FloEFD 101 - Pixel Sistemas · Unrestricted © Siemens AG 2017 Page 3 Siemens PLM Software What is...
Transcript of FloEFD 101 - Pixel Sistemas · Unrestricted © Siemens AG 2017 Page 3 Siemens PLM Software What is...
FloEFD 101
Unrestricted © Siemens AG 2017
Page 2 Siemens PLM Software
• Fully embedded in the PLM design environment, and with its unique automation technologies,
FloEFD helps engineers to both frontload CFD and carry out parametric studies throughout the
complete manufacturing processes,
• „Frontloading‟ refers to the practice of moving CFD simulation early into the design process where it
can help engineers examine trends and eliminate less desirable options, as well as reduce overall
simulation workflow time by as much as 75%.
What is FloEFD?
FloEFD for NX
FloEFD for Solid Edge User Interface
• FloEFD is an award-winning MCAD-embedded CFD
simulation tool for easy, fast,
robust and accurate fluid flow and heat transfer
analysis inside Siemens Solid Edge:
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What is the FloEFD unique Value
Proposition?
FloEFD is easy to use: Design-centric simulation
tool offering a single CAD-embedded environment
for design and analysis thus making CFD analysis
plug-and-play.
FloEFD is fast: Intelligent technology and
automation helps reduce the overall simulation time
for even complex geometries by as much as 75%
thus enabling fast exploration of the design space
and validation of the digital twin.
FloEFD is accurate: Thousands of engineers use
FloEFD to solve real world engineering problems
across a wide range of industries including
automotive, aerospace, manufacturing and
electronics.
FloEFD democratizes CFD: It is at the core of
SolidWorks Flow Simulation (NX and Solid Edge
versions of FloEFD offer some additional
functionality over SolidWorks Simulation*).
CAD
Embedded
Robust Cartesian Meshing -
SmartCells™
• Avoid manual mesh creation
• Extremely fast meshing
• Complex geometry capture
Innovative
Technologies
High Automation
• Automatic convergence
• Laminar-turbulent transition,
• Grid independent near wall
modeling
Effective Geometry
Handling
• No translation step necessary
• Design and Analysis are
synchronized
• Automatic fluid volume
detection
• Automatic change recognition
• Embedded in PLM workflow
Engineering Models
• “Real Geometry”
• “Thin Walls”
• “Thin Channels”
Short Learning Curve
• Easy to use by a designer
• Fast learning
• Multi-CAD Ready
Accurate and Fast
Complex Geometry
Handling
Ease-of-Use
by a non CFD expert
to drive out risk
110 Industrial CFD Benchmarks
* FloEFD Advanced CFD and LED modules
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FloEFD - Unique Combination of Enabling
Technologies drives Frontloading CFD
Embedded Solid Edge
Fast Automated Immersed Boundary
Cartesian Meshing
Intuitive Easy-to-use
Interfaces for Engineers
Unique Transitional Turbulence k - e model
Unique Modified 2 Layer Wall Function for
Boundary Layers
Multi-variant “What if?” Analysis
Automated Solution
Convergence Built-in
Frontloading CFD
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FloEFD Enabling Technology – Full CAD
Embedding and Integration
• FloEFD, Seamlessly integrated within Solid Edge:
Direct use of MCAD geometry
Automatic detection of the fluid region
No coming in and out of the CAD package for the CFD simulation
• Benefits
No translation step necessary with loss of geometrical fidelity
No complex definition of regions
Design and CFD models stay in sync.
Reduces re-synchronization effort and errors
5
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FloEFD Enabling Technology –
Fast Automated Meshing
• Immersed Boundary Meshing:
• Automatic meshing for fluid and solid regions
• Deals quickly with “dirty” CAD geometries
• Automatic mesh refinement/unrefinement
• Benefits
• No manual meshing time
• No CFD algorithm expertise required
• Reduces execution time yet delivers accurate results
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FloEFD Enabling Technology –
Intuitive Easy-to-use Interfaces for Engineers
• Engineering User Interfaces:
• Easy-to-use wizards provide guided model setup
• Comprehensive result analysis & visualization capabilities
• Optional MS Office-based results
• Benefits
• Eliminates the need for CFD expertise in the setup
• Reduces setup times
• Automates the product documentation
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FloEFD Enabling Technology –
a unique Transitional Turbulence k-ε model
• Laminar – Transitional – Turbulent k-E Model:
Automatic laminar to turbulent CFD modeling with universal, grid independent
modified 2 equation Wall Functions
Laminar, transitional, and turbulent flow regimes automatically determined -- no
need to specify flow characteristics
• Benefits
Direct ability to model flow regimes eliminates CFD specialist requirement
Shorter setup times and increased model accuracy compared to traditional
approaches
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FloEFD Enabling Technology – a unique
modified Wall Function for Boundary Layers
• Automatic Modified Wall Function:
Grid-independent near-wall modeling using “SmartCells” technology
Physically correct simulation of boundary layer phenomena for fluid flow
and heat transfer
Multiple scenarios automatically calculated
• Benefits
Accurate simulations including near-wall boundary condition effects
No specialized/expertise setup necessary
Reduces trial and error near-wall setup of traditional CFD approach
a) b)
c) d)
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FloEFD Enabling Technology –
Automated Solution Convergence Built-in
• Automatic Convergence Control :
• Very robust convergence behavior
• First run converges without additional numerical diffusion
• Benefits
• Reduces multiple re-runs due to lack of convergence
• Short run times enables multiple variant scenarios
• Eliminates CFD specialist tweaks for convergence, i.e. model modifications
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FloEFD Enabling Technology –
Multi-variant “What if?” Analysis
• Design Variant Analysis:
• “What-if” analysis without further definition of model data
• Project cloning feature
• Full support of product MCAD“configurations” and “instances”
• Modify design, run auto-mesh, execute!
