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This presentation will start with a brief introduction to CFD (Computational Fluid Dynamics) and what is required for an engineer to achieve accurate solutions. Next, a high level overview of fluid driven multiphysics will be presented with some examples including the new bi-directional coupling with MotionSolve™ to be released in HyperWorks 13. If time permits, we will also discuss how AcuSolve’s CCI (Code Coupling Interface) enables accurate and conservative code coupling to HyperWorks and other third party solvers.
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2014 European Altair Technology Conference
June 24-26, 2014 | Munich, Germany
Join, Contribute, Exchange Technical Session #2: Multiphysics & CFD
Moderator: Steve Cosgrove
14:00-16:15 @ Bodensee 1+2
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
• Opening Remarks and Presentation: Steve Cosgrove (15 min)
• Presentations: (20 min + 5 min Q/A)
• Dr. Fotis Konias, Altair Greece, “CFD Analysis on Gulfstream Landing Gear”
• Dr. Michael Arrigonia, ENSTA, “Indent Tests for Explosive Equation of State
Determination”
• Stephan Pitzing, Knorr-Bremse Systeme, “Simulating Thermal Balance of
Electronics – An AcuSolve Approach”
• Aymen Slimani & Dr. Jorg Sorensen, Magna Car Top Systems GmbH, “
Aerodynamic Simulation of a Cabriolet Soft Top Roof System with VWT”
• Mathias Reichert, Westinghouse Electric Germany GmbH, “Numerical
Simulation of Liquid Sloshing with SPH Method in Nuclear Power Plant
Facilities”
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Biomedical- Airflow in Canine Noses
• AcuSolve validated for sniffing in canine nasal passage
• Finest mesh used 58 mm element size (100 Mio elements)
CFD Mesh
Journal of Biomechanical
Engineering SEPTEMBER 2009,
Vol. 131
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Studying fluid flow
• Fluid flow can be studies in three ways
• Experimental fluid dynamics
• Theoretical fluid dynamics
• CFD: Computational fluid dynamics
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Equations (Navier Stokes)
continuity
momentum
energy
• The Navier Stokes equations are general, describing the majority of flows
• Non linear terms make them difficult to solve
• Another non-linearity is that most real world flow problems involve
turbulence in the fluid
Non linear terms
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Turbulence
• Turbulence is a phenomena which includes flow structures of
• large range of length scales (small and large eddies)
• Large range of time scales (low and high frequencies)
• There is no theorem relating Reynolds number to turbulent, but usually
• Low Re number -> laminar
• High Re number -> turbulent (e.g. pipe flow Re > 2500) Parallel layer, no
interaction
between layers
CFD code solves for Ui(mean velocity), Turbulence model gives impact of u’
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AcuSolve Turbulence Modeling Slide: Scales of Energy
Transfer in Turbulence Modeling
DES
LES
DNS
(SA,k-eps, k-omega, SST,…etc, etc..)
Co
mp
uti
ng
Co
st
DDES
Resolved=Computed by code exactly, Modeled=approximation
(LES)
RANS, URANS
(RANS)
(LES) (RANS)
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Turbulence
• Why is turbulence modeling important ?
• The turbulence determines the point of flow separation
• Different separation point different flow pattern, different performance (e.g. drag
coefficient of a car, lift coefficient of an airfoil)
Same BC, different turbulence model
AcuSolve DES DDES Exp. RANS (SA)
Separation 0.641 0.662 0.665 0.663
Reattachment 1.36 1.18 1.11 1.22
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
CFD solver technologies
• Primary technologies:
• Finite difference – Phoenix (Cham)
• Finite volume – StarCD, Fluent, CFX, SCTetra, CFD++, OPENFOAM
• Finite element –
• Galerkin formulation: CFDesign, Flotran, Fidap,
• Galerkin Least Squares formulation: AcuSolve
• Others include:
• Panel method – aerospace codes for external aero
• Spectral method – Nekton, Polyflow
• Lattice Boltzman Method (POWERFLOW, XFLOW)
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Challenges of CFD
• Pre-processing – Still the bottleneck
• 80% of the CFD analysis time is spent in pre-processing (cleanup, meshing)
• Up to 6 weeks for modeling an external automotive flow
• Fast and automated meshing algorithms are required (e.g. multi CPU)
• Model size from 0.5 Mio – 300 Mio cells (now up to 1,000 Mio)
• Large variation in element size (1e-5 … 20)
• CFD analysis (Solving) – Scalability, Quality, Robustness
• High CPU time for transient analysis (e.g. aero acoustics)
• CPU expensive models (e.g. turbulence, chemical reactions, multiphase)
• Clusters with up to 512 cores (e.g. Formula One teams)
• Mesh and numerical model have a strong impact on the solution
• Large differences in time/space scales
• Post-processing - Interactivity
• Huge amount of data (e.g. fine mesh, transient GB range)
• High computing time (streamlines, contour plot, math. operations)
• Post-processing on multi CPU client server machines
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multiphysics – A New Generation of Simulation
Multiphysics
At Altair
{
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multiphysics – A New Generation of Simulation
Block
Diagram
System
Modeler
ScicosPro
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multiphysics – A New Generation of Simulation
• Several levels of MP technology available to the users so you
can select the right level of coupling.
