CFD Analysis and Design Exploration with STAR-CCM+€¦ · · 2017-10-31CFD Analysis and Design Exploration with STAR-CCM+ ... • STAR-CCM+ ensures computational resources are

CFD Analysis and Design

Exploration with STAR-CCM+Joel Davison

Realize innovation.Unrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017

2017.10.24Page 2 Siemens PLM Software

Discover Better Designs, Faster!

STAR-CCM+

An integrated multiphysics solution for the Digital Product

Automated Meshing

Single User Interface

Comprehensive Multiphysics

Integrated Design

Exploration

Advanced Data Analysis

Application Specific

Workflows

Parallel Efficiency

Workflow Automation



STAR-CCM+


Realism with multiphysics

• Integrated multiphysics from a single user interface

• Improved accuracy by taking into account a greater range

of interconnected physical phenomena

• Built on a backbone of state-of-the-art, industry leading

CFD capabilities

• Both finite element and finite volume approaches

• No need to compromise

• Choose the scheme appropriate to the physics

• Integration with CAE tools to expand simulation scope

• Flexibility to us the right tool for the job

• Loose and fully coupled co-simulation with 1D & 3D

software solutions

“We’ve been able to deepen our analysis and drive engine designs

faster and more effectively with the same resources as before”

Jeff Schlautman, General Motors



STAR-CCM+


Realism with multiphysics

Fluid dynamics

Multiphase flows

Reacting flows

Solid mechanics

Particle flows

Rheology

Electrochemistry

Electromagnetics

Aero-acoustics

Fluid-structure

interaction

Conjugate heat

transfer



Mass flow outlet for coupled solver and compressible flows

Expands applicability and improves ease of use

Predict characteristic speed lines all the way to

surge

• Typically hard to converge operating points

towards surge with pressure outlet

Allows available boundary information to be applied

• For many applications only upstream data is

available

Use Cases

• Turbomachinery

D1406



Capsule DEM primitive particles

Improved accuracy in capturing the effect of particle shape

Reduces turnaround time compared to cylinders

Use cases

• Pharmaceutical tablet coating

• Biomass fuel production (wheat straw pellets)

• Fluidized bed gasifiers (feedstock particles)

• New materials research

D3485



Capsule DEM primitive particles

Capsules are spherocylinders

• Made up of two hemispheres connected by a cylinder

• No sharp edges on the surface of capsule

Contact can be modeled with other particle types

• Spheres, cylinders, clumps, composites, polyhedral,

coarse grain

D3485

Contacts with other particle types resolved



Simulations with capsules are faster compared

to cylinders and 5-sphere composites

• Test case: Fluidized bed simulation (10 s, 28320 particles)

• Performance benefit of capsule compared to composite

particle is increasing more than linearly with the number of

spheres per composite particle

Capsule Composite

(5 spheres)

Cylinder

Simulation

time (min) 80 96 87

Capsule DEM primitive particles - performance

D3485



Dynamic mechanism reduction (DMR)

Significantly faster high-fidelity combustion

Dynamic removal of unnecessary reactions

and species in Complex Chemistry

• Effective for chemistries with >50 species

Applications

• Multi-stream combustion in abatement

systems

• Transient combustion and emissions

in gas turbines, furnaces, burners0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

Sandia D, GRI3.0

Sandia D,Marinov

ECN spray H,Wang

ECN spray H,Lu

ECN spray H,Ahmed

CP

U t

ime

sp

ee

du

p

No Acceleration Clustering DMR Clustering + DMR



Dynamic mechanism reduction (DMR)

4x faster with retained accuracy with DMR

N-heptane spray bomb case: ECN spray H

Chemistry: Lu skeletal, 188 species



STAR-CCM+


Productivity with streamlined workflows and automation

• Designed with automation in mind

• Seamless process from geometry to results

• Consistent, robust and repeatable workflows

• Ensuring best practice with simulation templates

• No compromise between usability and functionality

• Easy to learn and use even for advanced

configurations and physics

• Single, flexible yet powerful scripting language

• Automate the complete workflow with Java

• Customize your experience with user designed panels

• Use Simulation assistants for step by step processes

“Compared to before, now we can simulate several dozen cases in

a reduced time. Thanks to this, the number of actual prototypes

being turned out has also been reduced, making an extremely

valuable contribution to lowering cost and man-hours alike.”

