STAR GLOBAL 2015 THE VALUE OF 3D SCANNING TECHNOLOGIES AS A COMPLEMENTARY TOOL TO STAR-CCM+ FOR VARIOUS CFD APPLICATIONS

Transcription

1 STAR GLOBAL 2015 THE VALUE OF 3D SCANNING TECHNOLOGIES AS A COMPLEMENTARY TOOL TO STAR-CCM+ FOR VARIOUS CFD APPLICATIONS Pier-Olivier Duval Philippe B. Vincent

2 AGENDA Our Organization 3D Scanning The Basics Portable Scanners Applications Scan to CFD Real Life Examples The Incubator The Racing Car The Street Luge Conclusion and Live Demo

3 OUR ORGANIZATION

4 OUR ORGANIZATION Creaform was founded in 2002 and acquired by Ametek in 2013 Head office in Lévis, Québec, Canada Engineering Services We develop, manufacture and distribute innovative portable 3D measurement technologies, and we are a leading provider of 3D engineering services Technologies 150 distributors worldwide Metrology Services We employ more than 385 people Creaform helps companies to seamlessly create, simulate, verify, and collaborate in 3D

5 MORE THAN 2000 CUSTOMERS... Aerospace Energy Mass Transportation Consumer Products

6 CREAFORM ENGINEERING SERVICES Services Modeling Solid Product, tooling Surfaces Class A, reverse engineering Software Simulation Analysis Linear, non-linear, implicit, explicit, modal, buckling & composite Dynamic response Random, sine vibration, transient Fluid dynamics (CFD) Steady or transient, heat transfer, multiphase, discrete element STAR-CCM+ Electric Schemes & programing Languages C & VHDL 3D images & graphics Design Concepts, photorealistic 3D images & animations Graphics User interfaces, labels, branding, logos, presentations

7 3D SCANNING

8 3D SCANNING - THE BASICS

9 3D SCANNING - THE BASICS

10 3D SCANNING - THE BASICS

11 3D SCANNING - THE BASICS

12 3D SCANNING - THE BASICS

13 3D SCANNING PORTABLE SCANNERS Fit in a small suitcase No rigid set-up Real time visualization Up and running in less than 5 minutes No particular experience from the user Direct mesh output in StarCCM+ compatible STL format

14 3D SCANNING PORTABLE SCANNERS CREAFORM 3D SCANNERS - ACCURACY. PORTABILITY. SIMPLICITY. The easiest 3D scanning experience, generating fast and reliable measurements. The truly portable metrology-grade 3D scanners delivering highly accurate measurements. The most accurate scanning and probing solutions, whether in lab or on the shop floor.

15 3D SCANNING APPLICATIONS 1. CONCEPT Competitive product analysis Measurement of product environment or connecting/surrounding parts Measurement of existing parts for aftermarket or custom equipment Clay model measurement/re Models and mock-ups measurement/re Styling and aesthetics Integration of prototype modifications into CAD file Form study, proof-ofconcept prototypes Ergonomy prototypes

16 3D SCANNING APPLICATIONS 2. DESIGN 3D scan-to-cad Reverse engineering (extracting design-intent) Packaging design Manufacturing Integration of prototype modifications into CAD file Prototype inspection Computational Fluid Dynamics (CFD) Finite element analysis (FEA) Interference analysis Deformation, geometry analysis Rapid prototyping/

17 3D SCANNING APPLICATIONS 3. MANUFACTURING Reverse engineering of dies, molds, fixtures, jigs and patterns Update of CAD file to reflect as-built tooling measurements Tooling validation/ Inspection Virtual assembly Tool/Robot path programming Part assessment before machining First article inspection Part-to-CAD inspection Supplier quality inspection

18 3D SCANNING APPLICATIONS 4. SERVICING As-built documentation of parts/tooling Marketing presentations, 3D training systems, serious gaming Digital archiving Wear and tear analysis Custom repairs/modification As-built documentation of parts/tooling before maintenance Reverse engineering for developing replacement/ Restoration parts Planning of complex assemblies disassembly/ Dismantling

19 SCAN TO CFD

20 SCAN TO CFD WHAT S THE MOTIVATION? Securing the first and fundamental step in a CFD analysis : obtaining the right numerical geometry Overcome imprecise or out-ofdate CAD data Confidence in the geometry is key to have confidence in the CFD analysis IN WHAT CASE? Drawings of HVAC system or old power plant are not available to build the CAD Modifications have been made on a vehicle, a plane or a boat Individual CAD are available, but assembly details and spacing between components are not Pump or turbine blades have been eroded by cavitation Etc

