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Karlheinz PetersMSC.Software Corporation
Simulation Based Design Processes for CFD Using Abstract Modeling
Current Situation – Manufacturing Industries
• Challenges– Growing pressure to do more & better with less
• Increasing focus on more efficient product development processes
– CFD Specific Issues: • Limited number of fluids simulation specialists available• Problems automating the CAD to CAE process
• Success by early adopters– Simulation Based Design (SBD) processes taking advantage
of increased use of simulations• Earlier in the development cycle • Repeated whenever changes are made• Increasing virtual tests – reducing physical tests
Overcome Development Status Quo
Project Engineering
CAD Design
CAE Analysis
Weak Feedback Loops
• Timeliness• Result Quality/Comparability
Why Simulation Based Design?
Holistic design approach, seamlessly integrating CAD, PLM and CAE to enable simulations at all levels of the engineering workforce– Design process promoting use of simulations early and
repeatedly resulting in shorter design cycles and better product performance
– Ensuring consistent quality of simulation results– Possibility to re-use simulation models independently of product
shape– Automatically capturing simulation know-how– Heavily automated to increase overall efficiency, avoid user errors
and expand simulation user base– Elimination of expensive non-value-added tasks
Vision: Product shape determined by results of simulation (design improvement process)
MSC’s Solution for CFD SBD Processes
• FluidConnectionTM
– Acquisition of PioneerSolutions Inc.– CFD pre-processor for highly automated
Simulation Based Design processes– Based on Abstract Models connecting
CAD with CFD Solvers – Will evolve into SimXpert CFD Workspace; first delivery planned
for Q 2/3 08’
SBD BenefitsActual customer example: 47% reduction of cost for total Product Development cycle due to new SBD process for CFD using FluidConnection
SBD CFD “Secret Sauce”MSC has acquired “Dirty hands” expertise and know-how with over 10 years trial & error and
subsequent successes implementing “SBD for CFD”
• No geometry data translation involved– Enables reliable automation of simulation process– All geometry work done with best suited tools & people
• Integrating existing CAD and solver software– Better and increased use of customer’s invested design tools
• Existing CAD (Dassault, PTC, UGS)• Selected commercial CFD Solver(s) of choice, Fluent, STAR-CD, AcuSolve, etc.• Proprietary CFD Code (ex. Aerospace)
– Currently supported: • CAD: CatiaV5, ProE• CFD: AcuSolve (Fluent: 12/07)
• In sync with SimEnterprise Abstract modeling concept– Separates model (CAE) authoring from it’s use
(creating a significantly larger simulation user base)– Repetitive, reliable simulations by designers/engineers – Fits into a PLM controlled Product Development environment– Expandable, e.g. to other simulation disciplines
Abstract Modeling Concepts
• Abstraction from 2 perspectives– Product abstraction– Functional abstraction
• Abstract Model Building blocks– components (product containers)– classes (CFD or functional containers)– relations (CFD class interface containers)– attributes (behaviors)– connectors
inlet air outlet
inlet – physics so - output
so - outputoutlet - physics
np - physics
Abstract Modeling Implementation
Two Roles– Author
• Creates and tests Abstract Models (description of physical behavior and meshing strategy) invariant to shape
• Vault for reuse– Production (Engineer-Designer-Analyst or “EDA”)
• Uses existing SBD CAD & CFD abstract models • Derives ‘automatically’ CFD input files• Executes CFD files • Obtains required output• Final report to PD team - iterate DOE,
design improvement and better cost
inlet air outlet
inlet – physics so - output
so - outputoutlet - physics
np - physics
Abstract Simulation
ModelSBD CAD
Model
CFD input files
Classic CAD & CFD vs. SBD CFD Process
Pre- Processor•Mesh•Physics
CAD System
Fluid Conn- ection
CFD input files
Run CFD
Collect Output
Report
Manual/Semi
automatic
CAD data base
SBD CAD
Product Shape
objects
SBD CFD
Product ‘behavior’
Abstract models
Highly automatic
RegularCAD Model
Tagged CAD Model
Tagged CAD Model
“CFD View”
Derive CFD relevant model(fluid space)
Add tags (Class Names) to CAD components
Import Classesfrom CAD
Completed Abstract Modelwith Components, Classes
and Attributes
Define ClassesIndependent
from CAD
Add Attributes to Classes
SBD CAD CreationUser: CAD Specialist
Abstract Model AuthoringUser: CFD Specialist
Automatic generation of:Simulation ModelMesh ModelSolver Input Files
Users:•CFD Specialist•CAD Specialist•Other Engineers
Product Development Process ComparisonTask Conventional SBD Compliant
Geometry CAD-system / single view CAD system / multi view (incl. CFD view)Geometry data transfer to simulation
Data translation for pre-processor frequently requiring manual user interaction
Geometry preparation done by non-CAD users with non-optimized tools
This task is avoided using SBD CAD practices; therefore no translation necessary
Meshing Manual, semi-automatic or automatic AutomaticPhysical model set-up
Individually per geometry instanceBest case: “manually” adapted input filesQuality of results varying with user know-how
and specific effort invested in task
Abstract models, re-usable for any CAD instance
Consistent quality of resultsCapture of company know-how
Total time Days to weeks Hours to days
Advantages Summary
Familiar tools / approach Automated process creating results significantly faster
Consistent result qualityRepetitive and reliable simulations by
designers & engineers
Case Study Summary
• Flexibility of Many to One Abstract Model(s)– Re-use through abstraction– Simple Y-Duct to complex air handler systems– Support for multiple CAD systems
Basic Many to One Abstract Model
Basic Many to One Abstract Model FluidConnection
CAD Model 1 CAD Model 2
FC Simulation Model1 FC Simulation Model2
FC Mesh Model1 FC Mesh Model2
FC CFD Model1 FC CFD Model2
Basic Many to One
Abstract Model FluidConnection
CAD Model3 CAD Model4
FC Simulation Model3 FC Simulation Model4
FC Mesh Model3 FC Mesh Model4
FC CFD Model3 FC CFD Model4
Different CAD system,SAME abstract model!
