floefd 101 - pixel sistemas · unrestricted © siemens ag 2017 page 3 siemens plm software what is...

FloEFD 101

Unrestricted © Siemens AG 2017

Siemens PLM Software

• Fully embedded in the PLM design environment, and with its unique automation technologies,

FloEFD helps engineers to both frontload CFD and carry out parametric studies throughout the

complete manufacturing processes,

• „Frontloading‟ refers to the practice of moving CFD simulation early into the design process where it

can help engineers examine trends and eliminate less desirable options, as well as reduce overall

simulation workflow time by as much as 75%.

What is FloEFD?

FloEFD for NX

FloEFD for Solid Edge User Interface

• FloEFD is an award-winning MCAD-embedded CFD

simulation tool for easy, fast,

robust and accurate fluid flow and heat transfer

analysis inside Siemens Solid Edge:



What is the FloEFD unique Value

Proposition?

FloEFD is easy to use: Design-centric simulation

tool offering a single CAD-embedded environment

for design and analysis thus making CFD analysis

plug-and-play.

FloEFD is fast: Intelligent technology and

automation helps reduce the overall simulation time

for even complex geometries by as much as 75%

thus enabling fast exploration of the design space

and validation of the digital twin.

FloEFD is accurate: Thousands of engineers use

FloEFD to solve real world engineering problems

across a wide range of industries including

automotive, aerospace, manufacturing and

electronics.

FloEFD democratizes CFD: It is at the core of

SolidWorks Flow Simulation (NX and Solid Edge

versions of FloEFD offer some additional

functionality over SolidWorks Simulation*).

CAD

Embedded

Robust Cartesian Meshing -

SmartCells™

• Avoid manual mesh creation

• Extremely fast meshing

• Complex geometry capture

Innovative

Technologies

High Automation

• Automatic convergence

• Laminar-turbulent transition,

• Grid independent near wall

modeling

Effective Geometry

Handling

• No translation step necessary

• Design and Analysis are

synchronized

• Automatic fluid volume

detection

• Automatic change recognition

• Embedded in PLM workflow

Engineering Models

• “Real Geometry”

• “Thin Walls”

• “Thin Channels”

Short Learning Curve

• Easy to use by a designer

• Fast learning

• Multi-CAD Ready

Accurate and Fast

Complex Geometry

Handling

Ease-of-Use

by a non CFD expert

to drive out risk

110 Industrial CFD Benchmarks

* FloEFD Advanced CFD and LED modules



FloEFD - Unique Combination of Enabling

Technologies drives Frontloading CFD

Embedded Solid Edge

Fast Automated Immersed Boundary

Cartesian Meshing

Intuitive Easy-to-use

Interfaces for Engineers

Unique Transitional Turbulence k - e model

Unique Modified 2 Layer Wall Function for

Boundary Layers

Multi-variant “What if?” Analysis

Automated Solution

Convergence Built-in

Frontloading CFD



FloEFD Enabling Technology – Full CAD

Embedding and Integration

• FloEFD, Seamlessly integrated within Solid Edge:

Direct use of MCAD geometry

Automatic detection of the fluid region

No coming in and out of the CAD package for the CFD simulation

• Benefits

No translation step necessary with loss of geometrical fidelity

No complex definition of regions

Design and CFD models stay in sync.

Reduces re-synchronization effort and errors

5



FloEFD Enabling Technology –

Fast Automated Meshing

• Immersed Boundary Meshing:

• Automatic meshing for fluid and solid regions

• Deals quickly with “dirty” CAD geometries

• Automatic mesh refinement/unrefinement

• Benefits

• No manual meshing time

• No CFD algorithm expertise required

• Reduces execution time yet delivers accurate results




Intuitive Easy-to-use Interfaces for Engineers

• Engineering User Interfaces:

• Easy-to-use wizards provide guided model setup

• Comprehensive result analysis & visualization capabilities

• Optional MS Office-based results

• Benefits

• Eliminates the need for CFD expertise in the setup

• Reduces setup times

• Automates the product documentation




a unique Transitional Turbulence k-ε model

• Laminar – Transitional – Turbulent k-E Model:

Automatic laminar to turbulent CFD modeling with universal, grid independent

modified 2 equation Wall Functions

Laminar, transitional, and turbulent flow regimes automatically determined -- no

need to specify flow characteristics

• Benefits

Direct ability to model flow regimes eliminates CFD specialist requirement

Shorter setup times and increased model accuracy compared to traditional

approaches



FloEFD Enabling Technology – a unique

modified Wall Function for Boundary Layers

• Automatic Modified Wall Function:

Grid-independent near-wall modeling using “SmartCells” technology

Physically correct simulation of boundary layer phenomena for fluid flow

and heat transfer

Multiple scenarios automatically calculated

• Benefits

Accurate simulations including near-wall boundary condition effects

No specialized/expertise setup necessary

Reduces trial and error near-wall setup of traditional CFD approach

a) b)

c) d)




Automated Solution Convergence Built-in

• Automatic Convergence Control :

• Very robust convergence behavior

• First run converges without additional numerical diffusion

• Benefits

• Reduces multiple re-runs due to lack of convergence

• Short run times enables multiple variant scenarios

• Eliminates CFD specialist tweaks for convergence, i.e. model modifications




Multi-variant “What if?” Analysis

• Design Variant Analysis:

• “What-if” analysis without further definition of model data

• Project cloning feature

• Full support of product MCAD“configurations” and “instances”

• Modify design, run auto-mesh, execute!

