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STAR GLOBAL 2015THE VALUE OF 3D SCANNING TECHNOLOGIES AS A COMPLEMENTARY TOOL TO STAR-CCM+® FOR VARIOUS CFD APPLICATIONS
Pier-Olivier DuvalPhilippe B. Vincent
AGENDA
Our Organization 3D Scanning The Basics Portable Scanners Applications
Scan to CFD Real Life Examples The Incubator The Racing Car The Street Luge
Conclusion and Live Demo
OUR ORGANIZATION
OUR ORGANIZATION
EngineeringServices
Technologies
MetrologyServices
Creaform was founded in 2002 and acquired by Ametek in 2013
Head office in Lévis, Québec, Canada
We develop, manufacture and distribute innovative portable 3D measurement technologies, and we are a leading provider of 3D engineering services
150 distributors worldwide
We employ more than 385 people
Creaform helps companies to seamlessly create, simulate, verify, and collaborate in 3D
MORE THAN 2000 CUSTOMERS...
Aerospace
Consumer Products
Mass Transportation
Energy
CREAFORM ENGINEERING SERVICES
STAR-CCM+
Modeling
Simulation
3D images & graphics
Services Software
SolidProduct, toolingSurfacesClass A, reverse engineering
AnalysisLinear, non-linear, implicit, explicit, modal, buckling & compositeDynamic responseRandom, sine vibration, transientFluid dynamics (CFD)Steady or transient, heat transfer, multiphase, discrete element
DesignConcepts, photorealistic 3D images & animationsGraphicsUser interfaces, labels, branding, logos, presentations
ElectricSchemes & programingLanguages C & VHDL
3D SCANNING
3D SCANNING - THE BASICS
3D SCANNING - THE BASICS
3D SCANNING - THE BASICS
3D SCANNING - THE BASICS
3D SCANNING - THE BASICS
3D SCANNING – PORTABLE SCANNERS Fit in a small suitcase Up and running in less than 5 minutes
No rigid set-up No particular experience from the user
Real time visualization Direct mesh output in StarCCM+ compatible STL format
3D SCANNING – PORTABLE SCANNERSCREAFORM 3D SCANNERS - ACCURACY. PORTABILITY. SIMPLICITY.
The easiest 3D scanning experience, generating fast and reliable measurements.
The truly portable metrology-grade 3D scanners deliveringhighly accuratemeasurements.
The most accuratescanning and probingsolutions, whether in lab or on the shop floor.
Competitive productanalysis
Measurement of product environment or connecting/Surrounding parts
Measurement of existing parts for aftermarket or custom equipment
Clay model measurement/RE
Models and mock-ups measurement/RE
Styling and aesthetics
Integration of prototype modifications into CAD file
Form study, proof-of-concept prototypes
Ergonomy prototypes
3D SCANNING – APPLICATIONS
1. CONCEPT
2. DESIGN
3D scan-to-CAD Reverse engineering
(extracting design-intent) Packaging design
Rapid prototyping/
Manufacturing Integration of prototype
modifications into CAD file
Prototype inspection
Computational Fluid Dynamics (CFD)
Finite element analysis (FEA)
Interference analysis Deformation, geometry
analysis
3D SCANNING – APPLICATIONS
3. MANUFACTURING
Reverse engineering of dies, molds, fixtures, jigs and patterns
Update of CAD file to reflect as-built tooling measurements
Tooling validation/ Inspection
Virtual assembly Tool/Robot path
programming Part assessment before
machining
First article inspection Part-to-CAD inspection Supplier quality
inspection
3D SCANNING – APPLICATIONS
4. SERVICING
As-built documentation of parts/Tooling
Marketing presentations, 3D training systems, serious gaming
Digital archiving
Wear and tear analysis Custom
repairs/Modification As-built documentation of
parts/Tooling before maintenance
Reverse engineering for developing replacement/ Restoration parts
Planning of complex assemblies disassembly/ Dismantling
3D SCANNING – APPLICATIONS
SCAN TO CFD
SCAN TO CFD
WHAT’S THE MOTIVATION?
Securing the first and fundamental step in a CFD analysis : obtaining the right numerical geometry
Overcome imprecise or out-of-date CAD data
Confidence in the geometry is key to have confidence in the CFD analysis
IN WHAT CASE?
