ICEngineSystem

PresentedBy
ANSYSInc.

Outline
BackgroundandMotivation
ICEngineSystem

Introduction
Scope
Properties
Workflowforcoldflowandportflowsimulations
Advancedsetup/customization
Otherusefulfeatures

Demo
FuturePlans
Summary

AmonginternalcombustionengineCFDapplications,
incylinderflowisofcentralimportanceindetermining
engineefficiencyandemissions

Exhaust

In-Cylinder

Turbocharging

Intake

Fuel Supply

Pumps

Cooling Jacket

Lubrication

RecentANSYSProgressinICEngineModeling
ContinuousprogresswitheachFluentreleasebringing
advancementsinphysicsandmeshing
FluentR14

FluentR12

Aftertreatment:selective
catalyticreduction,catalytic
converterlightoff
Combustion:Geqn
Multiphase:SSD

ICenginereport,ICspecific
vaporizationlaws,coherent
flamelet model,EGR,
ignitionUDF

2009

2010

2011

FluentR13
Keyframemesh,meshsmoothing,
DPMandcombustionextensions:
multiplesparkmodel,Veynante ECFM
forLES,KHRTbreakupmodel,

*TheWorkbenchICEnginesystemusesawelltestedsubsetofFluentfeatures

2012
FluentR14.5
Sprays:sprayanglevs.crankangle,
coneinjectionsectormeshes
Meshrelated:2nd orderintimeMDM,
contactdetection,cutcell w.BLremesh

Motivation
MeshCreation
Geometry
Decomposition

ICEngine
Geometry

SolverSetup

ManualApproachfor
simulatingincylinderflow
Gathertherequireduserinputneededtoaccuratelymodelthe
usersspecificengine.
WBICEtool
PreparetheGeometryandMesh:
Performfollowingoperationssemi
automatically
Decomposethegeometryinamannersuitableformodelingthe
motionofvalvesandpistonandthencreatethemesh
Geometry
SolverSetup
Manuallydecomposingthegeometryandmeshingtakes
Decomposition
between6hoursandacoupleofdays,dependingonexperience
MeshCreation
Learningcurveformanualgeometrydecompositionandmeshing
isverysteep!!
Setupandrunthesimulation:
Settingupthecaserequiresknowledgeofmodelslikedynamic
mesh,reactingflows,discretephaseetc.
Analyzeandinterpretresults

ICEngine
Results

Automatic
Report
Generation

ICEngineSystem:Introduction
ICEngineSystem
AnewWorkbenchAnalysisSystem
similartoFluidFlow(Fluent)or
FluidFlow(CFX)AnalysisSystems
ReducesthesetuptimeofICEcold
flowandportflowproblemsfrom
manyhourstofewminutes
FirstreleasedANSYSR14
SupportedonWindowsandLinux
platforms
Standard featureincludedwith
ANSYSFLUENT

ScopeofICEngineSystem
Automatedgeometrypreparationandmeshgeneration
forall4strokeengines
anynumberofvalves
allstandardshapesofpistonatthegivencrankangle
Automatedcasesetupforcoldflowandportflow
typesimulationsbasedonthebestpractices
includingmeshmotion
Userhooksforcomplexphysicssetup,e.g.sprayinjection,
combustionsimulation
Automatedreportgeneration

ICEngineSystemProperties

Forengines
withpiston
pinoffset

Usercanhook
boundary
condition
profiles

TheseICinputs
canbedefinedas
Parameters

Canbeusedto
setupa
customizedcase
Canbeusedto
performcustom
postprocessing

WorkbenchICESystem
ANSYSWorkbench

CAD

DesignModeler
ANSYSMeshing
Single
Mesh

Multiple
Meshes
(keyframes)
(newR14.5)

FLUENTSolver
CFDPost

Automatically
GeneratedReports

ColdFlowSimulationSetup
UsingICEngineSystem:

ColdFlowSimulationusingICEngineSystem
Automaticpreparationofgeometryformeshing
Automaticmeshingincludinginflationlayersand
layeringzones
Automaticsetupdynamiczones,events,andsolver
settings
HTMLreportcreation
Reducestheturnaroundtime(CADimporttoCFD
setup)tolessthananhour

GeometryPreparation

GeometryInputs

BasicGeometry
Information

Valvegeometryand
profileinformation
Optional
AnimationInputs
Advanced
Options

MeshGeneration

DifferentMeshingConfigurations
4layersbetweenvalve
andvalveseatatfully
closedpositionofvalve

onelayerinthegapat
fullyclosedpositionof
valve

DifferentMeshing Configurations

Inflationlayerintheport

NoInflationlayerintheport

DifferentMeshingConfigurations

Decompositionin
combustionchamber
regionforlayeredmesh

Nodecompositionin
chamberregionfor
engineswithverylittle
squishatTDCorpistons
withvalverecessregions

SolverSetup
ICEngineSystemwillautomaticallysetupthe
problem

Readsthevalveandpistonprofile
Createvariousdynamicmeshzones
Createinterfacesrequiredfordynamicmeshsetup
Setupthedynamicmeshparameters
Createalltherequiredevents,tomodelopeningandclosingof
valves,andcorrespondingmodificationsinsolversettingsand
underrelaxationsfactors
Setuptherequiredmodels
Setupthedefaultboundaryconditionsandmaterial
Setupthedefaultmonitors
Initializeandpatchthesolution

HTMLReport

Once the solution is complete, tool creates a

detailed report with all the settings , events,
results and images.