• Benefits

• Multiple “what-if” simulations result in optimum design

• Saves CFD specialist‟s resources for only most critical analyses



Democratizing CFD

• Wider Adoption of CFD

• 80/20 rule: Handle 80% of CFD

• FloEFD is a productivity tool!

• Typical target user:

• Mechanical Designer / Design Engineer (CAD Users)

• BSc in Engineering subject

• Domain expertise expected, but no training in CFD

• Many „routine‟ applications of CFD (pipes, manifolds, valves, pumps).

• Typical user deals with a limited application range.

• Frees up in-house CFD experts for high-end applications

• Typical Software Requirements:

• Ease of use

• Accuracy

• MCAD Variant analyses

• Optimisation



FloEFD vs. Traditional CFD

FloEFD Traditional CFD

Required numerical knowledge none high

User manual meshing time none high

Overall meshing time (CPU + user) low high

Model preparation time low high

Programming skill requirements none medium

Suitability for fast design cycles high low

Ease-of-use high low

Overall input time for user low high

Overall physics capability medium high

Typical user educational degree B.A., M.A. M.A., PhD

Typical user profile 90% Mechanical Engineers,

10% CFD experts

10% Mechanical Engineers,

90% CFD experts



FloEFD vs. Traditional CFD

CAD CAD CAD CAD

Ma

nu

fac

ture

Traditional CFD

Concept Detailing Prototyping Testing

Traditional

CFD

Traditional

CFD

Traditional

CFD

FloEFD

Concept Detailing Prototyping Testing

Ma

nu

fac

ture

CAD CFD CFD CFD



What can FloEFD Do?



FloEFD Application Types – Pressure Drop

• Device flow coefficient determination (cv/kv/Qn)

• Extrusion process optimization

• Jet pump dimensioning

• Filter efficiency

• Pump efficiency

• Fan curve determination

• HVAC ducting sizing/placement

• Aircraft ECS design



FloEFD Application Types – Heat Transfer

• Electronics Cooling

• Heat exchanger efficiency

• Injection molding device cooling

• Sterilization in food processing

• Rubber extrusion

• Windshield de-icing

• Solar towers

• Lighting

• Solar heating

• Engine cooling jackets

• Brake design

• Oil cooler design

• And many more….



FloEFD Application Types – Mixing

Processes

• Air conditioning duct design

• Spray nozzles

• Rubber co-extrusion

• Intake manifolds (EGR tracking)

• HVAC – contaminant tracking, emissions, fumes

• Furnaces and combustion



FloEFD Application Types – Flow Fields

• Aerodynamic testing

• Cavitation prediction

• Noise level optimization

• Intake and exhaust manifold design

• Automotive engine in-cylinder flows



FloEFD Application Types – Force Prediction

• Aerodynamic coefficients

• Operational forces for valves

• Wind loads on buildings, bridges, etc.

• Flow-induced loads for stress analysis

• Temperature distribution for

thermal stress analysis

• Torque prediction



FloEFD Meshing Technology

• Well defined and robust algorithm

• FloEFD supports:

• Flow Only (Fluid Cells)

• Conduction Only (Solid Cells)

• Fluid Flow and Heat Transfer (Fluid, Solid, SmartCells)

• Refining Fluid and Solid cells allows for higher resolution

• The real FloEFD technology is within SmartCells



SmartCells

• SmartCells are always present at the fluid-solid interface

• Modified wall function captures boundary layer without need for high cell count at wall

• Proprietary technology based on physical test and empirical results

• Developed originally at Moscow state university during 1980s



Solution Adaptive Meshing

• Solution adaptive mesh will refine mesh in localised volumes based on

flow gradients

• Automatic meshing requires little user input

• Solver does not start again, interpolates, continues

• Benefits:

• Non-expert users can generate very high quality grid

• Only refined in critical areas

• Higher accuracy with minimal increase in solve time



FloEFD Functionality

Feature

Sta

nd

ard

Flo

EF

D

Ele

ctr

on

i

cs

Mo

du

le

HV

AC

Mo

du

le

Ad

va

nc

e

d M

od

ule

LE

D

Mo

du

le

Flo

ED

A

Mo

de

ule

External (<M5) & internal flows / Steady-state and transient analysis ✓

Compressible gas, liquid & incompressible fluid ✓

Free, forced, and mixed convection ✓

Boundary layers, including wall roughness effects / Laminar & turbulent flows ✓

Heat transfer in fluid, solid & porous media ✓

Isotropic, unidirectional, biaxial/axisymmetrical and orthotropic thermal conductivities ✓

