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8/3/2019 ANSYS Advantage V4 I1 2010
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IdentIfyIng
electromagnetIc
Interference reduces rIsk
Driving vehicle
Performance
Page 9
fan of
simulation
Page 14
weather on
mars
Page 24
e x c e l l e n c e i n e n g i n e e r i n g s i m u l a t i o n
v o l u m e i v i s s u e 1 2 0 1 0
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editorial
ANSYS Advantage • Vme IV, Isse 1, 2010 11
Simulating ProductBehavior for the Real WorldEnginees se the beadth and depth f eading simatinsftwae t pedict hw pdcts wi behave in mti-dmainpeating envinments.
Pdct behavi neay aways invves diffeent types f
physica phenmena, t ne degee anthe.
Tempeate diffeences can infence mechanica stess,
f exampe, and ai fw and a stcte may impact
acstics change stcta ading. In sme cases,
ne dmain might be s pnnced that enginees cansafey igne appximate the minima infence f
thes. In a gwing nmbe f appicatins, hweve,
simatin accacy f meeting the tight pefmance
eqiements f tday’s sphist icated pdcts
demands that pdct devepes cnside the effects f
mtipe dmains.
Meeting sch chaenges pses big pbems if y
simatin ts ack sfficient capabiities t hande
mti-dmain appicatins. In many cases, cdes may
have ny dimentay fnctinaity in citica aeas, cnky
intefaces that make the sftwae diffict t n,
incmpatibiities that pevent the smth exchange fdata needed between sepaate packages. As a est,
simatin pedictins may be gssy inaccate; then
deadines sip, pdcts fai t pefm as they shd,
and nmes hadwae pttype cyces ae needed t
hiedy fix ast-minte gitches that shd nt have
cced in the fist pace.
In cntast, an integated site f sftwae with
technica depth in mtipe simatin dmains and ich
fnctinaity acss a bad ange f discipines pvides
a sid fndatin f handing these types f stins.
The cent isse f this magazine has exceent exampes
f cmpanies ptting sch techngy t wk inea-wd appicatins.
As tined in the atice “Diving Vehice Pefmance,”
Genea Mts enginees deveped the Chevy Vt
eectic ca sing fid dynamics sftwae fm ANSYS f
a wide ange f stdies, incding bdy aedynamics,
aifw thgh the gie, cing dag and sizing the heat
exchange. The engineeing team thee as eveaged the
sftwae t ptimize cmpnents n the vehices.
The atice “Wd-Cass Cmpsites Anaysis by
Ainghi” descibes hw acing yacht designes tk
advantage f cmpatibiity between sves by pefmingstcta anaysis n the cmpsite aminate h and
a the vesse cmpnents sing ANSYS stcta
sftwae, which was cped with fw anaysis f hyd-
dynamic stdies sing ANSYS fid dynamics sftwae.
An enginee at ITT Acstica Senss athed the
atice “Fishing with Mtiphysics” t ept n wk sing
sftwae fm ANSYS in diect cped-fied simatin
invving piezeectic, acstic and mechanica anaysis
t ptimize the designs f ndewate tansdces f
mniting hge fishing tawe nets.
Thee ae many me exampes in this isse — and a
mtitde f appicatins in the engineeing cmmnity —in which cmpanies pefm mti-dmain simatins
with the ANSYS integated site f state-f-the-at
techngies. Cmpanies cd ty t get by with ess-
capabe ts, pehaps as they’ve dne in the past. Bt
thee is mch at stake tday, fm ctm battes t
newspape headines t spe-cmpetitive makets. S
cpate exectives, engineeing manages and the
decisin makes mst ask themseves if sing ess than
the best-avaiabe simatin techngy is wth the
gambe that nthing wi g teiby wng. n
Jhn Kse
Senior Editor and Industry Analyst
i m a g e © s o
c p h o o . c o m / z g g y m a j .
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features5 electromagnetic interference
Avoiding the Perils of Electromagnetic Interference Identifying EMI early in development helps prevent future risk and related
high costs after products are shipped and in use.
7 Simulation-Driven Design for Hybrid and Electric Vehicles Simulation helps to identify and correct EMC/EMI problems early
in the development of innovative, next-generation vehicles.
9 automotive
Driving Vehicle Performance
Simulation helps to reduce drag and improve acoustic performanceof cars, including an electric vehicle.
11 Quest for the 200-mpg Car A revolutionary internal combustion engine gives rise to a supermileage
vehicle with the potential to transform automotive design.
14 turbomachinery
Fan of Simulation Voith Turbo reduces costs while developing quiet fans
by simulating a complete railcar cooling system.
17 electronics
Fishing with Multiphysics Direct coupled-field simulation, including piezoelectric, acoustic and mechanical analysis,
enables engineers to tune transducer performance for monitoring huge trawler nets.
SIMulATIoN@WorK
20 mining
It’s a Blast Technology from ANSYS helps to optimize the precise timing
of delayed detonations to get the biggest bang for the buck
in the mining industry.
22 automotive
Driving for DurabilityE-Z-GO engineers quickly and accurately design a reliable
utility vehicle part that saves manufacturing costs.
24 scientific instruments
How’s the Weather on Mars? Simulations are critical for calibration of instruments as well as fast
and accurate interpretation of data from the Phoenix Mars Lander.
26 scientific equipment
Exploring the Dark Side of the Universe Engineers at the Fermi National Accelerator Laboratory use ANSYS technology
in developing a precision camera for studying the far reaches of the universe.
24
22
www..o ANSYS Advantage • © 2010 ansys, Inc.
table of contents
2
Table of Contents
9
11
17
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table of contents
3
28 energy
Maintaining PowerA Brazilian power generation company expects to decrease maintenance
downtime by identifying the cause of wall erosion in a coal boiler.
30 built environment
Win, Set and Match at Wimbledon ANSYS software verifies the design of the innovative retractable roof
at Wimbledon by simulating the opening and closing mechanisms.
departments
31 analysis tools
Solutions for PCB Electromagnetic Interference Simulation Driven Product Development aids designers of printed
circuit boards in meeting electromagnetic compatibility requirements.
34 Predicting Circuit Board Hot Spotswith Electrothermal CosimulationMultiphysics analysis with SIwave and ANSYS Icepak accurately
determines thermal distribution on complex PCBs.
37 Boosting Memory Capacity with SSDs
Solid-state drives are a cost-effective way to add fast memory to workstations.
38 academic
Students Win Using Simulation-Driven Design Affiliation with ANSYS helps the University of Waterloo Formula Motorsports team win
an award for an innovative air intake design at the Formula SAE Michigan 2009 competition.
40 Teaching Simulation to Future Engineers ANSYS Workbench facilitates integration of simulation into the engineering curriculum.
42 partners
World-Class Composites Analysis by AlinghiEmbracing Simulation Driven Product Development, Team Alinghi
created their 33rd America’s Cup yacht.
44 Getting Out All the Breaks Pratt & Miller get ahead of the race by redesigning a brake pedal
using ANSYS with fe-safe fatigue analysis software.
46 tips and tricks
Topology PersistenceStreamline the innovative design process using direct CAD interfaces.
48 Best of Both Worlds: Combining APDL withANSYS Workbench for Structural Simulations
Using ANSYS Workbench techniques with APDL deliversthe most benefit from ANSYS structural mechanics solutions.
28
30
34
38
42
44
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table of contents
4
For ANSYS, Inc. sales information,
call 1.866.267.9724Email the editorial staff at
Executive EditorFran Hensler
Managing EditorChris Reeves
Senior Editor and Industry AnalystJohn Krouse
Art DirectorDan Hart
EditorsErik Ferguson
Shane MoeykensMark Ravenstahl
Ad Sales ManagerHelen Renshaw
Editorial ContributorNorth America
Support and Services
Editorial AdvisorTom Smithyman
DesignerMiller Creative Group
Circulation ManagerSharon Everts
Neithe ANSYS, Inc. n the seni edit n Mie CeativeGp gaantees waants accacy cmpeteness fthe mateia cntained in this pbicatin.
ANSYS, ANSYS Wkbench, Ansft Designe, CFX, AuToDYN, FluENT, GAMBIT, PolYFloW, Aipak,
DesignSpace, FIDAP, Ftan, Icebad, Icechip, Icemax,
Icepak, FWizad, FloWlAB, G/Tb, MixSim, Nexxim, Q3D
Extact, Maxwe, Simpe, Mechanica, Pfessina,
Stcta, DesignMdee, TGid, AI*Envinment, ASAS,
AQWA, AtreaGas, Bademdee, DesignXpe, Dp
Test, ED, Engineeing Knwedge Manage, Emag, Fatige,
Icep, Icewave, Mesh Mphe, PaaMesh, TAS, TASSTrESS,
TASFET, TbGid, Vista, VT Acceeat, CADoE, CSim,
SIwave, Tb Package Anayze, rMxpt, PExpt, HFSS,
F-Wave SPICE, VeifEye, QickEye, optimetics, TPA,
Ansftlinks, ePhysics, Simatin Diven Pdct
Devepment, Smat Engineeing Simatin and any and a
ANSYS, Inc. band, pdct, sevice, and feate names, gs
and sgans ae egisteed tademaks tademaks f
ANSYS, Inc. its sbsidiaies cated in the united States
the cnties. ICEM CFD is a tademak icensed by ANSYS,
Inc. A the band, pdct, sevice and feate names
tademaks ae the ppety f thei espective wnes.
About the Cover As industrial and consumer productscontain an increasing number ofelectronic components, electromagneticinterference can put both consumersand companies at risk. Related featurearticles discuss the value of earlysimulation to avoid EMI problems. Articles begin on page 5.
ANSYS, Inc.Sthpinte
275 Techngy DiveCannsbg, PA 15317
u.s.a.
WEB EXCluSIVESThese additional articles are available on www.ansys.com/exclusives/110.
academic
Where Do You Go When the Volcano Blows?When a volcano erupts explosively, it can generate pyroclastic flows, which are extremely
dangerous, turbulent, and super-heated currents that can travel at speeds up to 650 mph
and spread to cities hundreds of miles from their source. Researchers from the University of
Bari in Italy used fluid flow simulation software to model the interaction between a pyroclastic
flow and a single equilateral building. The team’s goal was to calculate the local flow field to
quantify the volcanic hazard, laying the groundwork for future studies in determining risk and
hazards prevention.
analysis tools
HFSS 12.0
This industry-standard RF and microwave simulation solution delivers significant new domaindecomposition technology for high-performance computing as well as other key performance-
related updates. The power of the HFSS product comes from many research and development
innovations, which have made it the most widely used software for solving 3-D full-wave
electromagnetic field simulations.
turbomachinery
Avoiding Stressed-Out Steam TurbinesSome of the most highly stressed parts of steam turbines in electrical power generation
systems are bladed disks — especially last-stage low-pressure blades that undergo the
greatest centrifugal force and bending produced in the entire turbine. Cracks can start at high-
stress locations and propagate, causing fatigue failure and turbine shutdown. Researchers at
Triveni Engineering and Industries Ltd., headquartered in India, are addressing some of the
challenges associated with optimizing blade designs using engineering simulation software.
industrial equipment
Gearing Up for Better MeasurementFlow meters measure fluid flow characteristics such as volumetric flow rates, pressures,
temperatures and material concentrations. Such measurement systems must be robust
and reliable, and they need to provide precise information. German manufacturer VSE
Volumentechnik GmbH uses engineering simulation software to develop more reliable
positive-displacement instruments through reduction of vibration, noise and pressure loss.
partners
Mesh Morphing Accelerates Design Optimization
When updating a component’s shape or position in a fluid dynamics parametric study, oneapproach is to update the initial geometry, remesh the entire domain and then rerun the
analysis. A time-saving viable alternative is to modify the mesh and rerun the flow analysis
without going back to the geometry step until the optimum configuration is determined.
This process requires using a mesh morpher tool. ANSYS software partner RBF Morph has
developed such a product, which interfaces with ANSYS FLUENT software for solving a wide
range of industrial applications.
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electromagnetic interference
5
Avoiding the Perils ofElectromagnetic InterferenceIdentifying EMI eay in devepment heps pevent fte iskand eated high csts afte pdcts ae shipped and in se.
By John Krouse, Senior Editor and Industry Analyst
Spe-phnes, GPS systems, e-eades, pcket-size
cmptes and the eectnics-based pdcts nhead
f yeas ag ae nw cmmnpace. Ftheme,
taditinay a-mechanica pdcts sch as cas, panes,
hme appiances and machine ts nw have inceasing
eves f eectnic cicity. Atmbies in patica have
been descibed as “cmptes n whees” becase s
many fnctins depend n eectnics, incding
diagnstics, engine cnt, baking and stabiity systems.
The maket f these eectnics-based end pdcts is
hge, with eectnics indsty evene estimated t be
$1.8 tiin in 2009.The bsiness dive f this pifeatin f eectnics
int sch a bad ange f appicatins is the sccess
and widespead se f semicndcts. These mateias
enabe pdcts t have geate and geate eves f
cmpex and highy cstmizabe fnctinaity at an
affdabe cst in smae and smae packages. In
patica, embedded inteigence in eectnics has
awed manfactes t pack npecedented eves f
feates and fnctins int pdcts, t penetate new
makets with innvative pdcts, and t ceate niqe
casses f pdcts that nce wee nimaginabe witht
tday’s advanced inteigent eectnics.
Bt thee is a catch. Designing this expanding ange
f smat pdcts eqies caef cnsideatin f faiy
cmpex eectmagnetic fied effects t avid maj
pbems in high-speed data channes. Mtifnctin ce
phnes, Wi-Fi-enabed aptps and the tansmitting
devices can intefee with snding eqipment if the
fy f taffic n these data spehighways is t stng
t cwded in a naw feqency ange.
Meve, nintended eectmagnetic intefeence(EMI) fm high eves f data being switched at vey fast
speeds in these eectnic pdcts has the ptentia
t case mafnctins within the device as we as in
snding eqipment. Intefeence with signas n high-
speed data channes in these pdcts can case a
manne f pbems, fm nisances sch as backgnd
nise n wieess phnes t ptentiay disasts signa
anmaies in citica cnt cicity in cas, panes and
medica eqipment, f exampe.
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electromagnetic interference
S widespead and ptentiay damaging ae the
effects f EMI that eectnics-based pdcts mst meet
inceasingy stict gvenment, intenatina and indsty
eectmagnetic cmpatibiity (EMC) standads. Faie tcmpy with these egatins caies stiff penaties and
may est in pdcts being banned in cetain cnties
being at the cente f gvenment investigatins, s
manfactes ndestandaby ae aways cncened that
thei pdcts meet these standads. Detemining EMC/
EMI is nt say a staightfwad cacatin, hweve,
in age pat becase f the tansient nate f
eectmagnetic emissins, which can depend n inte-
dependent eectica, mechanica and thema facts.
optimizing a design and ensing that emissins d
nt exceed pemissibe theshds ae diffict mti-
discipinay engineeing chaenges invving cnsideabetade-ffs. In deveping a high-end cmpte seve, f
exampe, the design team mst decide n ai vent
pacement by baancing thema and EMC effects, since
the ai vent can impve ai cicatin bt as pvide an
escape path f eectmagnetic waves. likewise, heat
sinks can incease heat tansfe fm chips int the ai,
bt they wi as incease pdct weight, size and
eectmagnetic emissins, becase heat sinks behave ike
intena antennas. likewise, fans incease ai cicatin bt
as heighten eectmagnetic backgnd nise.
Pedicting eectmagnetic emissin eves witht
the se f simatin is extemey diffict de t the
cmpexity f the age nmbes f intena and extena
signas impacting the eectnics device system.
Witht simatin, cacatins ae dne sing gss
appximatins and vesimpificatins that can ead t
incect ests. Sch ests becme evident ny when
cmpaed t tests n the acta hadwae pttypes,
pefmed ate in the design cyce. At this pint, sevea
bid–test–edesign iteatins say mst be pefmed
befe emissin eves ae weed sfficienty. Ding this
ate devepment stage, design changes becme
extemey expensive, and deays can ead t evenesses. As the windws f pptnity cse, cmpetits
win the ace t get pdcts t maket fist.
Wse yet, cmpanies may ttay negect t pefm
sfficient eves f eectmagnetic simatin ding
devepment, instead sing the techngy as a fensic
t in anayzing the cases f mafnctining pdcts
afte they ae bit, shipped, sd and in se by
cstmes. In these cases, csts can becme gigantic f
waanty mdificatins, pdct ecas, awsits,
damaged band vae and nfavabe pbicity that canhant a cmpany f yeas. Csts meased in the biins
f das can cc. N fim with eectnics-based
pdcts is immne — n matte hw age it is, hw ng
it has been in bsiness, hw favabe its image in the
eye f the pbic.
one f the mst effective ways f aviding sch
peventabe caamities is t se eectmagnetic emissin
and signa ppagatin ts p fnt in devepment
befe hadwae is bit. In these eay stages, enginees
have time t anayze ptentia pbems, evaate
atenative designs, and make changes eativey inexpen-
sivey and in a timey manne. Meve, engineeingsimatin ts that accnt f eectica, thema,
mechanica, magnetic and fid effects can be sed in
paae t ptimize pdct pefmance in ight f these
vais inteeated physics whie ensing that appicabe
emc .
using an integated site f sch ts, enginees can
accatey pedict EMC/EMI eves as we as tace any
pbem back t the physica ayt f the device. Then
key paametes in the mdes can be changed and the
designs stdied in a seies f simatins pefmed
nti eectmagnetic emissins ae within acceptabe
imits. using sch a pcess, enginees can expe
what-if scenais and aive at an ptimized design. The
atice “Simatin-Diven Design f Hybid and Eectic
Vehices” in this isse descibes sch techngies and
hw they can be appied in identifying and cecting
EMC/EMI pbems eay in design.
In this way, cmpanies can tiize eectmagnetic
simatin in saving time and mney ve pttype
testing and, pehaps mst imptant, in aviding the
massive peis f eectmagnetic emissin pbems
sfacing in pdcts aeady in se. Indeed, the etn n
investment f sing simatin techngy in sch afnt-end appach is hge. The atenative is cetainy
a isk nt wth taking when the benefits f Simatin
Diven Pdct Devepment have been s ceay
demnstated at cmpanies with the gd sense and
fesight t eveage sch a we-pven techngy in
the design cyce. n
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Simulation-Driven Design forHybrid and Electric VehiclesSimatin heps t identify and cect EMC/EMI pbems eayin the devepment f innvative, next-geneatin vehices.
