automation and standardization of cfd workflows and standardization of cfd workflows ... training +...
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Automation and Standardization of CFD WorkflowsDr. Wolfram Kühnel, MAHLE Behr GmbH & Co. KG
• Realize innovation.Unrestricted © Siemens AG 2016
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx2
© MAHLE
The company
Globalization
Standardization
Automation
Examples
– HVAC Wizard
– HEEX Wizard
Conclusion
Outline
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx3
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Group organizationBusiness units and products
The Company – The MAHLE Group
BUSINESS UNITS
Engine Systems and
Components
Founded 1920
Filtration and
Engine Peripherals
Thermal Management
Founded 1905
Aftermarket
BU1 BU2 BU3 BU4
MAHLE Behr GmbH
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx4
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The Company – The MAHLE Group
MAHLE worldwide
Production locations
Research and development centers
Headquarter:
Stuttgart, Germany
Facts (2015):
Employees: 75.635
Sales: 11,5 Bill. €
R&D Centers: 15
R&D Centers NA:
Farmington Hill
Troy
Lockport
Amherst
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx5
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Globalization
CFD and FEA engineers @ MAHLE Behr GmbH
USADetroit: /
ChinaShanghai: /
Wuhan: /
IndiaPune MBES: /
Pune MBIL: /
Germany
Stuttgart: /
BrazilJundiaí/Sao Paulo: -/
˜
´
R&D centers: #CFD/#FEA
< 5 engineers
5 – 9 engineers
> 9 engineers
Charleston: -/
FranceRouffach: /
For globally comparable simulation results
standardized processes and methods are mandatory!
Lockport: /
Luxembourg: /
Central department for simulation method
development
Development of 3D simulation methods
Validation
Documentation + Guidelines
Training + Support
Continuous improvement and enhancement
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx6
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Standardization + Automation
Automation of standardized simulation workflows helps to…
… ensure the compliance of the work to the guideline
… reduce manual effort and tedious work
… reduce errors
… reduce lead time
… work collaborative in a global world
Simulation Workflows
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx7
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Standardization + Automation
Simulation Workflows - Examples
Engine Cooling
HEEX Wizard
Air Conditioning
HVAC Wizard
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx8
© MAHLE
HVAC Wizard
Structure of an HVAC unit
Distribution housing
Blower-filter housing
Air filter
Evaporator
Heater
Mixing-flaps
Auxiliary - heater Blower
Outside-air-inlet
Recirculation-air-inlet
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx9
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HVAC Wizard
HVAC Wizard
Standardized CFD Simulation
Geometry preparation
Automatic Template Creation
Minor surface repair
Prepare/ organize geometry
Physical modeling
Boundary Conditions
Porosities
Heat Source
Rotate flaps
Modus flaps
Mixing flaps
Meshing
Wrapper
Surface Remeshing
Volume Meshing
Simulation run
Post-processing
Standard PowerPoint
report
Predefined scenes
Plots
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx10
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HVAC Wizard
The Tool
Installed as a STAR-CCM+ plug-in
Fully developed by MAHLE Behr
– > 60 Java source files
– > 270 subversioning revisions
– > 30 releases
The HVAC Wizard includes a customized GUI for three different CFD workflows:
Geometry preparation
Physical modeling
Rotate flaps MeshingSimulation
runPost-
processing
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx11
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HVAC Wizard
Meaning of “Temperature Control Curve”(TCC):
Air outlet temperature is controlled by mixing hot (from heater) and cold air (evaporator)
For computing the temperature control curve, only the mixing flap position is changed
-> Every point of the TCC is one steady simulation automated process
TCC – Rotation of flaps
Geometry preparation
Physical modeling
Rotate flaps MeshingSimulation
runPost-
processing
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx12
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HVAC Wizard
Automatic report generation (PowerPoint):
General informations
Scalar scenes
Bar pressure drop graphs
Residual plots
User defined quantities
Automatic PowerPoint Creation
Geometry preparation
Physical modeling
Rotate flaps MeshingSimulation
runPost-
processing
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx13
© MAHLE
Standardization + Automation
Simulation Workflows - Examples
Engine Cooling
HEEX Wizard
Air Conditioning
HVAC Wizard
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx14
© MAHLE
HEEX Wizard
What is a Temperature Cycle Test (TCT)?
