Customization and Automation of

Engineering Simulation Workflow

Mai Doan, Application Engineer

1 © 2011 ANSYS, Inc. June 21, 2012
Mai.Doan@ansys.com
 Agenda

1. Need for customization

2. Different Customization Methods
3. Application Customization Toolkit (ACT) and
Examples
4. Other Mechanical Customization possibilities
5. Other Fluid Customization possibilities
6. Other possibilities (Common)

2 © 2011 ANSYS, Inc. June 21, 2012

 Workflow Streamlining Using Design Points
and Optimization

Baseline Optimized
Design Design

3 © 2011 ANSYS, Inc. June 21, 2012

 Need for Customization

Capture the existing simulation process

Make repetitive operations automatic
Integrate CAE with other (or in-house) tools
Make the technology available to a wider group (non CAE experts)
….

4 © 2011 ANSYS, Inc. June 21, 2012

 Native and Data-Integrated Applications
Native applications
• Built entirely on WB2 Framework
• Embedded within the “Workbench” window
• Project Schematic, Design Exploration, Engineering
Data
• Fully supported by Workbench scripting
• Scripting language: Python

Data-integrated applications
– Share data and parameters with Workbench,
native applications, and other data-integrated
applications
– Independent UI, window
– E.g., Mechanical, Mechanical APDL,
CFX, FLUENT, DesignModeler
– Scripting Language: JScript, Scheme, APDL …
5 © 2011 ANSYS, Inc. June 21, 2012
 Workbench Scripting Overview
Application-level Scripting
• For task automation at the application level
– Mechanical, DM, Meshing: JScript
– CFX: CCL
– FLUENT: Scheme
– MAPDL: APDL

Workbench Scripting
• For task automation at project level
– Creating project, performing parameters simulations,
optimization etc.
• Works “hand-in-hand” with scripting in DIAs
– Can embed JScript, CCL, Scheme, APDL

6 © 2011 ANSYS, Inc. June 21, 2012

 Different Customization Methods
Application Customization Toolkit (ACT)
• Create new load/BC/results
• Integrate an external solver in Mechanical
Jscript (for DM, Meshing, Mechanical etc.)
• Task automation within the various applications
• Jscript add-in to add functionality in the application
Wizards (for DM, Meshing, Mechanical etc.)
• Creating a customized workflow within the DIA
Python Journaling
• For task automation at WB level (applicable for all applications available on WB)
– Creating Project, Performing Parameters simulations etc.
• Can use Jscript macros for DM, Meshing, Mechanical etc.
• Can use Scheme (Fluent), CCL (CFX), VBScript (Maxwell etc.)
External Connection Add-in
• Making external applications (not integrated with WB) to participate in workflow through
parameters
• Python scripting can be integrated to add functionality to WB
C# Add-in using Software Development Kit (SDK)
• Integrate external applications in workflow through custom systems
• WB GUI customization (addition of buttons, menu etc.)

7 © 2011 ANSYS, Inc. June 21, 2012

 An Introduction to Application
Customization Toolkit (ACT) and Examples

8 © 2011 ANSYS, Inc. June 21, 2012

 What is ACT
It is a Toolkit to customize Applications in Workbench

• In R14, ACT allows customization in the Mechanical application (Beta)

– Define customized boundary conditions and post-processing
– Replace command snippets with interactive objects
– Do much more than what the standard features in Mechanical
• Access node/element information, material, solution, results data …
• Perform: Crack propagation, Sub-modeling, MEMS, CMS (using ROM)
– Even replace the APDL solver with your custom solver!

• ACT would be available for more applications in future

• ACT provides an option to migrate APDL users to Mechanical

– Allow reusing legacy APDL developments in user-friendly way
– Gets the best of the two worlds!

• Developing ACT solutions is fast and efficient

– One doesn’t have to be a developer
– Simple ACT solutions can be developed in minutes
– ACT solutions are future ready!
9 © 2011 ANSYS, Inc. June 21, 2012
 Examples – What can be done ?

 Node coupling
 Sub-modeling simulation in Mechanical
 Acoustics simulation in Mechanical
 Custom result – “Contact Force Vectors”
 2D Convection Load extension
 Clamp and Displace extension
 Third party solver connection

10 © 2011 ANSYS, Inc. June 21, 2012

 Node Coupling

New extension for specific load creation

The Coupling object

11 © 2011 ANSYS, Inc. June 21, 2012

 Sub-modeling extension
Sub-modeling in Mechanical between 2 structural analysis
– Interpolation of displacement (CBDOF) and temperature (BFINT).
– Choose 2D-2D, 3D-3D or 2D axi-3D sub-modeling
– Choose Solid-solid & Shell-shell key or Solid-shell key
– Tabular data for multi-stepping

The sub-modeling extension was developed as an example just

to show the possibility. Since, sub-modeling is scheduled to be
released natively in Mechanical at R14.5, the extension is not
being developed further or distributed.

