A High Performance Computing Cloud Computing Environment for Machining Simulations

Abstract Machining is a pervasive manufacturing process used in industries such as automotive, aerospace, medical implants and oil and gas. Analysis of processes via physics-based modeling enables new and innovative designs for cutting tools, provides confidence of machined workpiece quality characteristics and allows reduction in machining cycle times and tooling costs. Progressively sophisticated analyses of machining processes have evolved with the inclusion of effects of full three-dimensional analysis of cutting tools and complex tool/workpiece kinematics. Detailed-level analysis of machined workpiece surfaces based on finite element method (FEM) allows prediction of residual stresses, work hardened layer depths and heat flow. However, with the increase in model sophistication has come with computational burden. This paper details a high performance computing (HPC) environment for finite element models used for machining analysis. First, the FEM model is reviewed and its extension to high core-count shared memory environments is described. Scaled performance improvements for up to forty cores are demonstrated and performance improvements documented. Next, an HPC cluster is designed and a specialized batch queuing software is implemented that allows submission, monitoring and management of large scale machining simulations. Finally, an infrastructure for delivering the HPC capability to customers through Software as a Service (SaaS) is introduced.