Non-Newtonian liquids / Real gases / Two-phase flow (fluid & particles) / Relative humidity ✓

Moving/rotating surfaces and/or parts ✓

Cavitation in incompressible water flows / Steam Modelling with Condensation ✓

2 Resistor Components / Heat Pipes / Electrical Conditions / PCB Smartpart ✓ ✓*

Extended Engineering Database ✓ ✓

Thermal Radiation Model (Absorption in semi transparent solids) DT DT/DO DT/DO/

MC

HVAC Comfort Parameters ✓

Pre-mixed / non-premixed steady state gaseous combustion ✓

High Mach Number Flow (M5-M30) ✓

Advanced LED modelling (2-resistor and T3ster derived compact model) ✓

ODB++ detailed PCB import (Explicit traces) / DELPHI multi-resistor network IC model ✓

* PCB smartpart only

DT = Discreet Transfer

DO = Direct Ordinates

MC = Monte Carlo



Return on Investment: Reliability (1/3)

• Reasons for products being late to market:

Only Mentor‟s tools reduce these pains:

- Verify Design Changes in Less Time

- Design Out Reliability Issues; and so

- Spend Less Time in Physical Prototyping



Return on Investment: Time (2/3)

• Impact on Thermal Verification:

• Mentor customers take ⅓ of time taken by everyone else

• Good thermal design avoids surprises during prototyping

% Design Time spent in Thermal Verification

Longer time spent

getting design closure

Causes product to be

late to market



x1,000

Production

Equipment

x1 x10

x100

x10,000

Pre-Development Design Prototyping Tryout

Product Development Stage (*) Cost of Fixing a Defect

At Design Stage $35

Before Procurement $177

Before Production $368

Before Shipment $17,000

On Customer Site $690,000

(*Source: Hiroshi Hamada, President of Ricoh, European Community Quarterly Review, 2002)

Time for Recognizing Mistakes

Cost to fix Problems $

Return on Investment: Cost (3/3)



FloEFD Offers Solid ROI Through

Productivity Gains Renault France (X2) Graco Spray Guns (X3)

Paul-Henri Matha,

Lighting Expert

Rick Anderson,

Senior Project

Engineer

“At Renault we have reduced

our headlamp costs by 50%

between 2014 and 2016 and we

are aiming for a further 50%

reduction in costs for our

Generation 3 LED headlamps by

2018-2020.

The big advantage with FloEFD

we found is that…one thermal

engineer can be over twice as

productive.”

“The complete design

process of all sizes took

only about 3-4 months or

about one-third as long as

would have been required

using the trial and error

method.”

https://www.mentor.com/products/mechanical/engineering-edge/volume6/issue1/driving-down-automotive-headlamp-costs-at-renault

https://www.mentor.com/products/mechanical/success/graco-success



FloEFD Offers Solid ROI Through

Productivity Gains

“FloEFD …enables design

engineers without a fluid

analysis background to

perform thermal simulation.

The result is that we got the

design right the first time, only

had to make one prototype,

and avoided expensive design

changes that typically occur in

the late stages of the

development process ”

Crane Corp. [Azonix] (X12) Bromley Technologies (X40)

“FloEFD has helped us to reduce

our Bob Skeleton aerodynamic

design times from 8 weeks to 8

hours.”

Dr. Tristan Bromley,

CEO & Elite Athlete James Young, Design

Engineer, Azonix

Corporation

https://www.mentor.com/products/mechanical/success/azonix-success

https://www.mentor.com/products/mechanical/engineering-edge/volume1/issue1/athlete-engineered-technology



Summary

• Moving Computational Fluid Dynamics simulations as early as possible in

the design cycle has the biggest ROI: „Frontloading‟

• FloEFD is an award-winning, well

validated, tried-and-proven solution to

frontloading of CFD with a 25 year

commercial pedigree and a large

installed base.

• FloEFD has demonstrated engineer productivity gains of X2 to X40 versus

time-consuming traditional CFD approaches,

• FloEFD is now available for both Siemens NX and Solid Edge with MCAD-

embedded versions following the recent acquisition of Mentor Graphics.

Pol. Ind. SIGMA Xixilion 2 - Planta 2ª - Oficina 1ª 20870 ELGOIBAR (Gipuzkoa) tel.: 943 74 86 02

www.pixelsistemas.com [email protected]

floefd 101 - pixel sistemas · unrestricted © siemens ag 2017 page 3 siemens plm software what is...

Documents