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Integrated Meshing in STAR-CCM+
Aly Khawaja
Overview
• The STAR-CCM+ meshing suite – a pipelined processsuite a pipelined process
• Conformal meshing – a strength
• Specialized meshers for specialized applicationsOn the horizon• On the horizon
• Putting it all together
Integrated/automated process from geometry to post-processing
The STAR-CCM+ meshing suite
• Surface meshing options– Surface wrapperpp– Surface remesher– Interactive tools
Volume meshing options• Volume meshing options– Tetrahedral mesher– Polyhedral mesher– Trimmed mesher– Boundary layer mesher– Specialized meshersp
• User creates a meshing pipeline
Surface preparation is the k ikey to process automation
Surface preparation – the key to automation
• At the forefront in automating CAD to surface processData import and organization• Data import and organization
– Working upstream to import data directly from your CAD/PLM system
– Retain assembly hierarchy, meta-data– Provide efficient ways to tag, filter data
Import edit create and preserve CAD geometry• Import, edit, create and preserve CAD geometry• Automatic meshers – surface wrapper, surface remesher• Interactive tools – boolean inflation imprinting etc• Interactive tools boolean, inflation, imprinting, etc.• Manual repair
State-of-the-art manual repair mode
• Dynamically updated diagnostics panel• Ability to browse problem areasy p• Atomic operations (swap/split/collapse
edges, etc.)• Mid-level operations (smooth fill holes• Mid level operations (smooth, fill holes,
inflate, imprint, etc.)• Repair feature edge errors
Undo/redo capability• Undo/redo capability• Elaborate selection/display controllers• Continually enhanced based on user
f db kfeedback
Intuitive, concise, functional
STAR-CCM+ Meshing pipeline example
Automation without sacrificing mesh control…
• Size per boundary• Size per feature curve• Size per feature curve• Curvature control• Proximity control• Volume source• Prism mesh control
Initial wall thickness– Initial wall thickness– Stretching– Total prism thickness
N b f l– Number of layers• Same sizing information can be used across all meshers• Ease of use has been a focusEase of use has been a focus
Conformal meshing – a strength
• Has been a strong point of STAR-CCM+ for several yearsCreate connected meshes with a one to one matching• Create connected meshes with a one-to-one matching between regions/domains – leads to higher solution accuracy
• Accept variety of input data– Data comes in prepped (connected parts, shared surfaces) –
use split-by-topologyuse split-by-topology– Disconnected parts – automatic interfacing via close part
browser, imprinting• Taking it a step further – conformal periodic meshing
Highly complex geometry – prepped CAD data
Automatic interfacing of disconnected parts
Automatic interfacing of disconnected parts
Close part browser
Imprint one/allp
Automatic interfacing of disconnected parts
• Allows convenient close part browsingclose part browsing through complex hierarchy
• Automatically imprints touching components and creates interfaces
• Potential to pipeline –one click operation f di t dfrom disconnected parts to conformal volume mesh
Automatic interfacing application
Automatic interfacing application
Conformal periodic meshes
Volume control – Finer surfaceSubsurface proximity based retractionFace mismatches cause solution inaccuraciesConformal mesh with no additional user specification
Specialized meshers for specialized applications
• Already have fully functional general purpose meshersSpecialized geometries need customized meshes for• Specialized geometries need customized meshes for
– Optimal cell count– Cell qualityq y– Solution accuracy
• Pushing the envelope for seamless integration of these h i t th STAR CCM+ hi itmeshers into the STAR-CCM+ meshing suite
Specialized meshers – 2.5D Extrusion
Specialized meshers – generalized cylinders
Detects cylindrical boundaries and produces swept meshes
Specialized meshers – Thin Mesher
• Automatic detection• High quality orthogonal cells in
thin regions• General polyhedra elsewhere• General polyhedra elsewhere
On the horizon…
SolidWorks assembly with SolidWorks assembly with
• Parallel meshingDistributed meshing using client server architecturey
multi-level hierarchy
ymulti-level hierarchy
– Distributed meshing using client-server architecture• Conformal meshing in conjunction with thin mesher
– Conformal conjugate heat transfer analysisj g y• 3D-CAD solid modeler
– Create and edit geometry from within STAR-CCM+• Intuitive, efficient, parts based meshing
– Preserving hierarchy, structure from within your PLM systemAnd much more
Assembly structure and all part names
Assembly structure and all part names
Assembly structure and all part names
Assembly structure and all part names
• And much more…
part names preservedpart names preservedpart names preservedpart names preserved
Putting it all together
A multi-pronged development philosophy…
• Continue to enhance existing main-stream meshers/tools for ease of use automation and accuracyfor ease of use, automation and accuracy
• Particular emphasis on your biggest bottle-necks of data-import, organization and surface preparationp g p p
• Forward thinking ideas and introduction of new meshers for optimal cell count/placement
… to provide a state-of-the-art CAE tool
Putting it all together
• Import data from CAD/PLM system, retaining part/assembly hierarchy, meta-data, etc.p y y, ,
• Edit, create geometry, intuitive surface preparation tools• Automatic, conformal meshing using application-specific
mesh typesmesh types• Complete control on distribution• Flow/thermal/stress, multi-physics simulationsp y• Parallel environment from start to finish• STAR-CCM+: a black-box simulation tool
i th d i i tin the design environment• Rapid turnaround for design
modificationsmodifications
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