richard johns - mdx

Over the years, CD-adapco has been at the forefront of a revolution in

computer-aided engineering in which CFD has become integrated into

the design process, enabling development cycles to be shortened.

The resulting benefits for the organization are reduced labor costs and

faster time to market.

Early design evaluations and “what-if” studies eliminate inefficient and

unsafe approaches, and validate and optimize correct ones before

committing to capital expenditure. Reduction in number of prototypes

saves the cost of testing and additional redesign.

In addition to developing CFD codes (including the industry leading

STAR-CD and STAR-CCM+), CD-adapco is involved in the development

of a range of associated application-specific expert system software

tools as well as providing CFD/CAE consulting services, sales, support

and all levels of training. Over 450 highly qualified and experienced

professional staff are employed globally.

What distinguishes CD-adapco is a willingness and ability to share its

skills and experience with clients, to do whatever is necessary to achieve

effective CFD solutions. With a track record of more than 20 years of

engineering analysis with specific experience in CFD and FEA, we

continue to develop, market, support and deliver analysis optimization

software tools that enhance product quality and reduce time-to-market.

Richard Johns

Director, Automotive

The Value of Engineering Simulation

02 Applications // Automotive

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Our utilization of CD-adapco Engineering Services worked really well. They provided us with excellent analysis on our project. Their work was responsive enough to provide us with answers that were required “now”, and well thought out so that they could provide us with a technology transfer that allowed us to learn how to perform similar analyses on our own.

John SponskyVolvo Power train

One of the driving forces in all successful companies is the continuing demand for reduction in product and process development time and cost, to maintain profitability and competitiveness.

uING Renault Formula One Team 2009 Season model.

The Value of Engineering Simulation

Applications // Automotive 03

www.cd-adapco.com/autoFor more information please visit our automotive hub:

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Since introducing STAR-CCM+ into our workflow we have managed to double our simulation throughput. Put simply it is a massive step forward. STAR-CCM+ is fast, robust and extremely easy to use. I am continually impressed with CD-adapco in terms of support and willingness to take on development requests. STAR-CCM+ is being developed at an incredible rate.

Jarrod Murphy - Head of CFDRenault F1 Team

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CD-adapco is a forward looking organization, dedicated to customer satisfaction, long term growth and improvement of its products

Steven MarshallValeo Climate Control Group

CD-adapco Engineering Services has been instrumental in the development of new analysis capabilities and transferring technology to our group to be implemented as standard works. In addition, in times of high volumes of analysis requests, CD‐adapco’s engineers have been outstanding in providing timely on and off‐site CFD support.

Jef f SchlautmanGM Power train

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STAR-CD & STAR-CCM+The fluid analysis requirements of the automotive industry are complex and varied. The need for virtual prototyping and use of analytical tools during all stages of design and development, plus the tight schedules and turnaround times, pose one of the most challenging environments for CFD.

CD-adapco’s leading status in the automotive industry has been achieved by its ability to combine accuracy and speed with the versatility to simulate the wide range of flow processes encountered in and around vehicles, including:

• Externalaerodynamics

•Aeroacoustics

•Water,snowanddirtmanagementaroundthecarbody

•BatterySystemsforEVS

•Brakesystemcooling

•Underhoodthermalmanagement

•Coolantjacketflowandheattransfer

•Radiatorsandfans

•HVACunits

•Passengercomfortassessment

•De-icingandde-mistingofwindscreens

•Intakeairductsandfilters

•Manifoldsandports

•Fuelinjectorsandcarburetors

•In-cylinderflow,chargepreparationandcombustion

•Exhaustsystemandaftertreatment

•Lubrication

•Crankcaseflowsandoildrainage

•Turbochargers

•Torqueconverters

•Fueltanks

•Alternators

•Pumps

•Headlamps

•Fuelcells

Fantastic software, fantastic support!

Thomas MahlerGM Power train


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CAD Embedding & IntegrationAt CD-adapco, we recognize that the CAD or PLM tool is the

backbone of the product design process and the starting point for

(almost all) simulation. Utilizing its full power puts parameterized

geometry control into the hands of the simulation engineer,

easing quick and automatic “what-if” design studies and enabling

simulation to drive design.

The result: the most seamless CAD-CFD solution on the market.

STAR in CAD: STAR-CCM+ and STAR-CD simulations can be setup, run and post-processed from

within popular CAD and PLM environments such as SolidWorks, CATIA V5, Pro/ENGINEER and

Unigraphics NX, or CD-adapco’s own parametric geometry modeling tool, STAR-Design.

CFD results are linked directly to the CAD geometry (a process called associativity). After any

modification in the CAD model the simulation results can be updated almost instantly by clicking

the “update solution” button, allowing the rapid and thorough investigation of the design space.

CAD in STAR: CD-adapco is committed to delivering flexible solutions that integrate seamlessly

with the full-spectrum of CAE processes. STAR-CCM+ and STAR-CD will work directly with native

CAD formats, such as Parasolid, IGES, STL and STEP.

Withtheautomaticfluidvolumeextractioncapability,simulationengineerscanside-steptime

consuming and laborious tasks that are often required to prepare CAD geometry for simulation.

From geometry to analyzing results

BuildyourCADmodel Open your CAD model

Problem definition

Build&Run

Update design

Process results

Many people in industry told us that we wouldn’t be able to simulate the complex motion of our PSZ oil pump using CFD. CD-adapco’s software helped us to prove them wrong. The insight we have gained through using CFD simulation has helped us to develop better oil and water pumps, more rapidly than ever before!

Dr Ing Thomas KrugerENTEC


Beyondofdoinganalysisanddelivering the analysis on time, what really differentiates the engineering services group at CD-adapco is the good industrial knowledge of the product that they are working on, which is missing in many other competing CAE consulting firms. I have really enjoyed working with the engineering services group at CD-adapco.

Allan WangManager Vir tual Technology GroupModine Manufacturing Company

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Allan WangManager Vir tual Technology GroupModine Manufacturing Company

CD-adapco’s geometry preparation and wrapping tools are the most automatic approach that exists. This technology has saved us weeks of clean up when carrying out air flow studies and provides us with significant time and cost savings.Walter Bauer - Head of CAEDaimler AG

At the heart of CD-adapco’s simulation process is a powerful,

automatic and fast tool for surface preparation. The surface

wrapper significantly reduces the number of man-hours spent on

surface cleanup and, for problems that involve large assemblies

of complex geometry parts, reduces the entire meshing process

to hours instead of days.

The surface wrapper works by automatically “shrink-wrapping” a high quality triangulated surface

mesh onto any geometrical model, closing holes in the geometry and joining disconnected and

overlapping surfaces, providing a single manifold surface that can be used to automatically

generate a computational mesh without user intervention.

Also included is a comprehensive set of surface-repair tools that allow users to interactively

enhance the quality of imported or wrapped surfaces, offering the choice of completely

automatic repair, user control or a combination of both.

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qWrapped surface mesh.


Surface Preparation & Wrapping

pImported CAD geometry.

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Mesh GenerationCD-adapco’s single integrated process provides the fastest, most automatic route from complex

CAD geometry to CFD mesh. Our automatic mesher generates either polyhedral or hexahedral control

volumes at the touch of a button, offering the ultimate combination of speed, control and accuracy. For problems involving multiple frames of reference, fluid-structure

interaction and conjugate heat transfer our mesh generation software can

automatically create conformal meshes across multiple physical domains.

An important part of mesh generation for accurate CFD simulation,

is the near-wall region, or extrusion layer. STAR-CD and STAR-CCM+

automatically produce a high-quality extrusion layer mesh on all walls in

the domain. In addition, you have the option to control the position, size,

growth-rate and number of cell layers in the extrusion-layer.

