Flow design development of a dual stream Diesel Oxidation Catalyst (DOC) using topology optimization

Transcription

1 the optimization company Flow design development of a dual stream Diesel Oxidation Catalyst (DOC) using topology optimization Markus Stephan, Björn Butz (FE-DESIGN GmbH, Karlsruhe, Germany) Volker Schaika (Albonair GmbH, Dortmund, Germany)

2 Overview 1. Introduction: Topology Optimization for Fluid Flow 2. Application Case: Diesel Oxidation Catalyst Introduction Flow Analysis Actual Design Topology Optimization Flow Analysis Optimized Design Final Design 3. Summary Slide 2 4/10/2013

3 FE-DESIGN Business activities SOFTWARE-DEVELOPMENT TOSCA Structure and TOSCA Fluid Customization and specific solutions on customer demand ENGINEERING SERVICES Excellent expertise and service in the CAE field for different industries Projects led with personal commitment and high reliability TRAINING, SUPPORT AND CONSULTING Slide 3 4/10/2013 Worldwide consulting and support by FE-DESIGN and its resellers Support of the selection process of CAE tools to efficiently meet company needs Basic and advanced seminars on TOSCA Structure and TOSCA Fluid Onsite trainings

4 Distribution partners of FE-DESIGN USA/Canada SimuTech Group Americas FE-DESIGN Optimization Inc. Belgium, Netherlands, Luxemburg 4RealSim UK Wilde Analysis Germany/Austria/Switzerland FE-DESIGN & Partner Turkey CAE Solutions, FIGES Scandinavia FE-DESIGN Czech/Slovakia T.S.E. India Enphiniti Russia OOO MES Japan CD-adapco, VINAS Korea SAMWON, CAE-CUBE, CD-adapco China Kingswell, FEAonline, FLYOND, PERA, Sili-Tech, Soyotec Taiwan Simutech South-East Asia Dazztech Brazil VirtualCAE Slide 4 4/10/2013

5 Topology optimization for CFD Example: HVAC duct Implementation Existing design CAD redesign and verification Design space Optimization result Optimization process Slide 5 4/10/2013

6 Topology optimization with TOSCA Fluid: Step by step Outflow 1 Outflow 2 Define the design space (e.g. CAD) Meshing as usual Define boundary conditions Run the optimization Inflow Design space Slide 6 4/10/2013

7 Topology optimization with TOSCA Fluid: Step by step Outflow 1 Free flow Outflow 2 Transition area (defining new channel shape) Prevented flow Inflow Design space Optimized channel shape Slide 7 4/10/2013

8 Introduction (1) CO + ½ O2 CO2 {CnHm} + {O2} CO2 + H2O CO + ½ O 2 CO 2 {C n H m } + {O 2 } CO 2 + H 2 O Source: Tognum: MTU & MTU Onsite Energy Source: Wikipedia Slide 8 4/10/2013

9 New design concept IN Flow Split Monolith 2 OUT Monolith 1 Slide 11 4/10/2013

10 Flow analysis results (actual design) Contours of total pressure Pathlines (coloured by velocity magnitude) Slide 13 4/10/2013

11 Total pressure, Pa FE-DESIGN Total pressure loss (actual design) A A B Flow path length B Overall total pressure drop 7920 pa Ex. monolith total pressure drop: 3150 pa Slide 14 4/10/2013

12 Flow uniformity and split ratio (actual design) IN A 2 OUT B 1 Flow A: 47,5 % Flow B: 52,5 % g = 0,925 g = 0,996 Slide 15 4/10/2013

13 Topology optimization : Objectives and constraints Objective Find a modified design proposal with low total pressure drop Constraints The new design may not exceed the existing design (maximum available design space) Inlet and outlet connecting ducts as well as the monolithic blocks have to be kept unchanged ( frozen zones ) Keep or enhance flow uniformity and flow split ratio Slide 16 4/10/2013

14 Topology optimization setup (1) Slide 17 4/10/2013

15 Topology optimization setup (2) 2 v v 1 v p v v 4 p v 3 p Slide 18 4/10/2013

16 Topology optimization run 4 individual optimization runs with TOSCA Fluid Ver 2.1 Convergence achieved after approx Iterations Wall clock run time approx. 12 h / 1 CPU (serial) / run TOSCA Fluid optimization progress Sedimentation pseudo Pressure drop Slide 19 4/10/2013

17 Derived designs Slide 22 4/10/2013

18 Comparison of designs Actual design Optimized design A Monolith 2 A Monolith 2 B Monolith 1 B Monolith 1 Slide 23 4/10/2013

19 Flow analysis results (comparison of designs) Actual design Optimized design Slide 26 4/10/2013

20 Total pressure, Pa FE-DESIGN Design comparison (total pressure loss) A Optimized design Actual design B Flow path length Total pressure drop reduction approx Pa - 60% Slide 27 4/10/2013

21 Flow uniformity and split ratio (optimized design) IN A 2 OUT B 1 (47,5 %) (52,5 %) Flow A: 49,2 % Flow B: 50,8 % g = 0,939 g = 0,982 Slide 28 4/10/2013 (g = 0,925) (g = 0,996)

22 Final design Redesign by consideration of manufacturing constraints Slide 29 4/10/2013

23 Summary: Flow performance Actual design Optimized design Total pressure drop, pa 7920 pa 6000 pa ( %) Total pressure drop (ex. Monolithes), pa 3150 pa 1238 pa ( %) Total pressure drop monolith A, pa 4140 pa 4650 pa Total pressure drop monolith B, pa 5330 pa 4870 pa Flow ratio A, % 47.5 % 49.2 % Flow ratio B, % 52.5 % 50.8 % Uniformity A Uniformity B Slide 31 4/10/2013

24 Summary CFD analysis and optimization of a new, two-way DOC concept Topology optimization helped to find a significant improved design variant using a first, rough design as the available design space The raw optimization results need to be reconstructed The achieved total pressure drop reduction compared to the actual design is 60% (relative to the optimizable sections) resp. 25% (over all) Flow split ratio and the individual flow uniformities at the monolithic inlet section have been improved resp. homogenized Based on the results of the topology optimization, a totally new, innovative, manufacturable and highly efficient design proposal could be found Total process time was approx. 1 to 2 weeks Slide 32 4/10/2013