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EnSight: A Powerful Tool for
Visualizing Fluid Flow Coupled with
Particle Simulation
Nicolas Spogis, Ph.D.Business Coordinator
E-mail: [email protected]
Daniel Schiochet NasatoBusiness Analist
E-mail: [email protected]
www.esss.com.br
Acknowledgements
Simulation of Grain Cleaning System Using
Coupled CFD, DEM and FEA Methods
Alberto Hö her Junior
Product Engineering - Combines
AGCO do Brasil
Simulation of an Aggregate Dryer Using
Coupled CFD and DEM Methods
Andrew Hobbs
Research Engineer
Astec, Inc.
www.esss.com.br
Agenda
• ESSS – The company
• Multi-physics
– Coupled Physics
• Simulation of an Aggregate Dryer Using
Coupled CFD and DEM Methods
• Simulation of Grain Cleaning System Using
Coupled CFD, DEM and FEA Methods
• Concluding Remarks
www.esss.com.br
~ 500 Customers
Auto
Aerospace
Appliances Oil & Gas
Metals
Turbomachinery
EMBRACO
WHIRLPOOL
ELECTROLUX
CARRIER
WEG
TECUMSEH
ARNO
EMBRAER
CTA
INPE
CONIDA
EQUATORIAL
ALSTOM
EDELCA
IMPSA
KSB
VOITH
EAFIT
THEBE
MAGNESITA
CSN
ARCELORMITTAL
VALE
CODELCO
GERDAU
PETROBRAS
MAERSK LINE
SAUDI ARAMCO
PDVSA
CHEVRON
STATION
EXXONMOBIL
ALSTOM
DAIMLER
SIEMENS
FORD
VDO
LUK
MAHLE
“Developing scientific
software and providing
leading-edge technology
for engineering problems,
ESSS brings to the market
know-how in numerical
methods and computer
science available only in
advanced research
centers.”
www.esss.com.br
Computer Aided
Engineering
SoftwareDevelopment
Divisions
Sales
Support
Training
Consulting
Custom Software Development
Software Customization
Team
Offices
~100 Members
www.esss.com.br
Multi-physics
• As companies start producing
more innovative and higher
quality products, the simulation
of individual physics is no longer
adequate for the design of many
products.
• Multi-physics simulation allows
engineers and designers to
evaluate their designs operating
under real-world conditions.
DEM
Structural
Fluids
Thermal
EmagPlantD(s)y(t)u(t)+
-
www.esss.com.br
Why do Coupled Simulations?
• Most industrial processes involve more than one
type of physics
• In many problems, the surrounding fluid effects the
particulate phase or the structure and vice versa
• Often, continuum methods alone cannot capture
bulk particle behavior, fluid/particle interaction or
the particle/particle interaction
• A multi-physics approach is needed:DEM (particle phase) + CFD (fluid phase) + FEA (Structure)
www.esss.com.br
Multi-Physics Post-Processor - EnSight
• EnSight allows engineers anddesigners to post-process theinteraction between:– Structural mechanics (FEA)
– Heat transfer (FEA, CFD)
– Fluid flow (CFD)
– Acoustics (FEM)
– Particles (DEM)
– Electromagnetics (FEM)
– Import CAD Geometries
• All within a single interface!
www.esss.com.br
Characteristics of particle-fluid systems
• Dilute– Cyclone separation
– Agitation: fluidized and spouted beds
– Entrainment: erosion, cleaning
• Dilute dense– Filtration, sedimentation
• Dense– Dense phase conveying
– Slurry transport
– Mixing
www.esss.com.br
EDEM / FLUENT Coupling
• EDEM can be coupled with ANSYS-FLUENT for
simulation of multi-phase flows at the particle-
scale.
• The coupling enhances ANSYS-FLUENT
multiphase models by including particle
characteristics (size distribution, shape,
mechanical properties, surface forces, etc.) which
strongly influence both particle and fluid dynamics
www.esss.com.br
FLUENT
iterated to
convergence
Drag forces on
DEM particles
calculated
DEM iteration
performed
Particle
parameters
updated
Momentum
sinks / sources
added to the
CFD mesh cells
Fluid velocity vector
EDEM / FLUENT Coupling Method
www.esss.com.br
Fluid Mass
Conservation
Momentum
Conservation
Particle Reynolds Number
0
FFFFF v
t
vLcell
Re
44.0
Re/)Re25.00.1(24
Re/24
687.0
Dc
1000Re
1000Re5.0
5.0Re
vvAcF Dd 5.0Free Stream
Drag Force
V
F
gpvvvt
n
i
D
FFFFFFFFFFF
Eulerian CFD-DEM Coupling Theory
www.esss.com.br
Heat Transfer
Ranz & Marshall
Mass fraction calculated using sample points
PFPPFPF TAhQ P
PFPF
d
NuKh
3/12/1 PrRe6.02 PNu
8.15
3/18.02/1
3/12/1
Re5.42
PrRe02.0Re5.02
PrRe6.02
P
n
F
P
n
FP
n
F
P
n
F
e
Nu
1500Re
1500Re200
200Re
P
P
P
Li & Mason
particles
pcp
pN
Vntm
Eulerian CFD-DEM Coupling Theory
www.esss.com.br
Multi-Physics
• The ANSYS Multi-field solver provides the ability to solve coupled-field
problems such as the following:
– MEMS Actuation (electrostatic/structural without fluid coupling)
– Electric Machines (magneto/thermal/structural coupling)
– Joule Heating (thermal/electric/structural coupling)
– Induction Heating (harmonic electromagnetic/thermal coupling)
– Induction Stirring (harmonic electromagnetic/thermal/fluid coupling)
– RF Heating (high-frequency electromagnetic/thermal/structural coupling)
– Thermal/Stress Analysis (thermal/structural coupling)
– Fluid Solid Interaction Analysis (fluid/structural coupling)
ESSS and DEM Solutions are implementing
EDEM / ANSYS Coupling
www.esss.com.br
EDEM / ANSYS Coupling
• EDEM simulates the
geometry movement and
calculate loads on the
structure due to particle
interaction
• ANSYS calculates the
stresses using loadsets
provided by EDEM.