PortFlowSimulationusing
ICEngineSystem

PortFlowSimulationusing
ICEngineSystem
NewfeatureinupcomingANSYSR14.5Release
Preparesthegeometryautomatically
Automaticmeshingusinghybridandcutcell
approaches
Setupandsolutionstrategybasedonthebest
practices
AutomaticsavingofimportantimagesandHTML
reportcreation
Reducestheturnaroundtime(CADimporttoCFD
setup)tolessthananhour

AutomaticGeometry
Preparation
Movesthevalvetoappropriateposition
Deactivatestheclosedvalveanddeletestheport
automatically
Removesthepistonbowl(ifneeded)andextendthe
cylindertoappropriatelength
Createdifferentshapesofinlet/outletplenum
Automaticallycreatestheswirl/tumbleplanesatthe
givenposition

AutomaticGeometryPreparation
OriginalGeometry

Finalgeometrywith
InletandOutletPlenums,
andportdeactivated

InputManagerfor
PortFlow

GeometryDecomposition

AutomaticMeshing
Cutcell andhybridmeshingsupport
Createpropermeshcontrolsandsizingto
getbettermeshinthechamberandvalve
gap
Boundarylayersinbothhybridandcutcell
meshing

AutomaticMeshing

AutomaticSolverSetup
ICEngineSystemwillsetupthesolverfromthebest
practicesforcutcell andHybridmeshing
Setappropriatesolvermethodsandcontrols
Settheboundaryconditions
Definesthedefaultmonitors
DoestheFMGinitialization

Automaticallycreatesthedefaultswirlplanefrom
geometryinformation,anddefinescustomfield
functionsforswirl

HTMLReport:

 Demo(56minrecorded
demoofcoldflowandport
flow)

RegressionandTimeStatistics:
Astrongregressionsuite
Morethan15engineswithvarioustopologies
fromdifferentcustomersarethereinour
regressionsuite,whichrunsondailybasis,to
maintainthestabilityandhighqualityof
software
Foreachoftheseenginesgeometrypreparation,
meshing,andsetupforcoldflowcaseiswithin20
min,andforportflowthisiswithin30min

Documentation:
Detailedexplanationofallthefeatureswithtipsonhowonecan
modifythedefaultbehaviorofthetool
Troubleshootingchapters:Alltheknowledgegainedsincethe
releaseof14hasbeencapturedanddocumented.Separate
sectionsfor:

Geometrycheck
Geometrypreparation
Meshgeneration
Solversettingup

Welldocumentedprocessexplaininghowtoolcanbeextendedfor
someofthefeatureswhicharenotsupportedbyautomation
Decomposingastraightvalveenginewithpocketsforlayeredmeshing
Handlinggeometriesinwhichsolidvalvesaremissing

DetailstepsforsettingupandrunningthetutorialsalongwithVideo
tutorials

ExtendingtheTool(AdvancedUsers)

Advancedsolversetupusing
journalcustomization.
Userwillbeabletosetupadvancedphysicsusingpre
iterationandpostiterationjournalhooks
Usingpreiterationjournalhooksusershouldbeableto
setupcombustionprobleminICEnginesystem:
Defineprofile,udf ,andchemkin,filepathandalsoother

variables
Compileandhooktheudf,alsodefinesomeudf related
variables
Deactivateportfluidzones
Setupenergymodel,turbulencemodel,speciesmodeland
dpm models
Defineinjections

SettingupCombustion:

ColdFlow
Setup
PreiterationJournal
Combustion
Setupwith
Spray

PreiterationJournalfile
forcombustion:
FileHandling
ModelControl

InjectionData

SetupMethod

Creatingnewzonesanddefining
advancedboundaryconditions.
YoucancreatenewZoneat
geometrylevelbydefining
aNamedSelectionwith
prefixiceuser
Extendtheboundary
conditionsbydefiningnew
boundaryconditionsin
UserBoundaryConditions
andMonitorSettings

HandlingEngineswith
CreviceRegion
Though,rightnow,thetoolwillnotdoanyspecial
treatmentforcreviceregion,onecanextendthe
toolbydoingfewmanualoperationstogetmore
controlincreviceregion
Separatethecrevicevolumeanddefine
propermesh
Defineinterfacestohandlethisnewcrevice
volume