By Scott Stanton, Technical Director of Advanced Technology Initiatives
and Mark Ravenstahl, Director of Marketing and Communications, Ansoft product group, ANSYS, Inc.
In the highy cmpetitive hybid eectic and eectic
vehice (HEV/EV) maket, pwetain enginees ae
chaenged t incease system efficiency, stabiity and
eiabiity. Pwe invetes pay a citica e in pwe-
tain systems. Typicay cmpising six insated-gate
bipa tansist (IGBT) mdes in a 4-inch by 6-inch
package, these devices switch hndeds f amps feectica cent n and ff vey apidy t pvide ac
pwe f the mt, cnt eectnics and the
systems. IGBT switching feqencies can ange fm
tens t hndeds f kHz, with tn-n ise times and tn-
ff fa times in the de f 50 t 100 nansecnds.
The fast switching speed f these devices makes
IGBTs extemey effective in pwe invete systems, bt
this switching speed is as the sce f tw maj
eectmagnetic pbems. Cndcted emissins (thgh
cent-caying stctes) ae geneay ess than 30 MHz
and can case pwe integity isses set p efected
waves f enegy that can ptentiay damage the inveteand the mt. radiated eectmagnetic fieds (thgh
ai) ae geneay geate than 30 MHz and can affect the
est f the vehice’s many eectnic systems.
Bth types f intefeence pbems mst be
cnsideed in meeting the eqied gvenment and
ANSYS provides a comprehensive set of simulation software to
study a wide range of electromagnetic and multiphysics behaviors
found in hybrid, electric and conventional vehicle designs.
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electromagnetic interference
7
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electromagnetic interference
ANSYS Advantage • © 2010 ansys, Inc.8
intenatina vehice eectmagnetic emissin standads,
s enginees espnsibe f pwe invete systems mst
design f eectmagnetic cmpatibiity/eectmagneticintefeence (EMC/EMI) in the fndamenta achitecte
f that system. This can be accmpished ny by fist
sving f the ndeying physics that gven the
behavi f EMC/EMI and then eveaging thse stins
acss cicits and systems. This simatin-diven
appach has the advantage f addessing the eect-
magnetic isses that mst be taken int accnt,
incding eectica cent qaity, pwe dissipatin and
the efficiency f the vea system.
Typicay, pefming these cacatins sing inea
cicit eements and simpe cicit sves eqies
nmes gss appximatins and vey simpifiedassmptins. By skipping the ccia step f simating
the ndeying physics, hweve, ests wi nt be
cect, and sevea hadwae pttype test-and-
edesign cyces may be cmpeted befe satisfacty
pefmance is achieved. In mst cases, these testing
cyces cannt take pace nti ate in the design pcess,
when csts can escaate significanty and deays
can ead t missed maket pptnities. Pedicting
tday’s eectmagnetic effects in the eay stages f
devepment, befe the pwe invete is bit, is vitay
impssibe witht the se f mtiphysics simatin.
A f ange f sch mtiphysics ts f stdying the
eectmagnetic behavi f eqipment sch as IGBTs is
avaiabe in the Ansft site f sftwae, which speciaizes
in eectmagnetic fied simatin as we as cicit and
system simatin. Ansft ts paticay sef in
pwe invete devepment incde:
• Simpe — a mti-dmain cicit and system
simat that can easiy integate cmpnents
acss eectica, thema, mechanica, magnetic
and fidic dmains
• Q3D Extact — a qasi-static cmptatina
fied sve f the cacatin f feqency- dependent esistance, indctance, capacitance
and cndctance paametes f cent-
caying stctes
• HFSS — a finite eement–based f-wave sve
f extacting paasitic paametes and visaizing
3-D eectmagnetic fieds
T accatey chaacteize the behavi f a switching
device sch as an IGBT, enginees typicay begin by sing
a paameteizatin wizad that takes int accnt pef-
mance cves and taba data fm specificatin sheets
avaiabe fm the vend. This pcess atmaticayextacts the eqied paametes (appximatey 140)
t aid in ceating a semicndct cicit mde f the
IGBT — instead f having t pefm this task manay.
Next, the physica ayt f the pwe invete
is impted fm a CAD gemety ayt t int
the Q3D Extact t. Fm the physica ayt,
Q3D Extact cmptes the feqency-dependent
esistance, patia indctance and capacitance (rlC)
ang the cndctin paths. Enginees then se the t
t ceate an eqivaent cicit mde f the system sim-
atin in Simpe sftwae. once this epesentatin
is ceated, it can be sed in cnjnctin with the semi-
cndct cicit mde t ceate an eecticay
cmpete mde f the IGBT. This can be sed with
the pwe sce, cnt system and ad t anayze
cndcted emissins.
The ests f these simatins can be sed with
HFSS sftwae t examine adiated emissins — a
patica cncen cnsideing the feqency hamnics
ceated as a cnseqence f the fast tn-n/tn-ff
times. T detemine this effect, ests fm the Simpe
t can be sed as inpt t the HFSS f-wave eect-
magnetic sve. The enginee then can btain a cmpete
ndestanding f adiated fieds and can cacate the
intensity at any given pint in space t detemine if
the invete package is in cmpiance with standads.
using this appach, the enginee can se Ansft
ts t design f EMC/EMI pbems in the invetesystem and tace the sce f the behavi back t
the physica ayt f the device. The design can then
be paameticay vaied and a seies f simatins
pefmed nti cndcted and adiated eectmagnetic
emissin eves ae within acceptabe imits. The vae
f the methd is that, nce the mdes and vais
epesentatins ae cmpete, they can be eadiy
mdified by changing a few key paametes, which aws
enginees t stdy vais atenatives and expe a wide
ange f what-if scenais. The appach pvides a
design that is within specificatins and entiey ptimized
— a befe a singe piece f hadwae is bit. In this way,the mtiphysics-based simatin appach saves time
and mney cmpaed t biding and testing pttypes,
and it enabes cmpanies t beat the cmpetitin t
maket with bette designed pdcts. n
Q3D Extractor model indicates current distribution of an IGBT package.
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9
Driving VehiclePerformanceSimatin heps t edce dagand impve acstic pefmancef cas, incding an eectic vehice.
By ansys avg Staff
A maj atmbie manfacte
sed a cmbinatin f a wind tnne
and fid fw simatin t edce the
vehice dag f a new pggabe
eectica vehice. The at cmpany
fnd that cmptat ina f id
dynamics (CFD) pvides aifw
anaysis ests faste, deiveing the
abiity t se me gemetic detai
than is pactica with a cay mde
and enhanced fw visaizatin
capacity and the vehice f diag-nstic ppses. The cmbinatin f
wind tnne testing and CFD made it
feasibe t achieve aggessive ange
and fe ecnmy tagets.
The aedynamics team stats
with cncepts and ideas pvided
by the design stdi. The pcess
begins with a cnsideabe amnt f
inteactin between the stdi and
the aedynamicists. The designes
wk t peseve the theme f the
vehice, and the aedynamicists
pvide feedback n shape changes
and mdificatins that cd be
sed t edce the vehice’s dag. The
bk f the wind tnne testing is
pefmed n a ne-thid–scae cay
mde that is cntinay mdified t
evaate vais design atenatives.
“Whie the wind tnne pays the
pimay e in the aedynamic
design pcess, we find seves in
sitatins in which wind tnnetesting des nt make sense, eithe
becase thee is nt engh time t
pefm tests becase we can’t
bid a cay mde f the gemety t
the eve f detai that we need,” said
Ken Kabn, staff enginee f Genea
Mts. “In these sitatins and
thes, we se ANSYS FluENT fid
dynamics sftwae t simate
aedynamic pefmance.” Kabn
added that his team can easiy set p
an atmatic batch n t evaate
sevea hnded diffeent fnt-end
aifw cnfigatins ve a weekend
— nattended. Fid dynamics
simatin as pvides the abiity t
mde the ndehd gemety t a
mch highe eve f detai and within
a me easnabe peid f time than
is pssibe with a physica mde.
T edce the time eqied t
anayze the age nmbe f iteatins
needed t ptimize a design, anefficient simatin pcess is sed t
atmate a cnsideabe ptin f
the mde setp pcess. This makes
it pssibe t semi-atmaticay n
many test pints witht se inte-
actin. F exampe, enginees can
wap a wkfw tkit and the
fid dynamics sftwae that gides
the se thgh pe-pcessing,
meshing, case pepaatin, jb
sbmissin, pst-pcessing and
epting. The mdes geneay ae
sbmitted t a high-pefmance
cmpting cste bit and IBM
PoWEr6™ bades. Enginees tiize
these capabiities with design f
CFD was used extensively to develop the front-end cooling airflow
characteristics of the Volt.
Volt external aerodynamics simulation using CFD
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automotive
10
expeiments (DoE) design f six
sigma t expe age design spaces
and identify the gba ptimmig.
In the case f the Chevy Vt,
aedynamics enginees btained
CAD data fm the design stdi
in Siemens NX™ fmat. The team
sed the fid dynamics sftwae’s
pe-pcess capabiities t bid a
tetaheda hex-ce mesh f the
vme snding the vehice’s
te sface with a pism aye next
t the bdy t capte bnday-aye
gadients. Vmetic efinement wassed t capte gadients in the
aeas f inteest, sch as the wake
and stagnatin pints. Bnday
cnditins wee defined t match the
wind tnne.
“F the stying sfaces, we
appied cassic atmtive ae-
dynamics best pactices by ensing
smth, cntins aifw and
the vehice,” Kabn said. “We
entained smke in the wind tnne
t pvide a high-eve macscpic
picte f fw diectin. Fid fw
simatin aws s t see mch
me than cd eve be btained
fm physica testing, sch as
pesse diffeentias fe and aft
f ndebdy cmpnents . In
genea, we pay cse attentin t
age sepaatin pints vtex
stctes cming ff the vehice,
becase they ceate a significant
dag penaty. We as taget veycean sepaatin fm the back f
the vehice.”
Fid dynamics anaysis payed the
pimay e in designing the gie,
adiat and eated cmpnents
t btain the ight amnt f aifw
thgh the gie t diect the
aifw whee it is needed and t
minimize cing dag. “We ked at
the pesse and vecity pfies t
ndestand hw the ai cmes thgh
the gie penings. We needed tmake se we wee getting engh
vme f ai t meet the mst
demanding engine cing ad
cases, sch as diving the ca thgh
Death Vaey deset,” Kabn said.
T sve specific pbems,
enginees ceated age aays
cnsisting f hndeds f design
vaiatins and tiized paae batch,
scheme and jna pcessing t
qicky anayze a f them. This made
it pssibe t qicky mde vais
design detais sch as gie penings,
gie texte, ai dams, heat exchange
size and psitin, and seaing andbaffing ndeneath the hd.
The engineeing team as sed
fid dynamics simatin t mitigate
and ptimize wind nise assciated
with the wipe bades n the Cadiac
CTS, CTS Wagn and SrX. They
fist detemined pesse and fw
vecity geneated by the wipes
ding the cncept design phase.
This infmatin was sed as inpt
t sftwae that pedicts acstic
pefmance. The abiity t evaatewind nise at an eay stage f
the design pcess heped avid
ate-stage pbems that wd have
been csty t cect.
Fid dynamics anaysis as
pedicts wind ads n vehice
cmpnents sch as snfs and
windws, especiay nde csswind
cnditins. This infmatin is fed int
stcta anaysis pgams sed
t ense that a cmpnents meet
high-speed eqiements. CFD as
estimates the tempeate and qaity
f ndehd aifw t the pwe-
tain indctin system.“CFD pays a vita e in ae-
dynamic and acstic design by
highighting the aeas we need t
wk n and by pviding diagnstic
infmatin that we cannt btain in
the wind tnne,” Kabn cncded.
“The techngy makes it pssibe t
qicky evaate hndeds f designs
in batch pcesses t expe the
cmpete design space s that
we knw we have the best pssibe
design. F exampe, this pcessmade it pssibe t edce dag fm
stat t finish.” n
Surface restrict particle traces indicate how the Volt's body sides and wheel arches were
streamlined, resulting in lower aerodynamic drag while maintaining the design theme.
Before
After
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Quest for the 200-mpg Car A evtinay intena cmbstin engine gives ise t a spemieagevehice with the ptentia t tansfm atmtive design.
By Heinz-Gustav Reisser, CEO, Niama-Reisser, LLC, Coshocton, U.S.A.
The N-r 1 spemieage vehice is
expected t pefm at an extemey
high eve f efficiency: tanspting
f adts 200 mies at 70 mies
pe h n ny ne gan f fe.
This vehice and its engine, pat f
the evtinay famiy f high-
efficiency Centifga Heinz Bxe
(CHB) engines, ae being deveped
by Niama-reisse, llC, in theui s.
Niama-reisse is a vehice and
ppsin sevice cmpany with a
dedicated engineeing depatment
speciaizing in cnsting, eseach and
devepment f intena cmbstin
engine design, maj sbsystems
and entie vehices. utiizing ANSYS
FluENT sftwae f fid fw and
ANSYS Mechanica techngy f
stcta and thema simatins,
the cmpany ffes a wide ange f
sevices f cstm engineeing
pjects. It as cndcts nging
eseach and devepment pjects
n innvative cncepts.
In deveping the spemieage
vehice, enginees sed ANSYS
FluENT sftwae t detemine dag
cefficient f mtipe vesins f
the N-r 1 vehice bdy she, savings ign i f icant t ime and expense
cmpaed t biding and testing
nmes physica pttypes.
Expeimenta wind-tnne ests
csey vaidated anaysis tpt and
enabed enginees t aive at an
aedynamicay ptimized design.
using the sftwae, the devepment
team weed the dag cefficient
fm 0.33 f the initia vehice bdy
she design t ess than 0.28 f thecent ptimized design.
The CHB engine beas i t t e
simiaity t taditina intena
cmbstin engines, in which
pistns mve p and dwn
in a ecipcating inea
mtin. In cntast, a
set f ppsing ts-
shaped pistns in the
CHB sci a te in
o o io .
Inceased efficiency is
attained sing tw cm-
pessin stkes pe cmbstin
chambe t tate the cank shaft. In
additin, a patented kinematic cnt
mechanism and inkage ate the
Prototype CHB engine attains high efficiency
with on-the-fly adaptive compression ratio,
engineered composite material components
and fewer parts.
Stress distribution of the CHB engine housing
overlaid on the geometry and mesh of the
ANSYS Mechanical model
engine’s cmpessin ati n the fy
whie in peatin. Pefmance is
fthe bsted thgh the se f
engineeed cmpsite mateias that
eqie n bicatin iqid cant
t maintain ppe peating tempe-
ates. Fewe mving pats, sch as
wist pins, vaves, wate pmp and i
pmp, ead t a 30 pecent edced
pat cnt and an inceased engine
pwe-t-weight ati.
Fluid flow analysis helped engineers to
reduce drag coefficients on the prototype
N-R 1 body shell.
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automotive
11
i m a g e © s o
c p h o o . c o m / n a r v .
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automotive
12
T stdy the cmbstin andthema behavi f the CHB, engi-
nees sed pedefined defats t
ceate a mving and defming mesh
(MDM) t set p in-cyinde gas fw
chaacteistics f mtipe fid
stcte inteactin (FSI) anayses. In
these stdies, mass ai fw was
detemined efficienty sing cmpex
ANSYS FluENT anaysis f me
than 12 miin eements. With this fid
mde, enginees cd effectivey
anayze in-cyinde cmbstin t
achieve a hmgenes mixte and
ptima bn. This, in tn, yieded the
highest-pssibe efficiency f a given
fe mixte.
ANSYS Mechanica sftwae
was as an intega pat f the CHB
devepment efft. In ne stage f
the pject, the engineeing team
sed the sftwae t anayze pistn
stesses whie appying eaistic
ads nt the pistn face and
In-cylinder gas flow characteristics simulated with CFD
Mass air flow represented in cylinder liners
for heat distribution purposes
Engineers used ANSYS Mechanical software to determine stress distribution in engineered
composite material pistons, which oscillate in a rotary motion.
incpating fictina cefficientsbetween the cyinde be and the
pistn mante. In patica, enginees
fcsed n engineeed cmpsite
mateia cmpnents t detemine
the feasibiity f vais designs and
t identify imminent stcta faie.
In these cases, when cmpsite
mateia cmpnents ae stdied in
eatin t adjacent meta pats,
cntact eements wee sef in
mdeing tching pats f dissimia
mateias. As, paameteizatin f
simatin mdes and bidiectina
cnnectivity with CAD sftwae wee
imptant t efect changes in
cmpnents’ dimensins s that
sensitivity stdies cd detemine
the best design in tems f pef-
mance, eiabiity and mateia csts.
This appach saves cnsideabe
time in physica pttype testing and
eads t ptima designs that ae
impactica t expe with mckps.
In this anaysis, the enginees
impted cmpnent gemety fm
the CAD system sing the ANSYSDesignMdee t. This techngy
was fast, seamess and hepf in
tasks sch as sface spitting t
pepae the gemety f meshing.
The simatin mde was ceated
sing mtipe settings sch as
tetaheda hex-dminant meshes
made with the ANSYS Wkbench
meshing appicatin. Bnday
cnditins (cnstaints, cntacts,
jints, ads, etc.) wee then definedsing ANSYS Mechanica techngy.
Fwing the stcta anaysis
stage, enginees sed the engineeed
cmpsite mateia cmpnent’s
m de g en e a t ed by AN SYS
Wkbench f an ANSYS Mechanica
thema anaysis. De t the diffeence
in expansin cefficients, this is vey
imptant f appicatins in which
cyinde ines ae cmpsed f
cmmn meta ays. The simatin
is pefmed t ense ppe pistn–
be gapping ding nma peating
tempeates, which ange fm 450
degees t 1,100 degees C.
Enginees fnd the se-
fiendiness and speed f ANSYS
Mechanica t be tw f the mst
imptant advantages f pdcts
fm ANSYS. The esting efficiency
in sftwae se awed the Niama-
reisse engineeing depatment t
eadiy cndct a seies f iteative
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automotive
13
simatins t efine the design, ths
aviding nmes tia-and-e
pttype test cyces. Indeed, pt-typing csts — pimaiy in the
devepment f the CHB engine
fami y — have been edced
60 pecent since the intdctin f
ANSYS pdcts at the cmpany.
Niama-reisse has empyed
ANSYS Mechanica capabiities f a
wide ange f the pjects with
significant advantages ve the
pevisy sed stcta anaysis
sftwae. In stcta beam appi-catins, stin times have been
typicay edced 70 pecent t 100
pecent with ANSYS Mechanica,
which as pvides mch faste and
me stabe pbem cnfigatins.
