CFD Analysis and Design Exploration with STAR-CCM+ Joel Davison

Transcription

1 CFD Analysis and Design Exploration with STAR-CCM+ Joel Davison Realize innovation.

2 STAR-CCM+ An integrated multiphysics solution for the Digital Product Comprehensive Multiphysics Integrated Design Exploration Automated Meshing Single User Interface Advanced Data Analysis Application Specific Workflows Discover Better Designs, Faster! Parallel Efficiency Workflow Automation Page 2

3 STAR-CCM+ An integrated multiphysics solution for the Digital Product Realism with multiphysics Integrated multiphysics from a single user interface Improved accuracy by taking into account a greater range of interconnected physical phenomena Built on a backbone of state-of-the-art, industry leading CFD capabilities Both finite element and finite volume approaches No need to compromise Choose the scheme appropriate to the physics Integration with CAE tools to expand simulation scope Flexibility to us the right tool for the job Loose and fully coupled co-simulation with 1D & 3D software solutions We ve been able to deepen our analysis and drive engine designs faster and more effectively with the same resources as before Jeff Schlautman, General Motors Page 3

4 STAR-CCM+ An integrated multiphysics solution for the Digital Product Realism with multiphysics Fluid dynamics Multiphase flows Reacting flows Solid mechanics Particle flows Rheology Electrochemistry Electromagnetics Aero-acoustics Fluid-structure interaction Conjugate heat transfer Page 4

5 Mass flow outlet for coupled solver and compressible flows Expands applicability and improves ease of use D1406 Predict characteristic speed lines all the way to surge Typically hard to converge operating points towards surge with pressure outlet Allows available boundary information to be applied For many applications only upstream data is available Use Cases Turbomachinery Page 5

6 Capsule DEM primitive particles D3485 Improved accuracy in capturing the effect of particle shape Reduces turnaround time compared to cylinders Use cases Pharmaceutical tablet coating Biomass fuel production (wheat straw pellets) Fluidized bed gasifiers (feedstock particles) New materials research Page 6

7 Capsule DEM primitive particles D3485 Capsules are spherocylinders Made up of two hemispheres connected by a cylinder No sharp edges on the surface of capsule Contact can be modeled with other particle types Spheres, cylinders, clumps, composites, polyhedral, coarse grain Contacts with other particle types resolved Page 7

8 Capsule DEM primitive particles - performance D3485 Simulations with capsules are faster compared to cylinders and 5-sphere composites Test case: Fluidized bed simulation (10 s, particles) Capsule Composite (5 spheres) Cylinder Simulation time (min) Performance benefit of capsule compared to composite particle is increasing more than linearly with the number of spheres per composite particle Page 8

9 CPU time speedup Dynamic mechanism reduction (DMR) Significantly faster high-fidelity combustion Dynamic removal of unnecessary reactions and species in Complex Chemistry Effective for chemistries with >50 species Applications Multi-stream combustion in abatement systems Transient combustion and emissions in gas turbines, furnaces, burners Sandia D, GRI 3.0 Sandia D, Marinov ECN spray H, Wang ECN spray H, Lu ECN spray H, Ahmed 0.6 No Acceleration Clustering DMR Clustering + DMR Page 9

10 Dynamic mechanism reduction (DMR) 4x faster with retained accuracy with DMR N-heptane spray bomb case: ECN spray H Chemistry: Lu skeletal, 188 species Page 10

11 STAR-CCM+ An integrated multiphysics solution for the Digital Product Productivity with streamlined workflows and automation Designed with automation in mind Seamless process from geometry to results Consistent, robust and repeatable workflows Ensuring best practice with simulation templates No compromise between usability and functionality Easy to learn and use even for advanced configurations and physics Single, flexible yet powerful scripting language Automate the complete workflow with Java Customize your experience with user designed panels Use Simulation assistants for step by step processes Compared to before, now we can simulate several dozen cases in a reduced time. Thanks to this, the number of actual prototypes being turned out has also been reduced, making an extremely valuable contribution to lowering cost and man-hours alike. Eiji Ihara, Kawasaki Heavy Industries Ltd. Page 11

12 STAR-ICE STAR-ICE is an add-on to STAR-CCM+, providing a customized workflow for setting up in-cylinder simulations within STAR-CCM+ STAR-ICE opens as a minimal model tree, separate from the full STAR-CCM+ simulation tree Contains only inputs relevant to the in-cylinder application Presents a top-down workflow Uses terminology and data inputs that are familiar to powertrain engineers Automates mesh-motion setup, saving valuable engineering time In various locations, provides feedback on input data to give the user an idea of the validity of their input data, e.g. valve lift curves and initial/boundary conditions as profile plots Page 12

13 STAR-ICE Workflow: Morph-Map Mesh Motion D571 The study here used publicly available TCC engine data, which was created with funding by General Motors through the General Motors University of Michigan Automotive Cooperative Research Laboratory, Engine Systems Division: handle/ / Page 13

