2008 International ANSYS Conference

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1 2008 International ANSYS Conference Simulation Driven Product Development using ANSYS Technology Padmesh Mandloi Rahul Kumar Samir Kadam 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2 Outline Industry CAE Trend and Vision ANSYS Custom Vertical Solution Examples Parametric Mesh Generation Port Flow Bench Pump Simulator Summary 2008 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

3 Industry CAE Vision and Direction CAE wide acceptance in the industry How CAE improves product development, reduces cost and time to market are well known in the industry The Next Step in industry CAE implementation Spearheaded by the leading industry leaders, the focus is now: How do we do our current simulation faster, better, and cheaper The recognized bottleneck is the significant time and manual resources needed Pre-processing and solution interpretation, preventing in many cases, the pursuit of effective design optimization Highlights the need to build application driven, customer specific vertical tools that allow automation of the underlying CAE process What can be automated Almost anything, from preprocessing, solution, and post-processing Automation made possible effective usage of optimization tool Ability to capture design knowledge, data and process through Simulation Process & Data Management tools 2008 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

4 ANSYS Custom Tool Offering User Defined Functions ANSYS APDL CFX CCL GAMBIT DGUI Scheme WorkBench Extending Existing Capability Building New Application on top of Existing Tool WorkBench Most advanced offering from ANSYS Allows process-automation in batch-mode Allows optimization with process-automation Customizable GUI Customized multi-physics simulation through single interface 2008 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

5 Examples Parametric Mesh Generation, Port Flow Bench, and Pump Simulator Automatic geometry and mesh creation based on userdefined parameters Showcase integration of different meshing technologies to automatically create high-quality mesh One-stop customized tool for a class of applications In-built application specific intelligence 2008 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

7 Challenges in Cabin Flow Simulation Difficult to keep pace with the continually changing design parameters and customer specifications Design may change by the time analysis is completed Automate and Customize the process that drastically reduce turnaround time Various parameters affecting cabin airflow distribution Location of inlets/outlets and gaspers Seat locations and pitch Passenger occupancy Large meshing time for a single set of parameters Large cell count for each case Need to optimize cell clustering to resolve flow features with minimum possible cell count 2008 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

8 Process Streamlining Import CAD with parameters Solid model of fluid region AUTOMATIC Set mesh sizes Adjust parameters Generate mesh (Workbench Mesher/TGrid) 2008 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

Mesh set up Global set up allows automated

on faces also possible for finer mesh near

console Sizing on passengers / seats 2008

11 Mesh set up Global set up allows automated mesh set up for CFD Individual Mesh control on faces also possible for finer mesh near critical regions Size information is kept after a parametric change Default CAD surfaces Sizing on windows Sizing on console Sizing on passengers / seats 2008 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

Sizing Functions to ensure smooth growth 2008

12 Meshing Optimization Refined Mesh Near the Gasper Outlets Coarser mesh in other areas Using Mesh Sizing Functions to ensure smooth growth 2008 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

13 Summary Rapid Meshing using parameterization and automation leads to significant reduction in manual efforts The same process can be extended to include the thermalflow simulation By specifying flow rates & temperatures into and out of the cabin Stress analysis and/or fatigue analysis of the structure or its components can be performed Using Pressure-Vessel Module in ANSYS Multi-disciplinary Design and Optimization (MDO) can be achieved Using Design Explorer 2008 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

PortFlowBench Design Process for Intake/Exhaust ports Flow Bench testing Time-consuming Expensive Virtual prototyping using PortFlowBench Challenges in using CAE for Port Flow Analysis Extremely

15 PortFlowBench Design Process for Intake/Exhaust ports Flow Bench testing Time-consuming Expensive Virtual prototyping using PortFlowBench Challenges in using CAE for Port Flow Analysis Extremely repetitive process from geometry to postprocessing for different valve lifts High level of manual intervention Leads to inconsistency Time consuming High quality mesh to accurately predict the swirl, tumble and flow-coefficient PortFlowBench Virtual prototyping tool based on FloWizard Completely automated CAD import Postprocessing High quality multi-block mesh with prism layers & local refinement Built-in procedures to guide the solution to convergence to do application specific postprocessing 2008 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

PortFlowBench: Process & Mesh Import CAD,

Boundary layered cells from valve and port

Review the mesh Create meshes/cases for all

local refinement near valves Run solution

quality Hex mesh in combustion chamber 2008

16 PortFlowBench: Process & Mesh Import CAD, specify lift values and boundary conditions Boundary layered cells from valve and port surfaces Create mesh for the first lift Review the mesh Create meshes/cases for all lifts Good quality tetrahedral mesh with local refinement near valves Run solution for all the cases Post process solution for first lift case Post process remaining lifts + Create HTML report Manual Auto Good quality Hex mesh in combustion chamber 2008 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

PortFlowBench: Results 5 4 Volumetric Flow Rate 3 2 1

Test Pressure # 3 (Predicted) 0 0 1 2 3 4 5 Valve

18 PortFlowBench: Results 5 4 Volumetric Flow Rate Test Pressure # 1 (Measured) Test Pressure # 1 (Predicted) Test Pressure # 2 (Measured) Test Pressure # 2 (Predicted) Test Pressure # 3 (Measured) Test Pressure # 3 (Predicted) Valve Lift 2008 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

19 Summary Order of magnitude time reduction Single tree-structured GUI for the entire CFD process Ease of Use Consistent setup High quality meshing and application specific best-practices lead to Close agreement between CAE solution and experimental results 2008 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

PumpSimulator: Introduction Challenges in modeling hydraulic pumps Complicated setup since dynamic mesh is required for moving parts Dirty CAD handling Specific meshing techniques Advanced physics

21 PumpSimulator: Introduction Challenges in modeling hydraulic pumps Complicated setup since dynamic mesh is required for moving parts Dirty CAD handling Specific meshing techniques Advanced physics like Cavitation Transient simulation PumpSimulator FloWizard based customized tool for a suite of hydraulic pumps Gear Pumps Gerotor Pumps Vane Pumps Piston Pumps Features Can handle reasonably dirty CAD TGrid technology for meshing complicated geometries Application specific meshing/setup/post-processing Cavitation modeling capabilities Parameterization Parallel computing capabilities 2008 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

22 PumpSimulator: User Interface Different pump types High quality automatic mesh Options for advanced clean-up Application specific inputs - Options for modeling cavitation 2008 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary

24 Summary Huge reduction in manual efforts because of Less CAD cleanup requirements Built-in best practices for automated meshing and case-setup Consistency Automation ensures that the meshing, casesetup and results are consistent across different designs 2008 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

25 Closing Remarks Ease-of-use Expert modeling know-how and best practices is built into the software tool Enhanced productivity Standardize modeling practices and procedures globally within an organization Consistency A standardized approach allows for reproducible results, irrespective of who does the simulations Knowledge Capture and Data Management Documentation and Reporting Archive and searchable Can be used for rapid optimization studies including six-sigma analysis 2008 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

26 Acknowledgements Parametric Mesh Generation David R Minns, ANSYS Europe Ltd., Riseley, UK (david.minns@ansys.com) PumpSimulator Rajiv Rath and Padmesh Mandloi, Fluent India Pvt. Ltd. Pune, India (rajiv.rath@ansys.com) 2008 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

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