21 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT Quickest process Minimal work on scanning software (align, close holes, create planes) STL is oriented and watertight StarCCM+ directly loads the STL

22 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT STEP-BY-STEP with the hockey helmet clay model VX interface after a 5 minutes session scan The raw scan provides a decent tessellation But it could be better if : The holes and defects were repaired Unnecessary triangles were eliminated to make the model lighter The model was oriented with proper axis and mirrored if required for asymmetric simulations This is all managed directly in VX

23 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT STEP-BY-STEP with the hockey helmet clay model In VX, the helmet model is transformed into a watertight and aligned shell in about 15 minutes STL is directly loaded in StarCCM+

24 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT STEP-BY-STEP with the hockey helmet clay model In surface repair: No free edges No non manifold edges No non manifold vertices Only a few «Face quality» issues

25 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT STEP-BY-STEP with the hockey helmet clay model Auto repair Surface Errors (A) results in an error free model with highlighted repaired faces

26 SCAN TO CFD THE PROCESS OPTION 1. DIRECT SCAN IN STL FORMAT STEP-BY-STEP with the hockey helmet clay model External aerodynamics case in StarCCM+ Dummy added to the geometry Trimmer with wake refinement and prisms layer Surface pressure for vents positioning on helmet

27 SCAN TO CFD THE PROCESS OPTION 2. PERFORM REVERSE ENGINEERING CAD modeller between Scan and StarCCM+ Complete CAD available (IGES/STEP/ )

28 PCB Scan SCAN TO CFD THE PROCESS OPTION 2. PERFORM REVERSE ENGINEERING Reconstructed CAD Using Catia STL of raw scan

29 SCAN TO CFD THE PROCESS OPTION 2. PERFORM REVERSE ENGINEERING

30 REAL LIFE EXAMPLES

31 REAL LIFE EXAMPLES - THE INCUBATOR 1. The Long range provides a rough point cloud 3. Stitching of point cloud and STL within reverse engineering process using Catia 2. Creaform s MetraSCAN gives the detailed geometry of fans and other components in STL format

32 REAL LIFE EXAMPLES - THE INCUBATOR 5. Fan interface model and residence time model are set up 4. Geometry is wrapped and meshed in StarCCM+ 6. Designs are compared to achieve the best flow

33 REAL LIFE EXAMPLES - THE RACING CAR - ACT TOUR Washable powder to remove light reflection Few targets on and off car for positioning reference Numerical model obtained after 8 hours of 3D scanning

34 REAL LIFE EXAMPLES - THE RACING CAR - ACT TOUR Unequal fresh air quantity to cool brakes Important separated flow when turning

35 REAL LIFE EXAMPLES - THE STREET LUGE Our luge team, the 3 Bobs, broke the world speed record in 2008, and we came very close to the 100 mph mark at that time. Since then, we have tweaked our gear, but we had a hard time figuring out how to improve the aerodynamics of our luges to gain even more speed. [Louis Etienne Bouchard]

36 REAL LIFE EXAMPLES - THE STREET LUGE 3D Scan Reverse Engineering CFD mesh with prisms layer

37 REAL LIFE EXAMPLES - THE STREET LUGE Pressure distribution, streamlines and lambda 2 criterion isosurfaces IMPROVEMENTS? On gears shoe covers, eliminate ripples on knee pads On luge gaps closing around wheels On positioning helmet tilt, arm and legs position relative to luge

38 CONCLUSION AND LIVE DEMO

39 CONCLUSION AND LIVE DEMO Scan to CFD StarCCM+ is Creaform s choice for CFD software as it accepts STL files (among other advantages!) Scanning is accessible, easy and fast! Creaform performs the whole scan-to- CFD process within an integrated team of engineers

40 CONTACTS PIER-OLIVIER DUVAL FEA/CFD Team Leader Creaform Engineering Services 5825 St-Georges Lévis, Québec G6V 4L2 Canada Phone: (418) WEB: PHILIPPE B. VINCENT CFD Engineer Creaform Engineering Services 5825 St-Georges Lévis, Québec G6V 4L2 Canada Phone: (418) WEB: