CAE Custom Tools
Introduction CAE Custom Tools Services I. Customization of STAR-CCM+ based on client needs. – Conversion of standard works to automation. – Creation of custom workflows to reduce errors/decrease – turn around time. Creation of vertical applications within ST STAR AR-C -CCM+ M+ – Support of the customized work, wit ithout ma main intenance ce fees. s. – ü The workflows can extend past STAR- CCM+ to perform complex multi-step analyses. ü Custom Tools ensure that best practice meshing and physics are respected at all steps in the process.
CD-adapco’s CAE Custom Tools in Industry • Bu Build ildin ing a clie client base se where re so sophist istica icated analysis lysis needs s to mig migra rate to st standard rd pro roduct ctio ion work. rk. • Clie lients s that are re lo lookin king to push sh analysis lysis clo close ser r to desig sign to sa satisf isfy y busin siness ss re require ireme ments. s. • Reducin cing turn rnaro round time imes s thro rough automa matio ion: • Quicke icker r re resu sult lts s (4 (4-1 -10x x sp speed up fro rom m CAD AD to re resu sult lts) s) • Erro Error r fre ree re report rtin ing • Repeatabilit ility y (Mo (Modif ifica icatio ions s and Comp mpariso risons) s) • F OCUS OCUS O O N T T HE HE E E NGINEER EERING P P ROBL EM BLEM
“STAR-CCM+ Pipeline”: From Concept to Results
STAR-CCM+ Java API STAR-CCM+ automation is extensible . • – The JAVA API also allows for external coding for automation tasks outside of STAR-CCM+. » Integration with CAD systems (direct downloads without files) » Creation of management ready reports from analysis » Creation of a customized and streamlined GUI – All Java libraries are available through automation within STAR-CCM+ » Link with other APIs - Microsoft Office Documents - Web Based Connectivity » Everything JAVA can do, STAR-CCM+ can do. » CAE Custom Tools is the World’s Expert in Automation
STAR-CCM+, Automate the entire workflow “Cust “C stom m Tool” l” GUI GUI Input: Input: Run: Me Run: Me Mesh Mesh sh/So sh/So Solve Solve lve/Po lve/Po Post Post st st Output: Output:
Paint Dipping Tool VOF (Volume of Fluid) Multiphase Analysis » Transient Mesh Motion » Specialized Post Processing » Technician-Level Users »
Paint Dipping Challenges Issues with Dip or Immersion Coating Can’t drain quick enough Leads to contamination Forms a bubble or void No coating
Paint Dipping Workflow – What they wanted … . • Run a virt virtual l pain int dip ip pro roce cess ss • Se Setup sp specia cial l post st pro roce cessin ssing to visu visualize lize the pro roble lems. ms. • Run “w “what-if -if” ” sce scenario rios s wit ith ease se.
Paint Dipping Tool – How they got it.
Liquid Hold up – 2010 Baseline vs. Modified Ba Base selin line Mo Modif ifie ied wit ith Sid Side hole les s
Water Jacket Design Tool CAD Based Tool. Direct CAD->PPT » Excel Driven Routine » Ability to create 100s of runs with just Excel or a Text » Editor Designer-Level User with Expert-Level switches »
Water Jacket Design Tool
Water Jacket Design Tool Imp mport rt/Org rganize ize CAD AD 1. Import to 3D-CAD 2. Imprint all bodies 3. Transfer to geometric Parts 4. Automatically create regions, boundaries and interfaces
Water Jacket Design Tool Report rtin ing Management ready presentation and spreadsheet. •
Water Jacket Tool Animation
Heat Exchanger In-Situ Design Tool Complete CAD -> PPT Workflow » GUI-Based Vertical Application with Excel Sheet Data » Support Allows Heat Exchanger Designers to run full vehicles with » no knowledge of full vehicle CFD Designer-Level User or Expert Level User »
Vehicle Thermal Management Automation. Skin Cooling Module Excel file Custom GUI
One place to put all of the data … Dual-st l-stre ream m heat exch xchanger r mo model: l:
Additional GUI Development to Support the Input Ø Detail il GUI Deve velo lopme ment § Me Mesh sh Se Setup GUI § Condese ser r Se Setup GUI § Interco rcoole ler r Se Setup GUI § Radia iator r Se Setup GUI § Fan Se Setup GUI § Po Post st-p -pro roce cessin ssing (N (No Me Menu) )