• Benefits
• Multiple “what-if” simulations result in optimum design
• Saves CFD specialist‟s resources for only most critical analyses
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Democratizing CFD
• Wider Adoption of CFD
• 80/20 rule: Handle 80% of CFD
• FloEFD is a productivity tool!
• Typical target user:
• Mechanical Designer / Design Engineer (CAD Users)
• BSc in Engineering subject
• Domain expertise expected, but no training in CFD
• Many „routine‟ applications of CFD (pipes, manifolds, valves, pumps).
• Typical user deals with a limited application range.
• Frees up in-house CFD experts for high-end applications
• Typical Software Requirements:
• Ease of use
• Accuracy
• MCAD Variant analyses
• Optimisation
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FloEFD vs. Traditional CFD
FloEFD Traditional CFD
Required numerical knowledge none high
User manual meshing time none high
Overall meshing time (CPU + user) low high
Model preparation time low high
Programming skill requirements none medium
Suitability for fast design cycles high low
Ease-of-use high low
Overall input time for user low high
Overall physics capability medium high
Typical user educational degree B.A., M.A. M.A., PhD
Typical user profile 90% Mechanical Engineers,
10% CFD experts
10% Mechanical Engineers,
90% CFD experts
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FloEFD vs. Traditional CFD
CAD CAD CAD CAD
Ma
nu
fac
ture
Traditional CFD
Concept Detailing Prototyping Testing
Traditional
CFD
Traditional
CFD
Traditional
CFD
FloEFD
Concept Detailing Prototyping Testing
Ma
nu
fac
ture
CAD CFD CFD CFD
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What can FloEFD Do?
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FloEFD Application Types – Pressure Drop
• Device flow coefficient determination (cv/kv/Qn)
• Extrusion process optimization
• Jet pump dimensioning
• Filter efficiency
• Pump efficiency
• Fan curve determination
• HVAC ducting sizing/placement
• Aircraft ECS design
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FloEFD Application Types – Heat Transfer
• Electronics Cooling
• Heat exchanger efficiency
• Injection molding device cooling
• Sterilization in food processing
• Rubber extrusion
• Windshield de-icing
• Solar towers
• Lighting
• Solar heating
• Engine cooling jackets
• Brake design
• Oil cooler design
• And many more….
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FloEFD Application Types – Mixing
Processes
• Air conditioning duct design
• Spray nozzles
• Rubber co-extrusion
• Intake manifolds (EGR tracking)
• HVAC – contaminant tracking, emissions, fumes
• Furnaces and combustion
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FloEFD Application Types – Flow Fields
• Aerodynamic testing
• Cavitation prediction
• Noise level optimization
• Intake and exhaust manifold design
• Automotive engine in-cylinder flows
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FloEFD Application Types – Force Prediction
• Aerodynamic coefficients
• Operational forces for valves
• Wind loads on buildings, bridges, etc.
