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1
Contact Us
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E. [email protected] © ICON Technology & Process Consulting
Introduction
ICON®
Mr. Simon Weston
Managing Director
CONFIDENTIAL
CONTROLLED DISTRIBUTION
ICON COPYRIGHT CONTROLLED
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AGENDA
Profile
Products & Services
Applications
Summary
Q&A
ICON INTRODUCTION
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ICON
PROFILE
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AMERICA – EUROPE - ASIA
ŠKODA-ICON Roadmap 2015+ | Confidential
Offices
Staff Locations
Partner
®
Expert industry partner for 25yrs
Simulation-driven product development
100+ CFD/CAE & Application specialists
Largest OS CFD development team for
industry
Over 1000 customers of Group
America - Europe – Asia
Intel® Partner
OS CFD market leader for automotive
industry since 2004
>65% of Top-20 automotive OEMs
employed ICON in the past 3 years
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ICON
PROFILE
ICON are not a standard ISV
Objective was to be more innovative/productive with CFD
Your Independent Engineering & Business Partner
Performance focus
®
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Engineering Partner
Software
Support
Consulting
Training
Process
Validation
Software-as-a-Service
ICON®
PRODUCTS & SERVICES
… 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuciear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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ICON®
SUPPORTED
INDUSTRIES
Aerospace
Build
Environment
Chemical
Oil
Nuclear
Rail
Automotive
Consumer
Products
Defense
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iconCFD
®
iconCFD Wrap iconCFD Mesh iconCFD Cold
iconCFD Thermal
iconCFD Optimize
iconCFD VOF
iconCFD ... etc.
SUPPORTED PROCESS
iconCFD Support & Documentation
iconCFD Process
• GUI
• MultiCase
• App GUI
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iconCFD 3.3
Process
Mesh
Cold
VOF
Thermal
Optimize
Move
L2P
Acoustic
React
iconCFD®
MODULES
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iconCFD®
MODULES
iconCFD 4.x
Process
Wrap
Mesh
Cold
VOF
Thermal
Optimize
Move
L2P
EMP
Acoustic
React
Block
Coupled
Turbo FSI
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APPLICATIONS
Modules - Automotive
iconCFD® Modules
Automotive Vehicle Applications
Confidential
Process Mesh Cold Thermal Optimize Move VOF L2P Acoustic React FSI Wrap
External Aerodynamics
External Aerodynamics with rotating wheels
Front End Air Flow (FEAF)
UHTM
Optimisation
Aero-acoustics
HVAC (Climatisation / Air-handling)
Brake Cooling
Powertrain cooling systems
Headlamp
Wading / Fording
Soiling / Water management
Fluid Structure Interaction (FSI)
Reacting flows
iconCFD® module
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APPLICATIONS
EXAMPLE - AUTOMOTIVE
• External Aero
• UHTM • Climate
• Headlamp
• Aero Acoustics • Optimization
• Soiling
• Wading
• Brake cooling
Source: Courtesy Koenigsegg
• Powertrain
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Setup & Upload
• <15 mins.
Meshing
• <2 hours
Solving
• <6 hrs Steady
• <24 hrs Transient
• <12hrs Adjoint
Download
• Reports: <60 secs
• Results: <1 hour
WHY ICON?
ROBUST INDUSTRY PROCESS
25 years of industrial experience incorporated into a single digital workflow.
<1 day training required
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DATA PREPARATION
iconCFD WRAP : FULL CAR CASE
AN INTEGRATED FRAMEWORK FOR WRAPPING AND MESH GENERATION OF COMPLEX
GEOMETRIES David G. Martineau1, Jeremy D. Gould1, and Jacques Papper1
ICON Technology & Process Consulting Ltd
ECCOMAS Congress 2016
Detailed model of a car including:
electrical components
exhaust system
cooling
power-train
suspension
14 STL files:
382 regions
36 million triangles Geometry courtesy of Skoda Auto a.s.
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Element size of 2.44mm
curvature refinement
<20mm hole size closed
Complete process:
Completed in 2h 42m
32 cores
Wrapped surface:
12.5M triangles
DATA PREPARATION
iconCFD WRAP: RESULTS
UHTM geometry:
36M triangles
Geometry courtesy of Skoda Auto a.s.
