Blue Collar Computing – OSC Approach to Industrial Outreach IDC HPC User Forum, Beijing

1. Blue Collar Computing – OSC Approach to Industrial OutreachIDC HPC User Forum, Beijing Ashok Krishnamurthy Interim Co-Executive Director ashok@osc.edu October 30, 2010

2. OSC Contributions to Ohio Academic and Industrial Research • Providing HPC resources and research support to higher education • Empowers over $85 million per year in research grants to the PIs that use OSC resources • Represents a return on investment on state dollars of 17:1 • Making Ohio industry more competitive through the use of modeling and simulation • Training the future workforce • New academic and certificate programs Our duty is to empower our clients, partner strategically to develop new research and business opportunities, and lead Ohio's knowledge economy

3. Providing Stable Computational Infrastructure Glenn IBM 1350 System • AMD Opteron processors • 9,500+ cores • 24 TBytes memory • 75+ teraflops • Blend of 4, 8 & 16 core nodes • Large processor count • Large memory SMP jobs Csuri GPU Environment • 16 nVidia C1060 cards installed on BALE • 18 nVidiaQuadroPlex 2200 S4 units installed on Glenn Mass Storage • ~1 PBytes disk • 80 TBytes tape • NFS, PVFS, iSCSI

4. OSC Supports Variety of Research Applications • Computational Fluid Dynamics • FLUENT (serial and parallel) • Flow 3D • OpenFOAM (serial and parallel) • Structural Mechanics • LS-DYNA (parallel) • ABAQUS (serial and parallel) • ANSYS • Altair Hyperworks • Mesh Generation/Pre-processing • Altair Hypermesh • Gambit • GridPro • Biosciences • Amber • Bioperl • BLAST OSC staff members maintain more than 30 software applications and provide access to more than 70 different software packages 4

5. OSC’s Industrial Outreach ProgramBlue Collar Computing

6. Ohio’s Emerging Areas of Excellence Future Ohio competitiveness is linked to application of computation to solve design, engineering, and research challenges through modeling, experimentation, and analysis. Premise: Council on Competitiveness case studies demonstrate how key U.S. industries applied computational science to gain a competitive edge over global competitors Numerous other national studies reinforce link between computation and competitiveness

7. OSC’s 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 competitiveness • Invited Talk: Towards a High Performance Computing Economy: Blue Collar Computing • Public and private sector researchers partner to: • Accelerate product development • Promote process improvement • Solve challenging scientific and industrial / business problems • BCC Impacts Time, Quality and Cost of Product & Service Development

8. Two 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 maker Novice - and some experienced – HPC users is to develop industry-specific portals in collaboration with industry-focused organizations EWI, PolymerOhio Blue Collar Computing Clients

9. OSC Portal Philosophy • Develop portal based HPC access to areas of strategic interest: BCC and biomedical sciences –Targeted (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 appliances” –Integrated applications that engage user

10. Partnership with Edison Welding InstituteEWI-OSC WeldPredictor Users Web browser • Secure website • Easy access to advanced weld modeling tools • Arc welding procedures • Single and multi-pass welding simulation • Output • Temperature • Hardness • Residual stress • Distortion https://eweldpredictor.ewi.org/

11. WeldPredictor Development History • WeldPredictor has been in development stage over past 4 years: • 2007 - Prototype launch • 2008 - Bug fixes • 2009 - Weld bead enhancement and accuracy improvement • 2010 - Deployment • Significant effort and funding were invested during the development • EWI project team members including S. Babu, S. Khurana, W. Zhang, W. Gan, J. Xu, H. Kim, and Y. Yang • OSC project team members including N. Ludban, L. Yang, and D. Hudak

12. WeldPredictor Was Recognized Internationally • About 550 engineers worldwide have used EWI WeldPredictor • EWI won the 2009 International Institute of Welding Sossenheimer Award for this innovative modeling software • A WeldPredictor paper was published in the Journal of Welding in the World, Volume 53, Issue 1/2, January/February 2009 • WeldPredictor was presented in a number of international conference: PVP2008, IABC2009, AeroMat2009, and GDIS2010

13. WeldPredictor Portal Impact • WeldPredictor 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 parameters • WeldPredictor changes industrial engineers’ thinking to solve a problem. They start thinking to apply modeling in problem solving.