• Flow-induced loads for stress analysis
• Temperature distribution for
thermal stress analysis
• Torque prediction
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FloEFD Meshing Technology
• Well defined and robust algorithm
• FloEFD supports:
• Flow Only (Fluid Cells)
• Conduction Only (Solid Cells)
• Fluid Flow and Heat Transfer (Fluid, Solid, SmartCells)
• Refining Fluid and Solid cells allows for higher resolution
• The real FloEFD technology is within SmartCells
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SmartCells
• SmartCells are always present at the fluid-solid interface
• Modified wall function captures boundary layer without need for high cell count at wall
• Proprietary technology based on physical test and empirical results
• Developed originally at Moscow state university during 1980s
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Solution Adaptive Meshing
• Solution adaptive mesh will refine mesh in localised volumes based on
flow gradients
• Automatic meshing requires little user input
• Solver does not start again, interpolates, continues
• Benefits:
• Non-expert users can generate very high quality grid
• Only refined in critical areas
• Higher accuracy with minimal increase in solve time
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FloEFD Functionality
Feature
Sta
nd
ard
Flo
EF
D
Ele
ctr
on
i
cs
Mo
du
le
HV
AC
Mo
du
le
Ad
va
nc
e
d M
od
ule
LE
D
Mo
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le
Flo
ED
A
Mo
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ule
External (<M5) & internal flows / Steady-state and transient analysis ✓
Compressible gas, liquid & incompressible fluid ✓
Free, forced, and mixed convection ✓
Boundary layers, including wall roughness effects / Laminar & turbulent flows ✓
Heat transfer in fluid, solid & porous media ✓
Isotropic, unidirectional, biaxial/axisymmetrical and orthotropic thermal conductivities ✓
Non-Newtonian liquids / Real gases / Two-phase flow (fluid & particles) / Relative humidity ✓
Moving/rotating surfaces and/or parts ✓
Cavitation in incompressible water flows / Steam Modelling with Condensation ✓
2 Resistor Components / Heat Pipes / Electrical Conditions / PCB Smartpart ✓ ✓*
Extended Engineering Database ✓ ✓
Thermal Radiation Model (Absorption in semi transparent solids) DT DT/DO DT/DO/
MC
HVAC Comfort Parameters ✓
Pre-mixed / non-premixed steady state gaseous combustion ✓
High Mach Number Flow (M5-M30) ✓
Advanced LED modelling (2-resistor and T3ster derived compact model) ✓
ODB++ detailed PCB import (Explicit traces) / DELPHI multi-resistor network IC model ✓
* PCB smartpart only
DT = Discreet Transfer
DO = Direct Ordinates
MC = Monte Carlo
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Return on Investment: Reliability (1/3)
• Reasons for products being late to market:
Only Mentor‟s tools reduce these pains:
- Verify Design Changes in Less Time
- Design Out Reliability Issues; and so
- Spend Less Time in Physical Prototyping
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Return on Investment: Time (2/3)
• Impact on Thermal Verification:
• Mentor customers take ⅓ of time taken by everyone else
• Good thermal design avoids surprises during prototyping
% Design Time spent in Thermal Verification
Longer time spent
getting design closure
Causes product to be
late to market
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x1,000
Production
Equipment
x1 x10
x100
x10,000
Pre-Development Design Prototyping Tryout
Product Development Stage (*) Cost of Fixing a Defect
At Design Stage $35
Before Procurement $177
Before Production $368
Before Shipment $17,000
On Customer Site $690,000
(*Source: Hiroshi Hamada, President of Ricoh, European Community Quarterly Review, 2002)
Time for Recognizing Mistakes
Cost to fix Problems $
Return on Investment: Cost (3/3)
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FloEFD Offers Solid ROI Through
Productivity Gains Renault France (X2) Graco Spray Guns (X3)
Paul-Henri Matha,
Lighting Expert
Rick Anderson,
Senior Project
Engineer
“At Renault we have reduced
our headlamp costs by 50%
between 2014 and 2016 and we
are aiming for a further 50%
reduction in costs for our
Generation 3 LED headlamps by
2018-2020.
The big advantage with FloEFD
we found is that…one thermal
engineer can be over twice as
productive.”
“The complete design
process of all sizes took
only about 3-4 months or
about one-third as long as
would have been required
using the trial and error
method.”
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FloEFD Offers Solid ROI Through
Productivity Gains
“FloEFD …enables design
engineers without a fluid
analysis background to
perform thermal simulation.
The result is that we got the
design right the first time, only
had to make one prototype,
and avoided expensive design
changes that typically occur in
the late stages of the
development process ”
Crane Corp. [Azonix] (X12) Bromley Technologies (X40)
“FloEFD has helped us to reduce
our Bob Skeleton aerodynamic
design times from 8 weeks to 8
hours.”
Dr. Tristan Bromley,
CEO & Elite Athlete James Young, Design
Engineer, Azonix
Corporation
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Page 30 Siemens PLM Software
Summary
• Moving Computational Fluid Dynamics simulations as early as possible in
the design cycle has the biggest ROI: „Frontloading‟
• FloEFD is an award-winning, well
validated, tried-and-proven solution to
frontloading of CFD with a 25 year
commercial pedigree and a large
installed base.
• FloEFD has demonstrated engineer productivity gains of X2 to X40 versus
time-consuming traditional CFD approaches,
• FloEFD is now available for both Siemens NX and Solid Edge with MCAD-
embedded versions following the recent acquisition of Mentor Graphics.
Pol. Ind. SIGMA Xixilion 2 - Planta 2ª - Oficina 1ª 20870 ELGOIBAR (Gipuzkoa) tel.: 943 74 86 02
www.pixelsistemas.com [email protected]