Thermal Desktop / STAR-CCM+®

Co-Simulation

Prepared for the STAR Global Conference

Matt Garrett

CRTech

March 17, 2015

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THERMAL DESKTOP

OVERVIEW

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CRTech Background

● Founded in 1992

● 5000 users in 40 countries

● Selected Customers: NASA (standard thermal tool at all centers, site license),

Boeing (standard thermal tool at all facilities, site license),

Lockheed Martin (standard thermal tool at most facilities),

Others: Aerospace Corp., Aerospatiale, DLR, General Motors, Goodrich, Hamilton

Sundstrand, Jacobs Sverdrup, Kawasaki, Los Alamos National Lab, Mitsubishi, Northrop

Grumman, Orbital Sciences, Raytheon, Sandia, Thales-Alenia, Toshiba, ULA, U.S. Air

Force, Army and Navy, ZF Friedrichshafen

● Products:

Thermal Desktop (3-D pre- and post-processing)

RadCAD: orbital heating, radiation, complex conduction

FloCAD: fluid network in CAD for piping, vessels, convection with thermal structures

SINDA/FLUINT (thermal and fluid network solver)

TD Direct (geometry cleanup and meshing)

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Thermal Desktop Suite

● Solves thermal and fluid networks using lumped

parameter methods

● Commonly used to create system-level models

● Complements CFD

Fast radiation calculations with RadCAD Transient, articulating geometry, specular reflection,

transmission, wavelength-dependence, etc.

Empirical, fast-solving fluid network models with

FloCAD

Transient, multi-phase, multi-species, compressible

Built-in flow network components

Turbines, pumps, compressors, heat exchangers

Orifices, valves, tees, bends, wall friction

Variable-molecular weight fluids, reacting flows

Used for: capillary loops, heat exchangers, water

hammer, etc.

● Simultaneous thermal and fluid solutions

● Optimization and reliability calculations4

CUSTOMERS USING CFD

AND THERMAL DESKTOP

TOGETHER

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STAR-CCM+ Model of Upper Stage Tanks

Coupled to TD Model of Piping/Structure

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SNC Dream Chaser®

Cabin

CFD Applied to TD Model

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NASA JPL Curiosity Rover

CFD Applied to TD Model

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Boeing Primary Exhaust CFD

Applied to TD Model

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NASA KSC Flame Deflector

CFD Applied to TD Model

From “Modeling of Heat Transfer and Ablation of Refractory Material due to Rocket Plume Impingement”, Michael F. Harris (QinetiQ), Dr. Bruce T. Vu (NASA KSC), Proceedings of the NASA Thermal and Fluids Analysis Workshop 2012, Pasadena, California 10

Anti-Ice Exhaust CFD Applied

to TD Model of Nacelle

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VISION FOR THE FUTURE

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Tight Coupling of STAR-CCM+ and

Thermal Desktop

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Loose Coupling Example: Using STAR-CCM+ to

Model Tee in a Sprinkler System

Pressure drop in Tee based

on correlation with uncertain

validity. Desirable to

test/replace with CFD results.

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FloCAD Sprinkler Model with

STAR-CCM+ Tee Model

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Summary

● CRTech Thermal Desktop complements CFD

Fast-solving, system-level, transient models

Radiation

1D piping networks with multi-phase, multi-species flow

● Customers already using STAR-CCM+ and Thermal

Desktop together

● CRTech and CD-adapco™ are working to make using

STAR-CCM+ and Thermal Desktop together better and

easier

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BACKUP SLIDES

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FloCAD Sprinkler Model

Tee K Correlation

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Aeroheating

● Loose coupling

● TD system-level model of a vehicle performing transient analysis of re-entry, initialized with

orbital results

● STAR-CCM+ model supplies external fluxes during re-entry

● TD Boundary Condition Mapper used to input data Already used by TD customers

Will determine best practices for STAR mesh type and density

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Compartment and Cabin Air

● Tight coupling

● TD system-level model of a vehicle (thermal and piping)

and passengers coupled with STAR-CCM+ model of

compartments and/or cabin

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Prelaunch Purge

● Loose coupling

● System-level spacecraft and launch vehicle model in TD

● STAR-CCM+ model provides fluxes from purge air to spacecraft and launch vehicle

● Alternative: automatically create reduced-order fluid model in TD from STAR-CCM+

model

For U.S. launches, spacecraft

models are typically built and

certified using Thermal

Desktop, then integrated with

standard launch vehicle

models, also built in TD.

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Rocket Nozzle

● Tight coupling

● STAR-CCM+ model of primary flow coupled to TD

model of cooling channels and associated piping

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Aircraft Fire or Burst Duct

Modeling

● Loose or tight coupling

● TD system-level model of aircraft assembly

● Coupled to STAR-CCM+ model of compartment with fire/hot jet, or uncoupled

STAR-CCM+ model of fire/hot jet provides fluxes to aircraft structure

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Fire Suppression System

● Tight coupling

● STAR-CCM+ model of room and spray from nozzles

● TD model of supply piping

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Electronics Cooling

● Tight or loose coupling

● Example 1: Heat Sinks (and perhaps Fans)

STAR model of heat sinks for performance characterization (by-pass

ratios, effectiveness)

TD model of electronics and structure, including transients and

system-level studies

● Example 2: Box-level

STAR model of flow through compartments, around boards (velocities,

heat transfer coefficient averages)

TD model at board, chassis, or compartment level, including any liquid

cooling devices

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Cryo Tank

● Loose coupling

● Example 1: Initial cold gas fill

Cold vapor enters before liquid does, and stresses light-weight

structures. TD can take over efficiently once liquid enters and

dominates.

Requires a hand-off: mapping of STAR final conditions to TD initial

conditions

● Example 2: Stratified tank recirculation

TD supplied system-level boundary conditions

STAR estimation of recirculation (boundary layer) velocities and

perhaps effective heat transfer coefficients (to both wall and surface)

TD estimations of drain profiles (liquid temps), pressure control system

events

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