Computation Fluid Dynamics – ANSYS Software Key Features and Best Practices Courtesy of Borg Warner Turbo & Emissions Systems Dr. Wim Slagter Lead Product Manager, ANSYS, Inc. Courtesy of CADFEM Russia
ANSYS, the company • ANSYS design, develops, markets and globally supports a comprehensive range of Design Parametric Exploration Simulation engineering simulation software • Proven software technologies for o Fluid Dynamics Emag o Structural Mechanics o Acoustics Fluid Structural o Electromagnetics o Multiphysics Acoustics CAD Meshing • Specialized tools, incl. Import o ANSYS Icepak (thermal/flow for electronics) o ANSYS nCode DesignLife (for fatigue) Post- • World’s largest pool of experts processing providing CFD Best Practices
ANSYS – addressing your current & future CFD challenges Transient or steady-state Laminar and turbulent flows Heat transfer Moving geometry and mesh Buoyant flows Rotating machinery Incompressible / compressible Solution-based adaptive remeshing Real gas modeling Multi-component flows, multi-phase Courtesy of BMW AG Filters/porous regions Reactions and combustion 1-way and 2-way Fluid-Structure Interaction Courtesy of GE Energy
Engineering Productivity: Geometry Modeling Key Enablers: Bi-directional CAD connections Links to almost any CAD system • Parametric, persistent process • Simulation focused: allows • engineers to do simulation driven product development CAD Neutral: Direct and Feature-Based Modeling Direct modeling allows for re- • Feature-Based Modeling! animating dumb CAD (geometry without parameters) models Extensive modeling solutions • Direct Modeling
Engineering Productivity: Workflow Geometry Meshing Problem Setup Post Processing Setup Wizards Customized Menus Increased Productivity through Automation and Customization!
Engineering Productivity: Accuracy & Speed • Advanced physical models Free surface profiles • Steady-state scheme • High-performance solvers • Transient scheme • Experiment RANS Get reliable answers faster, LES New steady-state scheme as accurate as transient Wigley hull simulation Re=395 without compromise on flow physics! User-defined LES for highest accuracy; RANS for all other areas 1.0 Hofmann et al [20] 0.9 CFD Head rise coefficient 0.8 0.7 0.6 0.5 0.4 0.0 0.5 1.0 1.5 Cavitation number Cavitating flow in a centrifugal pump can also be modeled in steady state Recondisation simulation
Integrated Design Exploration & Optimization Parametric CAD model Effective Flow Area Guide Curve Radius Guide Section Curve Length Angle Section Length Response Surface and Sensitivity Chart Gain deep insights necessary to optimize product performance, and produce better products faster! Baseline Design Optimized Design Tradeoff Chart Guide Curve Guide Curve Section EFA Angle Radius Length DOE generated with Design Points (mm 2 ) (Deg) (mm) (mm) Baseline 63 41 51 1100.2 Optimized 50 30 60.5 1180.4
Shape Sensitivities wrt Design Variables Adjoint flow solver: An understanding of the shape sensitivities with respect to design variables • in a single computation! A quantitative performance estimate due to a design change without the • need to simulate the actual change! Adjoint is a very efficient means of Drag s sensitivity Total p pressure d drop s sensitivity quickly exploring a design space with thousands degrees of design freedom! Estimated downforce improvement = 41.6N Actual downforce improvement = 39.1N Total p pressure d drop s sensitivity Downforc rce s sensitivity
Fluid-Structure Interaction Rigid Body FSI 1-way FSI 2-way FSI Fluid Flow Comprehensive suite of FSI capabilities for accurate prediction of a broad range of design scenarios Thermal Stress Courtesy of Embraco Deformation
Customer Example: Dyson Air Multiplier ™ Fan • Design objective: o Maximize amplification ratio for a given size and power consumption o 3 main design parameters, i.e. gap in annular ring, internal profile of ring, profile of external ramp • Customer benefits include: o Explored 10-fold of design variations than would otherwise have been possible (each day 10 instead of 1) o Improved performance 250% over original design Courtesy of Dyson
Customer Example: Exhaust Manifold • Design objective: o To optimize the dual-outlet exhaust manifold for robust performance o 4 main design parameters, i.e. outlet diameter of the manifold, thickness at inlet, external temperature, engine RPM • Design constraint: o Maximum displacement should not exceed 1.5 mm! Temperature Deformation Fluid Flow Von Mises Stress
Customer Example: Exhaust Manifold • Design objective: o To optimize the dual-outlet exhaust manifold for robust performance o 4 main design parameters, i.e. outlet diameter of the manifold, thickness at inlet, external temperature, engine RPM • Design constraint: o Maximum displacement should not exceed 1.5 mm! Temperature Deformation Effect of engine speed and thickness at outlet on All samples report maximum deformation maximum deformation below 1.5 mm Fluid Flow Von Mises Stress
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