Electronics Thermal Analysis and Management

Techniques:

Flow Network Modeling (FNM) Computational Fluid Dynamics (CFD) Finite Element Analysis (FEA) Heat Transfer Correlation Experimental Measurement Techniques

Software Packages:

1. IcePAK, IcePro, IceMax, QFin (www.icepak.com)2. FLUENT (www.fluent.com)3. Gambit (www.fluent.com)4. SINDA/FLUINT (www.crtech.com)5. FloCAD (www.crtech.com)6. I-DEAS (www.eds.com)7. Pro/Mechanica (cfdesign) (www.ptc.com)

Icepak.com : Products

Electronics Cooling Products

Fully interactive, object-based, thermal management software

The new Pro/Engineer-Icepak direct CAD interface

The Most Advanced Parasitic Extraction Tool for Analyzing Complex IC Package Designs

The optimized heat sink design and analysis tool

Icepak 4.0 Features

Model Building Features Automatic Mesh Generation Features Comprehensive Modeling Capabilities Advanced Physical Models Boundary Conditions for Flexible Model Building Solver Attributes Visualization and Reporting Miscellaneous Online Help and Documentation Supported Hardware

Icepak is a fully interactive, object-based, thermal management software tool.The Icepak design environment allows engineers to reduce design costs and reduce the time-to-market of high-performance electronic systems.

Icepak offers enhanced CAD geometry import in IGES and DXF formats for easy integration with other mechanical engineering CAD tools and EDA software. Icepak uses Fluent's flagship solver engine, FLUENT, providing complete flexibility to model complex geometries on unstructured mesh. FLUENT's sophisticated multigrid solver and segregated solution algorithm make Icepak calculations robust and fast.

Icepak provides features that are not available in other analysis packages, including accurate modeling of non-rectangular devices, contact resistance modeling, anisotropic conductivity, non-linear fan curves, lumped-parameter heat sink devices, external heat exchangers, and automatic radiation heat transfer view factor calculations.

Model Building Features:

Icepak's mouse-driven selection, placement, and sizing of predefined objects makes model building fast and easy. Complex geometries can be represented without approximations.

Object-based model building with predefined objects, including cabinets, blocks, fans, Printed Circuit Boards (PCB) and racks, vents, openings, plates, walls, ducts, sources, resistances, and compact heat sinks

Comprehensive object shapes, including rectangular blocks, cylinders, ellipsoids, elliptical cylinders, concentric cylinders, prisms of polygonal cross-section, prisms of varying cross-section, and ducts of arbitrary cross-section

Rectangular or circular 3D/2D fans with hubs, guards, and power specifications Inclined rectangular plates, fans, vents, openings, and resistances Advanced object for heat sinks - both detailed and compact model representations

are available

"ModelManager": A graphical "explorer-tree-style" model management tool that allows you to quickly create, edit, and manage objects, assemblies, libraries, projects, configurations & settings

Mouse-driven interactive GUI controls, including: o Mouse or keyboard control of placement, movement, and sizing of objects o Ruler option to guide in sizing/resizing of objects o 3D mouse-based view manipulation with dynamic rotation, translation, and zoom o Undo/redo functions o Active/inactive option for all objects o Error and tolerance checking o Flexible/Customizable units for all input fields o ModelManager entities o Advanced objects specification for heat sinks, IC packages, and fans o Graphical alignment tools

Parameterized geometry and boundary conditions - ability to set up and run multiple trials/design options from the Icepak interface

Geometry inputs using local coordinates Library functions, that allow you to store or retrieve groups of objects in a parts library Comprehensive material property database Geometry import from MCAD/ECAD:

o IcePro: A direct Pro/ENGINEER® to Icepak interface o IGES import feature included in Icepak o IDF wizard to import EDA PCB layout information

Editable model summaries, import to and export from spreadsheets Capability to setup user-defined macros Polygonal and circular shapes allowed for fans, vents, resistances, plates, openings

Automatic Mesh Generation Features:

