davison cdadapco 4202012
TRANSCRIPT
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Optimization using Isight,
STAR-CCM+ and CATIA V5
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• 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
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• 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
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• 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
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• 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
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• Full automation
– Capture knowledge
– Tool unification
– Adapt tool to your demands
• Meaningful results in a realist ic t imescale
Making 3D-CFD Optimization Practical
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• 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?
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EXAMPLE
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• 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
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• 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
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MODEL SETUP
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• 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
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CATIA Geometry
Runner 1 Runner 2 Runner 3 Runner 4
Driving splines
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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
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Optimization Loop Workflow
DOE component provides
modified spline definitions
STAR-CCM+ feeds back
pressure drop
CATIA modified geometry
STAR-CCM+ analyses
flowfield
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• 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
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• 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
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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
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• Boundaries fil led in CATIA
• Automated f luid extraction
Flow Domain Extraction
Imported solid domain
with filled boundaries
Extracted fluid
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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
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STAR-CCM+ - Isight Component
Parameters to expose to
Isight
Manual or Automatic
execution
Java for manual
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SHORT DEMO
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RESULTS
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• 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
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Pressure Field
Initial DesignBest Design
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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
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Wall Shear Stress
Initial DesignBest Design
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Uniformity
Initial DesignBest Design
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Flowfield
Best Design
Initial Design
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• 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
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Thank You