture at the punch radius corner,

wrinkles

0

1

0

1

ln

ln

t

t

b

b

rt

b

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yes

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Anisotropy /ˌænaɪˈsɒtrəpi/ is the property of being directionally dependent, as opposed to isotropy, which implies identical properties in all directions. It can be defined as a difference, when measured along different axes, in a material's physical or mechanical properties (absorbance, refractive index, conductivity, tensile strength, etc.) An example of anisotropy is the light coming through a polarizer. Another is wood, which is easier to split along its grain than against it.

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value should be greater than 1. Because the length should change but the thickness should remain the same.

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Questions for Exams

• Future Trends in Structural Analysis for Development of Products: Optimization and Robust Design – Design To Cost - Predictive Lifecycle Assessment (1)

• Describe challenges in product development which we discussed:

• Explain the meaning of the magic triangle – Quality, Time, Cost

• According to a McKinsey study, what is the influence on profit of a delay in time tomarket of 6 months? What is the influence of a 50% increase in development cost?

• Climate changes, CO2 emissions, shortage of resources

• Which main measures were identified for CO2 reduction in car development? New driveline concepts (hybrid, e-car), advanced material concepts. Explain the BMW i3 as an example

• List five main steps in the history of optimization – from trial and error to complexity management

• List three typical classes of optimimization and give an example for each of them (sizing, shape and topology optimization)

• Why is multidisciplinary optimization important? (take into account the requirements ofmultiple disciplines simultaneously, handle conflicting targets). Give an example for a conflict in multidisciplinary optimization in car development.

• Optimization versus robustness – what is the difference? What happens if a behaviour is„not robust“ (remember flying racing cars)

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• Future Trends in Structural Analysis for Development of Products: Optimization and Robust Design – Design To Cost -Predictive Lifecycle Assessment (2)

• List five sources for variability/uncertainty, and describe each ofthem with one sentence

• Is it possible to build two 100% identical cars? Why?

• How is a stochastic problem formulated – what are theinputs/outputs? What do „free stochastic variables“ and „design variables“ mean?

• How many stochastic variations of input parameters (i.e. number of simulations) are typically needed to get sufficient results?

• What do the „point clouds“ tell us (e.g. they show if there is a correlation between the parameters on the x- and y-axis, showoutliers, etc)

• Why are outliers bad?

• What is a decision map?

• What do the pie charts for a certain output parameter tell us?

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• Explain the major steps which could be used to find an „improved robust“ design using the picture to the right

• DOE – select parameter sets in design space, run simulations, select initial design

• Run optimization e.g. with response surface method

• Determine robustness – e.g. with a stochastic analysis

• Run SDI (stochastic design improvement) to obtain a robust improved result

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question with answer


Questions for Exams


• What is Design-To-Cost? Take cost into consideration as a design goal/constraint.

• In which product development phase is the majority of the cost already defined?

• Why is then simulation so important to reduce cost?

• Which challenges do we face so that we are looking into (P)LCA? (climate changes, CO2emissions, shortage of resources)

• What are the CO2 emission guidelines for cars from the EU and do they make sense withrespect to a LCA? Why/why not?

• List the main stages of the lifecycle of a product

• Definition of Lifecycle Assessment

• List and briefly describe the four components of an LCA process

• List five potential data sources for a lifecycle inventory

• Why is simulation important for (Predictive) Lifecycle Assessment?

• Explain the SLC project – are the results obtained in this project good with respect to a lifecycle assessment?

• Certain sample data are given for a super light car body (materials in car body, CO2 emission per kg for the production of each material, fuel saving, etc.). Compute the CO2 balance for the car body and write down your conclusion whether this balance is positive or negative and why.

• Why is the Human Factor in development and also LCA so important?

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Questions for Exams

• Simulation Data and Process Management (1)

• Introduction to SDM

• Motivation for Simulation Data and Process Management

• List and explain four industry trends in CAE which increase the need for SDM

• Increasing amount of product variants, boundary conditions, stochastic simulation, discipline combination

• What does “SDM” stand for, is data management all that is required?

• What is the general status regarding SDM in the industry today

• PDM established, SDM not - although needed

• Briefly explain PDM

• Management of product geometry structure and design data, configuration management

• What is a „200% car“

• Describe the virtual product development process with a descriptionwhere PDM and SDM are used (see slide 9)

• List and describe three main groups of SDM users with one sentenceeach

• Designers, expert analysts, enterprise users

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• Requirements for Simulation Data and Process Management

• List seven requirements for SDM which were discussed in the lecture

• Management of data

• Management of actions/processes

• Traceability

• User Interface

• Application programming interface

• Interactive handling and comparison of data

• Integration of multiple disciplines

• Access control

• Integration of suppliers

• Requirements regarding software and IT architecture

• Performance

• Integration with PDM/PLM

• Integration with physical test data

• Distributed SDM

• Configuration capabilities

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• Requirements for Simulation Data and Process Management

• You will be given one or more of these topics, describe this

requirement in more detail, for example:

• What are the specific requirements for managing data in an SDM

system? Ability to manage all data types typical for simulation, to

manage large volumes of data, to navigate and search quickly in

huge amounts of data; availability of life cycle actions

• What is „tracability“ and an Audit Trail Viewer

• What are the specific requirements regarding software and IT

architecture? Open architecture, scalability, load balancing and

failsafe, integration into existing IT infrastructures, backup strategy,

disaster tolerance

• What is „failsafe“?

• Which parts of an SDM system should be configurable? Data model,

actions/processes, user interface, access control, IT integration

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• Example: SimManager

• Describe the SimManager IT architecture as an example of a typical SDM system

• List and briefly explain four main groups of SDM functionalities using SimManager as example: Data Management, Process Management, Report Management, Collaboration, also be prepared forsome pinpoint questions, e.g.:

• What is a Work Request?

• How is data typically managed in an SDM – objectoriented or file oriented? Why?

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slide 45

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slide 44

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Questions for Exams

• IT Challenges Regarding Simulation WS 2014/2015• How many car models did Daimler Benz bring to the market from 1960-1990,

and from 2000-2010?• Which influence does this have regarding simulation and why?• How much does one physical car prototype cost approximately?• How many virtual crash tests were approximately executed for the C-class

which came to the market in 2007?• List the main types of computer architectures in the history of supercomputing

and give one example for each computer architecture (main frame, vector(mini)computers, RISC, RISC clusters, Intel x86 machines and clusters)

• What is the code name of the latest INTEL CPU family used for HPC?• How does a current supercomputer look like (x86 CPUs, Infiniband

interconnect, evtl. with GPUs)• You have a cluster of 16 cores and a program which can run in parallel for 90%

of the code. What is the (max.) speedup and what is the efficiency according to Amdahl’s law?

• Which example for a supercomputer was described in the lecture (SuperMUC), give an approximate description of the system (location, number of cores, number of nodes, peak performance, power consumption/cost, etc.)

• Which component of the SuperMUC is the biggest issue regarding reliability?• What are the consequences of energy cost? Energy-aware scheduling, run the

system at lower than nominal frequency especially not in turbo-mode, warm-water cooling.

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Good luck for the exam!

EXAM Q

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