Icepak provides a full range of meshing options: o Automatic unstructured body conforming o Automatic structured Cartesian meshing for convenient analysis of models

with predominantly rectangular geometric shapes o Automatic non-conformal (for unstructured and structured) to mesh regions

of the model separately, simplify meshing, and reduce the cell count, thereby increasing the speed of solutions

o Automatic tetra mesher to accommodate the very difficult geometric shapes Icepak's fully-automatic unstructured mesh generation lets you model complex

geometries with ease. Fully-automatic, unstructured mesh generation for true geometry representation (no stair-

stepped approximations) Hexahedra, tetrahedra, pentahedra, prisms, and mixed element mesh types for high

quality mesh on complex objects Coarse mesh generation option for first-cut analysis Full user control of meshing parameters and mesh deployment Intuitive mesh viewing tools that facilitate review of mesh quality

See Illustrative Meshing Examples

Comprehensive Modeling Capabilities:

Forced, natural, and mixed convection heat transfer modes; conduction in solids; conjugate heat transfer between solid and fluid regions

Surface-to-surface radiation heat transfer, with automatic view-factor calculation Laminar or turbulent flows Steady-state or transient analyses Volumetric resistances and sources for velocity and energy

Advanced Physical Models:

Icepak's depth in physical models ensures that you can include the flow and heat transfer physics that are important to your process, with the confidence that predictions will be accurate and dependable.

Choice of mixing-length or two-equation k-epsilon turbulence models RNG turbulence model is available Input for full anisotropic conductivity in solids Temperature-dependent material properties Contact resistance modeling Non-isotropic volumetric flow resistance modeling, with non-isotropic resistance

proportional to velocity (linear and/or quadratic) Internal heat generation in volumetric flow resistances Non-linear fan curves for realistic fan modeling Radiation view factor computation models - two methods are available: (1) Improved

hemicube method (2) Adaptive method Lumped-parameter models for fans, resistances, and vents Robust shell conduction model - accounts for planar/lateral conduction effects in zero-

thickness plates Resistance network model - can be used to model IC packages, once characterized in

terms of known resistance networks Network implementations to model external heat exchangers coupled to CFD

calculations; users specify mass flow rate through the heat exchanger and overall heat transfer coefficients

Ideal gas law available

Boundary Conditions for Flexible Model Building:

Wall/Surface boundaries with options for specification of heat flux, temperature, convective heat transfer coefficient, radiation, and symmetry conditions

Openings and vents with options for specification of inlet/exit velocity, mass flow rate, exit static pressure, inlet total pressure, inlet temperature, and turbulence parameters

Vents and resistances have an automatic loss coefficient calculation based on free area ratio

Fans, with options for specified mass flow rate or fan performance curve

Recirculating boundary conditions, for external heat exchanger simulation Planar heat exchanger for external heat exchanges Time-dependent and temperature-dependent sources Time-varying ambient temperature input Profiles of velocity, temperature, heat flux/heat transfer coefficients can be specified on

openings and walls Pressure boundaries can be a function of time Variable time-stepping for transient problems - any desired time step variation can be

specified; this is useful for problems where changes of interest occur over very small time intervals

Solver Attributes:

Icepak's state-of-the-art solver is the industry-leading finite volume solver used in FLUENT 5.6. Robust, fast, and accurate, Icepak uses a segregated solution algorithm with a sophisticated multigrid solver to reduce computational time.

State-of-the-art fluid flow and heat transfer solver for complex geometries Choice of first-order upwinding, for first-cut solutions, or a higher-order scheme for

improved accuracy Automatic adjustment of solver underrelaxation, for robust and fast convergence Parallel solver for multiprocessor machines - solver speedup depends on the size of the

problem and the number of processors Parallel solver for networked machines, NT or UNIX is available. Grid to grid interpolation for restart is available. Automatic setting to decouple the flow and energy solution to reduce the time to

convergence (by over 30%) in forced convection flows

Visualization and Reporting:

Icepak includes a full-function 3D object-based postprocessor, so you can interpret results with ease. Customized reports help you identify and compare trends during parametric analysis of design options.

