Multiphysics CAE for Engineering Innovation_ ICCMEH- 2014 Keynote

ATOA Scientific Technologies Multiphysics CAE for Innovation TM

Dr Raj C Thiagarajan

ATOA Scientific Technologies Pvt Ltd

Multiphysics CAE for Engineering Innovation ICCMEH- 2014 Keynote 17 Dec 2014

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoa.com | ICCMEH- 2014 Key Note

Why are we here?

2

• Mythology

• Theologist

• Philosopher

• Scientist

– Physics, Chemistry, Biology, Mathematics….

• Engineers

– Civil, Mechanical, Electrical, Chemical…

• Multidisciplinary

– Nano, Bio, Info, Cognitive

• Multiphysics CAE for Engineering Innovation


Engineering Innovations

3

• Shelter, Tools, Pottery, Textile..

• Wheel

• Arch Bridge

• Gun powder

• Mariners Compass

• Paper Making

• Printing Press

• New paper

• Arc lamp, Stem locomotive, Automobiles

• Polymer: Jet Engine: Composites: www:

• Mobile Phones : 3D printing


Industrial Engineering Innovation Cycle

4

• Wealth creation cycle

• Contributions for overall economic growth

• Long cycle and low Success Rate

• Simulation based product design for acceleration of Engineering innovation

Basic Research

Applied Research

Industrial Research

Innovation/ Product

development

Commercialization

Wealth Creation

ACADEMIC INDUSTRY


Simulation Based Product Design

5

• Simulation is considered third pillar of Science & Technology

• Simulations has No Cost constraints, harsh/unrealistic parameter range, EHS concerns.

• Reliable, efficient and affordability is the key driver for Concurrent Product Development and Innovation


Design Change Cost in product development • Cost of fixing = Stages X Times

• Cost of Design changes increases exponentially with product development cycle.

• 80% of the product cost is determined or committed at the concept design stage

• Management influence reduces over time

• CAE for first time right product development

Product Planning

Concept Design

Final Design

Pilot Production

Mass production

HIGH

Low

Act

ivit

y, In

flu

ence

Ind

ex,

Des

ign

ch

ange

Co

st

NPI Activity

@

Part

1X

@

Sub assembly

10 X

@

Final Assembly 100 X

@

Dealer

1000 X

@

Customer

10000 X

6


CAE for Engineering Innovation

7

Engineering Innovation

Multiscale Multiphysics

Multimaterial

Engineering is Conversion of Material into Useful Product

Industrial Drivers: Cost, Weight and Performance

CAX (CAD, CAE, CAM) product development for first time right

Multiphysics, Multimaterial and Multiscale for Innovative Design

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoa.com | ICCMEH- 2014 Key Note 8

Multiphysics


Multiphysics Modeling

9

• Product Design is Multiphysics but are Designed for Dominant Physics

• Technology adaptation trend vs industry

• Current Technology and maturity level Enables Affordable and Reliable Multiphysics Product Design

• Multiphysics Design for First time right cost effective, faster product development.


Multiphysics Modeling

10

Constitutes more than

one component with

governing equation.

• Coupling at Bulk, interface level:

– Magneto hydrodynamics , Reaction transport

– Fluid structure, aero elasticity, laser heating

• Coupling at time and length Scale (multiscale):

– atomistic to continuum Damage mechanics

• Coupling at Material Scale (multimaterial):

– Homogenization from nano, micro, macro


Multiphysics Examples

Multiphysics

Stru

ctu

ral

The

rmal

Flo

w

Aco

ust

ics

Dyn

amic

s

EM/O

pti

cs

Ch

em

ical

Bio

-Me

dic

al

Par

ticl

e

Industrial Examples

Aero elasticity Aircraft wing, wind turbine, helicopter blades, micro turbines, long bridges,

Fluid Structure Offshore foundations, Sloshing, actuators, compressors, Induction

Conjugate Heat transfer

Racing car, offshore pipes. Gas turbine, forming, welding, electronic packaging,

NVH, aero acoustics

Acoustic panels, sound barrier, sonar, Automobile, aero engine, speakers

Chemical Transport

Composite cure, reactive polymer flow, adhesive, Biomedical

Biomechanics BioCAE

Medical Imaging, Orthosis, prosthesis, ergonomics, Medical Therapy.

Piezo, thermo electricity

Ultrasonic probe, MEMS sensors, TE refrigeration, Electrical connectors.