• Coupled ability in a single solver (AcuSolve + thermal)
• Sequential simulation (AcuSolve + OS for linear FSI))
• Co-Simulation (AcuSolve + RADIOSS or Abaqus for non-linear
FSI)
14
Multiphysics – A New Generation of Simulation
OptiStruct,
RADIOSS
(Mechanics)
OptiStruct,
RADIOSS
(Thermal)
AcuSolve,
HyperXtrude
(Flow)
AcuSolve,
HyperXtrude
(Thermal)
FEKO
(HF Emag)
JMAG
(LF Emag)
ScicosPro
(Controls,…)
[coming soon]
MotionSolve
(MBD)
F-Tire
(Tire
Dynamics)
DesignLife,
FEMFAT
(Fatigue)
DSH Plus
(Hydraulics)
RadTherm
(Human Cft)
AcuSolve
FWH
Simulink,
CD Tire,
RMOD-K Tire
APA Partners
3rd Party
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AcuSolve Flow + Thermal Coupling in HW12
• Coupled Flow-Temp
Solve
• Unique to
AcuSolve!
• Nominal coolant flow
rate = 115 liters per
minute (LPM)
• Coolant – constant
properties
• Solids – temperature-
dependent conductivity
• Block - Steel
• Head - Aluminum
• Gasket – Stainless
Steel=
T
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Powertrain Boundary Conditions on AcuSolve model
• Boundary Conditions
• Inlet – 105 C, 115 LPM
• Outlet – Pressure = 0.0
• Cylinders – Fixed
Temperatures
• Most Solid Boundaries have
Convective Heat Flux
Coefficient with Sink
(Reference) Temperature
• Outside Surfaces
• 30 W/m^2-C with 30 C
• Major Inner Surfaces
• 100 W/m^2-C with 135 C
• Exhaust Ports
• 623 W/m^2-C with 790 C
• Cylinder Covers
• 625 W/m^2-C with 980 C
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Powertrain Model Description
• Surface mesh from SIMLAB, volume mesh in AcuConsole
• Total Mesh Count: ~7 Million nodes / ~39 Million tetrahedral elements
• Fluid: 4. million nodes 24 Million elements (all tet)
• Solid: 3. million nodes,15 Million elements
• AcuSolve accuracy and runtime if f(# of nodes) NOT # of elements
• Solving Fluid Flow / Turbulence / Energy equations
• Solution Time for Flow / Turbulence/Energy about 3.0 hours on
120 cores (10 nodes, 6 core Intel Westmere cpus)
• Effect of
varying
flow rate -
15%
• 115 LPM –
model
max temp
= 271.7 C
• 97.75 LPM
– model
max temp
= 276.0 C
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
First cylinder in block starved for cooling flow!
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AcuSolve + OS or RADIOSS Coupling in HW12
AcuSolve
Optistruct
(linear, static)
Radioss
(non-linear, implicit, dynamic)
P-FSI
(eigenmodes)
DC-FSI
(co-simulation)
Loads
(T,p,…)
Down force for rigid and elastic
4%
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
New in HW13:
• AcuSolve + MotionSolve Coupling
• AcuSolve/MotionSolve communicate using AcuSolve’s code coupling
interface (CCI)
• Wetted surfaces are “paired” with rigid bodies
• Loads/displacements exchanged at run time
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AcuSolve + Motionsolve Coupling
• Example of Riser with Fairing in an ocean current
• Fairing rotates (windmills) about riser with friction between the riser and Fairing
Water
Flow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AcuSolve Mesh Motion for MS Coupling Example
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Coupling AcuSolve + Structural
• Interface Conditions
• Traction continuity
• Displacement continuity
• Key Issues
• Spatial coupling
• Non-matching meshes
• Projection and interpolation
• Temporal coupling
• Explicit coupling schemes
• Implicit coupling schemes
Fluid
Solid
pf
tf
:
:
d d
P P
Displacement continuity
Traction equilibrium
on
on
f s fsi
f s fsi
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Explicit Coupling Schemes
• Explicit Coupling Schemes
• Conventional Sequential
Staggered (CSS)
(Felippa and Park, 1980)
• Generalized Sequential
Staggered (GSS)
(Farhat et al., 1995)
• Combined Interface Boundary
Conditions (CIBC)
(Jaiman et al., 2007)
• At each time step
Page 24
Apply fluid force
Advance s
tructu
re
2
3
1
Advance flu
id
CFD Solver
4
CSD Solver
t = tn
t = tn+1
Apply fluid force
:
:
*
*
d d + d
P P + P
Displacement prediction
Traction correction
on
on
P
f s fsi
C
s f fsi
Does not work for structures
in liquids
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Implicit Coupling Scheme
• Linearized fluid-structure system:
• Off-diagonal terms are not explicitly known
• Explicit coupling effectively has set to zero
• Can we replace by pseudo inverse
• Altair Invented Multi-Iterative Coupling (MIC) Scheme
• Predictor-corrector iterations
• Combined fluid+interface solver
ss sf s s
fs ff f f
A A q R
A A q R
1
sfA1
sfA
sfA
http://www.altairhyperworks.com/html/en-us/rl/ACUSIM/papers/OMAE2009-79804.pdf
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Last Slide ! HyperMesh 13.0 (CFD optimization)
• Exhaust system / design challenge
• Significant integration and ease of use improvement in 13.0
Min. pressure drop
Max. uniformity
Morphing
(design space)
initial optimized