No constant operating temperature for automotive heat exchanger
=> thermal stress
=> design of heat exchanger has to consider thermal loads for durability and long life-time
For component validation:physical TCT durability tests on temperature cycle test benches
In development phase:virtual TCT by coupling transient CFD (for time-dependant temperature distribution) with FEA (forthermal stress and life-time prediction)
Workflow of simulation of a Temperature Cycle Test (TCT)
0 90 180 270 360
t [s]
Tem
pera
ture
s/C
oolin
g A
ir M
ass
Flo
w
Temp. Charge Air in
Mass flow Cooling Air
Temp. Charge Air out
Example: test temperature profile (Charge Air Cooler)
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx15
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HEEX Wizard
Workflow of simulation of a Temperature Cycle Test (TCT)
Mapping of temperature data
Thermal stress data
Lifetime prediction and
most damaged position
CFD simulation
FEA simulation
Fatigue simulation
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx16
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EGR TCT
iCACTCT
RAD TCT
HEEX Wizard
HEEX
Wizard
EGR
CAC
RAD
iCAC
Unification of engine cooling simulation methods
RAD = Radiator
EGR =
Exhaust Gas Radiator
CAC =
Charge Air Cooler
iCAC = indirect
Charge Air Cooler
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx17
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HEEX Wizard
Standardized CFD Simulation of a Temperature Cycle Test (TCT)
HEEX Wizard
Geometry preparation
Imprinting
Meshing
Surface Remeshing
Volume structured (External)
Volume unstructured
(STAR-CCM+)
Physical modeling
Material database
Fin & TubesModeling
Boiling
Radiation
Simulation runPost-
processing
Massflowdistribution
Predefined scenes
Plots
Mapping (NASTRAN)
Positioning of models
Selective Mapping
Check of correct
mapping
Data transfer format
management
FEA (PERMAS ®)
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx18
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HEEX Wizard
Standard materials can be selected by ticking
Conjugate simulation of gas, solid parts and coolant
The fluids of tubes and fins are homogenized by porous
media:
– Pressure loss of tubes and fins is modeled via resistance
coefficients of porous media based on Psi-functions
– Dual-cell HX method to model fins and tubes based on
Nu-functions
– Psi- and Nu-functions are taken from the in-house
system simulation database BISS
Physical Modeling
MeshingPhysical modeling
Simulation run
Post-processing
Mapping
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx19
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HEEX Wizard
Standardized Post Processing
Standard screenshots of transient temperature evolution
of heat exchanger for creation of animated gifMeshing
Physical modeling
Simulation run
Post-processing
Mapping
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx20
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HEEX Wizard
Mapping of the temperature distribution of the CFD
solids to the NASTRAN geometry of the FEA simulation
– Mapping of steady and transient CFD results
(for selected time steps)
FEA simulation (in PERMAS®) of thermal load and
deformation for each time-step
Mapping of solid temperature from CFD to FEA
MeshingPhysical modeling
Simulation run
Post-processing
Mapping
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx21
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HEEX Wizard
FEA-Results of TCT Simulation
deformation magnification factor: 50
Temperature / °C
MeshingPhysical modeling
Simulation run
Post-processing
Mapping
-20
0
20
40
60
80
100
120
0 50 100 150 200 250 300
T /
C
t / s
Inlet Temperature Mapping
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx22
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MAHLE Behr CFD Wizards
Significant speed-up of turnaround times
Future major speed-up potential lays with geometry preparation (imprinting)
Turnaround times and speed-up of CFD Wizards
Manual
Setup
Macro
based workflow
HEEX-
WizardV9.04_09
timeHEEX-Wizard
Preparing
CAD geometry
Meshing Setup
Meshing
Physics Setup
Post-
processing
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx23
© MAHLE
Standardized, validated and automated simulation workflows promote simulation as an important and integrated part of the development process
STAR-CCM+ provides excellent interfaces to automate and customize the workflows
High reduction of lead-time by the MAHLE Behr Wizards
More than 50% reduction of manual effort by automation
Reduction of manual work reduces risk of errors and reduces need for re-work
Conclusion
MAHLE Behr GmbH & Co. KG, TD1M4, Dr. W. Kühnel, 2.9.2016, Simcenter_MAHLE-Behr_16-9_20160902.pptx24
© MAHLE
Thank you for your attention!