Eiji Ihara, Kawasaki Heavy Industries Ltd.



STAR-ICE

STAR-ICE is an add-on to STAR-CCM+, providing a customized

workflow for setting up in-cylinder simulations within STAR-CCM+

• STAR-ICE opens as a minimal model “tree”, separate from the full

STAR-CCM+ simulation tree

• Contains only inputs relevant to the in-cylinder application

• Presents a “top-down” workflow

• Uses terminology and data inputs that are familiar to powertrain

engineers

• Automates mesh-motion setup, saving valuable engineering time

• In various locations, provides feedback on input data to give the user

an idea of the validity of their input data, e.g. valve lift curves and

initial/boundary conditions as profile plots



STAR-ICE

Workflow: Morph-Map Mesh Motion

The study here used publicly

available TCC engine data, which

was created with funding by

General Motors through the

General Motors University of

Michigan Automotive Cooperative

Research Laboratory, Engine

Systems Division:

https://deepblue.lib.umich.edu/

handle/2027.42/108382

D571

https://deepblue.lib.umich.edu/handle/2027.42/108382



STAR-ICE

Workflow: Default Post-Processing Outputs

STAR-ICE automatically creates post-processing output in the form of plots and scenes

• Additional scenes can be created by the

user

• Copy/paste to create more scenes

• Turn on/off automatically-created

cross-sections

• Manually create new cross-sections

• Interactions to customize scenes/plots use

standard methods, familiar to STAR-CCM+ users



Fill report monitors from Solution History representations

Solution history (.simh) substantially reduces time & resources for

Data Analysis

• File sizes are typically 100X smaller

• We know that the time to…

• …Run simulations can take many hours to days

• …Animate through all states in .simh takes minutes

• …Advance between timesteps in .simh takes seconds

Rapidly create more effective time history plots

• Time history data can be quickly reviewed & animated

• Applying scalar extents for the whole time range make

animations easier to understand

Monitors can now be filled rapidly & easily using .simh content

• Dataset Functions can use .simh monitor data sources as input

D863

Time to run sim: ~2.5 days

Time to record simh anim: ~6 min



Fill report monitors from Solution History representations

Case study: Industrial Mixer

• Work with multiple sliding window Field Monitors to understand the effect of

different statistical approaches for averagingD863



Collocated Field Functions for min/max reports

Save time by getting more information from reports

• Reduce the user effort to return quantitative information from analyses

• Further your ability to effectively communicate your results

For Min/Max reports, we now return additional values

• Specify collocated Field Functions as a report property to…

• Find where the maximum temperature is for underhood cases

• Return the mixing intensity for min/max concentrations

• Return species concentrations for min/max Mixing Fraction



Collocated Field Functions for min/max reports

Case study: Industrial Mixer

• Track the location of the maximum tracer concentration

instantaneous sliding window = 10 running average



STAR-CCM+


Efficiency with HPC

• STAR-CCM+ ensures computational resources are

utilized with maximum efficiency

• Solvers that scale to hundreds of thousands of cores

• Parallel meshing reducing turnaround time and

enabling mesh generation on clusters

• Flexible licensing options designed around HPC

• Unique licensing options to ensure software cost doesn’t

limit hardware utilization

• Core count independent Power Sessions

• Usage based Power-on-Demand for cloud deployment

and burst capacity requirements

• Flexible Power Tokens enabling design exploration

“Being able to use the POD licensing scheme and run simulations

on a cloud has been a tremendous help for us in terms of

productivity.”

