CAD embedding and integration analysis of CFD and Electromagnetic simulation, with Confidence

Transcription

1 CAD embedding and integration analysis of CFD and Electromagnetic simulation, with Confidence Summary Fred Mendonça, CD-adapco, London Process Integration, Partnership, CAE Workflow, CAE Templates, Vertical Applications, Simulation-Based Design (SBD), Optimization, Upfront design/simulation

2 Topics CAD embedded CFD Coupled / Integrated CAE analyses (CFD and EMC) Confidence Verification and Validation With emphasis on Breakthrough technologies (CAD embedded CFD) Best practices (ending with validation)

3 Generalised work flow GEOMETRY MESHER CAE 1 CAE 2 1-WAY Data Exchange 2-WAY Data Exchange OPTIMISATION ANALYSIS

4 Vertical Application Example ABB Switchgear, Switzerland Coupling from EMC to CFD code Polopt outputs surface heat fluxes STAR-CD calculates the flow and temperature distribution Standardize on pro/e Component in a high voltage circuit breaker assembly Challenge can the solid temperatures be modeled accurately using a coupled EMC and CFD approach

5 Example; Data-process work flow Pro/E model STAR-Pro/E EMC code POLOPT Surface heat fluxes STAR-CD At high-power operations surface temperatures to recalculate solid properties

6 CAD CAE Integration Levels (ref Raimund Schweiger) CAD-embedded (All-in-one) PROS Full access to native geometry, features, parameters Best pre-requisites for geometry healing (know system best) No translation geometry translation Defeaturing CONS User is locked-in (difficult and expensive to change system) No simple substitution of CAE components May delay, or even prohibit, access to innovative new technologies May not support multi-cad environment CAD-coupled (Geometry) No geometry translation Defeaturing Supports rapid deployment of innovative technologies Relatively easy/cheap to replace Suitable for multi-cad environments Requires several native geometry kernels (vendor issue) Access to parameters may be limited Bi-directional data exchange with CAD may be limited CAD-linked (Standards) Relatively stable due to long term use Supports multi-cad and multi-cae environment Standards exist (IGES;STEP,VDA-FS, etc.) Geometry healing requires special software Higher potential to loose design content through translation No defeaturing Additional step in the CAD-CAE chain

7 CAD embedding multi CAD breakthrough technology The STAR-CAD Series (Designers doing linear analysis) STAR embedded in SolidWorks Unigraphics-NX Pro-Engineer Catia V5 The STAR-CAD Gateways (Analysts who understand non-linerities) Links embedded CAD to full-spectrum CFD

8 Example CAD-embedded STAR-Pro/E : Geometry/mesh

9 Example CAD-embedded STAR-Pro/E : Boundary setting

10 Example CAD-embedded STAR-Pro/E : Solution

11 Example CAD-embedded STAR-Pro/E : CAE Gateway

12 Example results in the fluid Temperature Velocity

13 CONFIDENCE metal heat-up (4 case inputs, 2kA, 4kA, 13kA and 18kA) Temperature animation Temperature histories MEASUREMENT

14 Summary - best practise include Verification and Validation? 1) Quantify the required outcomes 2) Make the model Verify the model Ensure the process is robust and repeatable Standardise/document the process Quantify uncertainties (e.g. mesh, models, boundary conditions) Ensure that the required outcomes are satisfied Validate the model Compare with analytical solutions and measurements (if available) 3) Release it to your Designers and Analysts

15 Polyhedral vs. Tetrahedral Meshing (mesh dependencies best practice) Efficiency + Accuracy + Easy-of-Use = Optimisation 7 MESH DEPENDENCY POLY TET 6 Delta P (kpa) hours < 3% error 6.3 hours > 5% error 10 hours hours Number of Cells