Outline

MEEG 512X: Computational Fluid Dynamics

Lecture 1: Introduction 1. Fluid Engineering
– Analytical Fluid Dynamics (AFD)
– E perimental Fl
Experimental Fluid
id D
Dynamics
namics (EFD)
– Computational Fluid Dynamics
Dr. J. Hu 2. What is CFD
Assistant Professor of Mechanical Engineering 3. Why use CFD
4. Where to use CFD
Technology Building 133
5. How to use CFD
E mail: jhu@bridgeport
E-mail: jhu@bridgeport.edu
edu 6. Evolution of CFD Application in Industry
Phone: 576-4757 7. Conclusions

Fluids Engineering Methods in Fluid Dynamics

Governing equations of fluid dynamics are highly non-linear; therefore,
• Engineers have different kinds of tools available for we need an arsenal of techniques to understand the processes.
solving fluids engineering systems
– Analytical Fluid Dynamics (AFD) Wind Tunnel
Water Tank
– Experimental Fluid Dynamics (EFD) EFD y
Dimensionless Analysis

– Computational Fluid Dynamics (CFD) CFD aids with interpretation

and simulating conditions not
Three possible experimentally
AFD EFD CFD Work
Together
AFD CFD

Highly Mathematical: Numerical Methods to Solve Equations:

Boundary Development of a pipe flow Bernoulli’s Equation Directly Solve Navier-Stokes (DNS)
Navier-Stokes Exact Solutions Solve Linear Forms of the Equations
Euler Equation Solutions Solve Non-Linear Equations
Plane Potential Flows (Inviscid) Experiments Used to Provide
Provides fundamental equations for solution, Unknowns and validate
∇•U = 0
DU 1 and can provide validations for codes and
= −∇p + ∇2 U + ∇ • ui u j
Dt Re experiment.

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 What is CFD?
Why use CFD?
•Computational Fluid Dynamics (CFD) is the analysis of a systems
involving fluid flow, heat transfer, and other associated phenomena, such as • Analysis and Design
chemical reactions, by using computer-aided methods. 1. Simulation-based design instead of “build & test”
•CFD is made ppossible byy the advent of digital
g computer
p and advancing
g with ‰More cost effective and more rapid than EFD
improvements of computer resources (500 flops, 1947 -> 3 petaflops, 2007) ‰CFD provides high-fidelity database for diagnosing flow field
2. Simulation of physical fluid phenomena that are difficult
for experiments
‰Full scale simulations (e.g., ships and airplanes)
‰Environmental effects (wind, weather, etc.)
‰Hazards (e.g., explosions, radiation, pollution)
‰Physics (e.g., planetary boundary layer, stellar evolution)
• K
Knowledge
l d andd exploration
l ti off flow
fl physics
h i

IBM WorkStation
Cluster at Purdue
ENIAC, 1946 (ftp.arl.army.mil)

Why use CFD? Where is CFD used?

• Where is CFD
Aerospace
Simulation(CFD) Experiment used?
• Aerospace Biomedical
Cost Cheap Expensive
• Automotive
Time Short Long • Biomedical
• Chemical F18 Store
Separation
Scale Any Small/Middle Processing
• HVAC
Information All Measured Points
• Hydraulics
Repeatable All Some • Marine
• Oil & Gas
Security Safe Some Dangerous • Power Automotive Temperature and
Generation natural convection
• Sports currents in the eye
following laser heating.

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 Where is CFD used? Where is CFD used?
• Where is CFD
Marine Sports
used? Chemical Processing
• Where is CFD used?
• Aerospacee
• Aerospace
• Automotive
• Automotive
• Biomedical
Polymerization reactor vessel - • Biomedical
• Chemical prediction of flow separation and
• Chemical Processing
Processing residence time effects.
• HVAC
• HVAC Scour downstream of a Hydraulics
flood control structure • Hydraulics
• Hydraulics
• Marine
• Marine
• Oil & Gas
• Oil & Gas
• Power Generation
• Power Generation
• Sports
• Sports HVAC
Oil & Gas Power Generation
Streamlines for
workstation ventilation Flow of lubricating Flow around cooling
mud over drill bit towers

How is CFD Used?

