SCALABLE INTEGRATED CIRCUIT SIMULATION ALGORITHMS FOR ENERGY-EFFICIENT TERAFLOP HETEROGENEOUS PARALLEL COMPUTING PLATFORMS

Integrated circuit technology has gone through several decades of aggressive scaling.It is increasingly challenging to analyze growing design complexity. Post-layout SPICE simulation can be computationally prohibitive due to the huge amount of parasitic elements, which can easily boost the computation and memory cost. As the decrease in device size, the circuits become more vulnerable to process variations. Designers need to statistically simulate the probability that a circuit does not meet the performance metric, which requires millions times of simulations to capture rare failure events. Recent, multiprocessors with heterogeneous architecture have emerged as mainstream computing platforms. The heterogeneous computing platform can achieve highthroughput energy efficient computing. However, the application of such platform is not trivial and needs to reinvent existing algorithms to fully utilize the computing resources. This dissertation presents several new algorithms to address those aforementioned two significant and challenging issues on the heterogeneous platform. Harmonic Balance (HB) analysis is essential for efficient verification of large postlayout RF and microwave integrated circuits (ICs). However, existing methods either suffer from excessively long simulation time and prohibitively large memory consumption or exhibit poor stability. This dissertation introduces a novel transient-simulation guided graph sparsification technique, as well as an efficient runtime performance modeling approach tailored for heterogeneous manycore CPU-GPU computing system to build nearly-optimal subgraph preconditioners that can lead to minimum HB simulation runtime. Additionally, we propose a novel heterogeneous parallel sparse block matrix algorithm by taking advantages of the structure of HB Jacobian matrices as well as GPU’s streaming multiprocessors to achieve optimal workload balancing during the preconditioning phase of HB analysis. We also show how the proposed preconditioned iterative algorithm can efficiently adapt to heterogeneous computing systems with different CPU and GPU computing capabilities. Extensive experimental results show that our HB solver can achieve up to 20X speedups and 5X memory reduction when compared with the state-of-the-art direct solver highly optimized for twelve-core CPUs. In nowadays variation-aware IC designs, cell characterizations and SRAM memory yield analysis require many thousands or even millions of repeated SPICE simulations for relatively small nonlinear circuits. In this dissertation, for the first time, we present a massively parallel SPICE simulator on GPU, TinySPICE, for efficiently analyzing small nonlinear circuits. TinySPICE integrates a highly-optimized shared-memory based matrix solver and fast parametric three-dimensional (3D) LUTs based device evaluation method. A novel circuit clustering method is also proposed to improve the stability and efficiency of the matrix solver. Compared with CPU-based SPICE simulator, TinySPICE achieves up to 264X speedups for parametric SRAM yield analysis without loss of accuracy

Gradient-Based Multi-Component Topology Optimization for Manufacturability

Topology optimization is a method where the distribution of materials within a design domain is optimized for a structural performance. Since the geometry is represented non-parametrically, it facilitates innovative designs through the exploration of arbitrary shapes. Due to its unconstrained exploration, however, topology optimization often generates impractical designs with features that prevent economical manufacturing, e.g., complex perimeters and many holes. Above all, existing topology optimization methods assume that the optimized structure will be made as a single piece. However, structures are usually not monolithic (i.e., single-piece), but assemblies of multiple components, e.g., cars, airplanes, or even chairs. It is mainly because producing multiple components with simple geometries is often less expensive (i.e., better manufacturability) than producing a large single-piece part with complex geometries, even with the additional cost of assembly. This dissertation discussed a topology optimization method for designing structures assembled from components, each built by a certain manufacturing process, termed the MTO. The prior art of MTO used discrete formulations solved by genetic algorithms. To overcome the high computational cost associated with non-gradient heuristic optimization, this dissertation proposed a continuously relaxed gradient-based formulation for MTO. The proposed formulation was demonstrated with three manufacturing processes. For the sheet metal stamping process, by modeling stamping die cost manufacturing constraints and assuming resistant spot welding joints, the simultaneous optimization of base topology and component decomposition was, for the first time, attained using an efficient gradient-based optimization algorithm based on design sensitivities. For the composite manufacturing process, a cube-to-simplex projection and penalization method was proposed to handle the membership unity requirement. With the multi-component concept, a unique structural design solution for economical composite manufacturing was achieved. The component-wise anisotropic material orientation design for topology optimization was presented without prescribing a set of alternative discrete angles as required by most existing material orientation methods. For the additive manufacturing process, the MTO method enabled the design of additively manufactured structures larger than the printer's build volume. By modeling manufacturing constraints on the build volume limit and elimination of enclosed holes, the optimized structure was an assembly of multiple components, each produced by a powder bed additive manufacturing machine. The first reported 3D example of MTO was presented.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/145989/1/yuqingz_1.pd