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Background mesh with no wrapping Background mesh with wrapping activated
DATA PREPARATION
iconCFD WRAP: RESULTS
Geometry courtesy of Skoda Auto a.s.
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Wrapping is able to close large holes in geometry, whilst still
capturing fine details:
Engine geometry Wrapped surface
DATA PREPARATION
iconCFD WRAP: RESULTS
Geometry courtesy of Skoda Auto a.s. Geometry courtesy of Skoda Auto a.s.
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DATA PREPARATION
iconCFD WRAP: SUMMARY
Example: Eccomas Demo Fabia
<6 engineer hrs Training
<30 engineer mins CAD Preparation
<2.5 computer hrs Wrapping
<15 mins engineer mins Case Preparation
<1hr 30 computer hrs Meshing
<5 hrs TOTAL
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Fully automatic
Fully parallel
Hexahedral-dominant
MESHING
With kind permission of:
Koenigsegg Automotive AB
iconCFD MESH
Number of cells 20M 100M
Number of CPUs 128 256
Meshing time <20mins <30mins
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iconCFD MESH
STRUCTURED MESHING IN CORNERS
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AERODYNAMICS
2009 v1.x VALIDATION
• Validation using experimental data from VW Group wind tunnels
Ref. 2009: SAE 2009-01-0333
“The technical and business benefits delivered by
the AeroFOAM process from ICON are significant”
VW Group Press Statement, July 2009
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AERODYNAMICS
2017 v3.x VALIDATION
Publication 2017:
An Extensive Validation of an Open Source
Based Solution for Automobile External
Aerodynamics
Presented SAE World Congress 2017
(Ref 2017: SAE 2017-01-1524).
Drag prediction of large palette of shapes (B-
car, Sedan, SUV, trucks) comparison versus
experimental data.
Transient and steady state simulation.
Static and moving ground.
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iconCFD
WHEELS ACCURACY - UNSTEADY
WD1 WD2 WD3 WD4 WD5 WD6 WD7 WD8 WD9
0.005
Sumec, M., Papper, J., Devaradja, R., Simanek, P. et al., "Industrial Application of an Advanced Elliptic-
Blending Turbulence Model for Wheels Aerodynamics Analysis," SAE Technical Paper 2018-01-0739, 2018
Alternative successful steady approach:
Cd [
1]
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EXP PANSPartially Averaged Navier Stokes
Intelligent transition URANS and NS
ζ-f PANS model available in iconCFD
Full unsteady 15 hrs on 700 cores
150 Mio cells
Less mesh dependence
Higher time steps = faster
iconCFD
iconCFD V.4
Wheels and ride height accuracy:
100% URANS 5% URANS, 95% Navier-Stokes
0.010
Cd [
1]
Investigation of a Modern and Hybrid Turbulence Modelling Approach for Transient Automotive Aerodynamic Simulations,
ECCOMAS 2016, Greece
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iconCFD
METHOD CALIBRATION
ICON Best Practice Experienced
Support Engineers Wind Tunnel Data
Client Specific Best Practice
integration
Easy-to-Use App on a cloud
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iconCFD MultiCase
Geometry courtesy of TUM WIND TUNNEL TEMPLATE
Easy WTT replacement. Above realWT geometry compared with boxWT.
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DES AND DYNAMIC MESH
iconCFD MultiCase
Geometry courtesy of Audi AG, I/EK-44
Correct rim pressure
distribution can only be
captured with dynamic
movement: MRF or
other velocity BCs are
not enough.
Delta wheel replacement
zero as WT test
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Pre-Processing
iconCFD Process
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ICON
WLTP
1. WLTP=Worldwide harmonized Light vehicles Test Procedure
2. It is a United Nations Global Technical Regulation (UN GTR)
3. Method for determination of emissions, fuel consumption, electric energy consumption and
range for light duty vehicles in repeatable and reproducible manner
4. Valid from 2018
Mass
Roll Resistance
CD X Af
F = f0 +f1V+f2V2
WLTP Cycle
Speed vs Tiime
Dynamometer lab CO2
Manufacturer
Regulation
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WHY ICON DWT
ACCURACY Methodology validated
against a large variety
of WTs, not just one.
Many different brands
and vehicle shapes.
2-4% Cd prediction
accuracy.
iconCFD® is capable
of capturing small
changes and correctly
predicts trends
between designs.