These advantages wee evident in
yet anthe appicatin, an innvative
tw-in-ne taie design that seves
as a gseneck taie cnnected t
a tck bed an attchment t adead-weight “bmpe taie” hitch.
The pevis anaysis sftwae pat-
fm had difficties in ceating the
3-mm fine mesh needed f detaied
anaysis; the pgam cashed ften
Structural beam analysis of two-in-one trailer design
becase f ng cmpte times
and meshing difficties. Meve,
mtipe sepaate steps had t be
pefmed t set p a cyindica
cdinate system necessay fthe anaysis. In cntast, ANSYS
Mechanica sftwae pvided the
cean, staightfwad se inteface
eqied t easiy set p sch
pbems with the cick f a mse. n
Selecting the Right Software for the Job
Niama-reisse an sbstantia benchmaking tcmpae cmptatina fid dynamics (CFD)
sftwae ffeings and seected the ANSYS FluENT
pgam f wk sch as detemining dag
cefficients f vehice aedynamics and anayzing
fid fw inside engine cy indes f pistn
cing stdies.
Fluid dynamics studies helped lower drag coefficients
for vehicle body shell.
otstanding cstme sppt fm ANSYStechnica sppt staff in these cmpex appicatins
and sbseqent exceptina fid fw simatin
ests gave enginees high cnfidence in pdcts
fm ANSYS. The sccesses with fid fw appi-
catins pmpted Niama-reisse t switch fm a
CAD-based finite eement package t ANSYS
Mechanica sftwae f stcta and thema
anaysis. The p-ANSYS decisin was based n
sevea cmpeing easns, incding:
• Sbstantiay deceased pcessing times with
ANSYS sftwae, typicay beynd 50 pecent
• Bette meshing capabiities egading impved
eement tansitining and highe mesh
densities in detaied egins f the mde
• Abiity t hande age assembies efficienty
with high-pefmance cmpting
• Bad base f integated stins in the
ANSYS pdct ptfi
• Staightfwad inteface and ease f se in
appying feates f cmpex pbems
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Fan of SimulationVith Tb edces csts whie deveping qiet fansby simating a cmpete aica cing system.
By Bernd Horlacher and Steffen Kämmerer, Development Engineers, Voith Turbo, Crailsheim, Germany
At cetain peating cnditins, the
highest nise eves in ai vehices
cme nt fm the engine bt fm
the cing nits, especiay the
fans. Inceasingy sticte exhast
egatins and gwing tpt
eqiements ca f highe and highe
cing pefmance, which cd
ead t geate nise ptin. Vith
Tb in Gemany deveped a pan taddess these cmpeting paametes
in the ai indsty.
Vith Tb is a eading cmpany
speciaizing in pwe tansmissin
sed in indsty as we as n the
ad, ais and wate. Eqipment fm
Vith Tb Cing Systems, a divi-
sin f Vith Tb, peates safey
and eiaby in aicas and c-
mtives a ve the wd, incding
high-speed tains (diese–hydaic,
diese–eectic and eectic). Thesecing systems, sed t c diese
engines, tansmissins, tansfmes,
invetes, thttes and dive mts,
eqie an indced ai mass fw that
is ceated sing high-capacity fans.
one disadvantage f cassic fan
design is that excessive nise is
emitted at tatina speeds f
3,500 pm and bade tip vecities
p t 360 km/h. T edce the snd
eve, enginees fm Vith Tb
Cing Systems and eseaches at
the univesity f Siegen in Gemany
deveped Vith SientVent™ tech-
ngy. Appying this techngy t
aicas and cmtives aike was a
chaenge: The cing systems in
aicas ae instaed n tp f the f
nde the f and, theefe, ae
qite cmpact when cmpaed with
the cing systems f cmtives.
Diesel engine ATR220 Pesa railcar with
a cooling system from Voith Turbo
Voith flow system for cooling fans
TbchageExhast Gas
Chage Ai
Tansmissin oi
CingWate
BypassVave
Heat
Exchange
Ce
Axe DiveTbTans-
iio
Diesemoo
Pmp
f
fCe
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turbomachinery
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turbomachinery
15
Bottom of the cooling system
showing obstructions
The inet t the fan is ften esticted,
s the fw enteing the bade
passages is ften highy distted.This can edce efficiency and incease
nise geneated by the fan.
The cing system cnsists f
f heat exchanges and thee axia
fans in which the fan inets aesepaated by meta patitins and
bcked by tbes/pipes and hding
pates. The scenai stdied was
a aica that had cme t est in a
aiway statin afte taveing at high
speed. Its fans ae sti tating at
f speed t dissipate the heat, bt,
becase thee is n nata wind, the
wam ai can be dawn back int the
heat exchanges. This ecicatin
fw cd degade the peatin
f the entie cing system. T
simate these cnditins accatey,
a age dmain tside the cing
system and aica was taken int
accnt. With neay 50 miin
eements, the mesh f the cing
system was necessaiy vey
age. The gid geneated
needed t stike a baance
between attentin t detai and
avaiabe esces t ense
that the simatin time waseasnabe, bt pats sch as
the fan wee finey discetized
t pedict aeas f sepaatin,
citica in btaining accate
stins.
F this mde, the heat
exchanges wee ideaized
and defined as a ps
medim. using the f ps
mde avaiabe in ANSYS
CFX sftwae, which is based
n Dacy’s law, the mde f theheat exchange was caibated
by adjsting the ss cefficient
t emate the chaacteistic
cve (ss f pesse vess
vme fw).
Visaizatin f the fw sing
steam ines did nt shw any
ecicatin fw thgh the heatexchanges f the cing system
mde with eithe the Vith standad
fan SientVent techngy. Each fan
shwed a cean tfw. By sing
fid dynamics techngy fm
ANSYS, the enginees wee abe t
detemine the vme fw ate f
each fan and distibtin f fw
fm the heat exchanges t the fans.
The team estabished fan design data
sch as tqe, ated inpt, pesse
incease and efficiency f the cm-
pete cing system — infmatin
that is nt easy t btain n a fan test
nde ideaized cnditins.
The enginees as sed the
ANSYS CFX Tb Nise mac,
Exhaust air from the fan
Roof-mounted cooling system (left) and under-floor cooling system (right)
Anthe key isse is that thee is
itte instaatin space, athgh
high ai thghpt is eqied. The
insta at in space is imited by
the ceaance f the vehice. (The
aica’s height and f cnt ae
imited becase the tain mst pass
thgh tnnes.) In additin, the fw
may be esticted by the systemsinstaed in the vehice, and the
fan hsing has a specific axia
instaatin height. Fm an acstic
pint f view, a ai vehice cing
system is an pen system becase
ces ae snd pemeabe.
T investigate the efficiency and
nise emissin f the SientVent fan
techngy cmpaed with thse f a
standad fan, design enginees in the
Bas ic Devepment ( eseach
and devepment) depatment sedfid dynamics in additin t thei
wn expetise. The ga was t
demnstate the peatina eiabiity
f a cmpete cing system sing
ANSYS CFX fid dynamics sftwae.
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turbomachinery
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Tip vortex
Turbo Post-Processing with
ANSYS CFD-PostT cmpement the ich cectin f
feates f genea fid dynamics
pst-pcessing, the ANSYS CFD-
Pst t pvides a set f additina
capabiities that specificay addess
the needs f tating machiney
designes and anaysts. These
capabiities ense that ses can
maximize the benefit gained fm
the insight pvided by thei sim-
atin ests.The t bmach iney ps t -
pcessing capabiities incde the
abiity t geneate pts in the eevant
tw-dimensina cdinate systems.
Meidina pts in axia–adia
cdinates can be sed, f exampe,
t assess cicmfeentiay aveaged
fw qantities. uned, bade-t-
bade pts ae indispensabe in
heping t identify pssibe design
impvements, awing the fw t be
visaized at any desied span-wisepsitin between hb and shd.
Specific chating ptins f
tating machiney as ae inc-
pated, awing ses t easiy
examine bade ading at a desied
psitin n the bade t k at
fw vaiatins ang ines fm hb
t shd, inet t tet, in the
cicmfeentia diectin.
A these pts and gaphs can
be integated int atmaticay
geneated epts based n tempates
pvided f a types f tating
machiney, fm pmps and fans t
tbines and cmpesss. The ept
tempates sppy standad machine-
specific definitins f qantities sch
as head ise, themdynamic efficiency
and ss cefficient, f exampe.
ANSYS CFD-Pst cntains a mac
f the pedictin f nise fm
w-speed fans f qick and simpe
assessment f fan acstics.
John Stokes, Requirements Manager,
ANSYS, Inc.
based n the lwsn mde, t
assess tna nise behavi. The
Tb Nise t shwed tends that
wee eqivaent t expeimenta
ests, and the t was, theefe,
sed t cmpae diffeent designs
t ense that the snd emissin
f the SientVent was mch we
than the standad fan.
The distance fm the SientVent’s
inet t the tet is nge than thestandad fan’s, casing the inet t be
cse t the bstcting pipes and,
in sme cases, the gnd. The
diectin change (defectin) f ai
between the heat exchanges and
the inet is as age. As a est,
the SientVent fan bades wee
designed s that the infw
des nt case a sepaatin.
In additin, the sbptima
infw de t bstctins can be
impved by eaanging the pipes
and thei attachments. Many f these
findings — btainabe ny thgh
fid dynamics — wi be fthe inves-
tigated in fte pjects.
Depending n the stage f
pdct devepment, deveping a
singe pttype fan f an existing
cing system thgh simatin
can edce csts by tw-thids.Simatin ts fm ANSYS ae
we estabished at Vith Tb.
Enginees in the Basic Devepment
depatment depend n engineeing
simatin, incding fid dynamics.
These enginees se hyddynamic
fndamentas t design tqe
cnvetes, hyddynamic cpings
(tb cpings) and hyd-
dynamic bakes (etades),
as we as a vaiety f
tbmachiney app i-
catins. The ANSYS CFX
pdct is empyed at
Vith Tb t simate
a vey cmpex sim-
atin ptfi — fm
incmpess ib e f w
t cmpessibe fws
and mtiphase fws t
viio ivigio.
This sftwae is a eqie-
ment t simate the fid fw intating machiney. n
Voith standard fan (left) and Voith SilentVent fan (right)
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Fishing withMultiphysicsDiect cped-fied simatin, incdingpiezeectic, acstic and mechanica anaysis,enabes enginees t tne tansdce pefmancef mniting hge tawe nets.
By Larry Clayton, Senior Staff Acoustical Engineer, ITT Acoustic Sensors, Salt Lake City, U.S.A.
Designing piezeectic tansdces t meet patica
pefmance eqiements is a demanding and taditinay
time-cnsming and impecise engineeing pcess.
Chaacteistics sch as pwe, sensitivity and bandwidth
depend n highy cmpex and inteeated eectica,
mechanica and piezeectic mateia ppeties, pat size
and shape, and the eectica and mechanica
paametes. Difficties ae cmpnded when tansdces
mst peate ndewate. T ptimize these devices,designes mst take int accnt speciaized acstic
and fid behavi.
Histicay, enginees devep designs f sch
tansdces with cmptatins fm ne-dimensina
(1-D)–eqivaent cicit mdes. These 1-D ts pvide
ny appximatins f tansdce behavi based n
simpified, mped cicit epesentatins f tansdces
sing indcts, capacits and esists. The esting
mdes d nt accatey epesent the te distibted
chaacteistics and mtipe-degee-f-feedm dynamics
f cmpex tansdces. Cnseqenty, nmes
pttypes mst be bit, tested and edesigned — ften
with hit--miss changes — nti the tansdce pefms
satisfactiy, at east nti it cmes cse t meeting
mst f the taget eqiements.
using the diect cped-fied anaysis capabiities f
ANSYS Mtiphysics sftwae, enginees at ITT Acstic
Senss (ITT-AS) have impemented a bette appach
based n finite eement anaysis t qicky and effectivey
aive at ptima tansdce designs witht the deays,
gesswk and inaccacies f the methds. FEAtiizes a f 3-D simatin f the tansdce with piez-
eectic, mechanica and acstic fmatins t
chaacteize dynamic espnses f the tansdce. Fid
stcte inteactin (FSI) and acstic eements mde
wate-aded behavi in detemining attibtes sch as
feqency-dependent beam pattens, diectivity, tansmit
pwe and eceive sensitivity.
The FEA appach was appied in ne ecent pject
in which an ITT-AS tnpiz tansdce was edesigned t
meet patica eqiements f a cstme sing
tansdce aays in its cmmecia fishing peatins.
The cmpnent was pat f a system f detecting whenhge tawe nets ae f and sbseqenty when enty
ptins f the net ae csed. Specificay, this eqied
ITT-AS enginees t devep a dp-in epacement f the
tnpiz with geate tansmit-and-eceive espnse ve
a badened feqency band with a patica esnant
feqency and beam width.
With these pefmance bjectives in mind, the ITT-AS
team sed thei extensive tansdce engineeing
expeience in iteativey making vais changes t the
design and simating device pefmance f each
mdificatin. Maj changes incded:
Significant tansdce shape mdificatin with•heavie mateia sed f the tai mass
F piezeectic eements, each with age•
aea and thinne depth t epace the igina tw;
tansdce ength emained nchanged
Deceased diamete f stess bt t edce the•
fce it geneates in ppsitin t head mtin Admittance curves show good agreement between simulation
predictions and measurements.
Model of a tonpilz transducer
ready for analysis
-30.0
-40.0
-50.0
-60.0
-70.0
-80.0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
2 0 l o g ( Y ) d B s
Frequency (Hz)
ansys piio Measement
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By exping these
mdificatins with
simatin, engineesqicky eached an
ptima design —
ne that significanty
impved tansdce
pefmance beynd
the eqiements speci-
fied by the cstme.
Specificay, bandwidth
was widened by me
than a fact f thee, and
tansmit eve inceased by 56 pecent. receive
espnse deceased by 7 pecent with edced ee-ment impedance bt emained abve the eqied vae.
The appach avided the deays f nmes pttype
testing cyces and the inaccacies f 1-D cacatins.
ITT-AS pefmed a singe pttype test cyce nea
the end f devepment t vaidate the design, instead
f the five t six cyces typicay needed with the
taditina bid-and-test devepment methds.
The simatin-based edesign began with enginees
impting CAD gemety (patitined int its vais pats
f the tansdce) int sftwae fm ANSYS t ceate the
anaysis mde. This mde was meshed sing axisym-
metic stcta eements f the passive tansdcecmpnents and diect cped-fied axisymmetic
eements f the active piezeectic ceamics cmp-
nents. Anistpic mateia ppeties (incding eastic
cmpiance, piezeectic stain and eative dieectic
pemittivity) epesented the active mateias. Enginees
enteed piezeectic mateia ppeties in ANSYS
fmat f paizatin ang the Y-axis density, and
the ss tangent was incded f the dynamic
simatins. linea is-
tpic ppeties, incding
density and damping,
epesented pass ivestcta mateias.
T detemine the
hamnic espnse f
the tansdce, enginees
a p p i e d s y m m e t y
dispacement bnday
cnditins t the centa
axis, cnstained the
base ang the Y axis,
and app ied v tage
bnday cnditins t
n des ep es en t i n geqiptentia psit ive
and negative eectdes.
Sht-cicit esnance
was cmpted with bth
eectdes gnded (0V),
Displacement contour of the first
interference mode indicates that it
arises from longitudinal extension
of the stress rod.
Basics of Piezoelectricity
Piezeectic ceamic mateias geneate an eectic
vtage in espnse t appied mechanica fce,
say a vibatin pesse vaiatin. Senss
based n this techngy ae sed in the atmtive
indsty f detecting exhast pesses and engine
vibatins, f exampe. Cnvesey, piezeectic
mateias pdce a fce when vtage is appied in
actat appicatins, sch as in sme ink-jet pinte
heads and diese engine fe injects.
Piezeectic tansdces — the geneic name
f these types f devices — can seve the da e
f geneating and sensing vibatins, geneay ai-
bne snd waves and ndewate acstics. Thisis the pincipe behind sna systems in which aays
f tansdces ae sed t detect ndewate bjects
by sending t a “ping” and measing the time
taken f a etn ech. one exampe f the many
types f tansdces fm ITT-AS is the tnpiz,
which is widey sed in sna appicatins f its
pecisin, w cst and eiabe pefmance.
and pen-cicit anti-esnance was cmpted with the
negative eectde gnded (0V) and n vtage appied
t the ps eectde. Enginees pefmed hamnicespnse anayses t detemine in-ai admittance f the
tansdce with +/-0.5V appied acss the active
eements. ANSYS pst-pcessing ts dispayed and
animated ests, incding mde shapes, pviding gd
insight int the mechanica behavi f the tansdce.
Tonpilz transducers from ITT-AS come in a wide range of shapes,
sizes and configurations for various applications.
Model of transducer
includes water loading
(blue dome-shaped mesh)
for acoustic performance
predictions.
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electronics
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F exampe, the dispacement cnt f the fist
intefeence mde indicated that it ase fm ngitdina
extensin f the stess d.
ANSYS simatins cntined t incde the effect f
wate ading f acstic pefmance pedictins. Wate
was mdeed sing axisymmetic acstic eements, and
fid–stcte inteface ndes wee paced at the adiating
face f the head mass. Fa-fied bndaies f the
wate wee mdeed by axisymmetic acstic ine ee-
ments that epesent a nnefecting bnday. Mateia
ppeties eqied f the acstic eements incded
density and speed f snd. Bnday admittance wasset t 1 f the acstic eements epesenting baffe and
fa-fied sfaces whee snd is fy absbed. Away
fm the absbing sfaces, the bnday admittance
was set t 0 (n snd absbed).
using this mde, enginees pefmed in-wate
hamnic espnse anayses f +/-0.5V (1V tta) appied
Major parts of the tonpilz transducer design
Ins and Outs of the Sound Mushroom
A typica ITT-AS tnpiz (a Geman wd meaning
“snd mshm”) tansdce cnsists f sevea
active piezeectic ayes sandwiched between a stiff,
w-mass adiating head and a mch heavie tai mass.
The devices may be designed with vais pat
cnfigatins and mnts f diffeent ndewate
appicatins, in which the tansdce can seve as a
snd-pdcing pject, an acstic hydphne
sens bth. Tansdces can be sed independenty
gped int aays with patica beam width and
diectivity at seected feqencies.
