Automation and Standardization of CFD Workflows and Standardization of CFD Workflows ... Training + Support ... © MAHLE HVAC Wizard Automatic report generation

Automation and Standardization of CFD WorkflowsDr. Wolfram Kühnel, MAHLE Behr GmbH & Co. KG

• Realize innovation.Unrestricted © Siemens AG 2016

MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx2

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The company

Globalization

Standardization

Automation

Examples

– HVAC Wizard

– HEEX Wizard

Conclusion

Outline


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Group organizationBusiness units and products

The Company – The MAHLE Group

BUSINESS UNITS

Engine Systems and

Components

Founded 1920

Filtration and

Engine Peripherals

Thermal Management

Founded 1905

Aftermarket

BU1 BU2 BU3 BU4

MAHLE Behr GmbH


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The Company – The MAHLE Group

MAHLE worldwide

Production locations

Research and development centers

Headquarter:

Stuttgart, Germany

Facts (2015):

Employees: 75.635

Sales: 11,5 Bill. €

R&D Centers: 15

R&D Centers NA:

Farmington Hill

Troy

Lockport

Amherst


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Globalization

CFD and FEA engineers @ MAHLE Behr GmbH

USADetroit: /

ChinaShanghai: /

Wuhan: /

IndiaPune MBES: /

Pune MBIL: /

Germany

Stuttgart: /

BrazilJundiaí/Sao Paulo: -/

˜

´

R&D centers: #CFD/#FEA

< 5 engineers

5 – 9 engineers

> 9 engineers

Charleston: -/

FranceRouffach: /

For globally comparable simulation results

standardized processes and methods are mandatory!

Lockport: /

Luxembourg: /

Central department for simulation method

development

Development of 3D simulation methods

Validation

Documentation + Guidelines

Training + Support

Continuous improvement and enhancement


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Standardization + Automation

Automation of standardized simulation workflows helps to…

… ensure the compliance of the work to the guideline

… reduce manual effort and tedious work

… reduce errors

… reduce lead time

… work collaborative in a global world

Simulation Workflows


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Simulation Workflows - Examples

Engine Cooling

HEEX Wizard

Air Conditioning

HVAC Wizard


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HVAC Wizard

Structure of an HVAC unit

Distribution housing

Blower-filter housing

Air filter

Evaporator

Heater

Mixing-flaps

Auxiliary - heater Blower

Outside-air-inlet

Recirculation-air-inlet


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HVAC Wizard

HVAC Wizard

Standardized CFD Simulation

Geometry preparation

Automatic Template Creation

Minor surface repair

Prepare/ organize geometry

Physical modeling

Boundary Conditions

Porosities

Heat Source

Rotate flaps

Modus flaps

Mixing flaps

Meshing

Wrapper

Surface Remeshing

Volume Meshing

Simulation run

Post-processing

Standard PowerPoint

report

Predefined scenes

Plots


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HVAC Wizard

The Tool

Installed as a STAR-CCM+ plug-in

Fully developed by MAHLE Behr

– > 60 Java source files

– > 270 subversioning revisions

– > 30 releases

The HVAC Wizard includes a customized GUI for three different CFD workflows:


Physical modeling

Rotate flaps MeshingSimulation

runPost-

processing


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HVAC Wizard

Meaning of “Temperature Control Curve”(TCC):

Air outlet temperature is controlled by mixing hot (from heater) and cold air (evaporator)

For computing the temperature control curve, only the mixing flap position is changed

-> Every point of the TCC is one steady simulation automated process

TCC – Rotation of flaps


Physical modeling


runPost-

processing


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HVAC Wizard

Automatic report generation (PowerPoint):

General informations

Scalar scenes

Bar pressure drop graphs

Residual plots

User defined quantities

Automatic PowerPoint Creation


Physical modeling


runPost-

processing


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Simulation Workflows - Examples

Engine Cooling

HEEX Wizard

Air Conditioning

HVAC Wizard


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HEEX Wizard

What is a Temperature Cycle Test (TCT)?