Leading commercial
product has scored
89% on the same
ranking test (iconCFD
scored 91%)
Ref: SAE 2016-01-1599 (April 2016)
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ICON SERVICES
DWT CALIBRATION
Innovative approach for pressure measurement in low speed aerodynamics
24 small (h:1.1mm) digital pressure sensors (MEMS) on flexible strip
Pressure distribution along a line/curve (up to 4 meters long)
Hundreds of sensors installed quickly (minutes) at any place of interest
Accuracy 5 Pa (Cp ≈0.01)
Connect multiple P-strips in a tree, reading all data through a single cable
Key data for better insight into flow field, essential for Digital WT calibration
P-Strip located on suction side of a rear
down-force wing
Several P-Strips connected to a tree to
gather data from hundreds of sensors
Pressure (Cp) from 14 p-strips (336
sensors) compared with CFD
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AERO DEVELOPMENT
RALLY CAR REAR WING
-Cp(c
orr
ecte
d)
x/c
1
central section
Rear wing for Skoda Fabia R5 developed by ICON engineers
Steady/k-ε-ζ-f
MOGA+EGO
ADJOINT
P-strips
Courtesy of Škoda Auto
Courtesy of Škoda Auto
Courtesy of Škoda Auto
Courtesy of Škoda Auto
Courtesy of Škoda Auto Courtesy of Škoda Auto
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iconCFD OPTIMIZE
OPTIMIZATION
Push inwards Pull outwards
Adjoint shape optimization
Adjoint simulation to calculate
sensitivities relating to cost
functions like lift or drag
Visualize and understand how to
improve
2013, Courtesy of
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iconCFD OPTIMIZE
OPTIMIZATION
Adjoint shape optimization
With iconCFD Optimize the vehicle
can automatically be modified
(morphed) based on the adjoint
sensitivities
Original
Morphed
2013, Courtesy of
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iconCFD MULTICASE
DES or RANS Primal Flow
Solution acceleration
through mapping of
previous flow field
Adjoint Shape
Optimization Solution Lossless Direct
Geometry Deformation
Automatic
Mesh
Generation
OPTIMIZATION CYCLE
Ref 2016: SAE 2016-01-1599
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iconCFD OPTIMIZE
Improved geometry morpher capability
Improved smoothing functionality Improved surface normal calculation Curvature smoothing for feature preservation Improved mapping on the geometry Improved smoothness of interpolation Forcing symmetry of geometry modifications Maintaining geometry connectivity. Option to define static, moving and following patches Adhere to total maximum displacement through adjoint iterations Thin wall treatment
MORPHING
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iconCFD Optimize
DUCT OPTIMIZE
Radiator duct optimization
Lamborghini “sesto elemento”:
Original duct
design Adjoint Topology
duct
Ref: OSCIC 2013, London
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OPTIMIZATION
DOE WORKFLOWS
USER optimizer morphing mesher-solver
Loop
USER POST
Design Space Exploration+ optimization
STL geometry morphing
Automatic mesh + RANS solution
Data mining: -Approximation model -Sensitivities -Variant comparator
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iconCFD VOF
WADING / FORDING
Car wading simulation in iconCFD3.2.X.
Simple, robust and quick setup using
iconCFD-Process MultiCase.
Possibility to combine VOF and AMI for
rotating wheels conditions.
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SOILING
WATER MANAGEMENT
Droplet deposition
Film transport
VOF
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CFD APPLICATION
SOILING
Soiling simulations are currently
implemented and calibrated according
to experimental results from climatic
wind tunnel.
Illustrative pictures
Illustrative pictures
The objective is to predict soiling
problems before the car
prototype is manufactured and
tested on track.
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iconCFD THERMAL
RADIATOR HEAT DISSIPATION
Transient heat transport
from radiator through engine
compartment
Centre-line engine bay
flow and wake structures.
Transient DES with buoyancy
effects and heat sources
(iso-surface of zero total pressure)
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iconCFD
CLIMATISATION
HVAC simulations to analyse:
Passenger comfort
Defog / Defrost
System efficiency
Duct optimisation
Ref 2012: Adjoint Duct Topology Optimisation
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BRAKE COOLING
iconCFD Thermal
Novel simulation methods
CHT
S2S radiation
User-defined
materials database
CHT interfaces are
managed automatically
Geometry courtesy of Audi AG, I/EK44
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Example: Side Mirror
iconCFD ACOUSTIC
Microphone 4
Microphone 84
Geometry
courtesy
of Audi AG
EK-44
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iconCFD VOF
GEARBOX
Courtesy
Engineering Services
Provider (Italy)
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iconCFD
ADAPTIVE TET. REMESHING
Proof of concept adaptive
tetrahedral re-meshing for
deforming domain
computations
Multi-boundary motion
Boundary element
smoothing
Internal mesh quality
optimizer
Local, conservative field re-
mapping throughout the run.