Energy-Efficient Technologies for High-Performance Manufacturing Industries

Ph.DDOCTOR OF PHILOSOPH

Developing and Improving a Thermometallurgical Model for 22MnB5 Steel in a Roller Hearth Furnace

Ultra-high strength steel (UHSS) such as Al-Si coated 22MnB5 are commonly used in the hot forming die quenching (HFDQ) process to produce light-weight automotive parts while maintaining good crashworthiness. The steel blank is typically austenitized in a roller hearth furnace, according to independently set heating zones and other parameters such as roller speed and part spacing. Most often these parameters are chosen heuristically based on experience, resulting in sub-optimal efficiency and part quality. To improve process efficiency and ensure complete austenitization before forming, a complete thermal-metallurgical furnace model that predicts the blank heating profile and the austenitization progress inside a roller hearth furnace is needed. This work introduces a framework for the furnace model, then evaluates three candidate austenitization submodels of different levels of complexity, including: a first order (F1) kinetics model, an Internal State Variable (ISV) model, and a phenomenological model. To address the drawbacks of conventional goodness-of-fit model derivation and evaluation method, the Bayesian model selection technique is introduced and used to evaluate the three candidates. This technique considers the uncertainties in the data, and the trade-off between model complexity and accuracy. Dilatometry data is used to calibrate the models and validate them. The selected austenitization submodel, ISV model, is integrated into the overall furnace model and its performance is validated using roller hearth furnace trials collected with instrumented blanks. The resultant coupled thermo-metallurgical furnace model provides a useful tool for researchers and industrial engineers to maximize production rate and ensure consistent part quality

SEIS: Insight's Seismic Experiment for Internal Structure of Mars.

By the end of 2018, 42 years after the landing of the two Viking seismometers on Mars, InSight will deploy onto Mars' surface the SEIS (Seismic Experiment for Internal Structure) instrument; a six-axes seismometer equipped with both a long-period three-axes Very Broad Band (VBB) instrument and a three-axes short-period (SP) instrument. These six sensors will cover a broad range of the seismic bandwidth, from 0.01 Hz to 50 Hz, with possible extension to longer periods. Data will be transmitted in the form of three continuous VBB components at 2 sample per second (sps), an estimation of the short period energy content from the SP at 1 sps and a continuous compound VBB/SP vertical axis at 10 sps. The continuous streams will be augmented by requested event data with sample rates from 20 to 100 sps. SEIS will improve upon the existing resolution of Viking's Mars seismic monitoring by a factor of ∼ 2500 at 1 Hz and ∼ 200 000 at 0.1 Hz. An additional major improvement is that, contrary to Viking, the seismometers will be deployed via a robotic arm directly onto Mars' surface and will be protected against temperature and wind by highly efficient thermal and wind shielding. Based on existing knowledge of Mars, it is reasonable to infer a moment magnitude detection threshold of M w ∼ 3 at 40 ∘ epicentral distance and a potential to detect several tens of quakes and about five impacts per year. In this paper, we first describe the science goals of the experiment and the rationale used to define its requirements. We then provide a detailed description of the hardware, from the sensors to the deployment system and associated performance, including transfer functions of the seismic sensors and temperature sensors. We conclude by describing the experiment ground segment, including data processing services, outreach and education networks and provide a description of the format to be used for future data distribution.Electronic supplementary materialThe online version of this article (10.1007/s11214-018-0574-6) contains supplementary material, which is available to authorized users

