Virtual Prototyping of Metal Melt Filters: A HPC-Based Workflow for Query-Driven Visualization

The advent of additive manufacturing has vastly increased the design space of filters for metal melt filtration. In order assess the large amount of possible filter designs before they are actually manufactured, a virtual prototyping workflow based on HPC simulations is proposed. A major challenge are the large data volumes produced even by single CFD simulations of metal melt flow and even more so by virtual prototyping settings, where a large number of filter designs must be evaluated. The LITE-QA framework addresses the large data problem by providing data management methods supporting both the simulation and the analysis phase: In the HPC environment, simulation data are compressed and indexed. In the analysis phase, search engine-like capabilities allow, e.g., for focused visualizations of filter regions that meet the search queries of the analyst. Building on the LITE-QA framework, a virtual prototypingVirtual prototyping study involving 84 new filter designs for metal melt filtration is conducted. Statistical analyses and comparative visualizations provide insights into the effects of geometric modifications of a reference design. Promising filter designs are identified where simulation results indicate an improved filtration efficiency, while only having a moderate effect on melt flow pressure. These virtual prototypes are proposed as candidates for further testing as physical prototypes.