simulation driven product development - uni … · simulation driven product development albrecht...
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© 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
Simulation Driven Product Development
Albrecht Gill Regional Sales Director
ANSYS Continental Europe [email protected]
© 2008 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
Some graphics courtesy of Gebr. Heller Maschinenfabrik GmbH and University of Sheffield
Golf Club/Ball Contact
Production Equipment
Jet Impact
Aerospace
High Speed Airflow of Soccer Ball
Biomed Fly Through
Lock and Key
Engine Cooling
Automobile Crankshaft
Building Explosion
Cell Phone Stress
Robotic Arm
Simulation, Innovation Everywhere
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Simulation Customer Pressures
MARGIN FOR
ERROR
Competition Regulations
Cost Constraints Lawsuits/Guarantees
Innovation Customer Expectations
Time to Market Time for Licensing/Certification
Skilled Labor
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The Changing Role of Simulation
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Evolution of Simulation
Knowledge Management
Advanced Tools/Technology
Integrated Systems
Workflow Management
Process Management
Enterprise Access
Data Management
© 2008 ANSYS, Inc. All rights reserved.
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Simulation Depth: Turbulent Scales
RANS LES
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Mes
hing
Em
ag
Ther
mal
Flui
ds
Stru
ctur
al • Advanced Capabilities – Nonlinear materials – Large deformation – 3D frictional contact – Structural dynamics – Explicit dynamics – Large overall motion
• High Performance Computing – Parallel processing – Highly scalable
• Customizable – User elements & materials – Scripting
Structural
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Fluids
• Advanced Capabilities – Multiphase – Multispecies flows – Reacting flows – Multiple reference frames – turbulence models
• High Performance Computing – Large models: >1 billion – Large clusters: >1024 cores
• Integrated – Unified meshing – Unified CFD solvers – Unified post-processing
Mes
hing
Em
ag
Ther
mal
Flui
ds
Stru
ctur
al
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Thermal
• Advanced Capabilities – Radiation – Phase change – Mass transport – Steady-state – Transient – Conduction – Convection – Far field decay – Time dependent boundary
conditions • Advanced Materials – Temperature dependent
Mes
hing
Em
ag
Ther
mal
Flui
ds
Stru
ctur
al
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Electromagnetics
• Capabilities – Magnetostatics – Electrostatics – Low & high frequency
electromagnetics – Circuit analysis & coupling – Joule heating
• Materials – Linear & nonlinear – Isotropic & anisotropic
• Automated Post-Processing – Field intensity, scattering
Mes
hing
Em
ag
Ther
mal
Flui
ds
Stru
ctur
al
© 2008 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary
Meshing
• CAD Associativity – Bi-directional – Persistent – Parametric
• Flexible – Geometry clean up – Multiple mesh methods – Advanced mesh controls
• Highly Automated – Automatic contact – Apply loads to features – Physics aware
Courtesy of Ford Motor Company
Mes
hing
Em
ag
Ther
mal
Flui
ds
Stru
ctur
al
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End-To-End Solutions In a Unified Environment
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Variation and Optimization
Geometry Model
CFD Mesh
CFD Analysis
Geometry Variation
Update Mesh
Update
CFD Analysis
Integrated Workflow
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Fluid-Structure-Interaction
Geometry Model
CHT FEM Mesh
CFD Analysis with CHT
Set-Up for Analysis of
Thermal Loads
Thermal Load Analysis
Thermal Stresses/
Displacements
Integrated Workflow
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• Conjugate heat transfer analysis including – Water jacket – Exhaust gas flow – Gray cast iron
• Static structural analysis with thermal and pressure loads from fluid flow analysis
• Fatigue Analysis – Requires particularly
accurate stress prediction
Tout=? Exhaust Gas outflow
Tin=650° Exhaust gas inlet
Simulation Process
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CAD Interface and Geometry Processing
• Bi-directional CAD interface to CATIA V5
• Fluid geometry extracted from CAD model
• Minor geometric simplification needed
• Fluid-solid interfaces automatically generated
• Single geometry model for both analysis types
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Mesh Generation
• Pure tetrahedral mesh for structural analysis – Quadratic elements – Local mesh refinement
in region of high stresses
• Tetrahedral/Prism mesh for CFD analysis – Prismatic layers to
ensure boundary layer resolution
– Y+<1.2 – ~ 3 million nodes
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Conjugate Heat Transfer Analysis
Streamlines colored with temperatures
Temperatures in solid
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Structural Analysis and Thermal Load Transfer
• Linear structural analysis • Thermal and pressures loads
imported from CFD analyses – Loads automatically
interpolated from CFD to structural mesh
• Care has been taken to correctly model stiffness of adjacent parts – Foundation stiffness – Remote displacements
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Structural Analysis and Thermal Load Transfer
Structural Displacements
Van Mises Stress