The tnpiz is ne f nmes types f tans-
dces designed and manfacted by ITT-AS. With
ve 50 yeas’ expeience, the cmpany is a eade in
designing and manfacting piezeectic tansdces
— and the eated eectnics f cnt ing,pcessing, cnditining and dispaying signas — in a
vaiety f appicatins, incding nava and indstia
sna, medica eqipment, i and gas systems, mtin
cnt, and heath and safety.
acss the ceamic eements
in the tnpiz stack. Fm this,
they then cacated acsticpefmance chaacteistics
(incding tansmit and eceive
espnse and impedance)
ve the feqency ange f
the anaysis. This cacatin
shwed significant impve-
ment in acstic pefmance
ve the igina design f
the tansdce.
upn cmpetin f the
hamnic espnse anaysis f the tnpiz mdes in
wate, ANSYS pst-pcessing ts wee sed t stdystin ests. The time-histy pst-pcess defined
acstic pesse and eectic cent vaiabes
fm which feqency-dependent tansmit espnse,
impedance and eceive espnse acstic pefmance
chaacteistics wee deived and gaphed. Enginees
eviewed cnt pts f dispacement and stess
vaiatins thght the new tnpiz, and they geneated
cnt pts f acstic pesse adiating fm
the head mass at the peak tansmit vtage espnse
(TVr) feqency. Beam pattens and diectivity
chaacteistics wee as deived fm acstic pesse
distibtins cmpted at the hamnic espnse anaysisfeqency steps.
This pject ceay demnstated the vesatiity and
tiity f ANSYS Mtiphysics techngy as a pwef
t f the design f cmpex cped-fied tansdces.
The stin significanty impved pefmance f the
tnpiz, exceeding a cstme eqiements. n
light Stiff Head Mass
F-laye ActivePiezeectic Eements
Pe-lad Stess rd
High-DensityTai Mass
Acstic AbsbeCveing Extei
The new tonpilz design shows significant improvement in transmit
response and bandwidth.
155
150
145
140
135
130
30 35 40 45 50 55Frequency (KHz)
T V R ( d B )
ANSYS New TnpizMin New Meased
Max New Measedoigina AVG Meased
AVG New Meased
electronics
Contour plot shows
acoustic pressure
radiating from the
head mass at the
peak TVR frequency.
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mining
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It’s a BlastTechngy fm ANSYS heps tptimize the pecise timing f deayeddetnatins t get the biggest bangf the bck in the mining indsty.
By Dale Preece, Global Technology Development
Orica USA Inc., Watkins, U.S.A.
In mining peatins, expsive basts ae jst as mch
abt pecisin cnt as abt bte fce. F efficiency,
mines mst se engh expsives t fagment and mve
as mch mateia as pssibe. on the the hand, the
amnt f expsive enegy is cnstained by bdgetay
estictins, as we as by imits n bast vibatins that can
distb adjacent mining pits and shake bidings in
neaby twns.
The key is a seies f we-panned expsins in which
ws f expsive-fied bast hes ae set ff with eectnic
detnats in a pecise-deay timing seqence meased
in tenths-f-a-miisecnd accacy. If timed jst ight,shck waves einfce and ampify ne anthe t pdce
maximm fagmentatin and mvement f ck, e,
ca and the mateias. othewise, the fagmentatin-
pdcing tensie waves efecting fm fee faces (incding
the vetica bench face f the mine pit) can be canceed t
by cmpessive waves fm adjacent basts, theeby
significanty weing expsive effectiveness.
The maj chaenge in this appach is detemining
the ptima detnatin deay, which depends n
nmes vaiabes, incding the cmpessive stength
and bitteness f mateia being basted, the type
f expsive sed, and the diamete, depth and spacing fbast hes. odinaiy, mining peats ty t find the
ight detnatin deay thgh expeience in specific mine
fieds and cnsideabe tia and e. Even afte mnths
f expeimentatin, hweve, many cmpanies eventay
sette n a deay that gets the jb dne satisfactiy
athe than spending me time tying t find the esive
ptima deay.
The agest sppie f expsives in the mining
indsty, oica is stdying pecise-deay timing as a pat
f its extensive ange f Basting-Based Sevices pvided
t cients in sme f the wd’s agest sface and nde-
gnd mines. F these stdies, ne f the ts oica
engineeing teams se is the ANSYS AuToDYN nninea
expicit dynamics sftwae, which the cmpany asempys f isk assessments f expsives manfacting
and distibtin t the mining indsty.
Maj feates make the sftwae paticay we-sited
t ck basting fagmentatin pedictin. Bit int the sft-
wae is a riede–Hiemaie–Thma (rHT) bitte mateia
mde f pedicting cack densities and fagmentatin in
ck. rHT accatey epesents pesse-dependent and
esida faie sfaces, eastic imit sfaces, and stain
hadening in a nified mde that accmates damage in
tensin and in cmpessin — tw citica stess states
that mst be ppey cdinated thgh pecise-timing
detnatin t achieve maximm fagmentatin.The capabiity t cpe Eeian and lagangian
fames f efeence in ANSYS AuToDYN sftwae is
The key to optimal blast performance is a series of well-planned
explosions in which rows of explosive-filled holes are set off
with electronic detonators in a precise-delay timing sequence
measured in milliseconds.
Surface coal mine blast geometry shows the portion of the field to
undergo 3-D simulation of delayed detonation and rock fragmentation.
The vertical bench face denotes the vertical walls of the pit where
blasted material moves and is removed by excavators and haulers.
Shock waves and pressure distributions are shown in the blast field with
a 2-ms detonation delay between the adjacent blast holes represented.
Shock waves (red) progress upward through the blast field and
combine next to the bench face and ground surface where individual
rock fragments form (dark blue).
Bast HesGemety Simated
Bench Face
Pit F
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shws fagmentatin f the vais detnatin deays. In
the accmpanying images, the pit face is epesented by
the bttm-mst edge f the ectanga css sectin.
Nte the symmetica damage patten f the 0-ms sim-
tanes detnatin, in which the nea-staight spaw ine
f fagmentatin is nifmy sepaated fm the pit face
by a cnsideabe distance. Damage and fagmentatin
impve with inceasing detnatin deays f 2 ms and
8 ms, and cve the geatest ptin f the ck mass at
15 ms — the deay at which maximm fagmentatin
ccs. Simatins shwed that geate deays demn-
state inceasingy degaded bast pefmance. At deays
geate than abt 50-ms, shck waves fm each he
behave faiy individay with itte inteactin with thsef the adjacent he.
The vae f sing ANSYS AuToDYN simatin
f sch stdies is that enginees nt ny can
qicky detemine ptima detnatin deay bt as
assess the impact f sing diffeent expsives and bast
he gemeties. As a est, oica can wk me csey
with cients and qicky pvide vaabe insight int
eveaging the highest pefmance pssibe fm
mining expsives. n
especiay hepf in bast fied mdeing. The Eeian fame
f efeence is best sited f epesenting expsive det-
natins becase the mateia fws thgh a gemeticaycnstant gid that can easiy hande the age defmatins
assciated with gas and fid fw. rck is mdeed with
the lagangian fame f efeence best sited f fag-
mented sids becase the mesh mves with the mateia
and aws f eaistic defmatin and beakage. These
tw fames f efeence ae cped in the ANSYS
AuToDYN sftwae s that enegy is easiy tansfeed
between the tw f accate mdeing f the entie bast
pcess.
A cmpeing ANSYS AuToDYN capabiity is the
incpatin f these feates int the thee-dimensina
simatins, making the sftwae the ny gica chicef mdeing and anayzing ck basting. These 3-D
feates wee sed in a ecent simatin f a sface ca
mine bast gemety. In this anaysis, bden (distance
between ws f bast hes) is 32.5 feet, spacing between
adjacent hes is 48 feet, and bast he diamete is 12
inches; the rHT mde was adjsted based n an 800
pnds pe sqae inch (psi) cmpessive stength f shae
t be basted apat. The vetica bench face dentes the
vetica was f the pit, whee basted mateia mves and
is emved by excavats and haes. Tw adjacent bast
hes ae mdeed in 3-D with diffeent deay times between
the hes, incding 0 miisecnds (ms) (simtanes
basts), 2 ms, 8 ms and 15 ms.
Tanscent c epesentatins shw the pedicted
pgessin f shck waves and pesse distibtins in
the bast fied, with a 2-ms detnatin deay between the
adjacent bast hes epesented as tw vetica ines. Shck
waves, shwn in ed, emege fm the bast hes, pgess
pwad thgh the bast fied, and cmbine next t the
bench face and gnd sface at a tensie stess f at
east 100 psi — the pesse, shwn in dak be, at which
individa ck fagments fm.
What is immediatey bvis fm this seies fsnapshts is that damage accmatin significanty ags
behind the initia detnatin and mvement f the shck
waves. This ccs becase damage and fagmentatin
ae a diect est f cack ppagatin, the ate f which
depends n cack tip vecity. The rHT mde cecty
teats the cack tip vecity as a factin (say abt
ne-qate) f the snic vecity f the mateia.
A cmpaisn f damage at 20 ms afte the secnd
detnatin in a css-sectina sice thgh the bast aea
A comparison of damage at 20 ms after the second detonation in a
slice through the blast area shows the various detonation delays.
Damage moves forward with increasing detonation delays of 2 ms and
8 ms, and reaches the pit face at 15 ms, at which maximum
fragmentation occurs near the pit face.
0-ms Delay 2-ms Delay
8-ms Delay 15-ms Delay
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automotive
22
Driving forDurabilityE-Z-Go enginees qicky and accatey
design a eiabe tiity vehice pat that savesmanfacting csts.
By Mike Neely, Design Processes and Services Manager
and Jing Heng Wen, Senior Project Engineer, E-Z-GO, Augusta, U.S.A.
Designing gged tiity vehices
eqies enginees t baance time and
cst with dabiity. E-Z-Go, a Textn
cmpany cated in the united States,
deveps dabe, high-pefmance
vehices f a vaiety f ff-ad ses.
In additin t being a eading man-
facte f gf cats, E-Z-Go
pdces tf maintenance vehices,
heavy-dty indstia mateia caies,
vesatie pesnne caies and
gged tai tiity vehices.
E-Z-Go enginees wee given ne
week t edesign a tiity vehice
fame t eiminate a bend that was
casing manfacting difficties.
The engineeing team had a age
amnt f physica testing data
avaiabe f the existing fame, which
had been capted n the cmpany’s
pving gnd. This data cnsisted
agey f time histies f ads
meased at the spinde with
acceemetes, and f stesses and
stains meased at vais pints n
the fame with stain gages. Diecty
tiizing the ad infmatin wd
have eqied a vey cmpex
nninea mde t incpate the f
dynamic behavi f the vehice —
ne that might take f days t sve,
and many simatin iteatins t
vaidate the mde and evaate
diffeent design atenatives.
The team sed ANSYS Mechanica
f this pject becase the sftwae
ffes vey pwef and fexibe design
ptimizatin capabiities. Sftwae
fm ANSYS makes it pssibe t
ptimize vitay any aspect f the
design, incding dimensins sch as
thickness, shape sch as fiet adii,
and pacement f sppts, ad,
nata feqency and mateia
ppeties. F the tiity vehice
appicatin, the E-Z-Go engineeing
team tk advantage f these
capabiities t ptimize the ads s
as t achieve the desied stess eve
in the design.
The enginee assigned t the
pject seected six ad cases fm
physica testing ests, incding
static ing, baking ve bmpe,
wheeing in a pthe and cneing.
He sed the meased fied-test data
in ne catin nea the edesign aea
t gide the ptimizatin pcess.
The stess in the X diectin was mst
imptant fm a fatige standpint,
E-Z-GO produces utility vehicles
that can be used to haul materials
over rough terrain.
The geometry of the original frame for the utility vehicle (left) and the geometry of the redesigned frame showing welds (right)
b a c g r o u n m a g e © s
o c p h o o . c o m / d a n t h o r n e r g .
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automotive
23
s this vae was sed as the design
bjective, whie stesses in the Y and
Z diectin wee sed as state
vaiabes cnstaints. The ads at
the fnt and ea axe end wee set
as design vaiabes. The enginee
detemined the best cmbinatin f
inpt ads t match the fied test
data and then ptimized the ading
f the cases. T veify the accacy
f the ad data, the simpified mde
then was n with the ad data
geneated by the ptimizatin t
make se that the stess eves in a
secnd cat in n the fame
matched the fied-test data.
At this pint, the simpified finite
eement anaysis mde behaved jst
ike the ea vehice in tems f stess
and stain n the fame, yet the
anaysis tk ny 30 mintes t n.
The enginee mdified the mde t
match the initia cncept f the
edesigned fame. Anaysis indicated
sme weak aeas, incding the
weding patten, s the mde was
mdified t stengthen the fame. He
then evaated the pefmance f
the new design against each f the
six ad cases geneated ding
the ptimizatin pcess. The ests
shwed that the maximm stess
in the new fame was 5 pecent t
10 pecent we than the centfame nde each f the five payad
sitatins.
The next step was veifying that
the fatige ife f the new fame was
bette nde the entie ading histy.
Enginees sed Designlife™ fatige
i fe est imat in sf twae f m
HBM-nCde t n the ent i e
ptimized ad data against bth the
new and the d designs t get a
cmpete picte f the fame dabi-
ity. The fatige ife estimatin pe-
dicted a nge ife f the new design
than f the d ne.
The fina step in the design
pcess was t n acceeated
dabiity tests n the new fame t
veify the fatige ife pedictins and
t demnstate that the new design
pvides eqa bette dabiity
pefmance than the igina fame.
The ptimized ad data cd be sed
as the ading envinment f
dabiity testing; hweve, E-Z-Go
enginees needed t acceeate and
simpify the test. They identified asimpe step ad that appximated
the mch me cmpicated time
histy data, which was acceptabe
becase the ga f the test was
t detemine nt the abste
dabiity pefmance bt, athe, the
eative pefmance f the tw
designs. The testing was cmpeted in
a eativey sht time. It veified that
the dabiity pefmance f the new
design was bette than that f thed design.
Based n the ests f the finite
e ement anays is , fat ige i fe
estimatin and dabiity testing, the
new tiity vehice fame design was
eeased f pdctin. The new
design demnstated that its eiabiity
and dabiity wee at east eqa t
the pevis design. This appach
sbstantiay edced engineeing
csts and heped E-Z-Go get the new
design int pdctin faste.n
HBM-nCode is now an ANSYS OEM supplier,which means that customers can efficientlyaccess advanced fatigue capabilities within theCAD-integrated environment of ANSYS Workbench.The ANSYS nCode DesignLife product helpsusers answer the question “How long will itlast?”, helping to avoid iterative physical testingand speeding up the development process.
DesignLife (from HBM-nCode) simulation shows the frame life for scheduled events with different
payloads for the original frame (left) and the new frame (right)
Original frame stress under
a specific loading condition
New frame stress under the
same loading conditions
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How’s theWeather on Mars?Simatins ae citica f caibatin f instmentsas we as fast and accate intepetatin f datafm the Phenix Mas lande.
By Jeff A. Davis, Post-Doctoral Fellow and Carlos F. Lange, Associate Professor,Computational Fluid Dynamics Laboratory, University of Alberta, Edmonton, Canada
Becase Mas is the panet csest t Eath, it has been
hst t nmes intepanetay missins. The Phenix
Mas missin was designed t stdy the histy f wate
and habitabiity ptentia in Matian actic ice-ich si.
As the Phenix Mas spacecaft anded n the Matian
sface in May 2008, cmmnicatins stpped
ding the switch t bite eay. Tw hs ate, a sigh f
eief epted when data fm the ande began steaming
in. With space missins, thee is ny ne sht atgetting it ight. Any min faw in the spacecaft its
instments cd est in the instantanes ss f yeas
f pepaatin and hndeds f miins f das.
Canada’s cntibtin t the Phenix Mas missin
has been t pvide the metegica site f
instments (MET) that mease the tempeate,
pesse, vecity and patice cntent in the panet’s
atmsphee. Mas has a niqe atmsphee cmpsed
mainy f cabn dixide (95.3 pecent), nitgen
(2.7 pecent) and agn (1.6 pecent). The gavitatina
cnstant n that panet is 38 pecent that f Eath’s,
and the atmspheic pesse n Masis 1 pecent f s. As a est,
pe-missin design and caibatin
expeiments f the ande and its
instments wee diffict and
expensive t pefm, making
nmeica simatins the mst
bvis ecnmicay viabe stin.
Even s, nmeica simatins have been
ntisy absent fm the extensive pepaatin pc-
ess f data cectin f eaie panetay missins. The
Phenix Mas lande is the fist pject that has sed
cmptatina fid dynamics t aid caibatin f a
panetay missin’s instments. The deck f the ande
cntains mst f the instments sed t cect extena
data. of patica inteest ae pesse, vecity and
tempeate senss [1], whse measements, nde
cetain cnditins, can be infenced by the ande itsef.
F exampe, the intena heat geneatin and emissin
f adiatin fm the ande’s sface may est in a
thema cnvective pme, which can incease temp-
eate measements. Simiay, bstaces psteam fm
vecity and pesse senss can ate eadings f
magnitde and/ diectin f Matian winds.reseaches at the univesity f Abeta caibated
these instments pe-fight thgh a age paametic
stdy sing ANSYS CFX fid dynamics sftwae by
vitay vaying the envinmenta cnditins and the
ande’s heat tpt. rests eveaed cetain wind
diectins in which the ande’s heat emissin cased the
west f the thee tempeate senss t shw highe-
than-atmspheic vaes [2]. The univesity f Abeta
team sed the ests f these fid dynamics simatins
Pesseso
Wind Sens
Tempeateso
P h o t o c o u r t e s y N A S A / J P L - C a l t e c h / U n i v e r s i t y A r i z o n a / T e x a s A
& M
U n i v e r s i t y .
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scientific instruments
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Model of the Phoenix Mars Lander
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t evaate the aw missin data and t find instances
when these wind diectins cced. This awed the
team t incpate an inceased measement
ncetainty f these cases. In this manne, simatin
was the key t peventing data fm being misintepeted.
A simia stdy was cmpeted f the pesse
sens, in which the pesse diffeence was ceated
with wind speed. The Tetae wind sens was a
cmpetey new design f the Matian ande, s it
eqied a me in-depth caibatin that fcsed nvecity measements. The cncept f this wind sens
iginated at the univesity f Abeta, and it was designed
and bit in Denmak. The wind eadings fm the Tetae
payed an imptant pat in data intepetatin fm the
Mas ande.