Fully-integrated, interactive, object-based visualized with: o Three-dimensional modeling o Dynamic mouse-based view manipulation (rotation, translation, zoom) o View selection and resetting options o Hidden line/surface removal o On/off toggling of object visualization o Mouse-driven cut-plane determination o Dynamic movement of cut-planes through the domain o Viewing planes that are arbitrary planar surfaces in the domain

Visualization of velocity vectors, contours, particle traces, or mesh on object faces, cut planes, and iso-surfaces

Point probes and XY plotting for data reporting Mouse probe for data probing on any post-processing object

Point summary tables Contours of velocity components, speed, temperature, pressure, heat flux, heat transfer

coefficient, flow rate, turbulence parameters, vorticity and many more quantities Velocity vectors - color-coded by temperature, velocity magnitude, pressure, or other

solved/derived quantities Animation for viewing of particle and dye traces Animation of vectors and contours in transient analyses Reporting to user-specified ASCII files of all solved quantities and derived quantities

(heat flux, mass flow rate, heat transfer coefficient, etc.) on all objects, parts of objects, and user-specified regions of the domain

Time history of solution variables at any point in the model Graphical monitoring of convergence history during the solution process Additional convergence monitoring tool - point monitors for solved variables to monitor

solution convergence Direct graphics output to printers and/or to user-specified files; hard copy options include

color or monochrome postscript, PPM,TIFF, GIF, JPEG, and RGB file formats Create animations directly from Icepak by writing out data MPEG and AVI formats Animation capability to write out MPEG movies and animated GIFs Seamless transfer of data between Windows NT and UNIX Single point object that can be used as a monitor point, post-processing object or for

point reports Ability to report fan operating points Autotherm users can export heat transfer coefficients and temperature for use in

Autotherm Data can also be exported to NASTRAN™, PATRAN™, and IDEAS™ Universal file

formats Data can be saved in point format on all postprocessing objects

Miscellaneous

Ability to remap mouse-button preferences 3D objects (e.g. block) can be converted to 2D objects (plate) and vice-versa Automatic save interval can be specified

Online Help and Documentation:

Context-sensitive online help for all panels/menus Bubble help available for all functional menus Tutorial manual, with validation examples Training manual

Supported Hardware:

UNIX workstations and PCs using Windows/NT

IcePro 3.1:The New Pro/Engineer-Icepak Direct CAD Interface

IcePro 3.1, the new Pro/Engineer-to-Icepak interface, builds on its successful integration of CAD software with Icepak’s thermal modeling software. The IcePro user can take advantage of many of Pro/Engineer's CAD and database features. By allowing the user to use simplification tools available in Pro/Engineer itself, the time required to get thermal models from CAD systems is reduced dramatically. The philosophy of the integrated Pro/Engineer CAD interface is to take advantage of design engineers' expertise in using Pro/Engineer to define the thermal model.

IcePro Features

Key Attributes in IcePro 3.1

Auto Export o Allows you to configure export to suppress/identify features o Auto-export to convert the ProE model to an Icepak model o Show un-exported features

Menu structure showing the auto export feature

Configure translation to do the following o Automatically simplify the geometry by suppressing features that modify a

protrusion, for example, rounds, chamfers fillets, etc. o Ignore small cut and protrusion features

Configure translation 

Results of translation shown in Icepak Apply sensible object recognition, such as patterns of cuts and extrusions Decompose complex shapes into prismatic shapes

Preserve the ProE model tree layout when transferred into Icepak

Image as viewed in ProEngineer

In addition, the manual export can also recognize extrusions, split polygons and preserve the ProE model tree. The features introduced in v 3.0 of the interface have been retained.

Key Attributes in IcePro 3.0

1. Easier object/face selection procedure through elimination of the surface/object abstraction procedure

Enhanced circular or rectangular geometry selection through curve selection2. Direct import of material property from Pro/E to Icepak 3. Retain the dimensional unit information from Pro/E 4. Easier procedure for cylinder/polygonal object selection

The objects highlighted in red show single-click polygonal object selection5. List manager – manage/edit/delete objects selected in Pro/E before exporting to Icepak

The List Manager is shown deleting objects

All of the following features in Version 2.0 have been retained in IcePro 3.0 and several feature improvements have been made as referenced above. The details for Version 2.0 are:

Version 2.0 of the Pro/E-Icepak direct CAD interface contains features that drastically reduce the time required to transfer a CAD model from Pro/E to Icepak. You can now export Icepak models from individual parts, directly from the assembly, or designate Icepak objects in individual parts from within Pro/E. There's also a feature that allows you to write out data without re-scanning the entire part/assembly.