14 STAR-ICE Workflow: Default Post-Processing Outputs STAR-ICE automatically creates post-processing output in the form of plots and scenes Additional scenes can be created by the user Copy/paste to create more scenes Turn on/off automatically-created cross-sections Manually create new cross-sections Interactions to customize scenes/plots use standard methods, familiar to STAR-CCM+ users Page 14

15 Fill report monitors from Solution History representations D863 Solution history (.simh) substantially reduces time & resources for Data Analysis File sizes are typically 100X smaller We know that the time to Run simulations can take many hours to days Animate through all states in.simh takes minutes Advance between timesteps in.simh takes seconds Rapidly create more effective time history plots Time history data can be quickly reviewed & animated Applying scalar extents for the whole time range make animations easier to understand Monitors can now be filled rapidly & easily using.simh content Dataset Functions can use.simh monitor data sources as input Time to run sim: ~2.5 days Time to record simh anim: ~6 min Page 15

16 Fill report monitors from Solution History representations D863 Case study: Industrial Mixer Work with multiple sliding window Field Monitors to understand the effect of different statistical approaches for averaging Page 16

17 Collocated Field Functions for min/max reports Save time by getting more information from reports Reduce the user effort to return quantitative information from analyses Further your ability to effectively communicate your results For Min/Max reports, we now return additional values Specify collocated Field Functions as a report property to Find where the maximum temperature is for underhood cases Return the mixing intensity for min/max concentrations Return species concentrations for min/max Mixing Fraction Page 17

18 Collocated Field Functions for min/max reports Case study: Industrial Mixer Track the location of the maximum tracer concentration instantaneous sliding window = 10 running average Page 18

19 STAR-CCM+ An integrated multiphysics solution for the Digital Product Efficiency with HPC STAR-CCM+ ensures computational resources are utilized with maximum efficiency Solvers that scale to hundreds of thousands of cores Parallel meshing reducing turnaround time and enabling mesh generation on clusters Flexible licensing options designed around HPC Unique licensing options to ensure software cost doesn t limit hardware utilization Core count independent Power Sessions Usage based Power-on-Demand for cloud deployment and burst capacity requirements Flexible Power Tokens enabling design exploration Being able to use the POD licensing scheme and run simulations on a cloud has been a tremendous help for us in terms of productivity. Mio Suzuki,Trek Bicycle Corporation Page 19

20 VALUE STAR-CCM+ An integrated multiphysics solution for the Digital Product Innovation with built-in design exploration Today s business pressures force companies to operate here to design better products Most companies operate here to reduce time and cost Validate Troubleshoot Design Automate Explore REACTIVE ENGINEERING LATE IN DEVELOPMENT PROCESS SIMULATION PURPOSE PREDICTIVE ENGINEERING EARLY IN DEVELOPMENT PROCESS Page 20

21 STAR-CCM+ An integrated multiphysics solution for the Digital Product Innovation with design exploration Built-in design exploration and optimization Easy to use with a familiar experience Comprehensive range of exploration options Gain insight into product behaviour and parameter influence with unique post-processing options Design Manager Facilitating parametric analysis No additional license required to enable sweeps Design manager with STAR-Innovate add-on Explore entire design space and find better designs Automatic search using embedded HEEDS technology Flexible license scheme to deploy design exploration With design exploration in STAR-CCM+ we learned what makes a good design and how to improve the performance of the system Andreas Ruch, ECS Analyst, Airbus Page 21

22 Zip operation Reduces turnaround time and enables design exploration DrivAer Model courtesy of TU Munich D3358 D892 Replace single surfaces to enable faster and more local design changes Automatically sew free edges Unite open parts Users can sew free or selected edges within a part or between parts either as: Discrete part generating Creates a new part Discrete Description generating Creates a new description of the input parts The perimeter can be remeshed automatically to improve quality Page 22

23 STAR-CCM+ An integrated multiphysics solution for the Digital Product Responsiveness with accelerated software development Three major releases a year: Delivering state-of-the-art technologies Includes over 100 new features and enhancements with each release Collaboration with customers to satisfy immediate simulation needs IdeaStorm for collecting, voting, and commenting on new feature requests Partnering with our users to anticipate simulation trends allowing them to stay ahead of their competition A proven track record of technological innovation since first release in 2006 With regular releases, new features are always being introduced into the code, which enables us to produce more accurate simulations quicker James Bertwistle, WSP Page 23

24 Continuous Innovation in Technology v12 Design manager Ray Tracing STAR-ICE v3 v2 v1 Native CAD import LES Combustion File-based Coupling Core Meshing Free-surface, VOF LES / DDES Combustion Lagrangian Multiphase Client-Server Core Fluid Dynamics Interactive Analysis v6 v5 v4 Power-on-Demand Thin Mesher Battery Simulation Power Session 3D-CAD CAD Clients Particle Dynamics Co-simulation Mesh Morphing Eulerian Multiphase Harmonic Balance STAR-View+ v9 v8 v7 Concurrent Meshing Volume Rendering Overset Gap & Contact Acoustics Simulation Assistant Parallel Meshing Adjoint Analysis STAR-Cast Power Tokens Optimate Directed Meshing Overset Solution History v11 v10 Core Electromagnetics Data Focus Core Solid Mechanics Core Viscous Flow Page 24