• Objective
– Prediction of structural
response for different
geometries and materials.
EDEM Model
Solve ANSYS
Model
Interpolate loads on
ANSYS mesh
www.esss.com.br
DEM-FEA Coupling Procedures
• 1-Way DEM-FEA
– Coupling - Steady State
– Get one time-step EDEM
result and interpolate loads
on ANSYS Mesh
EDEM
EDEM
ANSYS
ANSYS
• 1-Way DEM-FEA
– Coupling - Transient
– Transient EDEM loads
interpolated on ANSYS Mesh –
Load Steps
• 2-Way DEM-FEA
– Coupling - Transient
dev
elo
ped
Un
der
dev
elo
pm
ent
www.esss.com.br
Bucket Search Method
• The bucket search method is designed to alleviate the inefficiency problem that the global method has when the number of nodes increases.
• Interpolation Methods:– Conservative interpolation
– Profile preserving interpolation
• Computational Nonlinear Mechanics in Aerospace Engineering,
American Institute of Aeronautics and Astronautics, edited by S. Atluri,
ISBN 1563470446, Chapter 5, Fast Projection Algorithm for Unstructured
Meshes by K. Jansen, F. Shakib, and T. Hughes, 1992.
Area-weighted Interpolation
www.esss.com.br
EDEM-ANSYS 1-Way Coupling
Setup ANSYS Model Run EDEM Model
Export EDEM
LoadsCreate Named
Surface
Solve and Evaluate
ANSYS ResultsInterpolate Loads
With APDL
www.esss.com.br
Simulation of an Aggregate Dryer
Using Coupled CFD and DEM Methods
Andrew HobbsResearch Engineer
Astec, Inc.
www.esss.com.br
Astec Industries, Inc.
• 2007 Revenues $869 million
• Asphalt Group $240 million
Astec, Inc. (Asphalt Group)
based in Chattanooga,
Tennessee
America’s leading manufacturer of
equipment for aggregate processing,
asphalt road building and pipeline
and utility trenching
www.esss.com.br
• Hot Mix Asphalt (HMA) is made of various sizes of rock aggregates mixed
with liquid asphalt cement (AC) binder
• For the binder to adhere properly the aggregate must be completely dry
• 5% aggregate moisture is common for most locations
• Plant output of 350 Tons per hour = 35,000 lbs/hr H2O
• Approximately half total heat input goes towards the evaporation of H2O
Drying efficiency is a key aspect
of the HMA production process
Drying Rock in a HMA Drum Mixer
www.esss.com.br
• Hex/tet hybrid mesh
1.7 million cells
• Eulerian multiphase
• Realizable k-ε
• Eddy Dissipation
with 2 step CH4
reaction
• Premixed fuel/air
velocity inlet
• Adiabatic wall
conditions
Fluent 6.3
FLUENT Parameters
www.esss.com.br
• Geometry creation
• FLUENT grid without interior features
• Converge steady, multiphase FLUENT case with reacting
natural gas flame
• Change to FLUENT case to unsteady
• Setup EDEM, rotating drum with interior features
• Couple to EDEM as E-E with heat transfer between phases
• Run….
Coupled Simulation Methodology
www.esss.com.br
Simulation of Grain Cleaning System using
Coupled CFD, DEM and FEA Methods
Alberto Höher JuniorProduct Engineering - Combines
AGCO do Brasil
www.esss.com.br
Agricultural Innovations
• Massey Ferguson is part of AGCO Corporation. As an individual brand,
it is one of the biggest names in farm equipment throughout the world
with a 150 year history and heritage that confirms its leading role in
global agriculture.
• MF is truly international in its breadth of experience and sells its
products in more than 140 countries through a network of over 5000
dealers.
www.esss.com.br
• Objective:– Simulate Straw material and Soybean
separation on a Cleaning System
• Straw Material modeled as
14 spheres of 3mm radius
• Soy grain – 3mm radius
Grain Cleaning System Simulation
Initial Studies
www.esss.com.br
Cleaning System
• An 11 inch or 13 inch diameter fan assures high volume, low pressure air flow for increased cleaning capacity and exceptional grain quality.
• EDEM + FLUENT+ ANSYS Analysis – Evaluate particles trajectory.
– Ensure good particles separation.
• Identify the ideal air velocity:– To carryon raw material
– Keep the grains on the screens
• EDEM / ANSYS Analysis – Evaluate possible grain waste
and wear.
www.esss.com.br
Cleaning System Details
Particles
Inlet
Outlet
(storage)Grain transport
Grain / raw material
separation
Air blower
www.esss.com.br
Vibrating Screens Details
Displacement: y = 18.7mm z= 58.4mm
frequency 5.67Hz
Air Blower Top Screen
Air Blower Bottom Screen
Feed distributor
displacement: y = 17.9mm z= 81.4mm
frequency 5.67Hz
www.esss.com.br
Simulation Results
Particles Inlet
Outlet to Storage
Screw Auger
Separated Soybeans
Screw Auger
Particles Recirculation