SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Summary

CAD embedding and integration analysis of CFD and Electromagnetic simulation, with Confidence

Fred Mendonça, CD-adapco, Londonfred@uk.cd-adapco.com

Process Integration, Partnership, CAE Workflow, CAE Templates, Vertical Applications, Simulation-Based Design (SBD), Optimization, Upfront design/simulation

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Topics

CAD embedded CFD

Coupled / Integrated CAE analyses (CFD and EMC)

Confidence – Verification and Validation

With emphasis on

– Breakthrough technologies (CAD embedded CFD)

– Best practices (ending with validation)

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Generalised work flow

GEOMETRY

CAE 2

1-WAY Data Exchange

MESHER

2-WAY Data Exchange

OPTIMISATIONANALYSIS

CAE 1

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Vertical Application ExampleABB Switchgear, Switzerland

– Coupling from EMC to CFD• code ‘Polopt’ outputs surface heat fluxes• STAR-CD calculates the flow and temperature distribution • Standardize on pro/E

– Component in a high voltage circuit breaker assembly– Challenge – can the solid temperatures be modeled accurately using a

coupled EMC and CFD approach

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example; Data-process work flow

Pro/E model

EMC code POLOPT

STAR-CD

STAR-Pro/E

Surface heat fluxes

At high-power operations – surface temperatures to recalculate solid

properties

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

CAD – CAE Integration Levels (ref Raimund Schweiger)

– Full access to native geometry, features, parameters

– Best pre-requisites for geometry healing (know system best)

– No translation geometry translation– Defeaturing

– No geometry translation– Defeaturing– Supports rapid deployment of

innovative technologies– Relatively easy/cheap to replace– Suitable for multi-CAD environments

– User is locked-in (difficult and expensive to change system)

– No simple substitution of CAE components – May delay, or even prohibit, access to

innovative new technologies– May not support multi-CAD environment

– Requires several native geometry kernels (vendor issue)

– Access to parameters may be limited– Bi-directional data exchange with CAD may

be limited

– Geometry healing requires special software

– Higher potential to loose design content through translation

– No defeaturing– Additional step in the CAD-CAE chain

– Relatively stable due to long term use– Supports multi-CAD and multi-CAE

environment– Standards exist (IGES;STEP,VDA-FS, etc.)

CAD-embedded(All-in-one)

CAD-coupled(Geometry)

CAD-linked(Standards)

PROS CONS

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

CAD embedding – multi CAD – breakthrough technology

The STAR-CAD Series (Designers doing linear analysis)– STAR embedded in

• SolidWorks• Unigraphics-NX• Pro-Engineer• Catia V5

The STAR-CAD Gateways (Analysts who understand non-linerities)– Links embedded CAD to full-spectrum CFD

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example – CAD-embedded STAR-Pro/E : Geometry/mesh

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example – CAD-embedded STAR-Pro/E : Boundary setting

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example – CAD-embedded STAR-Pro/E : Solution

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example – CAD-embedded STAR-Pro/E : CAE Gateway

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Example – results in the fluidVelocity

Temperature

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

CONFIDENCE – metal heat-up (4 case inputs, 2kA, 4kA, 13kA and 18kA)

MEASUREMENT

Temperature animation

Temperature histories

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Summary - best practise include Verification and Validation ?

1) Quantify the required outcomes

2) Make the model– Verify the model

• Ensure the process is robust and repeatable• Standardise/document the process• Quantify uncertainties (e.g. mesh, models, boundary conditions)• Ensure that the required outcomes are satisfied

– Validate the model• Compare with analytical solutions and measurements (if available)

3) Release it to your Designers and Analysts

SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGHTECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM

Polyhedral vs. Tetrahedral Meshing (mesh dependencies best practice) Efficiency + Accuracy + Easy-of-Use = Optimisation

3

4

5

6

7

10000 100000 1000000 10000000

Number of Cells

Del

ta P

(kPa

)

POLYTET

MESH DEPENDENCY

43.25 hours

10 hours1.6 hours< 3% error

6.3 hours> 5% error