New Features in Version 2.0

1. Icepak and Pro/E users can now use the new interface with both assembly and part files. 2. If you have repetitive objects (for example, heat sink fins, PCBs) in your part or assembly

files, you do not need to pick these entities one-by-one. The repetitive features will automatically come into Icepak.

3. Major improvements to polygonal objects selection and how they were written out. 4. Create circular surfaces for fans and openings without actually creating the surface

abstractions, as long as you select the two common surfaces to create the object.

5. The xyz extends of the picked surfaces can now be used to define all prism blocks. 6. Easier and more flexible way to import inclined plates. 7. The new "Fast Write Data" button allows you to write data out without re-

scanning the entire part or assembly. This option should only be exercised if no geometric changes have been made, since the Icepak button was first pushed inside the current model.

8. The new feature "Remove All Objects" allows the user to select multiple objects without having to push "Remove Object" button for each one of the objects.

Icemax: The Most Advanced Parasitic Extraction Tool for Analyzing Complex IC Package Designs

Soon To Be Released!!

Icemax is the most advanced parasitic extraction tool for analyzing complex IC package designs. Icemax is based on state-of-the-art finite volume field solver technologies, which allow quick and accurate electrical characterization of IC package performance. Engineers and researchers involved in IC package design can now easily generate detailed, reliable RLCG information for the entire package in a matter of minutes. Output can be generated in matrix, SPICE, or IBIS formats.

Icemax Features

Icemax is the most advanced parasitic extraction tool for analyzing complex IC package designs. Icemax is based on state-of-the-art finite volume field solver technologies, which allow quick and accurate electrical characterization of IC package performance. Engineers and researchers involved in IC package design can now easily generate detailed, reliable RLCG information for the entire package in a matter of minutes. Output can be generated in matrix, SPICE, or IBIS

formats.

Import of layout data from Cadence, Synopsys, Zuken, Mentor Single-chip and multi-chip Modules Bond wire and C4 (flip chip) packages 4-point and 5-point JEDEC standards for 3-D representation of bond wire profiles Detailed 3-D modeling of solder ball and solder bump geometry AIF file input for net names and node coordinates Fully interactive, 3-D model viewing for full package or selected nets Full package characterization Automatic detection of nearest neighbors for mutual L/C calculations Flexibility in assigning source or sink boundary conditions Fast finite-volume field solver Lumped and distributed output

RLCG representation in matrix, SPICE and IBIS formats Ground/power net simulation Frequency-dependent parasitic extraction Buried, blind and through-hole vias 3-D field distribution plots Automatic reporting (Word, Excel)

QFin: The Optimized Heat Sink Design and Analysis Tool

Fluent and QFinsoft bring you QFin to help take the guesswork out of your design process. This software tool enables you to simulate every aspect of heat sink design and analysis. The software is quick and easy-to-use, with a comprehensive database of commercially available heat sinks and component casings as well as the ability to design a heat sink to your own specifications.

QFin Features:

General Program Capabilities

The core of Qfin 3 is an easy to use, parameterized, fully 3D designer, allowing the engineer to model an assembly consisting of a heat sink with multiple fans inside a cabinet. Several advanced air flow models ensure accurate boundary calculations, and an efficient direct solver calculates accurate heat transfer in seconds.

Because assembly designs are fully parameterized, Qfin3 allows easy range solving and optimization of virtually all design variables. Full histories are also available for both range solving and optimization, so that each solved design can be inspected along with its solution.

Other noteworthy program capabilities include the following:

Comprehensive project and assembly management through the Qfin3 Browser Easy import, export and emailing of projects and assemblies Import of Qfin2 assemblies Wizards for quick and easy creation of different types of heat sinks Fully 3D modelling of cabinet, heat sinks, and multiple fans Parameterized specification of fin and pin configurations 3D viewing of calculated boundary consitions (pressure, air speed, htc, etc.)

