Coreform Crunch

Coreform Crunch (beta)

There is no practical limit on the scale of models that simulation users would like to analyze. Coreform Crunch is new software written from the ground up to more accurately and efficiently handle complex models.

Coreform Crunch is the first commercial solver that uses smooth splines as the mesh to perform finite element analysis. This spline-based approach to FEA yields more accurate results than traditional mesh representations and decreases overall simulation time. Coreform Crunch is rapidly developing capabilities and establishing integrations with leading simulation and CAD software. Coreform is actively working with a number of customers in the automotive and defense industries during this development. If you are interested in becoming a Coreform partner, please contact us.


Faster, more accurate, more robust simulation

One of the biggest advantages to using splines in simulation is that, in contrast to mesh elements, the spline elements can have a large aspect ratio and still produce extremely accurate results, sometimes more accurate than well-formed mesh elements. The need for fewer elements reduces computation time, allowing you to run more simulations. For example, in a case study of a flex cable simulation, Crunch required 1,000 times fewer elements than mesh elements.

Using analysis-suitable geometry, Coreform Crunch is able to run analysis significantly faster than traditional FEA solvers. For example, to predict delamination and wrinkling of a flat flex cable after bending and temperature change, Coreform Crunch ran a simulation on a desktop previously impractical for a customer to run on their HPC.

Above left — Simulation results,   Above right — Flex cable illustration

Commercial code Coreform Crunch Comparison
Element count 10 million 10,900 ~1000x fewer elements
Element count Explicity statistics
5 million timesteps
Implicit dynamics
250 timesteps
~20,000x fewer timesteps
Element count 72,000
(2000 cores for 36 hours)
(5 cores for 12 hours)
1200x faster runtine
Approximate Exact Better geometry

Exact geometry representation

Another advantage to The CAD is exactly represented with splines rather than approximated with faceted mesh elements.

Fig. U-splines capture exact geometry

Proven technological foundation

Coreform Crunch is based on the same finite element method used in mainstream simulation software, but instead of writing our solutions to work on traditional faceted meshes, our solver natively supports smooth spline-based meshes. The smoothness across elements offers significant benefits over traditional higher-order elements, and is based on the isogeometric analysis (IGA) concept first introduced by Coreform Senior Advisor Dr. Tom Hughes in 2005.

Traditional FEA solvers use a discretized model consisting of nodes and node connectivity (a mesh) to construct basis functions for each mesh element. These basis functions are used to construct the system of finite element equations that approximates the solution for each discrete element. Linear basis functions are the most robust and most popularly used, thiThese are then combined into a large system of equations that models the entire domain. Applying boundary conditions, the solver can then solve for the unknowns.

Similar to traditional FEA solvers, Coreform Crunch uses the finite element method. However, the user can define the level of smoothness between elements, the degree of each element, and can also locally refine elements (hpk).

U-splines—a universal spline for FEA

For more than 15 years, Coreform and others have researched isogeometric analysis (IGA), and evaluated the use of splines, such as B-splines, NURBS and T-splines, for finite element analysis.

Coreform’s research led to its invention of unstructured splines (U-splines). The U-spline algorithm provides a new way to define basis functions over elements of differing polynomial degree whereas for T-splines and B-splines the degree must be the same everywhere. Even greater variations are admitted in higher dimensions. Also, U-splines permit mixed polynomial degree, element size, and local continuity in ways that are impossible for NURBS and T-splines. We can also handle unstructured meshes without modifying the algorithm.


Integration with ANSYS LS-DYNA

Smooth, U-spline geometry created in Coreform Crunch can be sent for spline-based simulation in LS-DYNA through the Bezier Extraction (BEXT) keyword. This is an efficient way to generate unstructured, detailed meshes for use for isogeometric analysis in LS-DYNA.

Integration with Trelis

Coreform Crunch is tightly integrated with Coreform Trelis, the industry’s leading hex meshing software. Coreform Crunch can also be run integrated with the Department of Energy’s CUBIT software to fit into existing workflows.

Integration with Autodesk Fusion 360

T-Spline models created in Autodesk Fusion 360 can be exported for use directly in Coreform Crunch.

Integration with MOOSE

Smooth, U-spline geometry created in Coreform Crunch can be sent for spline-based simulation in MOOSE through the Bezier Extraction (BEXT) keyword. This is an efficient way to generate unstructured, detailed meshes for use for isogeometric analysis in MOOSE for nuclear energy simulation.

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