COMPUTATIONAL ANALYSIS OF FEASIBILITY AND UTILITY OF DIRECT-ADHESION POLYMER-TO-METAL HYBRID TECHNOLOGIES FOR USE IN LOAD BEARING BODY-IN-WHITE AUTOMOTIVE COMPONENTS

Traditionally, metals and plastics are fierce competitors in many automotive engineering applications. This paradigm is gradually being abolished as the polymer-metal-hybrid (PMH) technologies, developed over the last decade, are finding ways to take full advantage of the two classes of materials by combining them into a singular component/sub-assembly. By employing one of the several patented PMH technologies, automotive original equipment manufacturers (OEMs) have succeeded in engaging flexible assembly strategies, decreasing capital expenditures and reducing labor required for vehicle manufacture. The basic concept utilized in all PMH technologies is based on the fact that while an open-channel thin-wall sheet-metal component can readily buckle under compressive load, with very little lateral support, provided by a thin-wall rib-like injection-molded plastic subcomponent, the buckling resistance (and the stiffness) of the component can be greatly increased (while the accompanied weight increase is relatively small). In the present work, the potential of direct-adhesion PMH technologies for use in load-bearing structural automotive components is explored computationally. Within the direct adhesion PMH technology, load transfer between stamped sheet-metal and injection-molded rib-like plastic subcomponent is accomplished through a variety of nanometer-to-micron scale chemical and mechanical phenomena which enable direct adhesion between the two materials. Multi-disciplinary computations are carried out ranging from: (a) computational investigation of the sheet-metal stamping process including determination of the residual stresses and the extent of stamped-component warping; (b) computational fluid mechanics of the filling, packing and cooling stages of the injection-molding process including determination of flow-induced fiber orientation in the molded plastic and the extent of residual stresses and warping in the injection-molded sub-component: and (c) structural-mechanics computational investigation of the effect of injection-molded component residual stresses and warping on their ability to withstand thermal loading encountered in the paint shop and mechanical in-service loading. The results obtained revealed that a minimal level of the polymer-to-metal adhesion strength (5-10MPa) must be attained in order for the direct-adhesion PMH technologies to be a viable alternative in the load-bearing body-in-white (BIW) components. In the present work, also various PMH approaches used to promote direct (adhesive-free) adhesion between metal and injection-molded thermoplastics are reviewed and critiqued. The approaches are categorized as: (a) micro-scale polymer-to-metal mechanical interlocking; (b) in-coil or stamped-part pre-coating for enhanced adhesion; and (c) chemical modifications of the injection-molded thermoplastics for enhanced polymer-to-metal adhesion. For each of these approaches their suitability for use in load-bearing BIW components is discussed. In particular, the compatibility of these approaches with the BIW manufacturing process chain (i.e. (pre-coated) metal component stamping, BIW construction via different joining technologies, BIW pre-treated and painting operations) is presented. It has been found that while considerable amount of research has been done in the PMH direct-adhesion area, many aspects of these technologies which are critical from the standpoint of their use in the BIW structural applications have not been addressed (or addressed properly). Among the PMH technologies identified, the one based on micro-scale mechanical interlocking between the injection-molded thermoplastic polymer and stamped-metal structural component was found to be most promising. Lastly, the suitability and the potential of various polymer-powder spraying technologies for coating metal stampings and, thus, for enhancing the polymer-to-metal adhesion strength in direct-adhesion PMH load-bearing automotive-component applications is considered. The suitability of the spraying technologies is assessed with respect to a need for metal-stamping surface preparation/treatment, their ability to deposit the polymeric material without significant material degradation, the ability to selectively overcoat the metal-stamping, the resulting magnitude of the polymer-to-metal adhesion strength, durability of the polymer/metal bond with respect to prolonged exposure to high-temperature/high-humidity and mechanical/thermal fatigue service conditions, and compatibility with the automotive BIW manufacturing process chain. The analysis revealed that while each of the spraying technologies has some limitations, the cold-gas dynamic-spray process appears to be the leading candidate technology for the indicated applications

THE APPLICATION OF DISCONTINUOUS GALKERIN FINITE ELEMENT TIME-DOMAIN METHOD IN THE DESIGN, SIMULATION AND ANALYSIS OF MODERN RADIO FREQUENCY SYSTEMS

