Process Integration and Comprehensive Solution … · – Solution Scenario: Comprehensive Combustion/CHT Vision Friday, October 03, 2014 2014 Automotive Simulation World Congress

Process Integration and Comprehensive Solution Paradigms: Engine Combustion, Conjugate Heat

Transfer, Durability and Fatigue

Laz Foley, ANSYS Inc.

Outline

• Simulation Trends • CAE in Powertrain Development • Solution Paradigm Challenges and Requirements • A Comprehensive Solution Practice Example

– Turbocharger Design • Conjugate Heat Transfer Work Flows

– Cylinder Head Design • Co-Simulation

– 1D-3D Coupling • Non-Linear FEA

– Gasket Optimization • CAE Toolkit Integration, Automation and Customization

– Solution Scenario: Comprehensive Combustion/CHT Vision Friday, October 03, 2014 2014 Automotive Simulation World Congress 2

Simulation Trends

Friday, October 03, 2014 2014 Automotive Simulation World Congress 3

Old Paradigms • Single Component

Simulation

• Single Physics

• Few Design Points

New Paradigms • Multi-Domain Simulation

(Component and System)

• Multi-Physics Simulation (flow, thermal, structural, electronic, systems)

• Extensive Design Exploration

CAE in Powertrain Development


Concept Modeling to Detailed Analysis

Courtesy: BMW AG

Solution Paradigm Challenges and Requirements • Interoperability across physics, scales and

user personas • Workgroup productivity via HPC usage • Design exploration with embedded

capabilities • Integrated multi-physics and co-simulation

with variety of tools in simulation toolkit • Multi-Disciplinary Optimization (MDO) and

Topology Optimization (TO) for all physics disciplines: Structural, Fluids, FSI

• Integrating FMEA work groups with CAE and driving CAT-CAE analyses including simulation as a calibration tool (MiL, SiL, HiL etc.)

• Cloud computing infrastructure, knowledge management, simulation data management/re-use


Conceptual Design Via Parameterization and Optimization • Parametric CAD Model

– Bi-directional connectivity with Workbench to enable CAD to PPT “push-button” process

– Automated and persistent work flows

– Easily extended to design exploration/optimization

• Non-Parametric CAD Model – Topology Optimization via

mesh morphing (Fluent, RBF-Morph) and/or adjoint methods


Mesh Morphing Control Volume

Adjoint Shape Sensitivity Contours


Preliminary Design

Impeller Aerodynamics

Strength and Durability

Full Stage Design & Simulation

Single Physics Verification

Enterprise HPC + Additional Physics

Systems Engineering Robust Design

Key Simulation Applications Within A Turbocharger Design System (Compressor)

Comprehensive and Integrated Design Process


1D Preliminary Design (VISTA CCD & CCM)

Optimization Loop (Solve with VISTA TF)

Full impeller geometry (BladeModeler)

Stress & Modal Analysis (Mechanical)

Volute Design (DesignModeler)

Volute meshing (ANSYS Meshing)

Post process results (CFD-Post)

Impeller Mesh (TurboGrid)

CFD (one or more points) (HPC execution in CFX)

Blade 3D geometry (BladeModeler)

Pre-Stress Modal (Mechanical)

Impeller CFD (CFX)

Design Life (nCode)

Attach impeller to volute (CFX-Pre)

Turbocharger Durability and Fatigue


• Fluid-Structure Interaction (FSI) including Conjugate Heat Transfer (CHT)

• Blade Flutter Analysis – Specify blade oscillation via FEM

modal analysis – Calculate aero-damping via CFD

• Forced Response Analysis – Blade excitation forces via CFD – Calculate deformation and stress

via FEM or ROM

• Life Predictions

Conjugate Heat Transfer (CHT) For Combustion System Design


• Variety of cross-physics and data exchange approaches used – Use of empirical heat data in a

zonal combustion face map – Measured or predicted heat

release profile imposed as energy source in gas exchange CFD model

– Iterative combustion to non-combustion approach

• Challenges include – Different user-personas (Designer,

CFD/FEM analyst), multiple simulation tools (1D/2D/3D), multiple functional groups (CFD, FEA, System)

