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  • Fully Automatic In-cylinder Workflow Using HEEDS / es-ice / STAR-CD

    Simon Fischer – Senior ICE Application Support Engineer – CD-adapco Nuremberg Office

    Gerald Schmidt – Director/Powertrain - CD-adapco New York Office

  • Introduction and Enabling Technology

    Workflow and HEEDS Portal Description – Underlying Scripts

    – Data Preparation

    – CAD Modification

    – Surface Preparation

    – Automatic Meshing

    – Physical / Numerical Model Setup

    – Running STAR-CD

    – Postprocessing

    Demo Study: The Optimized Race Engine

    Further Examples of Successful In-Cylinder and Related Studies

    Outline

  • HEEDS is a well established MDX tool applicable to many CFD problems – Red Cedar Technology recently developed dedicated HEEDS portals

    for pro-STAR, es-ice, and STAR-CD making it easier to define workflows for in-cylinder simulation

    The key enablers of MDX for in-cylinder simulation are robust moving mesh technology and high fidelity physics capability – A major focus of es-ice development has been to provide a fully

    automated robust meshing technology with minimum user intervention

    – STAR-CD provides a big library of state-of the art in-cylinder relevant physics models (from multi-phase to combustion chemistry)

    This presentation shows the possibility of in-cylinder simulation using a fully automatic HEEDS/es-ice/STAR-CD workflow

    Introduction and Enabling Technology

  • Generic scripted process of STAR-CCM+ surface preparation, es-ice fully automatic meshing and model setup, pro-STAR model setup, STAR-CD cluster submit, and es-ice/pro-STAR postprocessing

    Minimum User Interaction to Prepare Input Data

    Process, parameter setting/variation, io-operations, postprocessing managed by HEEDS MDO employing the STAR- CCM+ portal and recent STAR-CD, es-ice, and pro-STAR portals

    Meshing and physics parameters and results output managed through HEEDS parameter tagging

    Workflow Description

  • Generic scripted process of STAR-CCM+ surface preparation, es-ice fully automatic meshing and model setup, pro-STAR model setup, STAR-CD cluster submit, and es-ice/pro-STAR postprocessing

    Workflow Description: Underlying Scripts

  • Minimum User Interaction to Prepare Input Data – Surface preparation in STAR-CCM+ (GeometryPreparation.sim) (Geometry from CAD-Modeller, Imported CAD, Discretized Surface) – Naming convention – Orientation, Scaling, Valve and Piston position – CAD/surface repair (clean CAD, waterproof surface)

    Deliver Boundary Conditions in appropriately formatted files

    Workflow Description: Data Preparation

  • Process, parameter setting/variation, io-operations, postprocessing managed by HEEDS MDO employing the STAR-CCM+ portal and recent STAR-CD, es-ice, and pro- STAR portals

    Meshing and physics parameters and results output managed through HEEDS parameter tagging

    Workflow Description: HEEDS Process

  • Workflow Details: CAD Modification

    Optional: Direct CAD Design Parameter (if exposed) access through HEEDS‘s dedicated Portals: • here STAR-CCM+ Portal • Also available:

    NX, CATIA, CREO,...

    Parametrized STAR-CCM+ Geometry Preparation sim-File

  • Workflow Details: Surface Preparation

    • Input STAR-CCM+ Geometry Preparation sim-File • Automated Parts Based STAR-CCM+ Surface Remesh using es-ice best practices • (Optional) Automated Additional Static Part Volume Meshing • Export of es-ice -appropriate .dbs Surface file and additional ccm volume meshes

  • • Underlying meshing script featuring latest es-ice automatic meshing technology and best practice

    • User input is limited to a minimum of mesh parameters, e.g. mesh base size, prism layer thickness, etc.

