moving particle simulation
TRANSCRIPT
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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