In additin t the mde size and nmbe f sim-
atins pefmed, the datin f each simatin was a
fact. Ding the missin, the ande instmentatin had
imited time and pwe esces. Pwe and peating
time acatins wee cacated daiy, based n pevaiing
cnditins. T decide these acatins, stategic pannes
smetimes eqied inpt fm the simatin data, s it
was essentia f the univesity f Abeta team t have
apid simatin tnand n new cases.
The sht time-espnse eqiement was met by
nning the simatins in paae. Cases wee n n a
64-bit linx® cste with each nde cmpsed f tw
qad-ce opten™ 2350 AMD pcesss. Benchmaks
n the pbem ested in a spe-inea speedp f 4.47
n f CPus and a inea speedp f 8.00 n eight ces,
with each simatin nning cay n a singe nde. Theefficiency f the paae pcessing and mti-dmain
scheme sed in ANSYS CFX sftwae cmbined with
AMD’s mti-ce achitecte enabed new simatins
t be cmpeted within the time fame eqied f the
decisin-making pcess.
Caibatin f the Phenix Mas lande, sing
ANSYS CFX techngy, was deemed sccessf in bth
the pe-missin and peatin phases. The sccess has
awed f additina simatins t be pefmed t
aid in the expanatin f cetain phenmena fnd in the
w . n
Funding from the Canadian Space Agency is gratefully acknowledged.
References[1] Taylor, P.; et al. Temperature, Pressure, and Wind Instrumentation
on Phoenix MET. J. Geophys. Res ., 2008, v. 113. E00A18doi:10.1029/2008JE00308.
[2] Davy, R.; et al. Initial Analysis of Air Temperature and Related Datafrom the Phoenix MET Station and Their Use in Estimating TurbulentHeat Fluxes. J. Geophys. Res . In press.
Effect of the support on the velocity sensor. Red and yellow streamlines
indicate flow direction.
Temperature contours showing the effect of the lander’s heating on the lowest of the three temperature sensors
lwest Tempeate Sens
lwest Tempeate Sens
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scientific instruments
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scientific equipment
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Exploring theDark Side ofthe UniverseEnginees at the Femi Natina Acceeat
labaty se ANSYS techngy indeveping a pecisin camea f stdyingthe fa eaches f the nivese.
By Ingrid Fang, Mechanical Engineer, Particle Physics Division
Fermi National Accelerator Laboratory, Batavia, U.S.A.
Fm bsevatins f distant expding stas caed
spenvae, astphysicists knw that the nivese is
expanding at an acceeating ate, diven twad by what
they specate is the psh f negative gavity fms-caed dak enegy that nifmy fis thewise
empty space. Becase f its csmgica significance,
scientists ae eage t ean a that they can abt dak
enegy, which has yet t be diecty bseved becase f
its extemey w density and ack f inteactin with mst
fndamenta fces f the nivese. Essentiay, the ny
way t pbe the ppeties f dak enegy is t make
extemey pecise measements f the expansin ate
f the nivese.
This chaenge is being addessed by a pject caed
the Dak Enegy Svey, which is aimed at detemining the
histy f the expansin ate f the nivese by taking
images f ghy 300 miin gaaxies and measing thei
shape and edshift — the change in feqency f ight and
the eectmagnetic adiatin as the heaveny bdies
mve twad, away fm Eath. By making sch
measements, scientists wi be abe t investigate
the expansin f the nivese ve
tw-thids f its tta ife — fm the
time when the nivese was ny
a few biin yeas d.
Scientists wi phtgaph these
distant gaaxies sing its Dak Enegy
Camea (DECam) — ne f the agest
cameas eve bit sing chage-c p ed dev i ces ( C C Ds ) , t h e
same imaging techngy sed in
cnventina digita cameas. With
an end-t-end ength f 2.5 metes
and a weight f 3.6 metic tns, the
500-megapixe DECam wi be paced
Simplified model of the telescope
and camera structure
Temperature distribution at focal plane
for 20-degree C ambient temperature
Barrel and imager Z direction displacement
under vacuum load, thermal load and gravity
load at 20-degree C ambient temperature
n an existing
4-mete teescpe
at the Natina optica
Astnmy obsevaty’sCe T Inte-Ameican
obsevaty in nth-centa Chie.
obtaining ppe measements eqies that the
DECam’s CCDs be pecisey aigned with the teescpe’s
enses and pimay mi. An “aignment bdget” was
ceated t acate 10 micns t 15 micns f awabe
misaignment f each sbsystem in the camea.
The me than 300 pats and sbsystems f the
DECam wee deveped by individa membes f a
design team. The ath’s specific cntibtin was t
pefm detaied anaysis f these pats and sbsystems
sing ANSYS Mechanica sftwae t ense that dead-
weight defectins, vacm defmatins, thema dist-
tins and vibatin mdes f the camea wee within these
imits. The sftwae as was sed f thema stdies t
detemine tempeates f individa pats as we as tta
heat ad n the cing system. A cacatins wee
Detailed model of the
primary focus cage
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scientific equipment
ANSYS Advantage • Vme IV, Isse 1, 2010 27
Anatomy of the Dark Energy Camera
As designed, the Dak Enegy Camea cnsists f
cmpex ptica cmpnents that mst ppey aign
t accatey mease the distted shapes and
edshift f distant gaaxies.
A set f five fsed-siica ptica enses and eated
fites cmpise a cect assemby that fcses the
ight and sepaates t the eevant feqencies.
Fcsing is dne with a hexapd assemby that aigns
the camea with the teescpe’s pimay mi and
as pefms atea cectin t cmpensate f
stcta defectin as the teescpe mves. A shtte
mechanism cnts CCD expse time. Attached t the end f the cect is an image
system cntaining an aay f chage-cped devices
(CCDs) ced with iqid nitgen. readt cicit
bads that pcess signas fm the CCD aay ae
mnted in eectnic cates at the end f the image.
T check the aignment f cmpnents, Femiab
enginees sed ANSYS Mechanica sftwae t
accatey detemine defmatins, thema disttins
and vibatin mdes f the camea. The team as sed
the sftwae f thema stdies t detemine the
tempeate f individa pats as we as the tta heat
ad f the cing system.
made at tw ambient
t e m p e a t e s : 2 0
degees Cesis (C) and-5 degees C, based n
cimate cnditins at the
teescpe site. De t
the cmpexity f the
DECam, tw sepaate
anaysis mdes wee
ceated. A f mde f
the camea — which
cntained 679 highe-
de sid eements bt
witht a cmpnent
detai s — cmpteddispacements. These dispacements wee sed as inpt
t a detaied cage mde having 3,112K eements.
Femiab empyed the ANSYS Wkbench patfm
with ANSYS Mechanica sftwae t edce the time
eqied t ceate anaysis mdes sing CAD integatin,
atmatic meshing and fy paametic mdeing capa-
biities. They impted native CAD gemety diecty int
ANSYS sftwae and sed the ANSYS DesignMdee
t t simpify the gemety. The ANSYS Wkbench
envinment atmaticay detected and set p cntacts
and jints between pats f the assemby, with the
enginee mdifying cntact settings and enteing
additina mana cntact definitins.
ANSYS Wkbench saved mch time n the pject
becase its gaphica ts geaty steamined the
pcess f editing gemety and appying bnday
cnditins, ads, cntacts and me. In cntast, the
taditina appach eqies seecting a f the ndes n
a sface in de t define it. With the ANSYS Wkbench
patfm, the enginee simpy cicks n the sface
vme t appy the bnday cnditin, ad cntact.
Anaysis ests pvided detaied infmatin n the
defectin f the stcte and tempeate f the CCD
eadt pinted cicit bads. Pject enginees f
individa sbsystems examined the ests and madedesign changes t mitigate any isses. Mdes wee then
changed and esimated in an iteative pcess nti
the design was finaized t ense that each sbsystem
maintained ppe aignment. This gaanteed that the
DECam wd deive the accacy needed t tace back
tw-thids f the way t the beginning f the nivese. n
The Dark Energy Survey Collaboration consists of scientists fromFermilab, University of Illinois at Urbana-Champaign, University ofChicago, Lawrence Berkeley National Laboratory, University of Michigan,University of Pennsylvania, The Ohio State University, Argonne NationalLaboratory, NOAO/CTIO, CSIC/Institut d’Estudis Espacials de Catalunya
(Barcelona), Institut de Fisica D’Altes Energies (Barcelona), CIEMAT(Madrid), University College London, University of Cambridge, Universityof Edinburgh, University of Portsmouth, University of Sussex, ObservatorioNacional, Centro Brasileiro de Pesquisas Fisicas, Universidade Federal doRio de Janeiro, and Universidade Federal do Rio Grande do Sul. Fundinghas been provided by U.S. DOE, NSF, STFC (UK), Ministry of Education andScience (Spain), FINEP (Brazil) and the collaborating institutions.
The DECam (top) will be installed in the
prime focus cage of an existing telescope
(bottom). The telescope’s primary mirror
is located behind the covers at the
bottom right. Photo by T. Abbott.
CCD readt Eectnics
Shtte
Fites
coo
Hexapd
optica lens
Telescope and camera assembly at
mode 6 natural frequency of 14.006 Hz
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energy
www..o ANSYS Advantage • © 2010 ansys, Inc.28
Maintaining Power A Baziian pwe geneatin cmpany expects t decease maintenancedwntime by identifying the case f wa esin in a ca bie.
By Jairo Souza, Support Engineer, Henrique Monteiro, Support Engineer, and Leonardo Rangel, Project Coordinator
ESSS, Florianópolis, Brazil
Artur Ellwanger, General Manager, Marcelo Bzuneck, Plant Engineer, and Luiz Felippe, Senior Engineer
Tractebel Energia, Capivari de Baixo, Brazil
Fea f a edced enegy sppy in cming yeas has
made enegy geneatin a ht tpic in engineeing.
In Bazi, pwe is geneated by bth hydeectic meansand the se f fssi fes. The Jge laceda Pwe
Pant, wned by Tactebe Enegia, is ne f the agest in
latin Ameica and is espnsibe f a significant ptin
f the enegy distibtin in sthen Bazi. The cmpex
has thee pants f geneating eecticity. The agest
pant, uTlC, has a geneating capacity f neay 1,260
gigawatt-hs.
The age bie (10 metes by 20 metes by 60 metes)
at uTlC cntains f hiznta ws f six bnes,
feed by pveized ca. The bnes heat wate in
high-pesse stee tbes — caed steam pipes bie
tbes — within the was f the bie t ceate steam.
The steam is sed t spin a tbine, which, in tn,
geneates eecticity.
A cmmn pbem in ca-fied bies is esin f
the bie was. Wa esin pts peatin f the bie
at isk becase mateia faie in these aeas expses the
steam pipes t fe within the bie. Addessing this
pbem is qite csty becase f the mateias invved;
in additin, the bie mst be sht dwn whie epais
ae made. The assciated csts can be edced if esin
f the bie tbes can be minimized.
T find ways t minimize esin, the mechanism fesin mst fist be identified. Thee pssibe cases
f bie wa esin ae chemica attack cased by
bidp f sph, excessive expse t heat, and
bne misaignment. In the ast case, esin is fthe
aggavated becase patices f ca ae nt cmpetey
cnsmed and can physicay abade the bie was.
Thgh physica anaysis f the tbes, Tactebe
enginees wee abe t detemine that the case f the
esin in the uTlC bie was pbaby eated t bne
misaignment. Misaigned bnes bne cmpnents
can ead t incmpete cmbstin f the pveized ca,
esting in wa esin.Tactebe Enegia tgethe with ESSS, an ANSYS
channe patne in Sth Ameica, tned t an
ANSYS CFX engineeing simatin t cnfim the case
f the esin. The anaysis was set p t simate the
mtiphase fw (pveized ca and ai) within the bie.
The team anayzed the peatin f a singe bne and
Tractebel’s UTLC complete coal boiler
Steam Pipes
Bie
Bnes
its impact n the neaby bie was t gain a bette
ndestanding f the vea esin pcess.
The initia fw simatin cnsideed the cmpex
bne gemety in detai. Bnes ae cnstcted fmvais pates that fm the swie as we as a defect.
Bth hep t mix the aifw with the pveized ca t
ense the stabiity f the fame inside the bie. Fame
stabiity and ppe mixing assist in me efficient cm-
bstin. The simatin fcsed n esving the detais
f the bne fw t btain an accate tet fw pfie
f the bne that cd be sed in a age simatin f
the bie intei. The sftwae pvides the capabiity
t easiy extact desied ests fm the fist (bne)
simatin as bnday cnditins f the secnd
(bie) simatin.
In a secnd fw simatin, a age ptin f thebie was simated with the bne inet cated n
the ight side f the bie. The bjective was t
capte the effect f a singe bne n neaby bie was
t detemine if the wa shea patten aising fm
the bne fw matched the esin patten bseved
n the bie tbes.
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energy
ANSYS Advantage • Vme IV, Isse 1, 2010 29
The ests shwed that fw detaches fm the bne
t make cntact with the bie wa at a distance fappximatey 3 metes fm the bne. The mtiphase
simatin cnfimed that patices f ca fwing this
fw path wd each the bie wa at high speed.
By cacating the ate f esin n the bie wa, the
engineeing team was abe t map wa catins
that sffe me wea. The map btained fm the shea
data was vey cse t the wea data iginay btained
f the bie.
The fid fw ests enabed Tactebe enginees t
identify mdificatins that might be made t minimize wa
esin in the bie. Fte pjects wi invve ateing
the gemety f the mde and bnday cnditinst detemine whethe anticipated design changes wd
edce wa esin. It is estimated that the ateed design
wi edce bie dwntime fm nce evey thee yeas
t nce evey five yeas.
Witht the insight pvided by ANSYS CFX sftwae,
Tactebe wd have been imited t tia-and-e
testing t identify and mitigate the case f the
ndesiaby high esin. Tactebe was abe t detemine
the esin patten and make infmed and cst-effective
decisins egading the peatin f the bne and,
cnseqenty, the pant. n
Air velocity profile on symmetry wall;
red indicates areas of highest velocity
Advanced Simulation for Fossil Fuels ANSYS stins ae sed and the wd
evey day t stdy estabished ca, i and gas
cmbstin systems, as we as ctting-edge pwe
geneatin and pcess eqipment sch as xy-fe
cmbsts, chemica ping eacts, gasifies and
bimass fnaces.
The stdy f cmbstin and eated fw
phenmena in fssi fe eacts pvides citica
insights f etfitting existing eqipment
designing new pcesses. Engineeing simatin
stins fm ANSYS pvide a necessaycapabiities t incease pefmance and enegy
efficiency, t ndestand the sce, and t devep
stategies that edce the cabn ftpint as we as
cnt and edce ptant emissins fm a age
ange f fssi fe and bimass eact types.
Typicay, the simatin f cmbstin eqipment
incdes fid fws sch as eactin, adiatin and
thema phenmena. Ca and the fes ae
epesented as a secnday phase and ae fy
cped with fw, enabing simatin f a age
ange f paticate cncentatins fm dite fws
t packed beds. Sch anayses pvide cavecities, paticate cncentatins and taces,
cmpsitin f cmbstin gases, fe cnvesin
ates, and tempeates. These qantities enabe
the se t investigate peatina isses sch as
ca tempeate peaks, cmbstin efficiency
mixing pbems.
Additina engineeing detais can be simated
thgh a nmbe f speciay deveped feates.
F exampe, ptant fmatin, emissins and
mecy can be pedicted sing detaied chemisty
and ptant fmatin sbmdes. Simiay,
apppiate patice mdes ae avaiabe t aw
f pedictin f esin and/ sag bid-p
in fnaces.
Ahmad Haidari, Director Industry Marketing and Karl Kuehlert,Regional Director of Technical Services NA, ANSYS, Inc.
Wall shear stress pattern on boiler walls; red indicates areas of highest
wall shear (erosion)
Swirling effect on particles from the coal burner
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Win, Set and Matchat Wimbledon ANSYS sftwae veifies the design f the innvativeetactabe f at Wimbedn by simating thepening and csing mechanisms.
By Martyn Lacey, Founder, Advanced Computational Analysis, Nottingham, U.K.
built environment
The A Engand lawn Tennis and
Cqet Cb’s anna Champinships
has a eptatin as the wd’s
pemie tennis event. As pat f a
ng-tem pan f cnt ins
impvement f the faciity, a new
etactabe f ve Cente Ct at
Wimbedn was intdced in 2009 t
aw payes and spectats t enjy
the Engish smme weathe whie
pemitting pay t cntine in the
event f ain.
The united Kingdm–based
e n g i n e e i n g f i m A d v a n c e d
Cmptatina Anaysis (ACA) sed
sftwae fm ANSYS t veify pats
f the design f the new etactabe
f by cndcting bth static and
dynamic anayses t ense that the
f wd pefm ppey nde
ea-wd ads and stesses.Five yeas in devepment, the
17,000-sqae-ft etactabe f is
an eectmechanicay peated
stcte that incdes 10 mvabe
stee tsses that sppt a tans-
cent, weathe-esistant fabic
canpy. When pen, the f sectins
ae paked at ppsite sides f
the ct. T cse the f, the
cdinated eectmechanica
system mves the tsses apat
and, at the same time, nfds andstetches t the fabic between the
tsses, nti the tw sectins meet
in an veapping seam abve the
midde f the stcte.
Whie cnstctin cmpany
Gaifd Ty was espnsibe f the
Total stresses in the
beam sections as a result
of dynamic effects
Axial forces in the roof
structure as a result of
dynamic effects
vea bid f the 3,000-tn
f, the ambit is pject
invved many expet sbcntacts.
ACA was chaged with pefming
static and dynamic veificatin f the
mechanisms that pen and cse the
tsses. Capita Symnds (pincipa
stcta engineeing cnstants)
and Steet Cane Expess (mtive
cnt and atmatin speciaists)
cnstcted thee f tsses f
physica testing, bt it wd have
been extemey time- and cst-inten-
s i ve t b i d a p t type f
the entie f. T pefm a vita
anaysis that wd pvide accate
pedictive ests, ACA tned t
ANSYS Mechanica sftwae. The
veificatin pcess was designed t
ense that the mechanisms n each
tss wd pefm as expected. ACA cndcted bth static and
dynamic 3-D anayses f the f
tsses in a vita envinment,
cnfiming that they cd withstand
ea-w d physica ads and
mechanica stesses in bth mving
and at-est psitins. ACA fcsed
specia attentin n the eect-
mechanica actats between each
pai f tsses that ae
espnsibe f mving the
f. These actats ae sbject
t bvis physica fces, sch as
the weight f the tsses, as we
as me sbte fces, sch as the
changing tensin f the fabic canpy.