25 STAR-CCM+ An integrated multiphysics solution for the Digital Product Success with customer support A team of global experts to ensure our customer s success Dedicated support to provide help every step of the way Working closely with users to gain an in depth knowledge of their processes and requirements Providing immediate solutions to your simulation challenges A customer portal, available 24/7 Access to a huge library of knowledge base articles Track support queries and download software Chat to support engineers and engage with the STAR-CCM+ user community Support from the engineers at Siemens PLM is great. It s really nice to be able to call up an expert with a question, and they make you their first priority and help you be successful. Alex Stoll, Aeronautical Engineer, Joby Aviation Page 25

26 STAR-CCM+ Part of the Simcenter Portfolio for Predictive Engineering Analytics Realism at each stage of development by combining multiphysics, multi-disciplinary and systems simulation and test Innovative designs with multidisciplinary design exploration, and data analytics Best practices, collaboration and long-term knowledge with Teamcenter for simulation and data management in the context of the overall PLM system. Page 26

27 Simcenter TM : Delivering Digital Twin Experience Optimize Efficiency of Excavator for Realistic Soil Loading Challenge Predict fuel consumption, structure integrity and durability for different soil conditions Objective Full co-simulation, loads coming from hydraulic pumps/cylinder are piloting the 3D / CFD multi-body model. Provide arms and bucket motion, predict load and stresses based on DEM based soil particle analysis, alter the motion, and feed it back into the system model Solution Amesim Simcenter 3D Motion STAR-CCM+ Page 27

28 Simcenter TM : Delivering Digital Twin Experience Predict Gas Turbine Blade Shape Challenge Gas Turbines operate in an extreme environment, causing the blades to significantly deform. It impacts the overall efficiency, and life of the blade Objective Predict aerodynamic performance, cooling flow rates, blade loading and solid temperatures, stress and blade deflection. Deform the analytic CAD from the as-manufactured shape to the as-operated and feed it back for updated flow & thermal prediction Solution Simcenter STAR-CCM+ Simcenter 3D NX CAD Page 28

29 Simcenter TM : Delivering Digital Twin Experience Optimize Range and Thermal Comfort of Electrical Vehicle AC system Battery Cooling system Electric Powertrain Vehicle Challenge Extend electrical drive vehicle range while ensuring optimal passenger thermal comfort Cabin Control Objective Balance battery performance, to HVAC and control systems. Full system simulation with Battery and Electric Motors coupled with detailed 3D cell model to predict cell temperature variation, and optimize battery pack Page 29 Solution Simcenter Amesim STAR-CCM+ HEEDS

30 Simcenter TM : Delivering Digital Twin Experience Optimize NVH of Electrical Vehicle e-powertrain Structural and Acoustic Loads Challenge Optimize NVH (Noise & Vibration) from e-powertrain integration in vehicle reliability Vehicle NVH e-powertrain Integration Objective Predict structural and acoustic loading of e-powertrain in electric vehicle. Predict vehicle NVH from e- powertrain optimization. Enable combined optimization across e-powertrain and vehicle design. Solution STAR-CCM+ - SPEED Simcenter 3D Page 30

31 CGNS export to LMS Virtual.Lab Improves ease of use and expands applicability Provides a tight link between Simcenter portfolio tools Comprehensive solution for aero-vibro-acoustics analysis Write transient boundary pressure data to CGNS LMS Virtual.Lab computes acoustic solution More robust Hard coded parameters encapsulated; less scope for error No external file converter required New file format available from auto-export menu Mesh automatically exported at start of run Main applications are for modelling flow-induced noise sources: Side mirror noise Propeller noise Wind turbine noise Page 31

32 CGNS export to LMS Virtual.Lab Generate transient flow field in STAR-CCM+ Export files per timestep Import into LMS Virtual.Lab Transform dipoles into Neumann boundary conditions Compute acoustic solution DrivAer Model courtesy of TU Munich Page 32

33 Simcenter TM : Delivering Digital Twin Experience Frontload Vehicle Energy Management System Optimization Challenge Page 33 Top tank temperature Vehicle drag, radiator mass flow distribution 2 1 Systematically connect data and activities and close the loop between requirements, designs and verifications, through the engineering life cycle Objective Achieve engine cooling performance targets and meet system energy consumption / fuel economy requirements in prescribed operating conditions Solution Simcenter Amesim STAR-CCM+ Teamcenter for Digital Continuity

34 STAR-CCM+ An integrated multiphysics solution for the Digital Product Comprehensive Multiphysics Integrated Design Exploration Automated Meshing Single User Interface Advanced Data Analysis Application Specific Workflows Discover Better Designs, Faster! Parallel Efficiency Workflow Automation Page 34

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