Davison CDadapco 4202012

7/26/2019 Davison CDadapco 4202012

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Optimization using Isight,

STAR-CCM+ and CATIA V5



• 2011 Aberdeen group report – Getting Product Design Right the

First Time with CFD

• Top 2 business pressures:

– Shortened development schedules 50% – Better quality/reliability 37%

The Motivation for Optimization with CFD

32%

33%

48%

0% 10% 20% 30% 40% 50% 60%

Product would not be optimized

Fewer Scenarios tested

More physical prototypes required

Effect of Not Using CFD



• Long seen as uncomfortable bedfellows

– Optimization = Lots of design points

– CFD = Long hardware intensive runs, need for a “specialist”

• The industry demands change – Make it Faster

– Make it Cheaper

– Make it Better

Optimization and CFD



• Make it faster – Hardware no longer the limit factor

– Cloud computing – private and public

– Reduced wall clock time – easier to use

• Make it cheaper

– Less man hours – Revolutionary licensing model:

– Unlimited HPC

– Real time licensing

– Optimization tokens

• Make it Better – Integrated user environment

– Fully automated workflows

Making 3D-CFD Optimization Practical



• The motivation is there to:

– Produce better design

– In less time

• For best in c lass companies – 96% won’t compromise on accuracy

– Only 4% accept qualitative results

– 63% not willing to sacrifice accuracy for ease of use or cost of software

• Requirement is for both fast and accurate analysis

The Motivation for Optimization with CFD



• Full automation

– Capture knowledge

– Tool unification

– Adapt tool to your demands

• Meaningful results in a realist ic t imescale

Making 3D-CFD Optimization Practical



• Fastest growing engineering simulation

provider for 5 years

• Largest independent CFD focused provider

– 550+ employees across 21 offices

– Worldwide user base

• Speed Accuracy Quality User experience

Why Work with CD-adapco?



EXAMPLE



• Integration of STAR-CCM+ with CATIA & Isight

• Drive an automated workflow

• Study inf luence of geometry changes

– Provide a better optimized design

Aims and Objectives the Study



• Driven by major automotive OEM

• Goal

– Reduce manual interactions

– Improve design through optimization

• CFD group requested example integrating:

– Isight - Optimization

– CATIA V5 - Geometry

– STAR-CCM+ - Flow analysis

• Joint project between CD-adapco & SIMULIA

– Native STAR-CCM+ - Isight integration

Background to the current study



MODEL SETUP



• Geometry constructed in CATIA V5 R20

– Four port exhaust manifold

• Each “ runner” is a swept surface

– Spline for sweep defined by four points

– Points defined by external design table

• Excel design table has

– X,Y,Z coordinates for each point

– Coordinates to be driven by Isight

Geometry



CATIA Geometry

Runner 1 Runner 2 Runner 3 Runner 4

Driving splines





Optimization Loop Workflow

• Isight DOE component drives geometry modifications

• Excel spreadsheet reads modified coordinates, updates and saves

• CATIA opened in batch, updates part with geometry modifications

• New CATIA part generated

• STAR-CCM+ reads updated part, regenerates mesh and re-runs

• Pressure drop for each runnier is provided and captured by Isight



Optimization Loop Workflow

DOE component provides

modified spline definitions

STAR-CCM+ feeds back

pressure drop

CATIA modified geometry

STAR-CCM+ analyses

flowfield



• Design of experiment (DOE) component drives process

– L16 orthogonal array technique

– 4 points for the 1st midpoint of each runner

– -10%, -3%, +3%, +10% of original location

Isight Setup



• All processes executed in STAR-CCM+

– No external meshing/post employed

• Pre processing

– Automatic Meshing – Physics definition

• Post processing

– Total + individual

pressure drops

STAR-CCM+ Setup



STAR-CCM+ Workflow

StartingCFD

Template

Read inCATIAPart

Mesh Solve

Pre-defined

mesh, physics

& post but no

geometry

Direct read of

native CAD file

Automatic flow

domain

extraction and

volume mesh

Run stops

when pressure

drop stable



• Boundaries fil led in CATIA

• Automated f luid extraction

Flow Domain Extraction

Imported solid domain

with filled boundaries

Extracted fluid



Boundary Conditions

Exhaust port inlets with prescribed

mass flow of 0.0025 kg/s

Exhaust outlet with a fixed

pressure of 0 Pa relative to

ambient pressure



STAR-CCM+ - Isight Component

Parameters to expose to

Isight

Manual or Automatic

execution

Java for manual



SHORT DEMO





RESULTS



• Total reduction in pressure drop 6%

– 32% in a single runner

• First two runners greatest contribution to pressure drop

Pressure Drop

0

20

40

60

80

100

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

P

r e s s u r e D r o p

[ P a ]

Run Number

Pressure 3 Pressure 4 Pressure 2 Pressure 1 Total pressure



Pressure Field

Initial DesignBest Design



Parallel Coordinate Graphs

73.735 105.149 93.17 130.438

86.031 76.23 106.722

Pipe 1 Midpoint X Pipe 2 Midpoint X Pipe 3 Midpoint X Pipe 4 Midpoint X

36.576 29.425 15.754 88.158

9.301 5.033 47.252

Pressure 1 Pressure 2 Pressure 3 Pressure 4 Total Pressure

19.532

7.339

Inputs

Outputs



Wall Shear Stress




Uniformity




Flowfield

Best Design

Initial Design



• Practical application of CFD Optimization

– 2 hours wall clock time on laptop for 16 configurations

– Overall pressure drop reduced by 6%

• Isight used to integrate the different tools

– Leverage the automated capabilities of

STAR-CCM+ & CATIA

– Drive a DOE study

Conclusion



Thank You

Documents

Davison CDadapco 4202012