Ref. Menon, Mooney, Stapf, & Schmidt. Journal of
Computational Physics. 2015
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iconCFD REACT
Laminar reaction rates using
the Arrhenius rate model
Infinitely fast chemistry
Multi-species diffusion
model
Eddy breakup model
(reaction limited by turbulent
micromixing)
Coupling to Lagrangian two-
phase heat and mass
transfer
CHEMISTRY
Validation case: iconCFD React vs. alternative chemistry solver.
H2 detonation.
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iconCFD EMP
Accurate, engineering level
solutions to highly complex
flows
Liquid, vapor, and gas phases
represented by a single Favre
averaged momentum field
EULERIAN MULTIPHASE
Fuel atomization modeled as
turbulent mixing
Transport equation for
interfacial area predicts SMD
Phase change modeled
using Homogeneous
Relaxation Model (HRM) Flashing (left) and non-flashing (right) GDI injection. Volume render of
HRMFoam simulation (bottom), experiment footage (top). From E.T.
Baldwin / IJMF, Volume 87, December 2016, 90-101. Industrialisation by ICON
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iconCFD FSI
Non-linear membrane
simulation
Study of dynamic loads
using coupled Fluid-
structure analysis
Deformation due to high
speed aerodynamic loads
Courtesy
Non-Linear coupled simulation
Stress Field
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iconCFD PLATFORM
SOFTWARE-AS-A-SERVICE
Source: https://twitter.com/iconcfd
EC Commissioner Oettinger
commending innovative ideas in
ICON’s next generation digital
technologies.
Hannover Messe Apr. 2016
100% of aerodynamic development on
Koenigsegg One:1
100s of simulations in less than 8 months
250% downforce increase + 15% drag
increase at 250km/h
50% downforce increase at 440km/h
Ref. iconcfd.com/platform
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Example: ICSC Shanghai
Islam keynote: “Best in class aerodynamics &
aeroacoustics for new Audi A4”
ICON
EVENTS 2007 – 2013: ICON Open Source CFD
International Conference
http://www.opensourcecfd.com
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SUPPORT
TYPES
Software Product Support (bug fixing / new features etc…) Included with software
New features can be shifted to earlier releases upon agreement
Product Engineering Support (vehicle development / part development etc…) Aero / Thermal / Acoustic engineers deployed on-site or off-site
Process Support (workflow development / best practice development etc…) Process engineers deployed on-site or off-site
R&D Support (new concept development / new Multiphysics simulation
capability etc…) Collaboration with ICON software and methods development team of scientists
Software Development Support Development Trainings
Code review / integration
IT Support HPC issues, job scheduling, data management …
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SUMMARY
WHY ICON?
Simulation Engineering Experts for 25yrs
Simple, effective commercial & delivery model
Leading Open Source based CFD partner to industry for >13+yrs
65% of top 20 auto manufacturers have contracted ICON in last 3 yrs
Largest Open Source based CFD development team
100+ CAE Engineers in the group and continuing to recruit new talent
<1 day training required
Continuously innovating to stay ahead for 25yrs
Customisable architecture for coupled processes
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ICON®
RECOGNITION
“The technical and business
benefits delivered by the
AeroFOAM process from ICON
are significant” [VW Group Press Statement, July 2009]
EU Commissioner commends ICON next
generation digital WT at Europe’s largest
trade show [Hannover Messe, 26 April, 2016, https://twitter.com/iconcfd]
Thanks to ICON we have achieved outstanding
results in very tight time frame. The key role of
ICON in this achievement is undoubted. The
ICON on-site staff has demonstrated high level of
professionalism and education. [ Skoda Auto a.s. manager official letter, Jan 2014 ]
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QUESTIONS?
MORE INFORMATION?
www.iconCFD.com
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THANK YOU
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It must not redistributed, be reproduced in whole
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