12 © 2011 ANSYS, Inc. June 21, 2012

 Acoustics simulation in Mechanical using ACT
Acoustics features in Mechanical without any command objects
– Define acoustics elements, real constants & material properties
– Apply acoustics boundary conditions & loads
– Plot Far/Near field & Time/Frequency results
– Postprocess Pressure & SPL

13 © 2011 ANSYS, Inc. June 21, 2012

 Example simulations

Speaker

Underwater

14 © 2011 ANSYS, Inc. June 21, 2012

 Visualize the Contact Force Vectors

• Contact Force is not available for

visualization in Mechanical

• In MAPDL, we have access to the contact

force components

• Using APDL commands, we can get all the

force components

• Using ACT, we can visualize the contact

force vectors

15 © 2011 ANSYS, Inc. June 21, 2012

 Visualize the Contact Force Vectors
!
The Minimum and
Maximum values of
the result can be
defined as
“parameter” to
perform DP and DX
analysis

16 © 2011 ANSYS, Inc. June 21, 2012

 2D Convection Load extension
• Apply a convective boundary condition to the blade surface in a 2D axi-symmetric
analysis

Need to apply a convective

boundary condition to this surface

Since the model is 2D, convective

boundary condition is allowed
only on edges!

Using a command snippet we can

apply the convection load to the
surface!

• Instead, expose the same functionality via ACT

17 © 2011 ANSYS, Inc. June 21, 2012

 2D Convection Load extension
! APDL_script_for_convection.inp

/prep7
thickness = 0.001
film_coefficient = 200.
temperature = 120
cmsel,s,component

*GET,n_el,ELEM,0,num,max
*GET,mat1, ELEM,n_el,ATTR,MAT

et,100,152
keyop,100,8,2.
et,1001,131
keyo,1001,3,2
sectype,1001,shell
secdata,thickness,mat1
secoff,mid

emodif,all,type,1001
emodif,all,secnum,1001
type,100
esurf
fini
alls
/solu
esel,s,type,,100
nsle
sf,all,conv,film_coefficient,temperature
allsel, all APDL WB Mechanical
18 © 2011 ANSYS, Inc. June 21, 2012
 Clamp and Displace extension
LS-1 LS-2

LS-3

Load Step-1: Apply the pressure  Allow the body to bend

Load Step-2: Clamp the top surface in its deformed state
Load Step-3: Apply a deformation to the clamped surface

19 © 2011 ANSYS, Inc. June 21, 2012

 Solution using Command Snippet
Definition based on named selection
previously defined

LS 2

LS 3

20 © 2011 ANSYS, Inc. June 21, 2012

 Solution using ACT
User inputs in the APDL command snippets are
translated to ACT properties related to the newly
integrated ACT load:
• The location provided by the named selection is now
defined based on a scoping method compatible with both
named selection and direct geometry selection

• The load step number for clamping is available from a drop-

down menu initialized with the number of steps already
defined in the Analysis Settings object

• The X Displacement value for the next load step is defined

by a new property declared as a length. This makes this
property always consistent with the current unit system
activated in Mechanical

21 © 2011 ANSYS, Inc. June 21, 2012

 Stress Limit Damage extension
Post-process the maximum admissible criteria based on temperature dependent
properties in Mechanical

The relevant material property are retrieved directly from EDA

The material property can also be defined by the user directly in Mechanical (user
defined property)
22 © 2011 ANSYS, Inc. June 21, 2012
 Stress Limit Damage extension

23 © 2011 ANSYS, Inc. June 21, 2012

 FEInfo extension

24 © 2011 ANSYS, Inc. June 21, 2012

 Tosca integration in Workbench

Tosca structure is an Non-parametric

Initial design optimization solver (topological
optimization)
Optimal result

Optimal design
Verification
25 © 2011 ANSYS, Inc. June 21, 2012
 Using ACT extensions

26 © 2011 ANSYS, Inc. June 21, 2012

 Using the ACT extension for a Project
The “Extensions” option is
available in the menu bar of
the project page

Extension Manager to
Load / Unload
available extensions

View log file to review

messages generated
from the extensions
27 © 2011 ANSYS, Inc. June 21, 2012
 Using ACT in Mechanical
Refresh to reload the
extensions

Command line editor

Functions list
Info window

Output window

28 © 2011 ANSYS, Inc. June 21, 2012

 ACT Extension Basics
• An ACT extension consists of
– XML file
• Configures the UI content: buttons in the
toolbar and objects in tree
• Defines the extensions properties
• Configures behaviors for custom loads and
results.
• Binds application events to IronPython
script functions.
– IronPython script file
• Implements the extension functionalities: retrieving mesh data,
writing in the ds.dat file, computing a customized result…
• Event driven
– Functions are invoked by application generated events
• Supports access to external libraries
• The script file is typically placed in a folder in the same name as
the XML file

• One may have additional files/folders to organize the content better

– E.g. a separate folder for images, other resources etc.