ANSYS Mechanica techngy
sppted the f ange f simatin
and anayses needed t veify
the design f the f system.
ACA pefmed veificatin f thef’s design in a timey and cst-
effective manne s that cnstctin
cd pceed.
The etactabe f made its
Champinships debt in mid-2009,
when ain wd have thewise
intepted a match. As the tw f
sectins came tgethe, the capacity
ow o i ig ovio. n
Deflections in roof
structure, in the direction
of motion of the leading truss
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analysis tools
3131
Solutions for PCB
ElectromagneticInterferenceSimatin Diven Pdct Devepment aids designes f pinted cicitbads in meeting eectmagnetic cmpatibiity eqiements.
By Steven G. Pytel, Jr., Signal Integrity Product Manager, ANSYS, Inc.
In tday’s wd f highy cmpex
p inted cicit bads (PCBs) ,
ceating designs t meet eect-
magnetic cmpatibiity (EMC) tagets
is a necessity. Hweve, ding the
eay design stage, devepment f a
bst pwe deivey netwk (PDN)
is ften negected. Minimizing bad
esnances sing decping capaci-
ts and the ppe pwe and gnd
pane design wi edce adiated
emissins that case eectmagnetic
intefeence (EMI). Signa ayt
n the PCB is citica t cect
peatin f anag and digita
designs, and wi hep t edce
adiated emissins whie minimizing
intefeence n the signa nets.
Designing t meet these thee
bjectives with mdeatey t highy
cmpex PCBs eqies the se f
simatin t minimize time t maket
and cst. SIwave sftwae was
deveped specificay t pvidestins that hep enginees meet
the bjectives f a bst PDN, snd
signa integity (SI) and EMC/EMI
tagets. Athgh SIwave is pedmi-
nanty sed f pst-ayt extactin,
its dawing and cipping capabiities
can be sed t pefm Simatin
Diven Pdct Devepment f
pe-ayt simatin n patia
designs. SIwave techngy sppts
mtipe PCB ayt databases.
SIwave sftwae’s dynamicachitecte aws it t fit seamessy
int mst design pcesses whie
significanty edcing nnecing
engineeing csts. Designing a pwe
distibtin system (PDS) eies n
sevea anaysis types: esnant
cavity anaysis, netwk anaysis and
dc pwe ss anaysis. The esnant
cavity anaysis pvides an intitive
thee-dimensina k at vtage
diffeences between panes. F
exampe, a se can qicky identify
the catin f esnances between
panes t ndestand any vtage
diffeences that ae ccing between
these panes. Depending n the
esnance seveity, the est can be
detimenta t signaing by casing
i iio. ro
case a change in the ac bad
impedance. The esnances as
case efectins within signa ines,
eading t an enegy tansfmatin
that pdces adiatin.
Resonant Cavity Analysis
The vtage diffeence between
the Vcc (psitive vtage sppy) — the
age pane in Fige 2 — and gnd
is shwn. In additin, anthe paneindicates the vtage diffeence
between Vinpt (the smae pane in
the fige) and gnd. The Vinpt
pane has a shap esnance twad
the ppe ight f the sma pane, as
ciced. This cd be pbematic
becase it is ccing at the sce
f the switching fied-effect tansist
(FET) that cnvets the inpt pwe t
dc. Identifying this esnance sing
cavity anaysis pvides the catin
whee the netwk anaysis shd bepefmed s that the SI designe can
ndestand the ac impedance pfie.
A tw-dimensina netwk anaysis
simatin was pefmed t view
the impedance chaacteistics f the
Vinpt pane. A pt was added t
the sface f the bad at the tpt
f the FET. This cnnectin was made
between the Vinpt and the gnd
pins f the device (Fige 3).
Network Analysis Solution
The netwk anaysis stin
ptin f passive devices ses a
cmbinatin f cmptatina eect-
magnetic stins in cnjnctinwith sevea mdeing techniqes
t ceate accate stins. Passive
devices can be mdeed in thee
fms: simpe (feqency indepen-
dent), agithmic (eqatin-based
feqency dependent) and meased
Figure 1: SIwave software displays a multilayer
PCB imported from a layout design tool along
with a clipped microprocessor core power rail.
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32
data (in the fm f Tchstne®
netwk paametes). The igina
design (Fige 5A) shws that the
h ighe f eqencies indicate a
significant change in the impedance
pfie. The impedance pfie f theigina stin ges fm 1.5 hms
at 100 MHz t 105 hms at 700 MHz.
If thee is a signa peating at
and 700 MHz that efeences this
cavity, the signa wi be seveey
degaded de t enegy st by the
adiatin f the fieds. Adding a few
decping capacits between the
Vinpt and gnd panes can
signi f icant y edce the cavity
esnance and impve signa qaity
whie minimizing adiatin. A gdfist-de appximatin can be sed
t hep decide what capacit
chaacteistics shd be sed t
decpe the pane. Setting the
indct i ve eactance eqa t
the capacitive eactance and sving
f capacitance wi hep t btain the
capacitance needed. Hweve, this
eqies the designe t make an
appximatin f the eakage and
mnting indctance. This appxi-
matin is a gd fist-de stin,bt a f-wave stin tiizing
SIwave sftwae wi pvide a mch
me accate answe, incding a
spatia dependence.
using an appximatin, a 240 pF
capacit with an assmed eakage
and mnting indctance f 0.5 nH
was paced acss the Vinpt and
gnd pins f the device (Fige 4).
Fige 5B shws that, sing the
SIwave t’s f-wave netwk
anaysis, the age impedance vaia-tin has been geaty edced at the
highe feqencies. As expected,
the esnance shifted sighty we
bt with a mch smae magnitde
(appximatey 47 hms). T fthe
minimize th is peak, a secnd
decping capacit f 2 nF with
0.5 nH eakage and mnt ing
indctance was added t the ppe
eft cne f the Vinpt pane
(Fige 5C).
This capacit weed the veamagnitdes f the esnance by a
fact f five whie shifting the
esnance sighty we and ceating
a smae esnance f abt 8 MHz.
T ndestand the decping impact
n the entie Vinpt pane, anthe
esnance mde anaysis was
pefmed. The ests fm the
esnant cavity anaysis shw that the
tp haf f the Vinpt pane has beeneffectivey decped sing these
techniqes. The esnant mde
anaysis des nt eqie any sces
becase it is fcsed n the nata
cavities that cc within the bad.
DC Power Loss
In additin t pviding nde-
standing f the pwe distibtin
system ve feqency, SIwave
sftwae anayzes dc sses as we.
using a finite eement methd, the dcvtage dp, dc cent density and
dc pwe ss acss any pane,
tace, wiebnd can be anayzed.
This methd cnsides nnidea
etn paths in its stin, eaizing
that gnd is eative within a PCB.
The se seects the pint(s) t which
a stins wi be efeenced (se
def ines ea th/chass is gnd) .
This aws the designe t anayze
dc vtage, cent and pwe acss
vtage panes, gnd panes, viasand bndwies. In additin, the pwe
ss can be expted t ANSYS Icepak
sftwae t stdy the effects f je
heating n the bad. Fags can be set
Figure 2: SIwave resonance analysis depicts the voltage differences between nets Vinput and ground (smaller plane) and nets
Vcc and ground (larger plane). Resonant cavity analysis before (left) and after (right) addition of the decoupling capacitors
Figure 3: The addition of Port 1 for the
network analysis solution between nets
Vinput and ground
Figure 4: Cutout view of the Vinput (green) and ground (gold) shows the physical location of Port 1, 240 pF capacitor and 2 nF capacitor.
Vinput Vcc Plane
Port 1
Port 1
240 pF Capacitor
2 nF Capacitor
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t shw pbematic aeas that d nt
meet the specificatins set fth by
the designe. This can hep t detectp ayt designs in which t few
vias wee sed t cnnect pwe ais
n diffeent ayes within the PCB,
which may cmpmise eiabiity and
ead t system faie.
With a ppey designed pwe
distibtin system, EMI and signa
qaity isses ae geaty edced.
A designe can change the fcs fm
pane discntinities t ppe ayt
f signa taces that minimize cping,
efectins and insetin ss. Adesigne can adjst the feqency
sweep, simia t the tw-dimensina
netwk anaysis fm pwe deivey,
t stdy signa cnditining cncens
ve a bad feqency ange. Many
types f ccking achitectes ang
with signa achitectes can be
anayzed, incding, bt nt imited t,
cmmn ccking, sce synch-ns ccking, fwaded ccking and
embedded ccking, incding singe-
ended and diffeentia (incding pana
and badside cping) tansmissin
ine tpgies. Signa csstak
(cping), insetin and etn ss
can be anayzed, whie Tchstne
and F-Wave SPICE fies can be
expted f se in time dmain
cicit simatins. Nea- and fa-fied
simatins can be anayzed within
SIwave sftwae. These stinsaccmmdate feqency-independent
and feqency-dependent vtage and
cent sces. The atte enabe
the designe t accatey qantify the
pwe and feqency spectm f
switching devices. When sed in
Figure 6: Dc analyses between the voltage regulator module (VRM) and the two microprocessors in the middle of the board show voltage drop
across the plane (left), current flowing through the vias near the VRM (center), and current path from the VRM to the two microprocessors (right).
cmbinatin with Ansft Designe
sftwae, bffe mdes (anag and
digita) can be sed t atmaticayceate the feqency dmain pwe
spectm t be sed with the nea-
and fa-fied anayses.
SIwave sftwae’s vesatiity aws
it t seamessy fit int amst any
exist ing design f w f pwe
distibtin design, signa anaysis and
edctin f adiated fieds. SIwave
has the niqe abiity t bing thee
discipines tgethe (pwe integity,
SI and EMC/EMI design) in a singe
envinment. This enabes designenginees t make citica tade-ffs
with a high degee f cnfidence pi
t fabicatin, minimizing time t
maket and design cst whie ensing
bst designs that achieve fist-pass
system sccess. n
Figure 5: A) The original board design without any additional decoupling capacitors; B) analysis number two in which a 240 pF
capacitor was added across the Vinput and ground pins of the FET device; C) analysis number three in which an additional
2 nF capacitor was added in the upper left corner of the Vinput plane
100.00
80.00
60.00
40.00
20.00
0.00
1.00E+006 1.00E+007 1.00E+008
Cve Inf
Mag(Z(P1,P1))Vinpt
Feq [Hz]
Vinpt oigina
a
1.00E+009
Z M a g [ o h m ]
100.00
80.00
60.00
40.00
20.00
0.001.00E+006 1.00E+007 1.00E+008
Cve Inf
Mag(Z(P1,P1))Vinpt 3 with cap
Feq [Hz]
Vinpt with 240 pF Decping Cap
1.00E+009
M a g ( Z ( P 1 , P
1 ) )
B
100.00
80.00
60.00
40.00
20.00
0.001.00E+006 1.00E+007 1.00E+008
Cve Inf
Mag(Z(P1,P1))
Vinpt 3 with 2 caps
Feq [Hz]
Vinpt with 240 pF and 2 nF Decping Caps
1.00E+009
M a g ( Z ( P 1 , P
1 ) )
c
analysis tools
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have passed qaity cnt if nt f the se f eect-
thema csimatin.
The exampe bad cntains cmpex inte-
cnnectins f tace tings, pwe/gnd panes,
discete cmpnents (esists, capacits, indcts,
etc.) and anding pads f sdeing ICs and the semi-
cndct packages t the bad. Pwe t these ICs
and semicndct packages is pvided by a vtage
egat mde (VrM), with dc cent fwing fm the
VrM thgh a singe via t a main sppy pane wheethe cent speads t t feed a the semicndct
devices. Cncentatin f cent at the singe via is high,
esting in cnsideabe esistive ss at that pint.
Predicting Circuit BoardHot Spots with Electro-thermal CosimulationMtiphysics anaysis with SIwave and ANSYS Icepak accatey
detemines thema distibtin n cmpex PCBs.By Aaron Edwards, Technical Account Manager, and Kamal Karimanal, Lead Technical Services Engineer, ANSYS, Inc.
Excessive heat is the enemy f eectnic pats,
especiay integated cicits (ICs) in densey packed,
pwe-hngy eectnic devices. Inceased eves f
eectica cent eqiements in these appicatins mst
be cnsideed in the pinted cicit bad (PCB) design t
cmbat the geneatin f je heat.
Enegy efficiency can be ptimized by minimizingcent density eves, even at the expense f sighty
highe esistance paths. Hweve, a geneay enegy-
efficient cicit can n the isk f veheating at spts de
t spikes in cent fw ates at ca bttenecks in the
cicity. Whie sch bttenecks can be identified thgh
bad-eve cent fw simatins, thema anaysis is
needed t ense that heat dissipatin is sfficient and
that the tempeate ise de t cent spikes is bew
ecmmended eves.
Cent fw and thema anaysis simatins
pevisy wee pefmed sepaatey, bt nw they can
be cmbined in a mtiphysics-based bad-eve eect-
thema csimatin pvided by a ink between the
SIwave eectmagnetic fied sve and the ANSYS Icepak
thema anaysis sve f eectnics packages. In this
way, these tw sves wk tgethe as next-geneatin
ts that enabe enginees t accatey pedict heat
distibtin and tempeate in cmpex cicit bads.
ANSYS Icepak sftwae has been sed by eectnics
enginees as the best-in-cass thema management t
f many yeas. Cping SIwave techngy with thema
simatins adds an npecedented fideity that aws
enginees t make me-infmed decisins n the designbased n inceased awaeness f pwe dissipatin,
cent cnstaints and thema ht-spt catins. The
fwing exampe shws hw a bad design cd
Color-coded vector plot of current from SIwave software shows high-
density “current crowding” in red near the single via that connects the
top layer of the circuit board to the main power supply plane for all
semiconductor devices.
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ANSYS Advantage • Vme IV, Isse 1, 2010 35
SIwave sftwae was sed t stdy cent
distibtin thght this cicit bad, with the design
impted int the t fm its igina thid-paty ayt
envinment. By sing SIwave techngy, enginees cd
visaize the cent cwding at the singe via. What they
cd nt see fm this simatin ane was the thema
ht-spt in this egin and the exact tempeate ise
cased by the eectica cent fw thgh the via.
F the tempeate impicatins t be detemined,
the heat distibtin tpt fm the SIwave simatin
PCB Signal and Power Integrity
SIwave sftwae fm ANSYS is an eectmagnetic fied
sve that pefms badband signa- and pwe-
integity anaysis ang with dc vtage and cent
anaysis f cmpete pinted cicit bads and
integated cicit packages. Wheeas 3-D eect-
magnetic sves that eqie temends eves f
cmpte esces ae pactica in stdying ny
ptins f a cicit bad, the SIwave pdct
pvides a highy efficient and accate f-wave
stin f an entie cmpex bad sing a 2-D finite
eement methd techniqe that takes int accnt:
A discete cmpnents n the bad, sch as•
esists, indcts, capacits and feites
resnances that cc between intena panes•
retn path f taces that may tavese the•
entie bad
A tace and pane cping eevant t the•
simatin
regading je heating, SIwave sftwae can
pefm a dc Ir dp simatin that can sve f the
cent path f the panes. F a given vtage sce
pint and a cent daw catin, the SIwave pdct
can sve the exact path f the cent as it taves
fm sce t sink and can cacate the vtage dp
n the panes de t esistive sses. This insight is
imptant fm a thema pespective becase it
pvides vaabe insight int high-cent aeas that
wd ceate the mst esistive sses and, ths,tansate int the highest egins f heat dissipatin.
The abiity t k at the pefated pwe and gnd
ais pvides a eve f fideity that cd nt be
cped with thema design in the past.
Resonant mode simulation with SIwave software highlights the
locations of standing waves and indicates components that might
be coupling into the modes.
was ead int the ANSYS Icepak mde f thema sim-
atin. The cmbinatin f the ts detemined the
excessive tempeate ise in this egin and awed f
this design faw t be accatey detemined and cected
by enginees. This was a pefmed in the eay stages f
design, befe pttype mckp bads wee fabicated. n
The authors acknowledge contributions to this article fromKapil Sahu and Birenda David of ANSYS India.
ANSYS Icepak simulation (left) performed without the heat distribution input from SIwave software does not show the hot spot.
Temperatures approaching 110 degrees C were revealed using the two programs coupled in a cosimulation (right).
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ANSYS Icepak fid fw sftwae is sed by
eectnics design teams wdwide f a vaiety f
easns, incding:
Native as we as neta MCAD mde•
impt capabiities
Capabiity t impt eectnics ayt fies•
sch as Gebe, Cadence® and IDF fmat fies
Pdctivity enhancement thgh its ibay•
f IC package mdes
Macs f heat sink and themeectic ces•
use-fiendy mdes f fans, bwes and•
attach mateias
The capabiities achitected and bit int ANSYS
Icepak techngy ve a decade f cse indsty
cabatin fm the fndatin f the next
geneatin f mtiphysics-based cdesign methd-
gies. In the stdy f thema behavi f a typicacicit bad, this t has the capabiity t ead in
tace gemety f detaied anaysis f bth tace and
pane ayes, f exampe, and as t identify the
caized distibtin f diectina cndctivity
based n a bad metaizatin ayt. Accate as
we as cmptatinay pactica, this cndctivity
estimatin techngy fms the basis f the next
geneatin f mtiphysics-based bad-eve eect-
thema cdesign between SIwave and ANSYS
Icepak sftwae.
Thermal Management of Electronics Packages
ANSYS Icepak software has the capability to determine effective
conductivity of copper layers on a PCB based on metal content
and directionality on the board.
analysis tools
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Boosting Memory
Capacity with SSDsSid-state dives ae a cst-effective way t addfast memy t wkstatins.
By Jeff Beisheim, Senior Software Developer, ANSYS, Inc.
one f the main facts imiting the
size f simatins that can be n
n a wkstatin is the amnt f
physica memy ( rAM) avaiaben the machine. Me rAM can be
added, bt ny s many sts ae
avaiabe n the machine, and high-
capacity rAM is eativey expensive.
T hep aeviate this difficty,
eqatin sves ften tiize vacant
space n the had disk dive (HDD) —
the spinning medim that pvides a
faiy inexpensive means f ng-tem
stage f age amnts f data. A
250-gigabyte (GB) had dive — abt
as sma as y can get these days —can be pchased f ny abt $50
(u.S.), f exampe. The dawback is
an de-f-magnitde speed penaty,
with the eativey sw inpt/tpt
(I/o) speed f the HDD geneay
bew 100 MB/secnd, ften esting
in significanty nge n times.