Mesh Setup GUI § Me Mesh sh le leve vel l se setup for r use ser r § Ve Vehicle icle skin skin me mesh sh size size Leve vel l 1 Gro roup § Coolin ling mo module le me mesh sh size size Leve vel l 2 Gro roup CAD AD Pa Part rt List ist Leve vel l 3 Gro roup Leve vel l 4 Gro roup
Heat Exchanger In-Situ Custom Tool Animation
Results: Validation Ø Code Va Valid lidatio ion § Ve Vehicle icle in inclu cludin ing in interco rcoole ler r è è Ve Vehicle icle: XX XX
Intake Port Modeler Tool CAD … CFD CAD Based Tool. Direct CAD->PPT » Sophisticated Vertical Application » Specialized Multi-step workflow » Designer-Level User »
Intake Runner and Port Development Example The CFD auto-t -tool l allo llows s the desig signer r to ru run the analysis lysis and re revie view the re resu sult lts s ve very ry quickly ickly (< (< 1/2 day) y) Intake Manifold Iteration 1 Iteration 5 Iteration 6 Iteration 11 CAD … CFD Mass flow rate (g/s): Baseline Tumble index: Baseline Goal: Maximize flow with acceptable level of mixture motion
The Port Flow CFD Analysis Workflow Mesh Move Visualize Solve Valve CAD flow field in Import Create plots to CAD Rig understand Surfaces Geometry design changes Calculate Output to Data and Excel & Create PPT Images
Customized Port Flow Analysis Tool
Intake ke Po Port rt Tool l An Anima imatio ion
Fuel Rod Analysis Tool Automatic Handling of CAD Geometry » Dramatically Reduces Click-Intensive Workflow » Allows Atomic Level Detail on Rods and Spacer Grids » Individual Rod Selection - Intra-Rod Selection via “Banding” - Automatically Apply Reports to any Level of Detail » Turnaround Time Reduction from Weeks to Only Days »
Fuel Rod Fretting Challenges Flow Induced Vibration (FIV) “Fretting” • Causes Damage to the Fuel Rods Difficult to Predict Where This Will Happen. • Fuel Bundle Can Be 9x9 or More. • – Many Rods, Long Axial Distances To Find the Position of FIV, One Needs Many • Data Points, and Many Reports. CAD Data is not Typically Setup for this Type • of Analysis – Many Times, the Fuel Bundle is One Body Need an Automated Process to Split CAD • and Make Many Slices or “Bands” of Each Fuel Rod.
Fuel Bundle Needs to be Split Automatically • Cre reate a simp simple le GUI to Input Data Ab About the Fuel l Bu Bundle le • The Au Automa mated Tool l will ill Sp Split lit the Fuel l Rods s Individ ividually lly wit ith no Use ser r Intera ract ctio ion.
“Super Bands” are Needed to Cut Through the Fuel Bundle • The Use ser r Defin ines s “Su “Super r Ba Bands” s” that Cut the Fuel l Rods s in into Sp Specia cial l Gro roups. s. • The Numb mber r of Ba Bands s ca can be Use ser r Determin rmined. • These se ca can be use ser r cust cu stomize mized base sed on the Sp Space cer r Grid rid lo loca catio ions s
“Selection Sets” are Defined for Reports • The Use ser r Defin ines s Se Sele lect ctio ion Se Sets s Ba Base sed on Fuel l Rod Grid rid, Su Super r Ba Band Loca catio ion, and Individ ividual l Ba Band Loca catio ion. • Use ser-F r-Frie riendly ly Name mes s are re Ap Applie lied to these se Se Sele lect ctio ion Se Sets. s. • The Se Sele lect ctio ion Se Sets s will ill be use sed for r Report rts s
“Selection Sets” are Defined for Reports • Report rts s are re Genera rated Usin sing Se Sele lect ctio ion Se Sets s Inst stead of CAD AD Bo Boundarie ries. s. • An Any y Report rt ca can be Use sed (F (Force rce Report rt, Near-R r-Rod Ve Velo locit city, y, etc. c.) )
Fuel Rod Analysis Animation
Summary Custom Tools builds GUIs and batch tools to workflow • specifications. Clients see turnaround times reduce 4-10x. • Repeatable and Consistent Results. • Focuses the general functionality of STAR-CCM+ into a • documented, verified, and experimentally valid tool. CAE Custom Tools has a Proven Track Record in • Industry and is growing at 56% 2011 - 2012
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