Interface
HexMesh

CreviceRegion

OtherUsefulFeatures

Keygridsupport
Automaticcrankanglespecificdecomposition
Createmeshasperthecrankangleposition
Parametricsupporttogetmeshesatdifferent
crankangles
Youcansetupuptothemeshonce,andthenyoucan
createanynumberofdesignpointswiththeexposed
parameterslike:crankangles,minimumlift,or
connectingrodlengthandupdatethedesignpoints,
youwillhavetheappropriatemeshfilereadyatthose
givencrankangleswithoutanymanualintervention

Keygridsbasedonthecrankangle

Geometry
andMeshat
crankangle
nearTDC

Geometry
andMeshat
crankangle
nearBDC

UsabilityFeatures
Animationofvalveandpistonmotionforthecoldflow
simulationatgeometrylevel
Parametersupportforportflowsolutionandmesh
generationincoldflow
Usercanstartthecoldflowsimulationfromanycrank
angle,allthesettingswillbetakencareautomatically
Thissavesahugeamountoftime;earlierpeopleuse
toreachtherequiredcrankanglebymeshmotion
whichtakesalotoftime
AutomaticcutplanesandviewsinAMPforbetter
visualizationofthemesh

FuturePlans
SmoothtransitionfromColdflowtoSprayandCombustion
Automatedsetupforcombustionanalysis
Improvemeshingoptionsby
AutomaticallySwitchingbetweendifferenttailored
meshesduringsimulation(Keygridormesh
replacementapproach)

Note:Theplansarestilltentativeandtimelines,prioritiesetc.needstobeworkedout

Summary
NewstandardfeatureinANSYSFLUENTforIn
Cylindersimulations
Automatesincylindermodelcreation
Extensivelytestedondifferentengine
configurations
SupportedonWindowsandLinux
Quicktolearnandeasytouse!
Provideshooksforcustomincylindersimulations

Appendix

WorkFlow

Meshconfigurationof
ICEnginesystemforatypicalcantedvalveengine
No

FluidZone
Name

Meshtype

fluidch

Tet mesh

fluidvalveID
ib

Sweep meshwithat
leastonelayeratthe
top

fluidvalveID
port

Tet meshwith or
withoutprismlayer

fluidvalveID
vlayer

Layered meshwith1
or4layers

fluidlayer
cylinder

Layeredmesh

Fluidpiston

Tet mesh

Geometrydecomposition
Various zonesandnamedselectioncreatedautomaticallyforatypical
cantedvalveengine.

SmoothingLayeringapproach
Toretainatleast4
layersofcellsbetween
valveandvalveseat,
throughoutcycle

smoothing

layering

smoothing

Troubleshooting:GeometryCheck

PistonshouldbeatTDC
position(inR14.0)
ForParasolid geometry,setthe
CleanBodiesoptiontoNo
Importedgeometryshould
haveonlyoneflowvolume
withsolidvalves
Ensurethatthevalvesarenot
extractedfromtheport
volumeintheinitialgeometry
Ensurethatthevalvestem
protrudesoutoftheportbody
Ensurethatthevalveis
centrallyalignedtothevalve
guide.Anoffcenteredvalve
canresultintofailuresand
wrongresults

Troubleshooting:MeshGeneration

Ifcylinderchambermeshingfails
=>Deleteitspinchcontrolsandexecutethe
meshingagain

Ifsomefacesbelongingtoanamed
selectiongrouparenotselectedfor
theGeometryoptiontheybelongto,
thenthewarningisdisplayed
=>AddthesefacestotheGeometrylistof
theNamedSelectionitbelongsto

Ifthereareanysmallfacescausinga
meshingfailure,thenthesefaces
shouldbemergedwiththeir
adjacentfacesusingVirtualTopology
IfVlayermeshingfails
=>Trytoprojectandimprinttheedgeofthe
valvefaceonthevalveseat,inthe
directionofthevalve

Thiswillsplitthevalveseat.Then
decomposethegeometryagain.This
procedurewillcreateapropersweep
meshinthevlayer.

Troubleshooting:MeshGeneration
Vlayermeshingcanfailin
somecaseswheretheface
hasastep.
SelectShowthe
ProblematicGeometryfrom
thecontextmenuofthe
errormessageinthe
Messageswindow.Thiswill
pointtothefacewhichhas
thestep
ReducetheVLayerSlice
Angleparameterinthe
InputManager,suchthat
thefaceissplitintotwo.
ThenresettheMeshcell
andfollowthemeshing
proceduretoremeshthe
geometry.

StraightValveEngineswithValvePockets
Fullylayeredmeshcanbe
createdforstraightvalvediesel
engineswithvalvepockets
Instructionscanbeprovided
uponrequest(availablein
R14.5ICEManual)
Example:Hexmeshcreatedforlayering