System Level Cooling, Fatigue, and Durability. Co-Simulation. Stuart A. Walker, Ph.D.

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1 System Level Cooling, Fatigue, and Durability Analysis via Multiphysics Co-Simulation Stuart A. Walker, Ph.D.

2 Outline Motivation Presentation of process Presentation of tools Presentation of the results 2

3 Importance of External Automotive Visibility Dirt (soiling) Splash/spray Wiper lift off Aero acoustics (CAA) Aerodynamics via CFD Comfort Ventilation Heating Air conditioning Wind noise downforce Cooling Engine Transmission Brakes Condenser Stability Directional Cross wind sensitivity Performance Fuel economy Emission Max. speed Acceleration Spoiler oscillation, FSI dragforce 3

4 Importance of System Level Modeling Many important component level responses Temperature Stress Displacement Component responses are coupled via external aerodynamics, structural physics, and control systems Rotor example Rotor/Brake Pad Friction (hot side boundary conditions) External Aerodynamics (cold side boundary conditions) Heat Transfer Simulation to calculate rotor temperatures AcuSolve Coupled Model Thermo-structural Model (durability and fatigue) 4

5 Outline Motivation Presentation of process Presentation of tools Presentation of the results 5

6 Engine Block Cooling Example Desired result: Temperature in engine block Stress in engine block Displacement in engine block Important CFD physics Underhood flow for HTC on engine block Water jacket flow for engine block cooling Modeling approach Compute HTC from external aero calc Compute temperature in solid from internal water jacket model Compute stress/displacement in solid 6

7 General Approach Thermo-structural Model Combustion Simulation (hot side boundary conditions) Subcase 1: Bolt Pretension in Head Bolts Heat Transfer Simulation to calculate Engine Temperature loading Subcase 2: Lock Pre-tension Displacements Apply Temperature Loading External Aerodynamic Simulation (cold side boundary conditions) AcuSolve Coupled Model Subcase 3: Lock Pre-tension Displacements Continue Temperature Loading Apply Combustion Pressure Loading 7

8 External Aero Modeling External aerodynamics drive component level cooling Engine block cooled by underhood flow Radiator cooled by underhood flow Brake rotors cooled by flow through the wheel well Underbody Thermal Management Fluid flow Energy Transport Porous media Analysis Fluid and solid Velocity and pressure Temperature Drag/lift 8

9 Component Level Modeling Component designs Exhaust systems Radiator Blower/Fans Water jacket HX Detailed analysis Fluid and solid Velocity and Pressure Temperature 9

10 System Level Modeling Thermal management External aerodynamics Component level modeling Coupling for stress analysis AcuSolve Radioss Friction / Motor Dissipation / Combustion (hot side boundary conditions) External Aero/HX Simulation (cold side boundary conditions) Heat Transfer Simulation to calculate Engine Loading AcuSolve Coupled Model Thermo-structural Model (durability and fatigue) 10

11 Thermo-Structural Model 11

12 Outline Motivation Presentation of process Presentation of tools Presentation of the results 12

13 Modeling and Visualization Tools One team One solution Altair Engineering, Inc. HyperWorks Suite provides an integrated environment for pre/solve/post for system level vehicle coupling of FEA, CFD, MBD, and NVH physics 13

14 AcuConsole Pre-Processing Dedicated pre-processor for AcuSolve Fast and robust CFD meshing (e.g. 90Mio tetras external automotive 80min) HyperMesh Solver neutral CFD grid generator Powerful geometry cleanup/generation tools One pre-processor for structural and CFD analysis HyperMesh AcuConsole 14

15 Radioss CFD/FSI Solver Explicit multi-physics solver Coupled solver (structure + fluid) Suited for compressible flow AcuSolve Implicit multi-purpose CFD solver Finite element based Strong FSI capabilities (P-FSI, DC-FSI) AcuSolve Courtesy of HTT Radioss 15

16 AcuSolve General General purpose, 3-dimensional, unstructured CFD solver Based on Finite Element method (Galerkin Least Square, GLS) Originated at Stanford University by Prof. T.J.R. Hughes et. al. and further improved for industrial applications Incompressible, weakly compressible Navier Stokes solver Numerics 2 nd order accuracy (space and time) for all flow variables Scalable (e.g. customer runs on 1024 CPUs, 350Mio cells) Various turbulence models available (RANS, LES, DES) Transient / steady state Solving the fully coupled system Sliding mesh (rotating machinery) Moving/deforming mesh, ALE (Fluid-Structure) 16

17 AcuFieldView Post-processing Dedicated CFD post-processor (OEM version of FieldView, Intelligent Light) Supports only AcuSolve results Client-server architecture, 8 way parallel HyperView Solver neutral CFD post-processor Showing structural and CFD results in one framework pressure Top. Optim. streamlines eigenmodes HyperView AcuFieldView 17

18 CFD Optimization with HyperWorks Initial design Morphing Optimization Optimized design C w = 1 C w = 0.04 UI = 0.83 UI =

19 Component Level Optimization Success Story (CFD optimization) Case: Exhaust system, catalytic converter Objective: uniform flow, min. pressure drop Result: uniformity +12%, pressure drop -16% Case: Engine compressor, impeller blade Objective: maximize pressure ratio Result: pressure ratio +5.6%, Case: Evaporator, HVAC system Objective: uniform flow, min. pressure drop Result: uniformity +5.6%, pressure drop -7% 19

20 Outline Motivation Presentation of process Presentation of tools Presentation of the results 20

21 External Aero Solution Closed shell mesh generated in HyperMesh Shell mesh boolean CFD wrapping Starting point for The Virtual Wind Tunnel Ease of use AcuSolve behind the scenes 21

22 External Aero Solution 22

23 External Aero Results 23

24 Engine Block Loading 24

25 Static FEA Analysis in OptiStruct Thermo-structural Model Subcase 1: Bolt Pretension in Head Bolts Subcase 2: Lock Pre-tension Displacements Apply Temperature Loading Subcase 3: Lock Pre-tension Displacements Continue Temperature Loading Apply Combustion Pressure Loading 25

26 Temperature Results Cylinder Head 26

27 Displacement Results 27

28 Stress Results 28

29 Contact Pressure and Bore Deformation 29

30 Conclusion Altair HyperWorks Suite provides a complete vehicle simulation package Pre-processing HyperMesh/AcuConsole Virtual Wind Tunnel Solver AcuSolve CFD OptiStruct/Radioss FEA Post-Processing HyperView/AcuFieldView CFD/FEA Optimization HyperMorph/HyperStudy Stuart Walker, Ph.D. CFD Specialist swalker@altair.com altair.com Altair Innovation Intelligence 30

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