The discontinuous Galerkin finite element time-domain (DGFETD) method has been successfully applied to the solution of the coupled curl Maxwell’s equations. In this dissertation, important extensions to the DGFETD method are provided, including the ability to model lumped circuit elements and the ability to model thin-wire structures within a discrete DGFETD solution. To this end, a hybrid DGFETD/SPICE formulation is proposed for high-frequency circuit simulation, and a hybrid DGFETD/Thin-wire formulation is proposed for modeling thin-wire structures within a three-dimensional problem space. To aid in the efficient modeling of open-region structures, a Complex Frequency Shifted-Perfectly Matched Layer (CFS-PML) absorbing medium is applied to the DGFETD method for the first time. An efficient CFS-PML method that reduces the computational complexity and improves accuracy as compared to previous PML formulations is proposed. The methods have been successfully implemented, and a number of test cases are provided that validate the proposed methods. The proposed hybrid formulations and the new CFS-PML formulation dramatically enhances the ability of the DGFETD method to be efficiently applied to simulate complex, state of the art radio frequency systems

Timing Signals and Radio Frequency Distribution Using Ethernet Networks for High Energy Physics Applications

Timing networks are used around the world in various applications from telecommunications systems to industrial processes, and from radio astronomy to high energy physics. Most timing networks are implemented using proprietary technologies at high operation and maintenance costs. This thesis presents a novel timing network capable of distributed timing with subnanosecond accuracy. The network, developed at CERN and codenamed “White- Rabbit”, uses a non-dedicated Ethernet link to distribute timing and data packets without infringing the sub-nanosecond timing accuracy required for high energy physics applications. The first part of this thesis proposes a new digital circuit capable of measuring time differences between two digital clock signals with sub-picosecond time resolution. The proposed digital circuit measures and compensates for the phase variations between the transmitted and received network clocks required to achieve the sub-nanosecond timing accuracy. Circuit design, implementation and performance verification are reported. The second part of this thesis investigates and proposes a new method to distribute radio frequency (RF) signals over Ethernet networks. The main goal of existing distributed RF schemes, such as Radio-Over-Fibre or Digitised Radio-Over-Fibre, is to increase the bandwidth capacity taking advantage of the higher performance of digital optical links. These schemes tend to employ dedicated and costly technologies, deemed unnecessary for applications with lower bandwidth requirements. This work proposes the distribution of RF signals over the “White-Rabbit” network, to convey phase and frequency information from a reference base node to a large numbers of remote nodes, thus achieving high performance and cost reduction of the timing network. Hence, this thesis reports the design and implementation of a new distributed RF system architecture; analysed and tested using a purpose-built simulation environment, with results used to optimise a new bespoke FPGA implementation. The performance is evaluated through phase-noise spectra, the Allan-Variance, and signalto- noise ratio measurements of the distributed signals

Innovative mathematical and numerical models for studying the deformation of shells during industrial forming processes with the Finite Element Method