The ability to efficiently handle large computational meshes is critical

in successfully meeting the engineering challenges of the automotive

industry. Our tools are specifically designed to handle large models

quickly and efficiently, using a process that seamlessly meshes and

simultaneously solves and post-processes over multiple computing

resources without requiring additional effort from the user.

It’s this process that recently enabled STAR-CCM+ to became the first

commercial CFD package to create, set-up, mesh, solve and post-process

a problem with over one billion cells!

08

uDucati Mesh.


yMesh replace feature and the surface wrapper.

External AerodynamicsSTAR-CCM+ and STAR-CD play an essential role in the design and development of the external aerodynamics of vehicles ranging from racing cars to trucks and buses.By working closely with our OEM partners we have developed the most versatile and robust aerodynamics simulation toolkit on the market.

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Key features include:

Process: a robust and automatic process from CAD geometry to

post-processing, including state-of-the-art surface geometry clean-up and

manipulation tools and automatic hexahedral and polyhedral meshing.

LargeModelHandling: STAR-CCM+ is specifically designed to create,

set-up, run and post-process cases with hundreds of millions (if not

billions) of cells. Its client-server architecture allows you to make

the most of large parallel clusters, as cases can be set-up, run and

post-processed in parallel. By going from CAD geometry through to

post-processing, STAR-CCM+ removes the need to import and export

large data sets.

Dedicated set-up and post-processing: Includes tools such as automatic

calculation of the frontal area, lift and drag plots, as well as powerful

post-processing.

Multiphysics: Aerodynamicists increasingly need to consider passenger

noise levels and buffeting phenomena, dirt and water deposition, as well

as underhood thermal management. -adapco has both the required

physics models and experience in solving these complex, multiphysics

cases.

Steady and Unsteady flows: Many aerodynamic flows can be accurately

and efficiently solved using steady-state methods, whereas some

require unsteady flow features to be resolved. STAR-CCM+ and

STAR-CD have efficient steady and unsteady solvers, allowing you to use

the most appropriate approach for your case.

CD-adapco has invested heavily to produce the most productive and

robust process for simulating the aerodynamic performance of ground

based vehicles. It’s routinely used for the following applications:

•Liftanddragprediction

•Aeroacoustics

•Ventilation

•Wateranddirtmanagement

•Underhoodflows

•Brakecooling

•Drafting


uBrake cooling at Daimler.

ySimulation of vehicle aerodynamics.

pExperimental and simulation of rain soiling on Audi A2

Courtesy Audi AG & ICON.

zNASCAR drafting simulation featuring 40 cars and one billion cells!

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zNASCAR drafting simulation featuring 40 cars and one billion cells!

qFSI calculation with STAR-CD and MSc. Marc Von Mises stresses on a twin catalyst

exhaust manifold.

pTop: Imported STL surface representation.

pBottom: High-quality surface mesh automatically

generated by the surface wrapper.

Aftertreatment

STAR-CD, with its state-of-the-art models and efficient solvers, is ideally positioned to

deal with all aspects of aftertreatment system simulation, including flow distribution,

heat transfer and chemical reaction through the catalyst. STAR-CD users can also have

access to a powerful knowledge-based expert system called es-aftertreatment, which is

specially designed to deal with automotive aftertreatment simulations in as efficient a

way as possible.

So, whether STAR-CD is used alone or is combined with es-aftertreatment, the complex

processes are always captured efficiently and accurately.

STAR-CD and es-aftertreatment can also be used to target a of range aftertreatment

processes and devices including:

• 3waycatalyticconverters

• SelectiveCatalyticReduction(SCRs)

• Bothcatalyzedandnon-catalyzeddieselparticulatetraps

• Sulfurtraps

• LeanNOxtraps

• Flow,thermalandstresscalculations

From both the environmental and legislative perspectives, aftertreatment is one of the most important parts of the automobile. Modern automotive aftertreatment systems are complex and put a lot of demand on automotive designers and engineers. CFD analysis provides an ideal approach to a better understanding of these systems and can greatly help engineers with their optimization.

ySoot concentration and temperature profile in a Diesel Particulate Filter

Courtesy EMCON.

