CREATE Program Overview-NDIA-SEDivision-Workshop-08-18-2010

Computational Research and Engineering
Acquisition Tools and Environments
Dr. Douglass Post
CREATE Program Manager
Chief Scientist
DoD High Performance Computing Modernization Program
CREATE Overview
7/16/2010 Page-1
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
CREATE Program Concept
 Enable major improvements in the acquisition process
– Prevent defects and design flaws early in the acquisition process
– Reduce rework thereby enabling faster system deployment
 How?
– Inject multi-physics based predictions early within the design and
analysis process
– Develop and deploy production quality design and analysis software
that is adaptable and maintainable
– Develop and deploy multi-physics based Computational
Engineering tools that exploit next generation computer resources
 CREATE is a multi-year program, funded at $40M to date
– Funding started in FY2008
– Initiated by USD(AT&L) in 2008
CREATE Overview
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CREATE – Four Projects, Ten Products
 Air Vehicles
DaVinci - Rapid conceptual design
Kestrel - High-fidelity, full vehicle, multi-physics analysis tool for fixed-wing aircraft
Helios - High-fidelity, full vehicle, multi-physics analysis tool for rotary-wing aircraft
Firebolt - Module for propulsion systems in fixed and rotary-wing air vehicles
 Ships
RDI - Rapid Design and Synthesis Capability—Partnership with ONR and NAVSEA
NESM - Ship Shock & Damage-prediction of shock and damage effects
NAVYFOAM - Ship Hydrodynamics-predict hydrodynamic performance
IHDE - Environment to facilitate access to Naval design tools
 RF Antenna
SENTRI - Electromagnetics antenna design integrated with platforms
 Meshing and Geometry
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Capstone - Components for generating geometries and meshes
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32 Months After Program Start, CREATE
Is Beginning To Deliver Usable Software.
5 beta releases in FY09/10 with V&V and ~ 150 beta testers:
10 releases planned for FY10/11 and each succeeding year
Helios 2.0, Kestrel 2.0, SENTRI 2.0, NESM 1.0 and IHDE 2.0 plus:
Helios 1.0—Accurate calculation of rotorcraft vortex shedding
Kestrel 1.0—Rigid body CFD fixed wing AV with preliminary aeroelastics
SENTRI 1.0 and 1.5—Initial RF antenna design and analysis with V&V
NESM 0.1—Initial ship shock vulnerability analysis for underwater explosions
IHDE 1.0—Iinitial user interface for ship hydrodynamics
Rapid design: RDI 1.0 for Ships, DaVinci 1.0 for Aircraft plus SENTRI 2.0
Components: Capstone 1.0 for geometry and mesh, Firebolt 1.0 for gas turbines
Detailed ship hydrodynamics NavyFoam 2.0 (seakeeping, drag, resistance,…)
Developing approaches to improve scalability
More accurate vortex shedding
Antenna Radiation Near Fields
Free Space
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Kestrel vs. F-16 Flight Data
M=0.95, Alt.=10,000 ft
Path Forward
 DoD has an opportunity to substantially reduce
product development time
– Requires adoption of multi-physics based software design and
analysis tools by both government and industry
 We don’t have a lot of insight into how these
products can move into industry
– Council on Competitiveness studies document that industry
has been slow to adopt multi-physics software
 How do we make this happen?
CREATE Overview
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Back-up slides
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Present Systems Engineering
Iterated DesignBuildTest Cycles
Physical Product Physical Product
(Many) Design
F-22 Flight Test
• Long time to deployment
• Requires many lengthy and expensive
design/build/test iteration loops
• Process converges slowly, if at all
• Design flaws discovered late in process
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A Paradigm Shift in Product
Development Is Underway
 Past :
– Repeated DesignBuildTest Cycles
 Present:
– Occasionally Augment DesignBuildTest with Limited
Single-Physics Analysis by Use of Research or
Commercial Codes
 Future:
– Design Through Analysis, Multi-Physics Design and
Analysis with Supercomputer Power
– Repeated CADMeshAnalyze Cycles Followed by a Few
DesignBuildTest Cycles
CREATE Overview
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Physics-based Engineering Software
Helped The US Win Cold War.
• Nuclear weapons
are complex,
expensive, and
hard to test
• ~ 5 to 10 tests
per system
• DOE NNSA uses
tools for:
• Design
optimization, &
• DOE NNSA labs
own the biggest
Weapon Capability
Improved safety
Improved robustness
Improved yield
to weight
Computational Design
Test ban
Air Tests
CREATE Overview
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Computer Power
(even lighter,
Improvements over time:
(even lighter,
• Solution methods
• Spatial resolution
• Temporal resolution
(lighter, smaller)
• Geometric fidelity
•1-D to 2-D to 3-D
• Physics models
0.000000001 • …….
Atomic Bombs
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Critical Factors for Success
 We analyzed what worked and what didn’t
– Must have a lot of experience in computational
– Must have the right people—especially team
leaders who have demonstrated that they can
– Must have highly skilled and experienced
multi-disciplinary team
– Must have stable support
 We applied these principles to CREATE
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The CREATE Approach
 Software is being built by government-led teams
 Each product has a roadmap
– Each year there is a release of a usable application
– Each release builds on the previous release and adds the
increased capability called for in the roadmap
– Each release is beta-tested by targeted user communities
before production release
 Releases are scalable for massively computers
and responsive to user requirements
 Users can access the applications, but we don’t
plan to release source code
CREATE Overview
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Early Success: Rapid
Deployment of EP-3E
• Shadow-Ops: CREATE staff use computational tools
to support acquisition programs  provide
experience and establish connections and value
• Performed CFD analysis of impact of electronic
countermeasure pod for EP-3E flight clearance--Not
sufficient time for conventional process (flight tests)
Eliminated construction cost of wind tunnel model and tests
and need for contractor flying quality report.
Provided aircraft flying qualities characteristics within
required time frame.
Provided data required to issue flight clearance in time
for direct deployment.
• Reduced overall program cost and time.
•Only 1 flying qualities flight test required – Saving
between 3-4 flight tests.
• System was deployed in the forward theatre in
less than four months instead of twelve
POC: Ms. Ryan
Fitzgerald, FQ
Engineer NAVAIR
New Forward
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Another Early Success
Improved Flight Certification Process for Marine Corps UAV
Problem: Expensive and lengthy UAV flight
certification for small-vendor designs due to
physical testing required for flight data.
Solution: Joint Navy and CREATE Air
Vehicles Shadow-Ops STUAS project used
computational engineering tools to rapidly
and cheaply develop the flight certification
Benefits to DoD Aircraft Programs
Reduced time and cost by eliminating the need
for physical model testing
Enabled industry competitiveness through quick
Services assessment of many vendor designs
Provided unbiased performance data to STUAS
Program Office for assessment of contractor
Six new vendors are now able to compete for
UAV contracts
Engineers: Drs. Theresa Shafer / Gary N. McQuay - PMA-263 STUAS/Tier II UAS
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8 foot wingspan
Some companies have
adopted this paradigm.
• Reduced time to
market from 3 years
to less than 1 year
• Increased new
products delivery
from 1 every 3 years
to 5 per year
CREATE Overview
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Design and
Mesh Virtual
Analyze and Test Build and Test
Virtual Product
Physical Product
L. K. Miller, Simulation-Based
Engineering for Industrial Competitive
Advantage, 2010, Computing in Science
Distribution Specified on First Slide and Engineering, 12, 14-21

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