The doctoral thesis "Innovative mathematical and numerical models for studying the deformation of shells during industrial forming processes with the Finite Element Method" aims to contribute to the development of finite element methods for the analysis of stamping processes, a problematic area with a clear industrial application. To achieve the proposed objectives, the first part of this thesis covers the solid-shell elements. This type of element is attractive for the simulation of forming processes, since any type of three-dimensional constitutive law can be formulated without the need to consider any additional conjecture. Additionally, the contact of both sides can be easily treated. This work first presents the development of a triangular prismatic solid-sheet element, for the analysis of thick and thin sheets with capacity for large deformations. This element is in total Lagrangian formulation, and uses neighboring elements to compute a field of quadratic displacements. In the original formulation, a modified right Cauchy tensor was obtained; however, in this work, the formulation is extended obtaining a modified strain gradient, which allows the concepts of push-forward and pull-back to be used. These concepts provide a mathematically consistent method for the definition of temporary derivatives of tensors and, therefore, can be used, for example, to work with elasto-plasticity. This work continues with the development of the contact formulation used, a methodology found in the bibliography on computational contact mechanics for implicit simulations. This formulation consists of an exact integration of the contact interface using mortar methods, which allows obtaining the most consistent integration possible between the integration domains, as well as the most exact possible solution. The most notable contribution of this work is the consideration of dual augmented Lagrange multipliers as an optimization method. To solve the system of equations, a semi-smooth Newton method is considered, which consists of an active set strategy, also extensible in the case of friction problems. The formulation is functional for both frictionless and friction problems, which is essential for simulating stamping processes. This frictional formulation is framed in traditional friction models, such as Coulomb friction, but the development presented can be extended to any type of friction model. The remaining necessary component for the simulation of industrial processes are the constitutive models. In this work, this is materialized in the formulation of plasticity considered. These constitutive models will be considered plasticity models for large deformations, with an arbitrary combination of creep surfaces and plastic potentials: the so-called non-associative models. To calculate the tangent tensor corresponding to these general laws, numerical implementations based on perturbation methods have been considered. Another fundamental contribution of this work is the development of techniques for adaptive remeshing, of which different approaches will be presented. On the one hand, metric-based techniques, including the level-set and Hessian approaches. These techniques are general-purpose and can be considered in both structural problems and fluid mechanics problems. On the other hand, the SPR error estimation method, more conventional than the previous ones, is presented. In this area, the contribution of this work consists in the estimation of error using the Hessian and SPR techniques for the application to numerical contact problems.La tesis doctoral "Modelos matemáticos y numéricos innovadores para el estudio de la deformación de láminas durante los procesos de conformado industrial por el Método de los Elementos Finitos" pretende contribuir al desarrollo de métodos de elementos finitos para el análisis de procesos de estampado, un área problemática con una clara aplicación industrial. De hecho, este tipo de problemas multidisciplinares requieren el conocimiento de múltiples disciplinas, como la mecánica de medios continuos, la plasticidad, la termodinámica y los problemas de contacto, entre otros. Para alcanzar los objetivos propuestos, la primera parte de esta tesis abarca los elementos de sólido lámina. Este tipo de elemento resulta atractivo para la simulación de procesos de conformado, dado que cualquier tipo de ley constitutiva tridimensional puede ser formulada sin necesidad de considerar ninguna conjetura adicional. Además, este tipo de elementos permite realizar una descripción tridimensional del cuerpo deformable, por tanto, el contacto de ambas caras puede ser tratado fácilmente. Este trabajo presenta en primer lugar el desarrollo de un elemento de sólido-lámina prismático triangular, para el análisis de láminas gruesas y delgadas con capacidad para grandes deformaciones. Este elemento figura en formulación Lagrangiana total, y emplea los elementos vecinos para poder computar un campo de desplazamientos cuadráticos. En la formulación original, se obtenía un tensor de Cauchy derecho modificado (¯C); sin embargo, en este trabajo, la formulación se extiende obteniendo un gradiente de deformación modificado (¯F), que permite emplear los conceptos de push-forward y pull-back. Dichos conceptos proveen de un método matemáticamente consistente para la definición de derivadas temporales de tensores y, por tanto, puede ser usado, por ejemplo, para trabajar con elasto-plasticidad. El elemento se basa en tres modificaciones: (a) una aproximación clásica de deformaciones transversales de corte mixtas impuestas; (b) una aproximación de deformaciones impuestas para las Componentes en el plano tangente de la lámina; y (c) una aproximación de deformaciones impuestas mejoradas