HDD
SSD
HDD
SSD
For this study, approximately 1 million
degrees of freedom (DOF) were analyzed for
200 frequencies. Elapsed times are compared
for simulations on a workstation having two
file systems: one with a single SCSI 10k rpm
hard disk drive, another with four Intel® X25-E
64 GB SATA SSDs.
Considerable I/O was performed in an analysis requiring about 30 GB of disk space to
run the ANSYS distributed sparse solver on a workstation containing only 24 GB of RAM.
The reduced seek times for the SSD significantly improved I/O performance, thus helpingto shorten solution time as more cores are involved.
Solution Time for ANSYS Mechanical Modal
Analysis with Block Lanczos Eigensolver
SSD Scalability of Distributed ANSYS Simulation
This is whee eativey inexpen-
sive sid-state dives (SSDs) with
minima seek times in eading fies
can be tiized t damaticay qicken
stin times, paticay with
simatins invving high eves f
I/o t be pefmed. Whie expensive
eative t HDDs, SSDs ae cnside-
aby faste than HDDs and ae
appximatey tw t thee times ess
expensive than rAM f the same
nmbe f gigabytes. SSDs as ffe
sevea the advantages ve
HDDs, sch as n nise and high
mechanica eiabiity de t the ack
f mving pats — athgh SSDs d
cnsme me eecticity than HDDs
and have a sef ife imited by the
nmbe f times data can be witten
and ewitten at a given catin.
using SSDs with sftwae fm
ANSYS is faiy staightfwad.
once the wking diecty f thesftwae is set t the SSD fi e
system, a I/o eqests dne by
the sftwae wi then tiize the
SSD. The ecmmended cnfig-
atin f mtipe dives is rAID-0
(edndant aay f independent
disks), which distibtes data eqay
amng them.
In ANSYS Mechanica sftwae,
stins invving the spase sve,
distibted spase sve bck
lanczs eigensve nning in the
t-f-ce memy mde typicay
pefm the mst amnt f I/o and,
theefe, see the mst benefit fm
SSDs. In ne sch mda anaysis,
tansfeing 3 teabytes (TB) f data
t and fm the disk tk neay
40,000 secnds n a singe HDD
vess abt 5,000 secnds sing
SSDs in a rAID-0 cnfigatin. In
anthe case, a tbine anaysis with
the ANSYS distibted spase sve
eqiing age amnts f I/o n
an eight-ce wkstatin was cm-
peted in ess than 600 secnds with
SSDs, cmpaed with me than
1,700 secnds n HDDs. F thissimatin, each Distibted ANSYS
pcess had t ead/wite its wn set
f fies, esting in a cnsideabe
nmbe f I /o eqests t be
pefmed ding stin. n
4000
3500
3000
2500
2000
1500
1000
500
0
T o t a l E l a p s e d T i m e ( s e c )
1 Core 2 Cores 4 Cores 8 Cores
HDD
SSD
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
T o t a l E l a p s e d T i m e ( s e c )
Using 1 Core
HDD
SSD
analysis tools
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ANSYS Advantage • © 2010 ansys, Inc.38
Students Win Using
Simulation-Driven Design Affiiatin with ANSYS heps the univesity f WateFma Mtspts team win an awad f an innvativeai intake design at the Fma SAE Michigan 2009 cmpetitin.
By Anish Ganesh, Intake System Designer, University of Waterloo Formula Motorsports, Canada
The univesity f Wate (uW) Fma Mtspts
team is a stdent-peated ganizatin, based in Canada,that designs and bids an pen-whee ace ca t
cmpete in the anna Fma SAE cmpetitin.
oganized by SAE Intenatina (fmey the Sciety f
Atmtive Enginees), the anna cmpetitin chaenges
stdent teams fm and the gbe t design, fabicate,
maket and ace a fma-stye atcss vehice. The
cmpetitin is divided int tw main categies: static and
dynamic events. The static events cnsist f engineeing
design cmpetitin, maketing pesentatin, cst ept
and technica inspectin. The dynamic events incde
acceeatin, skid pad, atcss, fe ecnmy and a
22-kimete endance test.The univesity f Wate Fma Mtspts team
has made geat pgess in the design f thei 2010 ca.
one f the mst significant changes f the pcming
seasn is the tansitin t the secnd-geneatin Hnda
CBr 600 rr pwepant, which is ighte, smae and
me pwef than its incmbent, the Hnda CBr 600
F4i. This tansitin eqies many cmpnents t be
edesigned. FSAE ace ca cmpetitin es imit engine
pwe by esticting a ai f engine cmbstin t pass
thgh a 20-miimete he. Theefe, ptimizing the
fw f ai thgh the intake gemety is ccia in
pviding the desied engine pefmance. The uW teamsaw this e as an pptnity f innvatin, and it set
t t mdify the wa gemety appaching and depating
this ai fw estict t btain maximm fw f ai int
the engine.
using ANSYS CFX sftwae f a thee-dimensina
cmptatina fid dynamics (CFD) anaysis, the team
achieved an ptima design f the intake estict f the
engine with cnsideabe edctin in devepment time
and cst. The ga was t maximize the
pesse ecvey thgh the estict.
At the maximm peating cnditin f
the engine, the ptimized designimpves the pesse ecvey f the
estict by 4 pecent, whie the vea
ength f the design is inceased by ny
5 pecent.
The intake system designe sed ANSYS DesignMdee
sftwae t geneate a paametic epesentatin f the
2009 University of Waterloo Formula Motorsports car
estict gemety. The fid vme and face meshes
eqied f a the gemeties wee ceated in the ANSYSMeshing appicatin and wee impted int ANSYS CFX
sftwae, in which the fid ppeties and physics wee
defined and the fid fw simatins wee pefmed.
The stdents anayzed simatin ests sing the
ANSYS CFD-Pst pst-pcessing t.
The uW team cnsideed a nmbe f estict
gemety cncepts. The ANSYS CFD-Pst t was
sed t cacate pesse ecvey and t detect fw
Final design of the
air inlet restrictor
2009 car showing the air inlet that was redesigned
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ANSYS Advantage • Vme IV, Isse 1, 2010 39
sepaatin de t viscs effects and advese pesse
gadients f each f the gemeties. De t the pesencef fw sepaatin, sevea design cncepts, incding the
igina, wee discaded.
As t the emaining design cncepts, the team
seected the ne that demnstated the best pesse
ecvey f fthe efinement sing the ga-diven
ptimizatin t in ANSYS DesignXpe sftwae within
the ANSYS Wkbench envinment. This t impements
a design-f-expeiments pcede that ecgnizes the
paametes set in the gemety-ceatin stage. The t
vaies the paametes t defined anges, mdifies
the gemety and mesh, and btains stins f a the
anges atmaticay. Based n the ests eqied, ANSYS DesignXpe identified the thee ptimm
candidates that ffied the design eqiements. In this
case, the fina ptimized design was seected based n
this ptimizatin pcess. The ptimized estict design
heps t impve the vea pefmance f the engine by
bsting the fw f ai int the engine, theefe inceasing
cmbstin efficiency whie edcing emissins.
Fid fw simatin is a vita t f engine system
devepes. The abiity t impve pesse ecvey
To the Finish Line
Tday’s ndegadate stdents ae tmw’s
enginees and eseaches. Fma SAE is designed
t pmte caees and exceence in engineeing,
and, as a patne t the pgam, ANSYS pvides
its engineeing simatin sftwae t stdent
paticipants. Centy, neay 50 nivesity teams se
ANSYS t design thei fma cas, many with
tstanding ests.
“ANSYS is cmmitted t wking with nivesities
in many ways,” said Pa lethbidge, ANSYS
academic pdct stategy and panning manage.
“This exciting pject takes stdents t f the cass-
m and aws them t appy textbk theies t
ea wk expeiences. Fma SAE gives them a geat
fndatin in sing Smat Engineeing Simatin ts
that they wi empy thght thei caees.”
and minimize fw sepaatin in the estict design has
awed the team t maximize the pefmance andefficiency f the new pwepant. Fma Mtspt
teams extensivey se CFD simatin t qicky and
cst-effectivey evaate the pefmance f thei intake
system designs and t investigate the impact f design
changes n vea vehice pefmance. This pcess
eiminates the need f mtipe pttype cyces in which
f-size esticts ae cnstcted f physica
fw-bench testing.
The univesity f Wate Mtspts team wn the
2009 Fma SAE CFdesign Cmptatina Fid
Dynamics Awad pesented ding the 2009 Fma SAE
cmpetitin hed in May 2009 at the Michigan IntenatinaSpeedway. The uW team eceived the hn f thei se
f CFD t ptimize the ai fw thgh the estict f
thei 2010 intake system. n
The author has worked at ANSYS, Inc. as a technical writer for fourco-operative work terms. ANSYS CFX developers assisted him on variousaspects of the restrictor design. The Formula Motorsports team at theUniversity of Waterloo acknowledges ANSYS for its continual support indeveloping a winning car.
Pressure contours for the air inlet on the original design (top)
and two alternatives (below)
Velocity vectors on the original design (top) and two
alternatives (below)
University of Waterloo Formula Motorsports team in 2009
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40
Teaching Simulationto Future Engineers ANSYS Wkbench faciitates integatin f simatinint the engineeing cicm.
By Rajesh Bhaskaran, Swanson Director of Engineering Simulation, Cornell University, Ithaca, U.S.A.
Cne univesity is highy egaded
in the engineeing cmmnity: Its
Cege f Engineeing has been
anked as ne f the tp seven
engineeing pgams in the united
States by U.S. News & World Report.
Cne ses sftwae fm ANSYS
t depy mden simatin tech-
ngy in f ndegadate cses
in the mechanica and aespace
engineeing (M&AE) cica. The
cses cve divese sbject aeassch as fid dynamics, heat tansfe,
sid mechanics and nmeica
methds. These ffeings incde
eqied, ab-based casses as we as
eective, ecte-based casses.
Cne’s M&AE depatment is
tansitining t the ANSYS Wkbench
patfm s stdents can empy the
same se inteface and wkfw
egadess f sbject aea. This tans-
itin wi ceate a nifm eaning
expeience acss the M&AE ci-
ca. othe advantages eated
t ANSYS Wkbench incde a me
se-fiendy inteface, easie CAD
impts and atmatin f epetitive
tasks. The tansitin is ccing n a
cse-by-cse basis and is expected
t be cmpeted by sping 2011.
I M&AE 4272 F lu ids/Heat
Transfer Lab, Cne stdents se
ANSYS Academic sftwae t sim-
ate a fced cnvectin expeiment
cnsisting f thee sectins f a
smth-waed cica pipe. The fist
pipe sect in is nheated and
geneates a fy deveped tbent
vecity pfie; the midde sectin is
heated t pvide enegy inpt t the
ai; and the fina sectin is insated,
pviding an adiabatic mixing ength
that enabes a singe eading f the
fina ai tempeate. Instments
pvide measements f mass fw
ate and heat inpt, as we as
pesse and tempeate at vais
catins. A fid dynamics simatin
2010 courses at Cornell involving software from ANSYS
Schematic representation of the heated flow apparatus used in M&AE 4272 Fluids/Heat Transfer Lab at Cornell. A, B, C and D are pressure taps; labels 1 to 10 are locations of thermocouples.
Course Title TypeApproximateEnrollment Software
Mechanical Property & Performance Lab
Required 120 ANSYS Mechanical 11.0
Fluids/Heat Transfer Lab Required 120 ANSYS FLUENT 12.0
Finite Element Analysis Elective 40 ANSYS Mechanical 11.0
Intermediate Fluid Dynamics Elective 50 FLUENT 6.3
cespnding t this expeiment was
intdced in 2003 s stdents cd
see the expeimenta and simated
appaches side by side. FluENT/
FloWlAB sftwae was sed f
this nti 2009, when it was epaced
with the ANSYS Academic CFD
pdct, which nw fy integates
ANSYS FluENT sftwae.
The incpatin f ANSYS
FluENT and ANSYS Wkbench int
the ANSYS Academic CFD pdct
has a wed Cne t epace
FluENT/FloWlAB techngy whie
etaining imptant feates that
cntibte t a apid eaning cve
and ease f se. Stdents ean the
simatin pcess via web-based
ttias that se nmina data.
Stdents then epeat the cac-
atins sing thei wn expeimenta
cnditins. The gemety ceatinand mesh steps ae ptina, and the
sve step is simpified sing defat
settings. This pcess pvides
stdents with an adeqate stin
t the simatins whie awing
qick tnand time.
fw d h a a mx
6'6'
15"
8'
15" 15" 15" 15" 15"6"4" 3" 3" 3"
6"4"
a b c d
100"
1 3 4 5 6 7 8 910 (t) 2
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41
Stdents eview backgnd
infmatin n the simatin pcess
thgh a pesentatin whie waitingf the expeiment appaats t each
steady state. They ean that in the
fid fw simatin, ANSYS FluENT
sftwae sves a bnday vae
pbem (BVP) cespnding t the
expeimenta setp, biding n
BVP cncepts cnsideed in eaie
cses. The pesentatin asks
stdents t cnside what the
gvening eqatins, bnday
cnditins and dmain shd be
f this BVP. Stdents ean hwt specify the BVP in the sftwae via
the web-based tt ia , which
pvides a high-eve cncepta
desciptin f discetizatin, iteative
cnvegence and reynds aveaging
f the gvening eqatins.
The fid dynamics simatin
pvides ich visaizatin capabiities
that ae extemey sef in deveping
a physica ndestanding f fid
fws. The est pts shw the
axisymmetic tempeate fied in
the pipe, demnstating hw the heat
added at the wa diffses int the
fw. Stdents can see that the fw is
we mixed at the end f the adiabaticmixing sectin, which cnfims an
assmptin in the expeiment. The
cmpaisn between expeiment and
simatin f the tempeate
vaiatin ang the pipe axis can be
ptted ang with ests fm the
igina and efined meshes. The fina
bk tempeate ise btained fm
bth expeiment and simatin
agees we.
The steps in the ttia ae a
speset f the pject schematic in
the ANSYS Wkbench envinment.
A veificatin and vaidatin (V&V)
step fws the ests step t
einfce the imptance f checking
cmptatina ests thgh a
fma pcess. The veificatin step
cnsides the qestin: “Did we
sve the BVP cecty?” In this
intdctin t fid dynamics,
stdents ae eqied ny t efine
the mesh f the s imat in .The vaidatin step cnsides the
qestin: “Did we sve the ight
BVP?” Stdents check this by
cmpaing thei simatin ests
with expeiment. Simia web-based
ttias ae sed in the the M&AE
ndegadate cses; V&V is the
fina step in each ttia. Cne
pans t incpate the atest V&V
thinking int the ttias and t
in t dce s tdents t e ated
standads fm ASME and NAFEMS.In this way, V&V can be given a
me pminent and cnsistent e
in the cicm.Temperature distribution in the pipe obtained
using ANSYS FLUENT software
Temperature variation along the pipe axis
obtained from CFD and experiment
Steps in the tutorial (left) are a superset of the project schematic in ANSYS Workbench (right).
Thee is a cncen in academia
that the vehead f eaning t secmmecia simatin pdcts is
high, and this pevents integatin f
sch ts int the cicm. Cne
has been sccessfy addessing this
cncen with the hep f sftwae
inteface impvements ffeed by the
ANSYS Wkbench envinment.
These incde the integatin f
stcta mechanics and fid fw
simatin ts in a cmmn intitive
inteface and the atmatin f
epet i t ive tasks; the ts ae
agmented by caefy designed
nine ttias that teach sftwae
se and pbem-sving skis.
In tansitining the cses t
the ANSYS Wkbench patfm,
Cne pans t se the same ttia
stcte pevisy descibed,
expanding n the nifm stcte
ffeed by ANSYS Wkbench acss
appicatin aeas. Stdents wi be
abe t see that the same high-evepincipes appy whethe sving
sid mechanics thema–fids
pbems. Instcts at Cne
expect that if stdents see the
same stin pcess being fwed
epeatedy in diffeent sbject aeas,
they ae me ikey t intenaize
this appach and t appy it in new
sitatins. ANSYS Wkbench is
heping Cne t pvide stdents
with a gd fmative expeience
in simatin acss the M&AEcicm, ne that ndegadates
can cay int thei caees as
pacticing enginees. n
fluent f c
fluent f c m 2
eXpt
t
e m p e r a u r e [ k ]
X []
320
315
310
305
300
2950 1 2 3 4 5 6 7
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World-Class Composites Analysis by Alinghi
Embacing Simatin Diven Pdct Devepment,
Team Ainghi ceated thei 33d Ameica’s Cp yacht.By Shane Moeykens, Strategic Partnerships, ANSYS, Inc.
The Ameica’s Cp, saiing’s mst pestigis egatta,
staged its 33d event in winte 2010. The cntest pitted
tw 90-ft-ng mtih yachts against each the, a
beak fm the smae, cnventina sps f pevis
aces. Cmpaed with taditina yachts, mtih vesses
have a smae pptin f the bat in the wate,
especiay when “fying a h” — a tactic that ppsey
aises a bt ne f the hs t f the wate t dasticayedce hyddynamic dag. Becase mtihs ae s
wide, they can cay mch geate sai aea than simia-
sized mnhs, fthe inceasing hsepwe-t-weight
ati. The 33d Cp bats wee the fastest, mst pwef
and mst exteme in the ace’s histy.
Team Ainghi’s catamaan, Ainghi 5, few the cs
f the Sciété Natiqe de Genève, Switzeand.
A 23-membe design
team ceated the yacht
with scientific advice fm
Ece Pytechniqe Fédéae de
lasanne (EPFl). The Ainghi 5 is 90 feet
by 90 feet at the wateine, wide and nge
abve the wateine, and capabe f speeds in excess
f 40 knts. This giant is bit amst entiey f ight-weight, high-stength cmpsite mateias. Ding its
maiden vyage, the cew scceeded in fying a h, an
accmpishment that wed mch t the design team’s
detaied wk, which eied heaviy n simatin ts
fm ANSYS.
Design eqiements f the 2010 ace wee
npecedented. lading n stcta cmpnents and
vesse speed wee nike anything eve seen in Ameica’s
Cp acing. Becase f Ainghi 5’s width, the cew wd
be sbject t ife-theatening cnditins if the bat
capsized — they wd be ppeed 90 feet int the ai,
taveing at high speed — s safety was a maj cncenfm the beginning. optic-fibe senss pvided ea-time
mniting f stain n the h, Y-shaped spine and bm,
a cnstcted fm cmpsites.
Formed by the Swiss entrepreneur Ernesto Bertarelli in 2000
to compete in America’s Cup racing, Team Alinghi brought
the Cup to Europe in 2003 for the first time in 152 years.
