What is FloEFD? FloEFD for N. FloEFD for Solid Edge User Interface. Unrestricted Siemens AG 2017 Siemens PLM Software

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1 FloEFD 101

2 What is FloEFD? FloEFD is an award-winning MCAD-embedded CFD simulation tool for easy, fast, robust and accurate fluid flow and heat transfer analysis inside Siemens Solid Edge: FloEFD for N FloEFD for Solid Edge User Interface Fully embedded in the PLM design environment, and with its unique automation technologies, FloEFD helps engineers to both frontload CFD and carry out parametric studies throughout the complete manufacturing processes, Frontloading refers to the practice of moving CFD simulation early into the design process where it can help engineers examine trends and eliminate less desirable options, as well as reduce overall simulation workflow time by as much as 75%. Page 2

3 What is the FloEFD unique Value Proposition? FloEFD is easy to use: Design-centric simulation tool offering a single CAD-embedded environment for design and analysis thus making CFD analysis plug-and-play. CAD Embedded Innovative Technologies FloEFD is fast: Intelligent technology and automation helps reduce the overall simulation time for even complex geometries by as much as 75% thus enabling fast exploration of the design space and validation of the digital twin. FloEFD is accurate: Thousands of engineers use FloEFD to solve real world engineering problems across a wide range of industries including automotive, aerospace, manufacturing and electronics. Effective Geometry Handling No translation step necessary Design and Analysis are synchronized Automatic fluid volume detection Automatic change recognition Embedded in PLM workflow Robust Cartesian Meshing - SmartCells Avoid manual mesh creation Extremely fast meshing Complex geometry capture High Automation Automatic convergence Laminar-turbulent transition, Grid independent near wall modeling Engineering Models Real Geometry Thin Walls Thin Channels Short Learning Curve Easy to use by a designer Fast learning Multi-CAD Ready FloEFD democratizes CFD: It is at the core of SolidWorks Flow Simulation (NX and Solid Edge versions of FloEFD offer some additional functionality over SolidWorks Simulation*). Accurate and Fast Complex Geometry Handling Ease-of-Use by a non CFD expert to drive out risk Page Industrial CFD Benchmarks * FloEFD Advanced CFD and LED modules

4 FloEFD - Unique Combination of Enabling Technologies drives Frontloading CFD Embedded Solid Edge Intuitive Easy-to-use Interfaces for Engineers Fast Automated Immersed Boundary Cartesian Meshing Frontloading CFD Multi-variant What if? Analysis Unique Transitional Turbulence k - e model Automated Solution Convergence Built-in Unique Modified 2 Layer Wall Function for Boundary Layers Page 4

5 FloEFD Enabling Technology Full CAD Embedding and Integration FloEFD, Seamlessly integrated within Solid Edge: Direct use of MCAD geometry Automatic detection of the fluid region No coming in and out of the CAD package for the CFD simulation Benefits No translation step necessary with loss of geometrical fidelity No complex definition of regions Design and CFD models stay in sync. Reduces re-synchronization effort and errors Page 5

6 FloEFD Enabling Technology Fast Automated Meshing Immersed Boundary Meshing: Automatic meshing for fluid and solid regions Deals quickly with dirty CAD geometries Automatic mesh refinement/unrefinement Benefits No manual meshing time No CFD algorithm expertise required Reduces execution time yet delivers accurate results Page 6

7 FloEFD Enabling Technology Intuitive Easy-to-use Interfaces for Engineers Engineering User Interfaces: Easy-to-use wizards provide guided model setup Comprehensive result analysis & visualization capabilities Optional MS Office-based results Benefits Eliminates the need for CFD expertise in the setup Reduces setup times Automates the product documentation Page 7

8 FloEFD Enabling Technology a unique Transitional Turbulence k-ε model Laminar Transitional Turbulent k-e Model: Automatic laminar to turbulent CFD modeling with universal, grid independent modified 2 equation Wall Functions Laminar, transitional, and turbulent flow regimes automatically determined -- no need to specify flow characteristics Benefits Direct ability to model flow regimes eliminates CFD specialist requirement Shorter setup times and increased model accuracy compared to traditional approaches Page 8

