moving particle simulation

Moving Particle Simulation

Massimo Galbiati

m.galbiati@particleworks-europe.com

Particleworks Europe

▪ Particleworks Europe is the master distributor of the Moving Particle

Simulation software Particleworks from Prometech Software Inc

▪ European competence center

▪ We deliver high quality support to distributors and customers for the

industrial application of advanced mesh-less simulation techniques

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Particleworks Europe

▪ Simulation software

▪ Consulting services

▪ Training and know-how transfer

▪ to a wide spectrum of industrial

sectors HQ

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Moving Particle Simulation

▪ Particle-based CFD → mesh-less Navier-Stokes solver

▪ Liquid flow analysis (sloshing, free surface, oil splash, jets and spray, …)

▪ Fluid-solid heat transfer and temperature prediction

▪ Multi-phase flow

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Moving Particle Simulation

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Benefits of MPS: simulation early in the design process

▪ Drastically reduce pre-processing time, use the CAD as is, no mesh

▪ Faster simulation thanks to GPU acceleration and higher numerical

stability when dealing with multi-phase flow and complex-moving

geometries (gears, bearings, pistons,…)

▪ Simulation in days instead of weeks → Simulation earlier and integrated

into the design process → enables design improvement, optimization,

problems predicted and solved in the virtual world

One prototype, first time right

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Moving Particle Simulation vs. mesh-based CFD

Moving Particle Simulation Mesh-Based CFD

Pre-processing(geometry, mesh, setup)

1 h 1 week

CPU Time 5 [s] in 4 days on multi-core

5 [s] in 1,1 day on GPU1 [s] in 3 weeks

Cores 8 Intel Core i5-2400 - 3.10GH 32 Intel Core i5-2400

GPU TESLA K40

TOTAL TIME 1,5 DAYS WEEKs

▪ Comparison by Comer Industries on a reduction gearbox in 2016 using

Particleworks (MPS) and a Finite Volume CFD software.▪ Paper at https://particleworks-europe.com/index.php/ComerIndustries-Oilsplashing

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Applications

Courtesy of Courtesy of

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Partnerships

▪ Integration with third party software

▪ Simulation chains and loops

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▪ Driveline design

▪ Multi-body dynamics: MSC Adams via FMI, direct interface to Recurdyn

▪ Software as a service

▪ Straightforward data transfer with any FEA

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Ansys Workbench interface for ParticleworksHeat Transfer Analysis

Heat transfer coefficient

Structural

AnalysisPressure

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TRANSMISSIONS

Integration of design and lubrication analysis

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Simulation in the design process

▪ Simulations early in the design process → design improvement

▪ One prototype, first time right at lower costs, in less time

▪ Particleworks:

▪ makes the CFD process faster

▪ makes the process simpler and safer: best practices for lubrication analysis

developed and validated with a number of gearboxes manufacturers

▪ extends the use of simulation to driveline engineers

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Fast oil flow analysis using virtual prototypes

▪ Evaluation of different lube strategies, oil splash vs forced

▪ Evaluation of different conditions: rpm, oil level, temperature, …

▪ Evaluation of different geometries, internal baffles, housing, pump

location

▪ Extreme conditions, hill start, cornering, panic stop, …

Know-how via virtual prototypes

Ensure good lubrication and minimize temperature and power losses

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Case study

ELECTRIC

MOTOR

AXLE

COUPLING

GEARBOX

COUPLING GEARBOX DATA

Overall ratio: 11,43

Input speed: 700 - 6000 rpm

Both cw and ccw sense of rotation

0° - 30° - 60° - 90° working positionsApplication: WHEEL LOADER

Courtesy of

https://particleworks-europe.com/index.php/ComerIndustries-HighSpeedTransmissions

Ensure good lubrication and minimize power losses

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INPUT AXIS

IDLER AXIS

OUTPUT AXIS

WORKING POSITION 30° TO VERTICAL

Brg 1 Brg 2

Brg 3 Brg 4

Cases 1 2 3 4 5 6

Input speed [rpm] 705 705 2500 2500 6000 6000

rotation CW CCW CW CCW CW CCW

MPS Model Courtesy of

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Simulation vs Clear Case 2500 rpm - CCW

Look at the idler and input bearings

Pw predicted dry bearings at the input (top), confirmed by the clear case

Courtesy of

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DRY

GOOD LUBE

Simulation vs Clear Case Courtesy of

Pw predictions confirmed by the clear case 17

Design Enhancement - Spray Jet Examination

▪ Improving the lubrication of the gears will result in efficiency gains, critical in motorsport:

▪ Reduced overall temperature

▪ Option to run with less oil volume & decrease churning losses

▪ Improved component Life

Courtesy of

With a simple change to the geometry of the nozzle

we can increase both the spread and velocity of the

oil, increasing its effectiveness at both cooling and

lubricating the gear flanks, as well as giving a jet

angle that is a net contributor to shaft rotation,

rather than putting a reverse torque or load on the

shaft.

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Oil Pump Scavenge Under Dynamic Conditions

▪ For transmissions equipped with a single stage oil pump the location of the scavenge port is

critical.

▪ Particleworks allows to accurately position this and manage the flow of oil around it.

Courtesy of

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Output from gear box MPS simulations

▪ Oil distribution, qualitative visualization of oil flows

▪ Oil volumes and flow rates calculation (e.g. to bearings)

▪ Churning losses

▪ Heat transfer coefficient distribution on walls

▪ Heat transfer between fluids and solids → temperature

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E-MOTORS

Simulation chain and integration with Design

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E-motor design

3D electromagnetic analysis, power

losses

Internal cooling: oil jet analysis

Thermal analysis

Heat source from EMAG and cooling from oil jets, materials from e-motor design

Temperature, hot spots, comparison of different concepts / designs

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Particleworks workflow

E-motor fluid analysis

Heat Transfer

Coefficient

Thermal analysis

Temperature

▪ Windage effects

▪ Flow rate distribution in rotor-shaft

▪ Oil distribution and accumulation

Courtesy of

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Fluid and thermal

E-motor fluid analysis

Heat Transfer

Coefficient

Thermal analysis

Temperature

Moving Particle Simulation Finite Element Analysis

Courtesy of

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Temperature validation

▪ Ricardo validated the temperature predicted by the numerical process

▪ Target: max temperature difference (simulation – measure) ±5°C

▪ All points met this criterion with a max difference of ±2.8°C

Courtesy of

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IC ENGINE

Lubrication, piston cooling, gradeability, oil sump aeration …

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Piston cooling

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Comparison of average HTC on the piston @ 16000rpm

▪ Ducati was looking for a new design of the nozzle to guarantee the same

cooling efficiency of the original design, but with a lower flow rate

▪ A new design with comparable HTC and -20% flow rate was identifies

Same HTC

-20% flow rate

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Piston Temperature validation

▪ Wartsila compared local temperature

measurements and numerical predictions for

different operating conditions of the engine

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WATER MANAGEMENT, SNOW, SOILING

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Wading Simulation: coupling vehicle dynamics and water flow

This model has been developed by The National Crash Analysis Center

(NCAC) at The George Washington University under a contract with the

FHWA and NHTSA of the US DOT

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Tire – water interaction

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Snow modeling

▪ Particleworks has a DEM module (Discrete Element Method -

Granuleworks) that allows simulating dust, sand, … and also snow

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Contamination

▪ Aerodynamic solution imported from a third-part CFD and used to

calculate the rain drops trajectory

▪ Contamination, water suction in the HVAC, visibility, …

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m.galbiati@particleworks-europe.com

particleworks-europe.com