    • No expert knowledge of es-ice template mesh generation is necessary

    • Yet scripted meshing is open source and fully customizable for expert users

    Workflow Details: Automatic Meshing

  • Workflow Details: Automatic Meshing

    es-ice scripted meshing HEEDS portal to automatically

    • Script allowing for Automatic Parameter Tagging to expose parameters to a HEEDS design study (e.g. Make a mesh study)

    tag parameters

    e.g. Make a mesh study

  • Workflow Details: Automatic Meshing

    High quality moving mesh with NO user intervention

  • Workflow Details: es-ice Model Setup

    es-ice scripted model setup • Boundary conditions • Initial conditions • Predefined best practice

    setup scripts • Cold flow • Mixture preparation • Combustion study

    • All scripts open source and fully customizable

    • All scripts allowing for Automatic Parameter Tagging to expose parameters to a HEEDS design study

  • Workflow Details: pro-STAR Model Setup

    pro-STAR scripted model setup • Liquid phase setup for

    injector boundary conditions, liquid film, and spray physics

    • Predefined best practice setup scripts • Cold flow • Mixture preparation • Combustion study

    • All scripts open source and fully customizable

    • All scripts allowing for Automatic Parameter Tagging to expose parameters to a HEEDS design study

  • Workflow Details: Running STAR-CD

    Scripted cluster submit including all file handling (copying forth and back), monitoring jobs, etc., handling multiple computational resources

  • Workflow Details: Postprocessing

    es-ice postprocessing plugin HEEDS portal to automatically tag results

    Automatic Parameter Tagging to expose Results to HEEDS

    Enabling postprocessing in HEEDS for an MDX study

  • Workflow Details: Postprocessing

    • Scripted call of pro-STAR engine animation script

  • Workflow Details: Postprocessing

    Fully embedded postprocessing in HEEDS

  • Workflow Details: Project Management

    Fully integrated management of • Processes (Cold Flow,

    MixturePreparation, Combustion)

    and related • Design Exploration Studies (e.g.

    Single Baseline, Mesh Sensitivity, Geometry Optimization, ...)

    within the HEEDS Environment

  • The sample study features:

    Automatic CAD modification through STAR-CCM+ CAD modeler

    Automatic generation of moving mesh for intake and compression stroke for each design using es-ice

    Lagrangian spray, wall impingement, liquid film

    Tracking of fresh air, fuel, and residual through active species

    Turbulent flow field assessment with STAR-CD

    Evaluation of engine data

    Optimization of design through HEEDS

    Users touch neither the es-ice nor the pro-STAR GUI, leaving required expertise to a minimum

    Demo Study: An Optimized Race Engine

  • Design parameters: Piston bowl shape and injector direction

    Goal: Maximize fuel and maximize turbulence at the ignition point

    Demo Study: An Optimized Race Engine

  • Demo Study: Results

  • All engine relevant postprocessing through HEEDS UI

    Demo Study: Sample Results

    Baseline Best Design

  • Demo Study: Performance

    Model size: ~ 1 mio cells @ BDC (1 mm base size), time span 380 degrees crank angle (intake and compression stroke)

    Total turnaround time per design: ~ 3 hours – Preprocessing, meshing, and postprocessing on 1 CPU: ~ 25

    min

    – Run on 48 CPUs: ~2.5 h

    Parallel design assessment through HEEDS – Here 4 designs in parallel

    ~ 45 min per design occupying 192 CPUs

    – 100 designs evaluated in 83 hrs

    License requirements: – 2 es-ice pre/post

    – 4 es-ice run

    – 164 HPC STAR-CD

    – 4 enablestar

    – 5 STAR-CCM+

    – 1 HEEDS

  • Transient port flow optimization (Pre-Sales demo–confidential) – Maximize tumble and trapped mass through port design optimization – Fully transient: 300 designs in 2 days on 64 cores

    Diesel piston bowl shape optimization (JLR – customer presentation) – Presented at last year‘s European ICE Workshop in Maranello

    Prechamber gas engine workflow (Support demo for Caterpillar) Gasoline spray calibration in a bomb experiment (Internal training) – Calibrate spray break-up model to match experimental properties

    Automatic testing of es-ice automatic meshing performance (Internal) – Extraction of best practices and sensitivity study on meshing parameters

    for optimum mesh quality

    Evaluation of DARS combustion libraries in STAR-CD box model (Internal) – Tool to explore combustion libraries for auto-ignition and laminar flame

    speed in CFD operating mode, valuable for library validation

    Turbulent Jet Ignition (TJI) combustion model validation and best practice study (Internal) – Combustion model assessment and calibration

    Examples of Successful In-Cylinder and Related Studies Using HEEDS/es-ice/STAR-CD

  • The Application of HEEDS MDO to the Optimization of Diesel Piston Bowl Design,

    Paul Dunkley, Jaguar Land Rover

    (Presented in Maranello at the European ICE Workshop 2015)

    Paul D. of JLR stated that he can justify the investment in HEEDS purely

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