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pTop: Imported STL surface representation.

pBottom: High-quality surface mesh automatically

generated by the surface wrapper.

Based on the experience of hundreds of industrial underhood

simulations and thousands of hours of research and development,

CD-adapco provide the most efficient, no compromise solution for

underhood thermal management simulations on the market.

Complex geometry handling: CD-adapco’s surface wrapping and

meshing technology has been specifically designed to handle the

complex geometry found in underhood simulations.

No other approach goes from complex CAD geometry to high quality

volume mesh faster.

Dedicated physics models: STAR-CCM+ and STAR-CD have the

complete set of physics models required for accurate and efficient

underhood calculations. Including: convective and radiative heat

transfer, efficient bulk models for heat exchangers, a choice of

explicit or implicit fan models, multiregion meshing for conjugate heat

transfer, Multiple Reference Frame (MRF) and stress analyses.

Underhood Thermal Management

yUnderhood thermal management simulation

Courtesy Daimler.

STAR-CCM+ and STAR-CD’s underhood thermal management capabilities are built on a robust and automatic simulation process and dedicated physics models. They enable complete thermal predictions and coolant flow simulations, reducing development costs, shortening time-to-market and improving the thermal management of these vehicles.

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❐ FACTS

For the past thirty years leading automotive companies have relied on CD-adapco’s

state-of-the-art technology to improve their designs. STAR-CCM+, STAR-CD

and the STAR-CAD Series provide engineers with an advanced and complete

engineering simulation toolkit. This unique approach brings unrivalled ease-of-use

and automation to CAD preparation, meshing, model set-up and iterative design

studies, enabling engineers to deliver better results, faster.

CD-adapco’s automotive team have pioneered many new application areas as

diverse as brake cooling and crankcase analysis. The company has delivered CFD

and FEA projects to all the top automotive companies world wide. New product

releases, on going training and educational programs are helping customers keep

pace with the evolving automotive industry.

12 Applications // Automotive 13

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Expert Systems

i MORE INFORMATION: www.cd-adapco.com/products/es-solutions/es-sofc

es-sofc works with STAR-CD, as a specialized virtual design, prototyping and

testing environment. Typical issues that can be handled include: correcting the

distributions of fuel and oxidant to the stack, mitigation of excessive thermal

gradients along with temperature prediction for the calculation of thermally

induced stresses, and manifold/flow passage optimization. These aspects

together with gaining a better understanding of the electrochemistry and thermal

properties involved, lead to optimized solid oxide fuel cell performance.

Nevertheless, nothing can substitute experience and know-how when it

comes to analyzing complex industrial problems. With this in mind,

CD-adapco also offers a series of knowledge-based expert systems

that utilize our decades of experience in solving complex engineering

problems and address all aspects of design process from CAD to

post-processing.

These are collectively known as es-solutions and aim to achieve

the following:

•Producethehighestqualityresultsinshortest

turnaround times

•Useapplicationspecificbestpractices

•Provideapplicationspecificuserinterface

•Automatemodelset-up

•Allowaccumulationofknowledge

•Allowconsistencyandrepeatability

The basic capabilities of our products make them

probably the most reliable, accurate, efficient and

versatile CFD tool on the market.

pTurbocharger Analysis.

pStress loading on cylinder head assembly.

pICE Simulation, including spray,

combustion and moving boundaries.

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With an ever-increasing emissions emphasis - from legislators and consumers alike -

the challenges for Powertrain teams continue to grow. Whether it’s a new fuel, new

combustion mode or a new lightweight material, realistic simulation is an integral

tool in successfully bringing new technologies to market. As the leading provide of

CFD technology to the automotive industry, over two decades of intake-to-tailpipe

industrial know-how, CD-adapco is ideally placed to help Powertrain teams meet these

challenges.

