2008 International ANSYS Conference · – Expert modeling know-how and best practices is built into the software tool – Enhanced productivity • Standardize modeling practices

© 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2008 International ANSYS Conference

Simulation Driven Product Development using ANSYS Technology

Padmesh MandloiRahul KumarSamir Kadam


Outline

• Industry CAE Trend and Vision• ANSYS Custom Vertical Solution• Examples

– Parametric Mesh Generation– Port Flow Bench– Pump Simulator

• Summary


Industry CAE Vision and Direction

• CAE wide acceptance in the industry– How CAE improves product development, reduces cost and time to

market are well known in the industry• The Next Step in industry CAE implementation

– Spearheaded by the leading industry leaders, the focus is now:“How do we do our current simulation faster, better, and cheaper”

– The recognized bottleneck is the significant time and manual resources needed• Pre-processing and solution interpretation, preventing in many cases,

the pursuit of effective design optimization• Highlights the need to build application driven, customer specific vertical

tools that allow automation of the underlying CAE process• What can be automated

– Almost anything, from preprocessing, solution, and post-processing– Automation made possible effective usage of optimization tool – Ability to capture design knowledge, data and process through

Simulation Process & Data Management tools


ANSYS Custom Tool Offering

WorkBench• Most advanced offering from ANSYS• Allows process-automation in batch-mode• Allows optimization with process-automation• Customizable GUI• Customized multi-physics simulation through single interface

User Defined Functions

ANSYS APDL

CFX CCL

Extending Existing Capability Building New Application on top of Existing Tool

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Examples

• Parametric Mesh Generation, Port Flow Bench, and Pump Simulator– Automatic geometry and mesh creation based on user-

defined parameters – Showcase integration of different meshing technologies

to automatically create high-quality mesh – One-stop customized tool for a class of applications– In-built application specific intelligence



Parametric Analysis forAircraft Cabin Flow Simulation


• Difficult to keep pace with the continually changing design parameters and customer specifications– Design may change by the time analysis is completed

• Various parameters affecting cabin airflow distribution– Location of inlets/outlets and gaspers– Seat locations and pitch– Passenger occupancy

• Large meshing time for a single set of parameters• Large cell count for each case

– Need to optimize cell clustering to resolve flow features with minimum possible cell count

Challenges in Cabin Flow Simulation

Automate and Customize the process that

drastically reduce turnaround time


Process Streamlining

Import CAD with parameters Solid model of fluid

region Set mesh sizes

Generate mesh (Workbench

Mesher/TGrid)

Adjust parameters

AUTOMATIC


The parameters

Adjust seat / passenger / console

Passengers on/off

Design change of console


Features on & off


Mesh set up

Sizing on windows

Default CAD surfaces

Sizing on console

Sizing on passengers / seats

• Global set up allows automated mesh set up for CFD

• Individual Mesh control on faces also possible for finer mesh near critical regions– Size information is kept after a

parametric change


Meshing Optimization

• Refined Mesh Near the Gasper Outlets• Coarser mesh in other areas• Using Mesh Sizing Functions to ensure smooth growth


Summary

• Rapid Meshing using parameterization and automation leads to significant reduction in manual efforts

• The same process can be extended to include the thermal-flow simulation – By specifying flow rates & temperatures into and out of

the cabin• Stress analysis and/or fatigue analysis of the structure or its

components can be performed– Using Pressure-Vessel Module in ANSYS

• Multi-disciplinary Design and Optimization (MDO) can be achieved – Using Design Explorer



PortFlowBench


PortFlowBench

• Challenges in using CAE for Port Flow Analysis– Extremely repetitive process

from geometry to post-processing for different valve lifts• High level of manual

intervention• Leads to inconsistency• Time consuming

– High quality mesh to accurately predict the swirl, tumble and flow-coefficient

• Design Process for Intake/Exhaust ports– Flow Bench testing

• Time-consuming• Expensive

Virtual prototyping using

PortFlowBench

• PortFlowBench– Virtual prototyping tool based on

FloWizard– Completely automated

• CAD import Postprocessing– High quality multi-block mesh with

prism layers & local refinement– Built-in procedures

• to guide the solution to convergence

• to do application specific post-processing


PortFlowBench: Process & MeshImport CAD, specify lift values and

boundary conditions

Create mesh for the first lift

Review the mesh

Create meshes/cases for all lifts

Run solution for all the cases

Post process remaining lifts+

Create HTML report

Post process solution for first lift case

AutoManual

Boundary layered cells from valve

and port surfaces

Good quality tetrahedral mesh with local refinement near valves

Good quality Hex mesh in combustion chamber


PortFlowBench: GUI


PortFlowBench: Results

0

1

2

3

4

5

0 1 2 3 4 5Valve Lift

Volu

met

ric F

low

Rat

e

Test Pressure # 1 (Measured)Test Pressure # 1 (Predicted)Test Pressure # 2 (Measured)Test Pressure # 2 (Predicted)Test Pressure # 3 (Measured)Test Pressure # 3 (Predicted)


Summary

• Order of magnitude time reduction• Single tree-structured GUI for the entire CFD

process– Ease of Use– Consistent setup

• High quality meshing and application specific best-practices lead to– Close agreement between CAE solution and

experimental results



PumpSimulator


PumpSimulator: Introduction

• PumpSimulator– FloWizard based customized

tool for a suite of hydraulic pumps• Gear Pumps• Gerotor Pumps• Vane Pumps• Piston Pumps

– Features• Can handle reasonably dirty

CAD• TGrid technology for meshing

complicated geometries• Application specific

meshing/setup/post-processing• Cavitation modeling

capabilities• Parameterization• Parallel computing capabilities

• Challenges in modeling hydraulic pumps– Complicated setup since

dynamic mesh is required for moving parts

– Dirty CAD handling– Specific meshing techniques – Advanced physics like

Cavitation– Transient simulation


PumpSimulator: User Interface

Different pump types

High quality automatic mesh

Application specific inputs- Options for modeling cavitation

Options for advanced clean-up


PumpSimulator: Results


Summary

• Huge reduction in manual efforts because of– Less CAD cleanup requirements– Built-in best practices for automated meshing

and case-setup• Consistency

– Automation ensures that the meshing, case-setup and results are consistent across different designs


• Ease-of-use– Expert modeling know-how and best practices is built into

the software tool– Enhanced productivity

• Standardize modeling practices and procedures globally within an organization– Consistency– A standardized approach allows for reproducible results,

irrespective of who does the simulations• Knowledge Capture and Data Management

– Documentation and Reporting– Archive and searchable

• Can be used for rapid optimization studies including six-sigma analysis

Closing Remarks


Acknowledgements

• Parametric Mesh Generation– David R Minns, ANSYS Europe Ltd.,

Riseley, UK ([email protected])• PumpSimulator

– Rajiv Rath and Padmesh Mandloi, Fluent India Pvt. Ltd. Pune, India ([email protected])

mailto:[email protected]

mailto:[email protected]

2008 International ANSYS Conference · – Expert modeling know-how and best practices is built into the software tool – Enhanced productivity • Standardize modeling practices

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