14. Login page

15. Weld Geometry Selection

16. Status Page

17. E-Weld Predictor Example Output

18. Partership with PolymerOhio PolymerOhio-OSC PolymerPortal • Polymer Portal being developed in collaboration with PolymerOhio • The Polymer Portal will offer: • Computational resources and software for modeling/simulation • Expertise in polymer science and engineering • Training • Databases with relevant material properties • Advanced instrumentation • Business intelligence and strategy • Offering Moldex3D and Ximex for industry and education training Web front end –Pylons –JSON –Tomcat –mySQL –JUnit –Apache –Ant –Python and Java Software components supporting the OSC Portals

19. Polymer Portal Computational Application: Prediction of Nanofiber Composite Processing • Problem: 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 properties • Solution: Use multi-physics modeling and simulation to identify optimum processing routes for nanotechnology based fiber composites

20. Nanofiber Design Portal

21. MEP Advanced Modeling and Simulation • Funded by NIST MEP for PolymerOhio and OSC • Goals: • Raise awareness of MS&A in Polymer industry and MEP system • Make cost-effective computational methods available to SMEs • ~$700K for 1st year • Case studies provide MEP model to: • Illustrate MS&A value to production and profitability • Assist companies in application selection • Develop training for high value-added MS&A apps • Engage companies in employee training for MS&A • Provide broad access to low-cost, productivity-enhancing apps Projects (6 Projects) Outreach to Industry (50 Visits) Productivity Audits (24 Audits) Training (4 Courses) App Access (5 Apps)

22. Light 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 RAM

23. Optimized Control Arm with minimum weight, & comparable steelstiffness Metallic and Hybrid Composite Design Optimized Shape Volume of control arm before optimization: 106.9 in^3 Volume of control arm after optimization: 132 in^3 Hybrid Control Arm Damage Initiation at 8000 lb Fracture at 13000 lb Failure Mechanism contribution Damage Growth at 12000 lb

24. Development Costs – Design Landscape Estimated savings using HPC analysis: $233,000 *HPC-based analysis not applicable, existing desktop based analysis sufficient **Cost assumed to be for new unit design and qualification, installation costs ignored

25. Partnership with Center for Automotive ResearchPHEV Battery Simulation 26

26. PHEV Battery Simulations • Goal: Achieve a better understanding of the characteristics and behavior of lithium-ion automotive batteries arranged in parallel • Configuration 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 OSC’s Remote MATLAB Services • Funding: OSU Center for Automotive Research 27

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

28. OSC’s Workforce Development ProgramRalph Regula School of Computational Science

29. Expert in Applications Engineers/ scientists in university and business Applying protein folding simulations to discover candidates for new drugs Certificate and graduate programs; OSC training courses Understand use of modeling for business and research Current workforce College graduates Using commercial computational package or service to test strength of new container design Certificate program Undergraduate minor program OSC training program Applying models to engineering and architecture fields Ohio PLTW students and teachers Modeling simple physics phenomena: statics, gravity, pendulum PLTW training course for teachers; course given to students Education: Building a workforce competent in computational science Level Audience Example Programs Cause and effect relationships and simple modeling principles Middle and high school students and teachers Model of disease transmission in human population Teacher professional development programs; workshops for middle and high school students

30. Certificate Program to Meet Employer Needs • Certificate programs • Focus on skills needed by employers • “Stackable” certificates starting with basic skills and working up to advanced skills • Level 1 Certificates • Meet competencies of undergraduate minor • Will require mathematics review for displaced workers • Possible certificates: • Modeling and Simulation • Parallel computing • Visualization • Programming and algorithms for computational scientists • Level 2 Certificates • More specialized, focused on specific computational expertise

31. RRSCS Industry Certificate Program Underway • First of several “stackable” certificates in place at Sinclair Community College • Plans to extend to Columbus State CC • Expect an advanced certificate in polymer manufacturing later this year • Working with PolymerOhio and Moldex3D • Working with the National Association of Manufacturers on a second advanced certificate program in metal stamping

32. Challenges: Lessons Learned in Industry Engagement • High 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 requirements • Commercial software and licensing is a HUGE bottleneck • Engage with your state economic development agency early • Workforce development is very important • Clearly understand your cost to provide industrial support

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