No constant operating temperature for automotive heat exchanger

=> thermal stress

=> design of heat exchanger has to consider thermal loads for durability and long life-time

For component validation:physical TCT durability tests on temperature cycle test benches

In development phase:virtual TCT by coupling transient CFD (for time-dependant temperature distribution) with FEA (forthermal stress and life-time prediction)

Workflow of simulation of a Temperature Cycle Test (TCT)

0 90 180 270 360

t [s]

Tem

pera

ture

s/C

oolin

g A

ir M

ass

Flo

w

Temp. Charge Air in

Mass flow Cooling Air

Temp. Charge Air out

Example: test temperature profile (Charge Air Cooler)


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HEEX Wizard

Workflow of simulation of a Temperature Cycle Test (TCT)

Mapping of temperature data

Thermal stress data

Lifetime prediction and

most damaged position

CFD simulation

FEA simulation

Fatigue simulation


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EGR TCT

iCACTCT

RAD TCT

HEEX Wizard

HEEX

Wizard

EGR

CAC

RAD

iCAC

Unification of engine cooling simulation methods

RAD = Radiator

EGR =

Exhaust Gas Radiator

CAC =

Charge Air Cooler

iCAC = indirect

Charge Air Cooler


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HEEX Wizard

Standardized CFD Simulation of a Temperature Cycle Test (TCT)

HEEX Wizard


Imprinting

Meshing

Surface Remeshing

Volume structured (External)

Volume unstructured

(STAR-CCM+)

Physical modeling

Material database

Fin & TubesModeling

Boiling

Radiation

Simulation runPost-

processing

Massflowdistribution

Predefined scenes

Plots

Mapping (NASTRAN)

Positioning of models

Selective Mapping

Check of correct

mapping

Data transfer format

management

FEA (PERMAS ®)


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HEEX Wizard

Standard materials can be selected by ticking

Conjugate simulation of gas, solid parts and coolant

The fluids of tubes and fins are homogenized by porous

media:

– Pressure loss of tubes and fins is modeled via resistance

coefficients of porous media based on Psi-functions

– Dual-cell HX method to model fins and tubes based on

Nu-functions

– Psi- and Nu-functions are taken from the in-house

system simulation database BISS

Physical Modeling

MeshingPhysical modeling

Simulation run

Post-processing

Mapping


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HEEX Wizard

Standardized Post Processing

Standard screenshots of transient temperature evolution

of heat exchanger for creation of animated gifMeshing

Physical modeling

Simulation run

Post-processing

Mapping


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HEEX Wizard

Mapping of the temperature distribution of the CFD

solids to the NASTRAN geometry of the FEA simulation

– Mapping of steady and transient CFD results

(for selected time steps)

FEA simulation (in PERMAS®) of thermal load and

deformation for each time-step

Mapping of solid temperature from CFD to FEA


Simulation run

Post-processing

Mapping


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HEEX Wizard

FEA-Results of TCT Simulation

deformation magnification factor: 50

Temperature / °C


Simulation run

Post-processing

Mapping

-20

0

20

40

60

80

100

120

0 50 100 150 200 250 300

T /

C

t / s

Inlet Temperature Mapping


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MAHLE Behr CFD Wizards

Significant speed-up of turnaround times

Future major speed-up potential lays with geometry preparation (imprinting)

Turnaround times and speed-up of CFD Wizards

Manual

Setup

Macro

based workflow

HEEX-

WizardV9.04_09

timeHEEX-Wizard

Preparing

CAD geometry

Meshing Setup

Meshing

Physics Setup

Post-

processing


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Standardized, validated and automated simulation workflows promote simulation as an important and integrated part of the development process

STAR-CCM+ provides excellent interfaces to automate and customize the workflows

High reduction of lead-time by the MAHLE Behr Wizards

More than 50% reduction of manual effort by automation

Reduction of manual work reduces risk of errors and reduces need for re-work

Conclusion


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Thank you for your attention!

Documents

Automation and Standardization of CFD Workflows and Standardization of CFD Workflows ... Training + Support ... © MAHLE HVAC Wizard Automatic report generation