Full HTML reporting for solutions, range solves, optimizations, and transient solutions

Browser

The main Qfin 3 window is called the browser, and provides easy access to the following functions:

Project and assembly management (including importing, exporting, mailing, copying) Component management (heat sinks, fans, etc.) Online documentation (overview, tutorials) Program settings (user information for reports, unit systems) Product support Product license management

Qfin 3 stores all projects, assemblies and component geometries in its own internal data repository. As such there are no "file open/save" kind of functions, but you can export and import projects, assemblies, and components for transfer between users. To make this process even easier, there is a one-click "e-mail selected project/assembly" function.

In the future Qfinsoft will also offer a module that will allow shared network repositories, where engineers can share projects, assemblies and components (with password protection if required).

Designer

The new designer has a CAD-like interface and allows you to design a complete assembly, including cabinet, heat sink, and fan geometries at once. Solving is done directly from within the designer, allowing for quick and easy design-solve-modify-solve cycles.

The 4 views are all OpenGL based and can be independently configured and rotated. As an example, during normal design 3 of the views can show orthographic front, top, and side views, while the 4th shows a 3D view. After solving the 4 views can all be set to perspective projected 3D mode, showing air speed, ambient temperature, heat transfer coefficient and solution temperature respectively.

All elements of an assembly design are parameterized, allowing range solving and optimization using virtually any design variable available in the model.

Other features of the designer include:

Tree based view of assembly and model Selection of geometry using tree or directly in 3D view

All elements of model visible in 3D view, including cabinet, fans, sources and local boundaries

Customizable color selection for all geometrical elements Direct solving, range solving, transient solving and optimization from within designer Automatic snapshots of 3D view in all reports Automatic mesh creation, overridable for each geometrical element Fan positioning relative to heat sink

Solver

Qfin3 uses several advanced radiation and convection models to calculate boundaries very accurately, as well as a very efficient direct solver for heat transfer determination.

The end result of all this advanced technology is that Qfin3 can solve most assemblies in a matter of seconds, which is especially beneficial during range solving and optimization, where multiple solutions must to be generated.

Other features of the solver include:

User selectable radiation calculations Full user-specified ambient conditions (including pressure calculation from altitude) Accurate forced convection modelling for each kind of fan setup (ducted or impingement) Effective modelling of air flow from multiple fans Automatic determination of fan operating point if fan curve is specified Independent meshing of heat sink elements, allowing fine grained control of mesh sizes

in different parts of heat sink Full HTML solution reports (soon to be fully customizable)

Optimizer

Optimization in Qfin3 has been vastly expanded and improved from Qfin2. Because assembly designs are fully parameterized, virtually any model parameter can be selected as an optimization variable.

Qfin3 also allows simultaneous optimization of multiple functions, as well as flexible specification of multiple constraints.

Most solution variables, like pressure drop and average htc, are also available as selectable "monitors" during an optimization run. Full reporting is standard, including full reports of each design that was solved during the optimization process.

Various optimizer settings also allow the user to specify optimization stop conditions, as well as cabinet constraint and resizing measures to be taken during optimization.

FLUENT is the world leading CFD code for a wide range of flow modeling applications. With its long-standing reputation of being user-friendly, FLUENT makes it easy for new users to come up to productive speed. Its unique capabilities in an unstructured, finite volume based solver are near-ideal in parallel performance. To ensure that FLUENT is ready to deploy right out-of-the-box, we have put it through a comprehensive program of industrial-strength testing.

General Modeling Capabilities

Complete mesh flexibility All speed regimes (low subsonic, transonic, supersonic, and hypersonic flows) Parallel processing Solution-based mesh adaptation Steady-state and transient flows Inviscid, laminar, and turbulent flows Newtonian or non-Newtonian flows Full range of turbulence models from simple k-epsilon models to large eddy simulation

(LES) Heat transfer including forced, natural, and mixed convection, conjugate heat transfer,

as well as several radiation models Chemical species transport and reaction, including homogeneous and heterogeneous

combustion models and surface reaction models Free surface, Eulerian and mixture multiphase models Lagrangian trajectory calculation for dispersed phase modeling

(particles/droplets/bubbles) Phase change model for melting/solidification applications Cavitation model Porous media model Lumped parameter models for fans, radiators, and heat exchangers Dynamic mesh capability for modeling flow around moving bodies Inertial (stationary) or non-inertial (rotating or accelerating) reference frames Multiple reference frame and sliding mesh options Mixing-plane model for rotor-stator interactions Acoustics analogy for prediction of flow-induced noise Materials property database Integrated problem set-up and post-processing Extensive customization via user-defined functions

GAMBIT CFD Preprocessor

Fast geometry modeling and high quality meshing are crucial to successful use of CFD. GAMBIT gives you both. Explore the advantages:

Ease-of-Use

GAMBIT has a single interface for geometry creation and meshing that brings together all of Fluent's preprocessing technologies in one environment. Advanced tools for journaling let you edit and conveniently replay model building sessions for parametric studies.