At the heart of this toolkit for reciprocating Internal Combustion Engines (ICE), are es-ice

and STAR-CD. es-ice provides a dedicated environment to set-up and run ICE calculations,

encapsulating the process and best-practices that CD-adapco has developed over years

of industry experience. In turn, es-ice drives STAR-CD, which is replete with physics models

specifically developed for efficiently simulating combustion, multiphase sprays and liquid films,

heat and mass transfer, transient and turbulence effects, and moving boundaries.

Flow, Thermal, Stress: Both in and outside the combustion chamber, CD-adapco is recognized for

delivering innovative, multiphysics solutions. For example, CD-adapco’s partners can now perform

engine structural integrity and coolant flow simulations including boiling, conjugate heat transfer and thermal

stresses, all through one GUI, using one mesh and one solver.

Some of the applications that STAR-CD & STAR-CCM+ routinely tackle are:

•Intakeandairducts

•Filters

•Manifolds

•Ports

•Carburetors

•Fuelinjectors,includinggasolineordieselprimaryspraybreak-upandliquidfilms

•In-cylinderflow

•Combustion

•Couplingtochemicalkineticsolvers,suchasDARSandChemkin

•SIandCIengines,evenwhenoperatinginHCCIorCAImode

•1D-3Dcoupled&multi-cylindersimulations

•EGR

• Exhaustandaftertreatment

• Crankcaseventilation

• Turbochargers

• EngineStructuralIntegrity

• BoilinginCoolantflows

• Fueltankfillingandsloshing

EngineWith an ever-increasing emissions emphasis - from legislators and

consumers alike - the challenges for Powertrain teams continue

to grow. Whether it’s a new fuel, new combustion mode or a

new lightweight material, realistic simulation is an integral

tool in successfully bringing new technologies to market.

uIntake to tailpipe simulation of a V6 engine.

Contours of velocity magnitude.


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ModelingofBatterySystems&Installationsfor Automotive ApplicationsIt is difficult to find any auto OEM that does not have either EV vehicles in production or in advanced

development. Batteries have emerged as a key technology to the success of any EVs and this has

resulted in a business environment with OEMs, tier 1 suppliers and cell manufacturers forming JVs

and alliances to deliver complete battery pack solutions.

pLithium ion battery 3D. pLithium ion battery hybrid model.

{The World’s First Mass-Produced Electric Vehicle

Courtesy Tesla Motors.

One aspect of battery systems that has rapidly gained increased

engineering importance is that of thermal management;

temperature affects lifetime, durability, performance and safety,

all of which are critical to the success of the vehicle. It has

also become apparent that the CAE tools, upon which the auto

industry relies heavily for product development, have not been

available to address thermal management of large-scale battery

installations.

The problem is technically challenging - cell performance depends

on temperature, yet temperature depends upon the cell, pack,

cooling system and installation design and operating conditions.

Although analysis tools are available to address vehicle thermal

management issues, these have not until now been able to solve

large-scale problems whilst coupled to cell models.

ModelingofBatterySystems&Installationsfor Automotive Applications

To deliver an optimum solution, CD-adapco and Battery Design LLC formed

a partnership in early 2009 to deliver a fully coupled flow-thermal-cell

solution for solving large scale battery problems. CD-adapco has been

developing and using analysis software for fluid flow, heat transfer

and stress analysis for nearly 30 years and is heavily ensconced in

the automotive industry worldwide; one particular area of strength is

total vehicle thermal management. Battery Design LLC is a company

specializing in the design and modeling of Li-ion batteries for more than

a decade and consults widely to the battery and cell industry.

Specifically, all of the fluid flow and heat-transfer capabilities, including

multiple fluid-solid domains, conjugate heat transfer, multi-phase flow,

radiation etc available in STAR-CCM+ are coupled to the full range of

cell models developed by Battery Design LLC. These include fast simple-

circuit models for routine thermal analysis to enhanced electro-chemistry

models where non-linear behaviour is critical, such as short circuits

and thermal runaway. Additionally, all of the powerful pre and post

processing tools required for CAD import, surface preparation, automatic

meshing, model setup and visualization are available in the STAR-CCM+

environment.