Alinghi flies the colors of the Société Nautique de Genève,
Switzerland, and comprises more than 100 team members
of 20 different nationalities.©s g/a.
Starting the build: laying out honeycomb core material hull mold at
Decision SA, Switzerland©c b/a.
Alinghi 5 sandwich composite with
the aluminum honeycomb core© a.
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ANSYS Advantage • Vme IV, Isse 1, 2010 43
The catamaan has tw
hs, bit sing a sandwich-
stcted cmpsite with an aminmhneycmb ce. This specia cass f
cmpsite mateia is fabicated by attaching tw
thin-bt-stiff skins t a ightweight-bt-eativey-thick
ce. The thickness f the hneycmb ce pvides the
sandwich cmpsite with high bending stiffness and ve-
a w density. Anags t an I-beam, the hneycmb
fanges cay diect cmpessin and tensin ads — as
d the sandwich facings — and the web caies shea
ads — as des the sandwich ce. Cmmny fnd
in high-tech aespace appicatins, an aminm
hneycmb ce pvides exceent stength, weight and
csin-esistance chaacteistics. The skins f thesandwich-stcted cmpsite ae a mixte f cabn
fibe, epxy and pe-impegnated aminates.
The h is fmed sing a femae md. laminate
ayes ae appied at pedetemined thicknesses and
ientatins, and then heated. This aye is bnded t the
hneycmb ce. The inne skin is bnded t the hney-
cmb stcte, cmpeting the sandwich cmpsite.
Eight t 10 ayes f cabn fibe mateia ae appied
tside the hneycmb ce, with anthe 10 ayes n
the inside. Nminay, the h cnsists f 21 ayes,
incding the aminm hneycmb ce.
Given the es gvening the Ameica’s Cp ace,
teams have eativey itte time t design a vesse fm
scatch. Even the amnt f time avaiabe f pttype
testing is imited; hence, the design team mst ey heaviy
n cmpte simatin. “Ding design, cnstctin
and n-the-wate ptimizatin f the yacht and systems,
the maj fact eading t sccess is the efficient se
f time,” said Kt Jdan, the Ainghi enginee
espnsibe f stcta mdeing. “The abiity t tst
engineeing simatin ts whie mving fm vita
design diecty t systems n the wate — with minima
ften n intemediate pttype testing steps — is aninheent eqiement f the Ameica’s Cp cmpetitin.
F these easns, we seected ANSYS as excsive
sppie f engineeing simatin stins.”
Evey cmpnent f the Ainghi 5 ndewent ineaand nninea stcta anaysis. This wk incded a
aminate ptimizatin stdy f the h that cnsideed
mtipe ad cases. Bth mac- and cnstitent-eve
ppeties f the aminate mateias wee taken int
accnt, specifying thtpic mateia ppeties f
each individa aye in the h’s sandwich-stcted
cmpsite, sing she eements and the ANSYS
Mechanica sve. The skin f the sandwich-stcted
cmpsite exhibits nnthtpic behavi de t the
cmbined infence f each f the individa ayes,
thei stacking de and aignment. T expedite this
ptimizatin stdy, ANSYS Mechanica ns wee at-
mated sing batch fie exectin. Stcta anaysis was
caied t n the cmpsite-fabicated Y-shaped spine
and bm sing she eements and a symmety pane.
Whie fabicated fm cmpsites, these cmpnents
acked any st f hneycmb ce.
Athgh the time fame awed imited pttype
testing, faie testing was pefmed n sme f the
stcta cmpnents sing test eqipment at EPFl. F
the aminate mateias, cycic testing was cndcted t
detemine when the fibes cmmenced beaking dwn.
Inspectin f the aminates between tests was dne singtasnd measements.
Cncent with the stcta anaysis, Ainghi
pefmed fw anaysis sing ANSYS CFX sftwae.
Vitay evey cmpnent was evaated fm a hyd-
dynamics pespective, paying patica attentin t the
mast, the tw main stcta spas cnnecting the twin
hs, the dde and the daggebad. “The chaenge
is t detemine the ptima cmpmise between the
stcta eqiements and the hyddynamic eqie-
ments,” said Jim Bngene, Ainghi fw simatin
enginee. “Thick, bnt bdies pefm we fm a
stcta pespective, bt thin, naw-pfie bdies aedesied f thei dag ppeties. By wking excsivey
with engineeing simatin ts fm ANSYS, we had the
abiity t cpe stcta anaysis with fw anaysis,
taking advantage f the cmpatibiity between sves
within the ANSYS pdct site.” n
One of the key design features of the Alinghi 5 is its
light but stiff Y-shaped central spine. Consisting of a
minimal truss system of compression members and the cable
stays below them, the spine transmits the vessel’s huge loads.© a.
ANSYS Composite PrepPost software was evaluated by the team,
which noted its usefulness for determining characteristic material
properties of laminate materials, taking into account stacking of the
layers (orientation, layering order, etc.).© a.
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44
Getting Out All the BreaksPatt & Mie get ahead f the ace by edesigning a bake pedasing ANSYS with fe-safe fatige anaysis sftwae.
By Gary Latham, Design Office Manager, Pratt & Miller Engineering, New Hudson, U.S.A.
In wd-cass at acing, mechanics
ften epsitin the bake peda face
t cmpy with dive pefeence.
Bt mving the peda ff cente int-
dces a significant twisting mment
— a sitatin that inceases stesses
which can ead t meta fatige.
Patt & Mie Engineeing is
ecgnized and the wd as a
fmidabe fce in bth mtspts
and high-eve engineeing. The Patt
& Mie team discveed that ne f
its ace cas pematey demn-
stated sma cacks n its bake
peda faces. Thei initia investigatin
shwed that the cacks stated neathe pivt pin, which ed the team t
eaize that mechanics wee epsi-
tining the peda face. As the peda
face was mved fathe and fathe
ff cente, the esting twisting
mment ested in a cack at the
high-stess catin. Ftnatey,
enginees discveed the pbem
befe any accidents cced.
Brake pedal crack with simulation of equivalent stresses
Becase the igina peda design
had nt taken int accnt any afte-
maket mdificatins, Patt & Mieenginees set t t edesign the
citica cmpnent. The ga was
t geaty incease the fatige ife
witht cmpmising ace pef-
mance. Simpy veengineeing any
pat is nt an ptin in mtspts,
as weight is sch a vita cnside-
atin. race ca enginees have t
skit the imit n pats: Weight csts
speed, ap times and, timatey, the
ace. With the next ace scheded
jst thee days away, the pat had tbe designed, veified and machined
qicky. T get an ptima edesign
in the shtest amnt f time, the
Patt & Mie engineeing team
empyed stcta mechanics sim-
atin sing the ANSYS Mechanica
pdct tgethe with fe-safe™
fatige anaysis sftwae fm Safe
Techngy limited.
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tips and tricks
ANSYS Advantage • © 2010 ansys, Inc.46
Topology Persistence Steamine the innvative design pcess sing diect CAD intefaces.
By Robin Steed, Senior Applications Specialist, ANSYS, Inc.
Many f thse invved in engineeing simatin fee that
embedded CAD ts shd be sed f pfnt sim-
atin becase they ae tighty inked t the CAD mde,
wheeas CAD-neta systems, sch as thse empyed
in sftwae fm ANSYS, ae bette sed dwnsteam f
the design pcess f vaidatin. Hweve, sing the
ANSYS diect CAD intefaces pvides sme benefits that
CAD-embedded ts cannt ffe.
ANSYS diect CAD intefaces d mch me than
impt gemety. They aw access t the ive gemety
in a CAD system. The tansatin fm native CAD t
the ANSYS Wkbench patfm is pefmed thgh
appicatin pgamming intefaces (API) pbished by the
CAD vends. These APIs pvide diect access t the ive
mdes (what y’e wking n nw, nt what is saved),
which ae tansfeed t ANSYS Wkbench witht any
Topology using ANSYS CAD interfaces is persistent and allows for process streamlining.
Original Model
F i l e - B a s e d T r a n s f e r
A N S Y S D i r e c t I n t e r f a c e
Changed Dimensions Added Rounds
Face Moves
Face Persists
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tips and tricks
ANSYS Advantage • Vme IV, Isse 1, 2010 47
additina intemediate fies tansatin. This pcess
pvides the mst accate and eiabe gemety
tansfe pssibe.
APIs as aw sftwae fm ANSYS t access the
infmatin, sch as paametes, attibtes incding
named egins and mateia ppeties, and, mst
imptant, tpgy. Witht tpgy, many f the
advanced capabiities enabed thgh the ANSYS
Wkbench envinment wd nt be neay as sef.
Tpgy can be thght f as the names f paces n
a map: Cnties ae tined, and each space is abeed
with a cnty name. In the same manne, bdies, faces
and edges in a 3-D mde have names intena t the
CAD system. This aws the system t cate egins
cnsistenty as changes ae made t the mde. What if
smene gave y a map f the wd with a sepaate ist
f cnty names? What if they gave y a map with the
cnty names paced in the wng catins? The map
wdn’t be vey sef. This is exacty what happens
when gemety fies ae tansfeed sing a neta
fie fmat.
As an exampe, stat with a simpe fie in a CAD
system, expt a STEP fie, and then impt the STEP fieint the ANSYS Wkbench patfm. Within ANSYS
Wkbench, assign a niqe c t each face f the
mde (f exampe, sing a meshed bdy in CFD-Pst).
retn t the CAD system and change the gemety
sighty. Expt this new mde as a STEP fie and epace
the igina mde in ANSYS Wkbench, esing the
existing setp. When viewed in CFD-Pst, the same
intena faces emain (ike the names f the cnties in
the map exampe), bt thei catins have a mved.
Each face is nw epesented by a new c.
The same pbem ccs when adding new featest the mde, sch as chamfeed nds n the edge f
the bx. New faces shw as ange in the exampe, bt,
when sing STEP tansfe, pevisy existing faces ae
nw ange. If these cs wee gemety peatins,
mesh cnts, ads and bnday cnditins, then a
catins wd eqie pdating; n a cmpicated
mde, it might be bette t stat fm the beginning.
If the same pcede is fwed sing an ANSYS
diect inteface t tansfe the gemety, a the faces
etain thei igina c. ony the new nds appea
ange. New faces can sti pse pbems if they need t
be seected addessed in y anaysis, bt this is sti
mch ess wk than having the new faces scambed
amng the existing faces.
Becase the sftwae cannt ndestand what the
gemety is, it eies n intena names t keep tack f
whee t d things. If these intena names ae st
eaanged sing fie-based tansfe, pcesses appied
t the egins epesented by these names wi nt
be eevant.
ANSYS Wkbench enabes ese f the anaysis
pcess when changes ae made t gemety.
This pcess appies t gemety peatins in the ANSYS
DesignMdee t, mesh settings in ANSYS Mechanica
and Meshing Patfm, and ads and bnday cndi-
tins in the vais simatin envinments. With a diectCAD inteface, gemety changes in the CAD
system ae simpy pdated thgh the entie ANSYS
Wkbench pject. Gemety can be changed witht
the need t eappy these settings.
This tpgica pesistence is as a key enabe f
design expatin, in which ANSYS Wkbench can
atmaticay pdate the CAD mde and en mtipe
anayses. Tpgica pesistence edces setp time
f gemety mdificatins, s this time can be sed t
expeiment with pssibe design changes, eiminate bad
ideas qicky and highight pmising candidates — a withvey itte wk p fnt. This edces the vaiabe cst f
simatin and aws f design innvatin — t pvide
vae f y, y depatment and y cmpany. n
What if smene gave y a map f the wd with
a sepaate ist f cnty names? What if they gave y a
map with the cnty names paced in the wng catins?
This is exacty what happens when gemety fies ae
tansfeed sing a neta fie fmat.
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Best of Both Worlds:Combining APDL with
ANSYS Workbench forStructural Simulationsusing ANSYS Wkbench techniqes with APDl deivesthe mst benefit fm ANSYS stcta mechanics stins.
By Pierre Thieffry, Lead Product Manager, ANSYS, Inc.
Whethe y ae a ngtime ANSYS
Mechanica APDl se wndeing,
“What is s gd abt ANSYS
Wkbench that eveyne sggests I
se it?” an ANSYS Wkbench se
thinking, “I can’t find the bttn, s
hw can I se this feate?” y can
make bette se f ANSYS mech-
anica stins by cmbining a f
the avaiabe techngies. Ding s
wi aw y t achieve pcesscmpessin whie pefming me-
advanced simatins.
APDl — ANSYS Paametic
Design langage — is the pimay
angage sed t cmmnicate
with the ANSYS Mechanica APDl
sve. This scipting angage can be
sed t atmate cmmn tasks
even t bid a paametic mde.
APDl encmpasses a wide ange f
the feates, sch as if-then-ese
cnstcts, d-ps, and vect and
matix peatins.
The ANSYS Wkbench patfm
aws ses t ceate new, faste
pcesses and t efficienty inteact
with extena ts sch as CAD
systems. It pvides a fndatin f
easy mtiphysics simatin and
enhanced cmpany-wide cmmni-
catin f simatin ests. Thse
pefming a stcta simatin se
a gaphica inteface (caed the
ANSYS Wkbench Mechanica
appicatin) that empys a tee-ike
navigatin stcte t define apats f thei simatin: gemety,
cnnectins, mesh, ads, bnday
cnditins and ests.
By tiizing the ANSYS Wkbench
patfm, the se saves time in many
f the tasks eqied t pefm a
simatin. The bidiectina inks
with a maj CAD systems ffe a
vey efficient way t pdate CAD
gemeties ang with the design
paametes. The meshing ts
avaiabe in ANSYS Wkbench ae
based n sme f the best ag-
ithms ANSYS has deveped — f
exampe, stcta ses can nw
benefit fm techngies that nce
wee avaiabe ny t CFD ses, and
vice vesa. The ANSYS Wkbench
Mechanica appicatin has pven
t be a vey efficient way t qicky
set p mechanica anayses. At-
mated cntact detectin is pbaby
the mst nticeabe advantage as
cmpaed t the ng-standing
ANSYS Mechanica APDl inteface.
ANSYS Wkbench incdes at-matin capabiities in additin t thse
pvided by APDl. F exampe, when
king at design vaiatins, a se can
easiy pefm gemetic vaiatins
by diecty mdifying the paametic
CAD mdes. In the case f cped
anayses sch as thema–stess
pestessed mda anayses, a data
shaed amng the vais simatins
ae handed atmaticay, awing the
se t fcs n designing a bette
pdct athe than having t wy
abt fie management.
As an ANSYS Wkbench
Mechanica appicatin se, y may
tips and tricks
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wish t pefm tasks that ae nt
nativey avaiabe. F exampe,
cnside that y want t se a
mateia mde nt avaiabe fm
engineeing data, t se a cntact
ptin nt avaiabe fm the mens, even t pefm a me-cmpex
task, sch as a sbmde ing
anaysis. The stin is t inset
apdl Commands bjects t send
additina instctins t the sve.
When y cick n the Solve icn,
the ANSYS Wkbench Mechanica
app icat in adds these APDl
cmmands t the inpt fie f the
ANSYS Mechanica APDl sve. The
Commands bjects (as efeed tas snippets) can be incded at
the Geometry eve f mdifying
eement types mateia ppeties
(Fige 1). At the Connections
eve, additina cntact ptins
nn-inea sping definitins can
be intdced. Cmmands inseted
nde the anaysis banch pvide
the fexibiity t add pe-pcessing
act ins , ads and bnday
cnditin definitins, stinsettings. When sed nde Solution,
cmmands aw accessing the APDl
pst-pcesss and cd be sed,
f exampe, t pefm cmpex
peatins n ests t expt
data t an extena t. Commands
bjects can be edited manay,
existing macs can be diecty
impted. The Named Selections i
ANSYS Wkbench Mechanica ae a
key cmpanin feate t Commands
bjects, as they ae cnveted t
nda eement cmpnents that
can be efeenced.
If y ae an ANSYS Mechanica
APDl se and y cmpany has
ceated and vaidated APDl macs
f many yeas, these scipts can be
esed diecty with sight changes.
The cent vesin f the ANSYS
Wkbench p ject schemat ic
cntains a Mechanica APDl system
that can be inked t a stcta
anaysis (Fige 2). Y can then se
Figure 1. APDL commands for defining
additional material properties
Figure 2. Applying APDL scripts to a base
ANSYS Workbench model
macs t peate n the mde the ests f the ANSYS Wkbench
Mechanica anaysis. The ANSYS
Mechanica APDl system wi accept
a ist f APDl fies t be exected
seqentiay n any data that is
pvided by the psteam anaysis.
Ftheme, y can define inpt and
tpt paametes fm the vaiabes
f y APDl scipt and cmbine them
with the paametes in the pject.
F exampe, APDl vaiabes can bemixed with CAD dimensins t
pefm design vaiatins. A standad
sve ptins, sch as jb definitin
and icensing ptins, ae defined with
Figure 3. Multiple scripts applied to a model
and solver option definitions
the ANSYS Mechanica APDl system
(Fige 3).
It is ikey that ses wi nt be
abe t cnvet a thei existing
pcedes at nce, bt y can stat
with the pcesses that wi mst
benefit fm the advantages f the
ANSYS Wkbench patfm. And if
y have an entie pcede scipted
in APDl that des nt eqie any
se inteface, y pbaby dn’tneed t se ANSYS Wkbench f
that specific case.
ANSYS Mechanica APDl ses
may want t take a k at the
benefits f the ANSYS Wkbench
patfm t see hw mch time can be
saved n gemety impt and mdifi-
catins, meshing, cntact detectin
and genea mde setp. If y ae
an ANSYS Wkbench se and have
fnd y need fnctinaity that is ntavaiabe as a bttn men, then
eaning APDl is definitey wth
investing the sma amnt f time that
can est in hge dividends. n
tips and tricks
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The chances of jamming this blender with oranges are probably fewer than
jamming it from crosstalk emitted by other electronics all around us.
Electromagnetic Interference. EMI. A prime suspect in recent auto and aircraft
safety issues. And the hidden culprit in what may be the most daunting
engineering challenge of our time.
Today’s most innovative and quality-driven companies are just beginning to
understand the domino effect of modern products bursting with ingredients.
Electronics and a cacophony of other interconnected systems and physical
components each one talking over the other.
This new era of smart products doesn’t seem so smart if you try to design things
the same old way. Product design leaders rely on ANSYS engineering simulation
software for analyzing the interplay of electromagnetic emissions, structural
mechanics and fluid dynamics.
Are you talking to me?