Courtesy of Kommerling Kunststoff GmbH

CAD/CAE Integration

GAMBIT can import geometry from virtually any CAD/CAE software in Parasolid, ACIS, STEP or IGES format. Native CATIA V4 import and Pro/E Integration is also available (add-on). Tolerant modeling and healing capabilities are automatically providing connected solid geometry during import.

Aerospace valve solid model imported with GAMBIT's native CATIA V4 translator

Fast Modeling

GAMBIT provides a concise and powerful set of solid modeling based geometry tools. Using these, the fluid domain can be extracted from imported geometry and further decomposition can be performed using simple Boolean operations

Valve CFD fluid domain after geometry Boolean and construction operations in GAMBIT

CAD Cleanup

GAMBIT's semi-automatic cleanup tools can be used to repair and prepare the geometry for high quality meshing. Holes, overlapping faces, small features, sharp corners, etc. are quickly identified and various tools are directly accessible to resolve any problems.

Intelligent Meshing

Different CFD problems require different mesh types, and GAMBIT provides you with all of the options you need in a single package. GAMBIT's meshing toolkit lets you decompose geometries for structured hex meshing or perform automated hex meshing with control over clustering. Triangular surface meshes and tetrahedral volume meshes can be created within a single environment, along with Cartesian core, pyramids and prisms for hybrid meshing using automatic size distribution to correctly capture sharp curvature and small gaps.

GAMBIT builds on Fluent's established leadership in tools for automated meshing combined with user control.

Valve CFD mesh using HexCore meshing technology and automatic cell size distribution

ESP: Blue Ridge Numerics, Inc.

Blue Ridge Numerics, Inc. develops and globally markets CFdesign®, an affordable and practical fluid flow, heat transfer and electronics cooling simulation software fully integrated in the Pro/ENGINEER environment. Developed specifically for product development teams, CFdesign is the only CFD package in the world to fully leverage the native Pro/ENGINEER assembly and facilitate a parametric relationship between design and analysis. On average, a company using CFdesign for Pro/ENGINEER can reduce by 70% the time it takes to develop, test, and prove a new product while reducing projects costs by 65%.

General Information

Partner:    Blue Ridge Numerics, Inc.Address:    3315 Berkmar DriveAddress 2:    Suite 2BCity:    CharlottsevilleState:    VACountry:    USAPostal Code:    22901Phone:    434-977-2764Fax:    434-977-2714Web Site:    http://www.cfdesign.com

Contact Information

Name:    Jim SpannTitle:    Vice President, MarketingPhone:    502-243-4858Fax:    502-243-4857Email:    jim.spann@cfdesign.com

Partner Functionality: Flexible Engineering

Engineering Analysis

Product Information

PTC Approved Interface:    Yes

Product Name:    CFdesign for Pro/ENGINEER Product Description:

   CFdesign features a true parametric relationship with part geometry and assemblies, and automatically produces the optimal mesh required for reliable simulation results. Further shortening the learning curve, CFdesign even uses the same navigation controls and part identification methodology as Pro/ENGINEER. As added benefit, CFdesign can automatically pass thermal analysis results to Pro/MECANICA as input for structural simulations. Powered by proven numerical techniques and leading-edge computational methods, CFdesign is a comprehensive tool to optimize a wide spectrum of mechanical and electronic systems for internal/external fluid flow and heat transfer performance. Used by more than 1,200 companies in nearly every industry,

including Aerospace, Automotive, Electronics, HVAC, Materials Processing, Medical, Plumbing, Power Generation, Pumps, Test Equipment, and Valves, CFdesign has been embraced by Pro/ENGINEER customers around the world as the new standard for design analysis and optimization.

Integrated with which PTC Products:

   Pro/Engineer