9 FloEFD Enabling Technology a unique modified Wall Function for Boundary Layers Automatic Modified Wall Function: Grid-independent near-wall modeling using SmartCells technology Physically correct simulation of boundary layer phenomena for fluid flow and heat transfer Multiple scenarios automatically calculated Benefits Accurate simulations including near-wall boundary condition effects No specialized/expertise setup necessary Reduces trial and error near-wall setup of traditional CFD approach a) b) Page 9 c) d)

10 FloEFD Enabling Technology Automated Solution Convergence Built-in Automatic Convergence Control : Very robust convergence behavior First run converges without additional numerical diffusion Benefits Reduces multiple re-runs due to lack of convergence Short run times enables multiple variant scenarios Eliminates CFD specialist tweaks for convergence, i.e. model modifications Page 10

11 FloEFD Enabling Technology Multi-variant What if? Analysis Design Variant Analysis: What-if analysis without further definition of model data Project cloning feature Full support of product MCAD configurations and instances Modify design, run auto-mesh, execute! Benefits Multiple what-if simulations result in optimum design Saves CFD specialist s resources for only most critical analyses Page 11

12 Democratizing CFD Wider Adoption of CFD 80/20 rule: Handle 80% of CFD FloEFD is a productivity tool! Typical target user: Mechanical Designer / Design Engineer (CAD Users) BSc in Engineering subject Domain expertise expected, but no training in CFD Many routine applications of CFD (pipes, manifolds, valves, pumps). Typical user deals with a limited application range. Frees up in-house CFD experts for high-end applications Typical Software Requirements: Ease of use Accuracy MCAD Variant analyses Optimisation Page 12

13 FloEFD vs. Traditional CFD FloEFD Traditional CFD Required numerical knowledge none high User manual meshing time none high Overall meshing time (CPU + user) low high Model preparation time low high Programming skill requirements none medium Suitability for fast design cycles high low Ease-of-use high low Overall input time for user low high Overall physics capability medium high Typical user educational degree B.A., M.A. M.A., PhD Typical user profile 90% Mechanical Engineers, 10% CFD experts 10% Mechanical Engineers, 90% CFD experts Page 13

14 Manufacture Manufacture FloEFD vs. Traditional CFD Traditional CFD Concept Detailing Prototyping Testing CAD CAD CAD CAD Traditional CFD Traditional CFD Traditional CFD FloEFD Concept Detailing Prototyping Testing CAD CFD CFD CFD Page 14

15 What can FloEFD Do? Page 15

16 FloEFD Application Types Pressure Drop Device flow coefficient determination (cv/kv/qn) Extrusion process optimization Jet pump dimensioning Filter efficiency Pump efficiency Fan curve determination HVAC ducting sizing/placement Aircraft ECS design Page 16

17 FloEFD Application Types Heat Transfer Electronics Cooling Heat exchanger efficiency Injection molding device cooling Sterilization in food processing Rubber extrusion Windshield de-icing Solar towers Lighting Solar heating Engine cooling jackets Brake design Oil cooler design And many more. Page 17

18 FloEFD Application Types Mixing Processes Air conditioning duct design Spray nozzles Rubber co-extrusion Intake manifolds (EGR tracking) HVAC contaminant tracking, emissions, fumes Furnaces and combustion Page 18

19 FloEFD Application Types Flow Fields Aerodynamic testing Cavitation prediction Noise level optimization Intake and exhaust manifold design Automotive engine in-cylinder flows Page 19

20 FloEFD Application Types Force Prediction Aerodynamic coefficients Operational forces for valves Wind loads on buildings, bridges, etc. Flow-induced loads for stress analysis Temperature distribution for thermal stress analysis Torque prediction Page 20

21 FloEFD Meshing Technology Well defined and robust algorithm FloEFD supports: Flow Only (Fluid Cells) Conduction Only (Solid Cells) Fluid Flow and Heat Transfer (Fluid, Solid, SmartCells) Refining Fluid and Solid cells allows for higher resolution The real FloEFD technology is within SmartCells Page 21

22 SmartCells SmartCells are always present at the fluid-solid interface Modified wall function captures boundary layer without need for high cell count at wall Proprietary technology based on physical test and empirical results Developed originally at Moscow state university during 1980s Page 22