Drawings of HVAC system or old power plant are not available to build the CAD
Modifications have been made on a vehicle, a plane or a boat
Individual CAD are available, but assembly details and spacing between components are not
Pump or turbine blades have been eroded by cavitation
Etc
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMAT
Quickest process Minimal work on scanning software
(align, close holes, create planes) STL is oriented and watertight StarCCM+ directly loads the STL
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMATSTEP-BY-STEP
with the hockey helmet clay model
VX interface after a 5 minutes session scan
The raw scan provides a decent tessellation
But it could be better if :
The holes and defects were repaired Unnecessary triangles were eliminated to make
the model lighter The model was oriented with proper axis and
mirrored if required for asymmetric simulations
This is all managed directly in VX
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMATSTEP-BY-STEP
with the hockey helmet clay model
In VX, the helmet model is transformed into a watertight and aligned shell in about 15 minutes
STL is directly loaded in StarCCM+
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMATSTEP-BY-STEP
with the hockey helmet clay model
In surface repair: No free edges No non‐manifold edges No non‐manifold vertices Only a few « Face quality »
issues
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMATSTEP-BY-STEP
with the hockey helmet clay model
Auto‐repair Surface Errors (A) results in an error‐free model with highlighted repaired faces
SCAN TO CFD – THE PROCESS
OPTION 1. DIRECT SCAN IN STL FORMATSTEP-BY-STEP
with the hockey helmet clay model
External aerodynamics case in StarCCM+ Dummy added to the
geometry Trimmer with wake
refinement and prisms layer Surface pressure for vents
positioning on helmet
CAD modeller between Scan and StarCCM+ Complete CAD available (IGES/STEP/…)
SCAN TO CFD – THE PROCESS
OPTION 2. PERFORM REVERSE ENGINEERING
SCAN TO CFD – THE PROCESS
OPTION 2. PERFORM REVERSE ENGINEERING
STL of raw scan
Reconstructed CAD
PCB Scan
Using Catia
SCAN TO CFD – THE PROCESS
OPTION 2. PERFORM REVERSE ENGINEERING
REAL LIFE EXAMPLES
REAL LIFE EXAMPLES - THE INCUBATOR
1. The Long range provides a rough point cloud
2. Creaform’s MetraSCAN gives the detailed geometry of fans and other components in STL format
3. Stitching of point cloud and STL within reverse engineering process using Catia
REAL LIFE EXAMPLES - THE INCUBATOR
4. Geometry is wrapped and meshed in StarCCM+ 6. Designs are compared to achieve the best flow
5. Fan interface model and residence time model are set up
REAL LIFE EXAMPLES - THE RACING CAR - ACT TOUR
Washable powder to remove light reflection Few targets on and off car for positioning reference
Numerical model obtained after 8 hours of 3D scanning
REAL LIFE EXAMPLES - THE RACING CAR - ACT TOUR
Unequal fresh air quantity to cool brakes Important separated flow when turning
REAL LIFE EXAMPLES - THE STREET LUGE
“Our luge team, the 3 Bobs, broke the world speed record in 2008, and we came very close to the 100 mph mark at that time. Since then, we have tweaked our gear, but we had a hard time figuring out how to improve the aerodynamics of our luges to gain even more speed.” [Louis‐Etienne Bouchard]
REAL LIFE EXAMPLES - THE STREET LUGE
3D Scan
Reverse Engineering
CFD mesh with prisms layer
REAL LIFE EXAMPLES - THE STREET LUGE
On gears shoe covers, eliminate ripples on knee pads On luge gaps closing around wheels On positioning helmet tilt, arm and legs position relative to luge
Pressure distribution, streamlines and lambda 2 criterion isosurfaces
IMPROVEMENTS ?
CONCLUSION AND LIVE DEMO
CONCLUSION AND LIVE DEMO
StarCCM+ is Creaform’s
choice for CFD software as it
accepts STL files (among other advantages!)
Scan to CFDCreaform
performs the whole scan-to-
CFD process within an
integrated team of engineers
Scanning is accessible, easy and
fast!
PHILIPPE B. VINCENTCFD EngineerCreaform Engineering Services
5825 St-GeorgesLévis, Québec G6V 4L2CanadaPhone: (418) 833-4446
E-MAIL:philippe.vincent@ametek.comWEB:www.creaform3d.com
CONTACTSPIER-OLIVIER DUVALFEA/CFD Team LeaderCreaform Engineering Services
5825 St-GeorgesLévis, Québec G6V 4L2CanadaPhone: (418) 833-4446
E-MAIL:pier-olivier.duval@ametek.comWEB:www.creaform3d.com
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