Flow Optimization of CC Manifold: Coupling HyperWorks and Cradle Solutions

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1 Flow Optimization of CC Manifold: Coupling HyperWorks and Cradle Solutions Eric Hansenne CAE Manager Michal Wanski, Marc Ratzel Mitsushi Okada Support Engineer

2 COMPANY PROFILE AUTOMOTIVE SUPPLIER PRIVATELY OWNED & SELF FINANCED R&D CENTER IN BELGIUM TURNOVER ~800M ANNUAL INVESTMENTS ~43M HEADCOUNT ~6000 WORLDWIDE FACTORIES ~43

3 CAE CAPABILITIES SOFTWARE ABAQUS (SIMULIA) STANDARD & EXPLICIT GLYPHWORKS (NCODE) HYPERWORKS (ALTAIR) HYPERMESH HYPERSTUDY HYPERFORM DESGIN LIFE (PARTNER P.) SC TETRA (PARTNER P.) CAE COMPETENCES Safety Feasibility Acoustics Exhaust system Durability Flow & thermal NVH

4 Introduction MANIFOLD DEVELOPMENT CHALLENGES COMPACT DESIGN THERMAL MANAGEMENT REDUCED TIME TO MARKET EMISSIONS REDUCTION COST EFFECTIVE SEVERE ENVIRONMENT (HIGH T, CORROSION,...)

5 Typical Development Process PACKAGING THERMAL EMISSIONS DURABILITY MANUFACTURING EXTERNALS DESIGN BRACKET POSITION SENSORS POSITION HEATSHIELDS / INSULATION 1ST MATERIAL SELECTION INTERNALS DESIGN ASSEMBLY PROCESS MATERIALS SELECTION LOCAL DESIGN CHANGES MATERIALS SELECTION LOCAL DESIGN CHANGES CAE TECHNIQUE USED AT THAT STAGE

6 Objectives Optimized flow Uniformity > 90% Backpres. < 100mbar Scope of this project Outer skint < 350 C No mode in[0, 250]HZ Durable Thermo-mechanical Road events Out of scope for this project

7 CFD Meshing (HyperMesh) Clean up Close gaps Supress features Close holes Extract wetted surface Meshing 1st layer thickness estimation (important for turbulence model) tetra + BL generation ( cells)

8 CFD Model inflow SUBSTRATE BRICK REFERENCE SECTION (UNIFORMITY) outflow

9 Set up General process: Five different set ups to eveluate a design Case Runner 1 Runner 2 Runner 3 Runner 4 1 wall wall wall inflow 2 wall wall inflow wall 3 wall inflow wall wall 4 inflow wall wall wall 5 inflow inflow inflow Inflow For this study wall 1 wall 2 wall 3 inflow 4

10 CFD Setup INPUT MASS FLOW RATE (g/s) 80 OUTLET PRESSURE (mbar) 250 GAS 950 C K-ε TURBULENCE MODEL SUBSTRATE CHARACTERISITCS: α= 3.19 β= 2330 (FORCE VOLUME MODEL) PRIMARY OUTPUT BACKPRESSURE FLOW UNIFORMITY SECONDARY OUTPUT VELOCITY MAX HIGH SPEED AREA LOW SPEED AREA CPU TIME ~ 30min RUN (WinXP, 32bit)

11 Uniformity Index (UI) UI measures how uniform the flow is through a given section γ n i = 1 = 1 ( w i w 2 n w )² A A i λ = uniformity index A i = local cell area A = total brick area w i = local velocity n = number of cells n w = mean velocity = i =1 w i n A A i UI=0% Whole flow going through a single channel UI=100% Flow equally spread over all channels Individual channel velocity vector

12 Morphing (basics) Constant BL thickness

13 Morphing 1 st set of shapes S4 S1 S5

14 Effects of shape 1,4,5 Streamlines initial S4 S5 S1

15 Effects of shape 1,4,5 Velocity in cross section initial S4 S5 S1 Zero or negative effect on uniformity

16 Morphing 2 nd set of shapes Runner 4 S6 S3

17 Morph Constraints Runners design unchanged Islands frozen (contact areas) Outlet face remains flat (substrate)

18 Process Description DRAFT CONCEPT CFD MODEL HYPERMESH CFD MESHING CFD SOLVER SC TETRA HYPERSTUDY PERFORMANCES MODEL UPDATE HYPERMESH - MORPHING NOK O K SCT Post

19 Optimization s3 s6 Pressure Drop Uniformity Index % 1, % 86% 85% scaling factor on shape 1 0,5 0 pressure drop (m mbar) % 83% 82% 81% uniformity inde ex 7% -0, % 79% 78% % iteration # iteration #

20 Initial design Optimized design

21 Initial design Optimized design Max velocity mag.[m/s] = 16.5 Min velocity mag.[m/s] = 4.2 Uniformity Index = 0.80 High Speed Area = 0.14 Pressure Drop [mbar] = 35.6 Max velocity mag.[m/s] = 12.6 Min velocity mag.[m/s] = 2.9 Uniformity Index = 0.87 High Speed Area = 0.2 Pressure Drop [mbar] = 38.7 Velocity in cross section

22 Next Steps Integrate ALL individual runners Morph runners (remove constraints) Include all runners design space Case Runner 1 Runner 2 Runner 3 Runner 4 1 wall wall wall inflow 2 wall wall inflow wall 3 wall inflow wall wall 4 inflow wall wall wall 5 inflow inflow inflow Inflow

23 Conclusions Integrated early stage optimization Coupling HyperStudy, SC/Tetra, Morphing Increase of uniformity by 7% 1 day meshing/morphing + 1 day HyperStudy = 2days No extra budget needed Altair Partner Program, CFD solver on demand Clear added value in development Multiphysics procedure achievable Include manufacturing, fatigue,. in optimization