en la dirección normal a través del espesor, mediante la consideración de un grado de libertad adicional. Los objetivos son poder utilizar el elemento para la simulación de láminas sin bloquear por cortante, mejorar el comportamiento membranal del elemento en el plano tangente, eliminar el bloqueo por efecto Poisson y poder tratar materiales elasto-plásticos con un flujo plástico incompresible, así como materiales elásticos cuasi-incompresibles o materiales con flujo plástico isocórico. El elemento considera un único punto de Gauss en el plano, mientras que permite considerar un número cualquiera de puntos de integración en su eje, con el objetivo de poder considerar problemas con una significativa no linealidad en cuanto a plasticidad. Este trabajo continúa con el desarrollo de la formulación de contacto empleada, una metodología que se encuentra en la bibliografía sobre la mecánica de contacto computacional para simulaciones implícitas. Dicha formulación consiste en una integración exacta de la interfaz de contacto mediante métodos de mortero, lo que permite obtener la integración más consistente posible entre los dominios de integración, así como la solución más exacta posible. La implementación también considera varios algoritmos de optimización, como la optimización mediante penalización. La contribución más notable de este trabajo es la consideración de multiplicadores de Lagrange aumentados duales como método de optimización. Estos permiten condensar estáticamente el sistema de ecuaciones, lo que permite eliminar los multiplicadores de Lagrange de la resolución y, por lo tanto, permite la consideración de solvers iterativos. Además, la formulación ha sido adecuadamente linealizada, asegurando la convergencia cuadrática del problema. Para resolver el sistema de ecuaciones, se considera un método de Newton semi-smooth, que consiste en una estrategia de set activo, extensible también en el caso de problemas friccionales. La formulación es funcional tanto para problemas sin fricción como para problemas friccionales, lo que es esencial para la simulación de procesos de estampado. Esta formulación friccional se enmarca en los modelos de fricción tradicionales, como la fricción de Coulomb, pero el desarrollo presentado puede extenderse a cualquier tipo de modelo de fricción. Esta formulación de contacto es totalmente compatible con el elemento sólido-lámina introducido en este trabajo. El componente necesario restante para la simulación de procesos industriales son los modelos constitutivos. En este trabajo, esto se ve materializado en la formulación de plasticidad considerada. Estos modelos constitutivos se considerarán modelos de plasticidad para grandes deformaciones, con una combinación arbitraria de superficies de fluencia y potenciales plásticos: los llamados modelos no asociados. Para calcular el tensor tangente correspondiente a estas leyes generales, se han considerado implementaciones numéricas basadas en métodos de perturbación. Otra contribución fundamental de este trabajo es el desarrollo de técnicas para el remallado adaptativo, de las que se presentarán distintos enfoques. Por un lado, las técnicas basadas en métricas, incluyendo los enfoques level-set y Hessiano. Estas técnicas son de propósito general y pueden considerarse tanto en la aplicación de problemas estructurales como en problemas de mecánica de fluidos. Por otro lado, se presenta el método de estimación de errores SPR, más convencional que los anteriores. En este ámbito, la contribución de este trabajo consiste en la estimación de error mediante las técnicas de Hessiano y SPR para la aplicación a problemas de contacto numérico. Con los desarrollos previamente introducidos, estaremos en disposición de introducir los casos de aplicación centrados en el contexto de procesos de estampado. Es relevante destacar que estos ejemplos son comparados con las soluciones de referencia disponibles en la bibliografía como forma de validar los desarrollos presentados hasta este punto. El presente documento está organizado de la siguiente manera. El primer capítulo establece los objetivos y revisa la bibliografía acerca de los temas clave de este trabajo. El segundo capítulo hace una introducción de la mecánica de medios continuos y los conceptos relativos al Método de los Elementos Finitos (MEF), necesarios en los desarrollos que se presentarán en los capítulos siguientes. El tercer capítulo aborda la formulación del elemento sólido-lámina, así como del elemento de lámina sin grados de libertad de rotación que inspira el sólido-lámina desarrollado. Esta parte muestra varios ejemplos académicos que son comúnmente empleados en la bibliografía como problemas de referencia de láminas. El cuarto capítulo presenta la formulación desarrollada para la resolución de problemas de contacto numérico, consistente en una formulación implícita de integración exacta mediante métodos mortero y multiplicadores de Lagrange aumentados duales. Este capítulo incluye, asimismo, varios ejemplos comúnmente encontrados en la bibliografía, que generalmente son considerados para su validación. El quinto capítulo presenta la formulación de plasticidad empleada, incluyendo algunos detalles técnicos desde el punto de vista de la implementación, así como varios ejemplos de validación. El sexto capítulo muestra los algoritmos de remallado adaptativo desarrollados en el contexto de este trabajo, y presenta varios ejemplos, que incluyen no solo casos estructurales, sino también de mecánica de fluidos. El séptimo capítulo encapsula algunos casos de validación y aplicación para procesos de estampado. El capítulo final comprende las conclusiones, así como los trabajos que podrían continuar el presente estudio.Postprint (published version