Mio Suzuki,Trek Bicycle Corporation



STAR-CCM+


Automate

VA

LU

E

Validate Troubleshoot Design Explore

SIMULATION PURPOSE

Most companies operate here

to reduce time and cost

Today’s business pressures force

companies to operate here to design

better products

PREDICTIVE ENGINEERING EARLY IN DEVELOPMENT PROCESS REACTIVE ENGINEERING LATE IN DEVELOPMENT PROCESS

Innovation with built-in design exploration



STAR-CCM+


Innovation with design exploration

• Built-in design exploration and optimization

• Easy to use with a familiar experience

• Comprehensive range of exploration options

• Gain insight into product behaviour and parameter influence with unique post-processing options

• Design Manager

• Facilitating parametric analysis

• No additional license required to enable sweeps

• Design manager with STAR-Innovate add-on

• Explore entire design space and find better designs

• Automatic search using embedded HEEDS technology

• Flexible license scheme to deploy design exploration

“With design exploration in STAR-CCM+ we learned what makes a

good design and how to improve the performance of the system”

Andreas Ruch, ECS Analyst, Airbus



Zip operation

Reduces turnaround time and enables design exploration

Replace single surfaces to enable faster and more local design

changes

• Automatically sew free edges

• Unite open parts

Users can sew free or selected edges within a part

or between parts either as:

• Discrete part generating

• Creates a new part

• Discrete Description generating

• Creates a new description of the input parts

The perimeter can be remeshed automatically to improve quality

D3358

D892

DrivAer Model courtesy of TU Munich



STAR-CCM+


Responsiveness with accelerated software development

• Three major releases a year:

• Delivering state-of-the-art technologies

• Includes over 100 new features and enhancements

with each release

• Collaboration with customers to satisfy immediate

simulation needs

• IdeaStorm for collecting, voting, and commenting on

new feature requests

• Partnering with our users to anticipate simulation trends

allowing them to stay ahead of their competition

• A proven track record of technological innovation since

first release in 2006

With regular releases, new features are always being introduced

into the code, which enables us to produce more accurate

simulations quicker

James Bertwistle, WSP



2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Client-Server

Core Fluid

Dynamics

Interactive Analysis

v1

Native CAD import

LES Combustion

File-based Couplingv3

Core Meshing

Free-surface, VOF

LES / DDES

Combustion

Lagrangian

Multiphase

v2

Mesh Morphing

Eulerian Multiphase

Harmonic Balance

STAR-View+

v4

Power Session

3D-CAD

CAD Clients

Particle Dynamics

Co-simulation

v5

Power-on-Demand

Thin Mesher

Battery Simulationv6

Power Tokens

Optimate

Directed Meshing

Overset

Solution History

v7

Simulation

Assistant

Parallel Meshing

Adjoint Analysis

STAR-Cast

v8

Concurrent

Meshing

Volume Rendering

Overset Gap &

Contact Acoustics

v9

2016

Core Solid

Mechanics

Core Viscous Flow v10

Core

Electromagnetics

Data Focusv11

Continuous Innovation in Technology

2017

Design manager

Ray Tracing

STAR-ICEv12



STAR-CCM+


Success with customer support

• A team of global experts to ensure our customer’s

success

• Dedicated support to provide help every step of the way

• Working closely with users to gain an in depth

knowledge of their processes and requirements

• Providing immediate solutions to your simulation

challenges

• A customer portal, available 24/7

• Access to a huge library of knowledge base articles

• Track support queries and download software

• Chat to support engineers and engage with the

STAR-CCM+ user community

“Support from the engineers at Siemens PLM is great. It’s really

nice to be able to call up an expert with a question, and they make

you their first priority and help you be successful.”

Alex Stoll, Aeronautical Engineer, Joby Aviation



STAR-CCM+

Part of the Simcenter™ Portfolio for Predictive Engineering Analytics

• Realism at each stage of development by combining

multiphysics, multi-disciplinary and systems simulation and test

• Innovative designs with multidisciplinary design exploration,

and data analytics

• Best practices, collaboration and long-term knowledge with

Teamcenter for simulation and data management in the context

of the overall PLM system.