Courtesy: Mercury Marine

Cylinder Head Temperature Predictions Courtesy: Cummins

CAD to Fatigue for Cylinder Head Design: Process Overview


CAD to Fatigue for Cylinder Head Design: Key Requirements/Deliverables • Parametric CAD for Design Points and

Optimization • Predictive Combustion (CFD) • Conjugate Heat Transfer Simulation

(CFD) – Head, Liners, Valves, Seats, Guides

etc. – Thermal Resistance/Contact – Boiling

• Thermal/Stress/Fatigue Simulation (FEA) – Non-Linear Materials/Contact,

Gaskets, Bolt Pre-Tension, Threading, Life

Friday, October 03, 2014 2014 Automotive Simulation World Congress 12 Threaded Bolts

Water Jacket Boiling

Co-Simulation: 1D/3D Coupling


Diesel Intake Manifold (EGR) Courtesy: Cummins

• Typical Coupling Applications – Intake/Exhaust Manifolds, AIS, Filters,

Mufflers, EGR/PCV, Catalysts, Cylinders • Dynamic Coupling with 1D

Simulation Tools – GT-Suite, WAVE, Virtual Engines for

engine simulation • Solution Benefits

– Capture of complete system level interactions, accurate CFD boundary conditions etc.

– Insights into cylinder-to-cylinder performance, variations etc.

– One coupled engine cycle with ~1M CFD cells < 3h on 64 CPU’s (large model)

Gasoline Intake Manifold

Motorsports: Intake Manifold & Exhaust Cross-Pipe

Non-Linear FEA: Gasket Optimization


Cylinder Head Gasket Model Courtesy: Cummins

• Durability and Fatigue prediction challenges include – Highly non-linear material – Contact status modeling

• Solution Benefits – Rich suite of hyper-elastic models – Special gasket elements – Curve fitting module to determine

material input from test data

Gasket Components

Soft Gasket Stiff Gasket Compressive Stress Contours

Steady State vs. Transient Loading and Fatigue


• Steady state loads do not always produce the highest stresses • Cyclic stresses can cause failure at loads lower than material tensile/yield

strength • Transient loading behavior critical for fatigue/life predictions

ANSYS Customization Suite

• Two-Tier Customization Suite – SDK: Workflow and data integration of 3rd

party software – ACT: Custom interfaces for WB/Mechanical

and Beyond

• SDK already used by partners such as nCode, fe-safe and many others

• ACT has been used to customize interfaces and build vertical applications


CAE Toolkit Integration, Automation and Customization


Controls, signal processing, embedded software

1D modeling of components (hydraulic, cooling etc.)

1D modeling of components (engine and vehicle)

3D modeling of components and sub-systems, ANSYS as a Server


Comprehensive Combustion/CHT Solution Vision

Summary

• Some key take ways from this comprehensive solution paradigm – Engine design is much more than developing a combustion

system – Depth and diversity within all physics and at all stages of a design

process is necessary (combustion, fluid, thermal, stress, durability, fatigue)

– Tools and processes that cater to different user personas and disciplines within a design process is important (Designer, Analyst, Systems)

– A collaborative and common platform for integrated CAE is a requirement given product design demands (engine calibration, packaging, controls development, system optimization etc.)

• ANSYS is committed to the continuous advancement of its integrated solution work flows and processes


Process Integration and Comprehensive Solution Paradigms: Engine Combustion, Conjugate Heat

Transfer, Durability and Fatigue

Laz Foley, ANSYS Inc.

Documents

Process Integration and Comprehensive Solution … · – Solution Scenario: Comprehensive Combustion/CHT Vision Friday, October 03, 2014 2014 Automotive Simulation World Congress