Simulating battery systems is intrinsically a transient problem - the

State-of-Charge (SOC), and hence the battery characteristics, are changing

continuously. Additionally, thermal transients are of fundamental interest,

typically for a drive cycle of around 20 to 30 minutes. The software

has therefore been designed to be able to undertake such unsteady

calculations in which the flow, thermal and electrical time-scales are

accounted for properly.

One of the challenges to solving such problems is not just the possession

of an appropriate analysis tool but also a clear engineering process. The

ability to go from a battery design and experimental cell data to a viable

installed thermal result. Much effort has been devoted to developing this

process so that when the STAR-CCM+ solution is delivered, users will be

able to deliver realistic results as fast as possible.

Applications // Automotive

..::AUTOMOTIVE

yMercedes S400 thermal analysis showing installed lithium ion battery pack.

Courtesy Daimler

yLithium ion battery - Courtesy BEHR.

17

From noise control to rapid windscreen de-misting, excellence in passenger

comfort is a competitive necessity. CD-adapco’s CFD solutions are widely

used for the design of all aspects of automobile climate control systems,

ranging from optimization of individual components to ensuring that the

overall system provides passenger comfort and safety at all times. As well as

producing data such as velocities, temperature, humidity and noise levels,

STAR-CD and STAR-CCM+ are able to predict how comfortable a typical

occupant would be in that environment. Using the thermophysiological

models even heat generated by the passengers can be accounted for.

Simulations in this area include:

•HVACunits

•Fans

•Heatexchangers

•Recuperatorsimulations

•Condensersimulations

•Ductsandfilters

•Cabinflowandthermalcomfort

•De-icingandde-mistingofwindscreens

•Aeroacoustics

•AuxiliaryPowerUnits(APUs)andFuelCells

Climate Control & Passenger Comfort

pFull cabin simulation, including passenger comfort, and de-icing.

pIn-cabin flow paths - Courtesy Behr.

The basic capabilities of our products make them probably the most reliable, accurate, efficient and versatile CFD tool on the market.

..::AUTOMOTIVE


yPassenger comfort simulation.

AUTOMOTIVE::..


Other Examples…

Other examples include:

•FluidStructureInteraction

•Aquaplaning

•FuelCells

•Actuators

•Fueltankfillingandsloshing

•Pumps

•Torqueconverters

•Alternatorthermalmodeling

•Pumps

If you haven’t seen the application you’re interested in, or even if you have, contact

us to discover how CD-adapco can help improve the performance of your product,

cut time-to-market or optimise your existing simulation processes.

As the world’s leading provider of CFD solutions to the automotive industry, CD-adapco has enabled our partners to improve the performance of almost every part of modern road vehicles through simulation.

pSpray injection for an F1 airbox.

pFuel tank filling. pTorque converter performance. pSolid oxide fuel cell.

{Isosurface of total pressure on motor scooter.

pAquaplaning.

{Truck aerodynamics - Courtesy Fieldview.

Global Offices

Asia-Pacific Offices

AmericasHeadquarters • Melville, NY • [email protected] Offices: Atlanta GA • Austin TX • Cincinnati OH • Detroit MI • Houston TX

Lebanon NH • Los Angeles CA • Seattle WA • State College PA • Tulsa OK

EuropeHeadquarters • London, UK • [email protected] Offices: Aberdeen • Lyon • Nuremberg • Oslo • Paris • Rome • Turin

[email protected]

CD-adapco [email protected]

CD-adapco Korea Seoul [email protected]

CD-adapco [email protected]

For a full listing of our worldwide offices and Resellers, please visit www.cd-adapco.com

ResellersCDAJ JapanYokohama • [email protected]

CDAJ ChinaBeijing • [email protected]

richard johns - mdx

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