SimcenterTM : Delivering “Digital Twin” Experience

Optimize Efficiency of Excavator for Realistic Soil Loading

Challenge

Predict fuel consumption, structure integrity

and durability for different soil conditions

Objective

Full co-simulation, loads coming from

hydraulic pumps/cylinder are “piloting” the

3D / CFD multi-body model. Provide arms

and bucket motion, predict load and

stresses based on DEM based soil particle

analysis, alter the motion, and feed it back

into the system model

Solution

• Amesim

• Simcenter 3D Motion

• STAR-CCM+




Predict Gas Turbine Blade Shape

Challenge

Gas Turbines operate in an extreme environment,

causing the blades to significantly deform. It impacts

the overall efficiency, and life of the blade

Objective

Predict aerodynamic performance, cooling flow

rates, blade loading and solid temperatures, stress

and blade deflection. Deform the analytic CAD from

the as-manufactured shape to the as-operated and

feed it back for updated flow & thermal prediction

Solution

• Simcenter

• STAR-CCM+

• Simcenter 3D

• NX CAD




Optimize Range and Thermal Comfort of Electrical Vehicle

Challenge

Extend electrical drive vehicle range while

ensuring optimal passenger thermal comfort

Objective

Balance battery performance, to HVAC and

control systems.

Full system simulation with Battery and

Electric Motors coupled with detailed 3D cell

model to predict cell temperature variation,

and optimize battery pack

Solution

• Simcenter

• Amesim

• STAR-CCM+

• HEEDS

AC system

Battery Cooling

system

Vehicle

Electric

Powertrain

Cabin

Control




Optimize NVH of Electrical Vehicle

Challenge

Optimize NVH (Noise & Vibration)

from e-powertrain integration in

vehicle reliability

Objective

Predict structural and acoustic

loading of e-powertrain in electric

vehicle.

Predict vehicle NVH from e-

powertrain optimization.

Enable combined optimization across

e-powertrain and vehicle design.

Vehicle NVH – e-Powertrain Integration

e-Powertrain Structural and Acoustic Loads

Solution

• STAR-CCM+ - SPEED

• Simcenter 3D



CGNS export to LMS Virtual.Lab

Improves ease of use and expands applicability

• Provides a tight link between Simcenter portfolio tools

Comprehensive solution for aero-vibro-acoustics analysis

• Write transient boundary pressure data to CGNS

• LMS Virtual.Lab computes acoustic solution

More robust

• Hard coded parameters encapsulated; less scope for error

No external file converter required

• New file format available from auto-export menu

• Mesh automatically exported at start of run

Main applications are for modelling flow-induced noise sources:

• Side mirror noise

• Propeller noise

• Wind turbine noise



CGNS export to LMS Virtual.Lab

Transform

dipoles into

Neumann

boundary

conditions

Compute

acoustic

solution

Import into

LMS

Virtual.Lab

Export files per

timestep

Generate

transient flow

field in

STAR-CCM+

DrivAer Model courtesy of TU Munich




Frontload Vehicle Energy Management System Optimization

Challenge

Systematically connect data and activities

and close the loop between requirements,

designs and verifications, through the

engineering life cycle

Objective

Achieve engine cooling performance

targets and meet system energy

consumption / fuel economy requirements

in prescribed operating conditions

Solution

• Simcenter

• Amesim

• STAR-CCM+

• Teamcenter for Digital Continuity

2

1

Top tank

temperature

Vehicle drag, radiator

mass flow distribution



Discover Better Designs, Faster!

STAR-CCM+


Automated Meshing

Single User Interface

Comprehensive Multiphysics

Integrated Design

Exploration

Advanced Data Analysis

Application Specific

Workflows

Parallel Efficiency

Workflow Automation



Documents

CFD Analysis and Design Exploration with STAR-CCM+€¦ · · 2017-10-31CFD Analysis and Design Exploration with STAR-CCM+ ... • STAR-CCM+ ensures computational resources are