29 © 2011 ANSYS, Inc. June 21, 2012

 Extension structure

Customization Toolkit WB Project/Mechanical

Mechanical
toolbar Materials

Geometry
XML definition Pre-Processing Python
object scripts Mesh

Simulation data
Post-Processing
Results
object

UI Events

30 © 2011 ANSYS, Inc. June 21, 2012

 Other possibilities
(Mechanical)

31 © 2011 ANSYS, Inc. June 21, 2012

 Automation in Mechanical: Jscript macro

• Objectives: Apply Transient Force & Moment Loads from Excel

– Transient Force and Moment load consists of thousands (30,000+) of data points
– Applying these loads manually with so many inputs is impossible

• Solution:
– A new script is written for this automation
– This solution works fine on all versions on Mechanical (R11 to R14)

32 © 2011 ANSYS, Inc. June 21, 2012

 Automation in Mechanical
• Objectives: Automate Contact Generation and Naming from Excel
– Defining various contacts from Named Selections
– Rename the contacts appropriately : ContactType – sourceNS -to- targetNS
– Keep the generated contacts in a group for easy identification
– Have an Excel file for interactive and easy input

• Solution:
– A script is written for this automation
– A macro enabled Excel file helps user to provide correct inputs
– An additional script is also provided to rename contacts appropriately (not generated
from Excel file)

33 © 2011 ANSYS, Inc. June 21, 2012

 WB simulations from MS Excel
• WB simulations can be performed with user inputs in Excel

Both the Design Points are solved,

Projectisisstarted
WB simulation saved. in
Provide the the background.
Parameters for MaxStudy-1
Result from deformation values from
the Design Point Updating…those analysis are updated in
studies Excel

• WB Python journal is used for getting inputs from MS Excel, performing the simulation
and publishing results back to MS Excel
• Similarly other simulations (FLUENT, HFSS etc.) can be done

34 © 2011 ANSYS, Inc. June 21, 2012

 Customization possibilities
(Fluids examples)

35 © 2011 ANSYS, Inc. June 21, 2012

 WB simulations from MS Excel
• WB simulations can be performed with user inputs in Excel

Provide the
Parameters for
the Design Point
study
Both the DPs areissolved,
WB simulation startedProject
in is
DP1saved.
simulation is done.
the background.
DP1 simulation is
DP2Pressure
Updating…
Updating…drop values from those
analysis are updated in Excel

• WB Python journal is used for getting inputs from MS Excel, performing the
simulation and publishing results back to MS Excel
• Similarly other simulations (Mechanical, HFSS etc.) can be done

36 © 2011 ANSYS, Inc. June 21, 2012

 Customizing Mixing Simulation in WB

• Generate the
Mixing Tank
interactively
• Geometry
Parameters are
exposed in WB
for design point
studies
• Different
analyses can be
combined easily
• An unified
customized
report can be
generated
37 © 2011 ANSYS, Inc. June 21, 2012
 Using the Excel Component in WB

d and L are independent

d is constrained only if d> 0.05L

(d and L are now dependent)

L = 30
d=3

0.05*L = 1.5  constrained d = 1.5

38 © 2011 ANSYS, Inc. June 21, 2012

 Custom GUI on WB
A custom GUI opens that allows a
Pipe Flow CFD Simulation

Provide the dimensions of the pipe

Provide the inputs

The Some standard
residuals
Provide solverare results
controls
are displayed
displayed as the for a quick
A suitable mesh with
Provide check
simulation is progressing
theY+inputs
appropriate is
Validate the flow condition
generated
Plots some
Provide generated
inputsarefor
availableresults
extracting for display
(radial
View
Provide the inputs Mesh
Open CFD Post for an
Open a standard
Generate Meshreport profiles)
interactive post-
(with plots, contours,
processing
vectors etc.) Iterate

39 © 2011 ANSYS, Inc. June 21, 2012

 Customizing Mixing Simulation in WB

• Generate the
Mixing Tank
interactively
• Geometry
Parameters are
exposed in WB
for design point
studies
• Different
analyses can be
combined easily
• An unified
customized
report can be
generated
40 © 2011 ANSYS, Inc. June 21, 2012
 Other possibilities
(Common)

41 © 2011 ANSYS, Inc. June 21, 2012

 External Application Integration
• External Connection
– Allow external applications to participate in the workflow defined through the project
schematic

– Allow custom Toolbar button and menus

42 © 2011 ANSYS, Inc. June 21, 2012

 External Application Integration
Example:
• nCode is integrated in
Workbench Project Schematic
using C# add-in (SDK)
Typical Usage:
• Integrate in-house/third-party
codes deep in WB workflow
• Create Customized GUI on WB

43 © 2011 ANSYS, Inc. June 21, 2012

 Conclusion

• ANSYS provides multiple methods to extend and

customize Workbench
• Power and complexity range from basic scripting to
full programming
• Choose method that best fits your needs

44 © 2011 ANSYS, Inc. June 21, 2012

 THANK YOU!

45 © 2011 ANSYS, Inc. June 21, 2012