Electromagnetic Heating

Non conventional / Non Conduction heating: Laser, RF, Microwave

Battery Physics

Solid Oxide, Lithium , Fuel Cell, Battery powered automobile


Multiphysics Design: Stethoscope

12

• Acoustics Performance improvement

• Sound propagation

• Noise effects

• Material, Geometry

• Electromagnetic, electrostatic => acoustical energy


Multiphysics Design: Chest Belt

13

• Bio electrical signal propagation in cardiac tissue using the FitzHugh-Nagumo equations and the Complex Ginzburg-Landau equations.

• Electromagnetic physics to model the electrical field distribution on a realistic 3D geometric model of the heart and torso.

• Inverse problem solving for smart chest belt.


Multimaterial


Composites Multi

Material

Advanced Materials

Noble Aluminum Steel

Multimaterial Product Design

15

• From “ All steel” , “All Aluminum ” All Composites” To Multimaterial

• Leverage the best of material for product performance.

• Challenges

• Fabrication

• Multiphysics

• Multifunctional

High COST Low

Hig

h

W

EIG

HT

Lo

w

Performance: High


Multiphysics Design of Materials

Structural Elastic constants

Super structural

Thermal Thermal conductivity

Superinsulation

Electromagnetic permeability and permittivity

Metamaterials

Acoustic Sound transmission loss

Acoustic bandgaps

Transport Diffusion

Permeability Super flow

Design Extremel


Multiphysics Design of Materials

Physics Governing Eqs* Constitute Eqs* Comments

Structural Static:, Navier’s equation, Hooke’s law

for stress strain relation. F, volume

forces, σ,stress tensor, e, strain tensor,

D, stiffness matrix

Thermal Heat Equation, Fourier’s law: ρ,density.

Cp, heat capacity, k, thermal

conductivity, Q,heat source.

Acoustic Helmholtz eq: ω, angular freq, ρ0, fluid

density, cs, speed of sound, q, source,

Dtl, transmission-loss coefficient, Wi,

incident and Wt is the transmitted sound

power.

Diffusion

Fick’s law, Diffusion Coeff. c is the

concentration, D is the diffusion

coefficient, and R is a reaction rate

Porous flow Darcy’s law, Permeability, : v, velocity, μ,

dynamic viscosity, K, permeability and P,

Pressure. P

xvK

* Equations from COMSOL documentation

c

NDeff

ave


Metamaterial Simulation Results

18

Acoustic Super lens

Ultrasonic Meta Surfaces

Composite cloaks

Electrostatic resonance

Negative refraction


Multiscale


Multiscale Modeling

• Multiscale model is a mathematical model formed by combining partial model at different length and time scales.

• Away from predicting known properties towards new materials with novel properties.

• Products engineered from Atomic scale

Multi scale modeling Framework


Multiscale: damage mechanism

21

Structure

Part

Laminate

Fiber

Matrix

Molecular

ATOMIC

0.3345 nm

0.142 nm

0.669 nm

c

ba


Multi example


Nano Foam

23

Engineers Quest is to develop materials with higher properties at lower weight

Simulation based material design for superior properties

• Super specific stiffness

• Super insulation

Nano

Micro

Macro

After US 7838108

Vf

No

rmal

ized

Pro

per

ty

Air Material 2


Multiscale Modeling Super Structural

24

• Engineer the pore size for superior properties

• Example: Tooth enamel: Bio polymer+ mineral fillers

• Defect insensitive pore size

• Nano to micro to macro properties


Multiscale Modeling Super Insulation

25

• Nanogel/ Aerogel : Thermal conductivity lower than still air to about 0.002 W/mK

• Nanoscale Knudsen effect, Phonon scattering

• Conduction, convection and Radiation = k

• U value for Fenestration product performance

• Building Thermal Simulation for annual Energy and Cost Saving

(From:http://www.ameriluxinternational.com/html/architectData/nanogel/documents/nanogelData.pdf)

2 pm


Multiphysics Modelling C

AD

Structural Elastic constants

Super structural

Thermal Thermal conductivity

Superinsulation

Electromagnetic permeability and permittivity

Metamaterials

Acoustic Sound transmission loss

Acoustic bandgaps

Transport Diffusion

Permeability Super flow

CA

M

CAE

3D

PR

INTIN

G


Thank You!

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