Versatile Many to One Abstract Model
CAD Model1
FC Simulation Model1
FC Mesh Model1Abstract Model
Class Schematic Abstract Model
Class SchematicFC CFD Model1
inlet_2d
outlet_2d
Global fluid
shell_2d
board_2d
insulation_2d
multi_2d
steel_2d
solid
void
no_es
air
alum
glass
glass_wool
urethane
steel
wood
heatair_pcA
air_pcB
air_pcC
air_porousA
no_blyr_2d
sizeA_2d
no_blyr
sizeB_2d
sizeC_2d
blyrA
blyrB
sizeA
sizeB
sizeC
no_mesh
Compact Versatile – Many to One Model
inlet_2d
outlet_2d
Model/Global fluid
shell_2d
board_2d
insulation_2d
multi_2d
steel_2d
solid
void
no_es
air
alum
glass
glass_wool
urethane
steel
wood
heat
air_rotateA
air_pcA
air_pcB
air_pcC
air_porousA
no_blyr_2d
sizeA_2d
no_blyr
sizeB_2d
sizeC_2d
blyrA
blyrB
sizeA
sizeB
sizeC
no_mesh
Problem Definiton and Output MeshAll
Class/Class Relations Only
Y-Duct CAD Model
Y-Duct Instance of Versatile Many to One Model
inlet_2d
outlet_2d
Model/Global fluid
shell_2d
board_2d
insulation_2d
multi_2d
steel_2d
solid
void
no_es
air
alum
glass
glass_wool
urethane
steel
wood
heat
air_rotateA
air_pcA
air_pcB
air_pcC
air_porousA
no_blyr_2d
sizeA_2d
no_blyr
sizeB_2d
sizeC_2d
blyrA
blyrB
sizeA
sizeB
sizeC
no_mesh
Problem Definition and Output MeshAll
Class/Class Relations Only
Y-Duct Abstract Model
Blower CAD Model
Blower Instance of Versatile Many to One Model
inlet_2d
outlet_2d
Model/Global fluid
shell_2d
board_2d
insulation_2d
multi_2d
steel_2d
solid
void
no_es
air
alum
glass
glass_wool
urethane
steel
wood
heat
air_rotateA
air_pcA
air_pcB
air_pcC
air_porousA
no_blyr_2d
sizeA_2d
no_blyr
sizeB_2d
sizeC_2d
blyrA
blyrB
sizeA
sizeB
sizeC
no_mesh
Problem Definiton and Output MeshAll
Class/Class Relations Only
Blower Abstract Model
Blower CFD Results
VelocityPlots
Enclosure CAD Model
Enclosure Instance of Versatile Many to One Model
inlet_2d
outlet_2d
Model/Global fluid
shell_2d
board_2d
insulation_2d
multi_2d
steel_2d
solid
void
no_es
air
alum
glass
glass_wool
urethane
steel
wood
heat
air_rotateA
air_pcA
air_pcB
air_pcC
air_porousA
no_blyr_2d
sizeA_2d
no_blyr
sizeB_2d
sizeC_2d
blyrA
blyrB
sizeA
sizeB
sizeC
no_mesh
Problem Definiton and Output MeshAll
Class/Class Relations Only
Enclosure Abstract Model
Enclosure CFD Model
Air Velocity Temperature
Value of Abstract Modeling for SBD
• Enables highly automated Simulation Based Design processes for CFD
• Works with existing CAD systems and CFD solvers• Re-usability of abstract models
– Geometry / shape independent– Supports best practices and consistent quality of results– Capturing of simulation know-how
• Model authoring and model use separable• Ongoing SimEnterprise integration
– Data/File management– Process management– Support for MD applications and common data model