23 Solution Adaptive Meshing Solution adaptive mesh will refine mesh in localised volumes based on flow gradients Automatic meshing requires little user input Solver does not start again, interpolates, continues Benefits: Non-expert users can generate very high quality grid Only refined in critical areas Higher accuracy with minimal increase in solve time Page 23

24 Standard FloEFD Electroni cs Module HVAC Module Advance d Module LED Module FloEDA Modeule FloEFD Functionality Feature External (<M5) & internal flows / Steady-state and transient analysis Compressible gas, liquid & incompressible fluid Free, forced, and mixed convection Boundary layers, including wall roughness effects / Laminar & turbulent flows Heat transfer in fluid, solid & porous media Isotropic, unidirectional, biaxial/axisymmetrical and orthotropic thermal conductivities Non-Newtonian liquids / Real gases / Two-phase flow (fluid & particles) / Relative humidity Moving/rotating surfaces and/or parts Cavitation in incompressible water flows / Steam Modelling with Condensation 2 Resistor Components / Heat Pipes / Electrical Conditions / PCB Smartpart * Extended Engineering Database Thermal Radiation Model (Absorption in semi transparent solids) DT DT/DO DT/DO/ MC HVAC Comfort Parameters Pre-mixed / non-premixed steady state gaseous combustion High Mach Number Flow (M5-M30) Advanced LED modelling (2-resistor and T3ster derived compact model) ODB++ detailed PCB import (Explicit traces) / DELPHI multi-resistor network IC model Page 24 * PCB smartpart only DT = Discreet Transfer DO = Direct Ordinates MC = Monte Carlo

25 Return on Investment: Reliability (1/3) Reasons for products being late to market: Only Mentor s tools reduce these pains: - Verify Design Changes in Less Time - Design Out Reliability Issues; and so - Spend Less Time in Physical Prototyping Page 25

26 Return on Investment: Time (2/3) Impact on Thermal Verification: Mentor customers take ⅓ of time taken by everyone else Good thermal design avoids surprises during prototyping % Design Time spent in Thermal Verification Longer time spent getting design closure Causes product to be late to market Page 26

27 Return on Investment: Cost (3/3) Cost to fix Problems $ Product Development Stage (*) At Design Stage $35 Before Procurement $177 Before Production $368 Before Shipment $17,000 On Customer Site $690,000 (*Source: Hiroshi Hamada, President of Ricoh, European Community Quarterly Review, 2002) Cost of Fixing a Defect x1,000 x10,000 x1 x10 x100 Page 27 Pre-Development Design Prototyping Tryout Time for Recognizing Mistakes Production Equipment

28 FloEFD Offers Solid ROI Through Productivity Gains Renault France (X2) Graco Spray Guns (X3) At Renault we have reduced our headlamp costs by 50% between 2014 and 2016 and we are aiming for a further 50% reduction in costs for our Generation 3 LED headlamps by The big advantage with FloEFD we found is that one thermal engineer can be over twice as productive. Paul-Henri Matha, Lighting Expert The complete design process of all sizes took only about 3-4 months or about one-third as long as would have been required using the trial and error method. Rick Anderson, Senior Project Engineer Page 28

29 FloEFD Offers Solid ROI Through Productivity Gains Crane Corp. [Azonix] (X12) Bromley Technologies (X40) FloEFD enables design engineers without a fluid analysis background to perform thermal simulation. The result is that we got the design right the first time, only had to make one prototype, and avoided expensive design changes that typically occur in the late stages of the development process James Young, Design Engineer, Azonix Corporation FloEFD has helped us to reduce our Bob Skeleton aerodynamic design times from 8 weeks to 8 hours. Dr. Tristan Bromley, CEO & Elite Athlete Page 29

30 Summary Moving Computational Fluid Dynamics simulations as early as possible in the design cycle has the biggest ROI: Frontloading FloEFD is an award-winning, well validated, tried-and-proven solution to frontloading of CFD with a 25 year commercial pedigree and a large installed base. FloEFD has demonstrated engineer productivity gains of X2 to X40 versus time-consuming traditional CFD approaches, FloEFD is now available for both Siemens NX and Solid Edge with MCADembedded versions following the recent acquisition of Mentor Graphics. Page 30

31 Pol. Ind. SIGMA Xixilion 2 - Planta 2ª - Oficina 1ª ELGOIBAR (Gipuzkoa) tel.: comercial@pixelsistemas.com