CFD Basics – CAD to Solution Example
•Geometry and domain
•Governing equations for physical models:
Navier-Stokes equations (momentum), continuity
4h
equation,
q , energy
gy equation,
q , ideal ggas law,, chemical reaction 1h 1h
CAD Geometry
equations, and turbulent models (RANS, LES, DNS), etc.
Surface
Meshing
Surface Clean-up
2h
•Coordinates:
Volume
Cartesian, cylindrical and spherical coordinates Meshing
•Boundary
Boundary and Initial Conditions: Post processing
Post-processing •
•
no-slip wall, symmetry, velocity inlet/outlet
•Flow conditions: (From
DaimlerChrysler, 8h
Compressible/incompressible, turbulent/laminar, single
Germany)
phase/multi phase, chemical reaction, free surface, surface tension, CFD Solution
etc. Cd-adapco

3
 Trends in Use of CFD from 1980s to Early 1990s
CFD Basics – CAD to Solution Overview
• Cost is very high, usage limited to • CFD is an ‘afterthought’
Discipline CFD
COMPONENT
FUNCTION companies with big companies and – Fix problem with prototype
SOFTWARE
fluid industries: • Provides insight
CAD • Understand flow patterns
•Geometry
G t B Building
ildi
– Aerospace/defense
1. CAD Modeler – Automotive • Last minute model build
Meshing

•Geometry Import and Mesh – Fluid machinery design – Rushed & error prone
2. CAD Importer Generation • Requireimmense computation – Coarse mesh
resources – Simplified models
– Meshing algorithms are resource
– Accuracy is a concern
CFD
exhausting and require special expertise • Product design rely on physical
ution

•Physics and Boundary – Mainframe and Unix systems are prototyping

3
3. Pre-Processor
Pre Processor
Pre/Post/Solu

standard
d d equipment
i – More
M ddesign
i iterations
it ti
Condition Selection
• Only general-purpose CFD – More things to fix
4. Solver
•Numerical Analysis – Simplified geometry – Harder to fix
5. Post-Processor – For expert use – Impacts cost and time to market
•Solution Revealed to User

Cd-adapco

Trends in Use of CFD from 1995 to 2005 Trends in Use of CFD from 2005 to present

• CFD used in late design • Expanding of CFD in design

– Equipment modeled before final prototyping across all industries
• Integration of CFD software
• Modeling errors reduced within the design process
– Build model earlier • More detailed modeling
– Better models with turbulence, wall treatment, multiphyscis, etc. – Turbulence models
– Finer mesh – Physical or chemical phenomena
• Hardware costs reduced – Finer mesh
• Improved links to CAD
– Move from workstations to high-end PCs
– CAD embed CFD analysis
– Parallel computing – Easier geometry preparation
• CFD Vendors • Collaborative designg
– Speed mathematical algorithms • Design optimization
– Increase ease-of-use issues
• Application of CFD in industries are expanding Companies adopt CFD
during design stage
Flomerics

4
 Example of Collaborative Design Integration of CFD in Design Process

• EE: signal integrity and • Challenges faced by companies

timing constrain component • Advances in CAD and CFD integration
placement • Automated geometry abstraction
¾Upp to 80-90% of nets are
• M hi generation
Meshing ti
constrained
• ME: thermal design needs • High- performances solvers
layout and architectural • Rapid advances in desktop compute power
flexibility • New knowledge-enabled "process-centric" user environments for
¾Heat sinks cover up to 60- non-expert design engineers that leverage the expertise and best
80% of PCB practices of CAE/CFD domain experts will lead to a much broader
g
utilization of digital performance
p simulation in the context of PLM.

Flomerics

CAD and CFD integration CAD and CFD integration

Traditional Product Design Process
• Most commercial CFD codes today are unable to solve directly using
the native MCAD geometry
• Translation from the native MCAD data into some neutral format such
as Parasolid
• Design intelligence associated with the geometry such as assembly
hierarchy, constraints and features are lost and only dumb geometrical
entities remain.
• Full bi-directional associativity between the analysis data and the
MCAD model.

Flomerics
Geometry preparation = geometry simplification

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 CAD and CFD integration FEA and CFD integration

Flomerics Abaqus

Development of Commercial CFD Codes Development of Commercial CFD Codes

• CFD was introduced in the 1960s as research codes in universities and • General-purpose CFD packages have developed over the years
government research labs • Ability to handle complex geometry
• First commercial general-purpose CFD software (PHOENICS) was •Advanced meshing tools
introduced in 1981 •20+
20+ turbulent models
• Structured hexahedral elements •Multi-physics submodels
•Steady/unsteady •Advanced solver
•Compressible/incompressible •Accurate
•Laminar/turbulent •Versatility and control STAR-CCM+
•Chemically-inert/reactive •Need expertise to use •Integrated process
•Single-phase/two-phase •Surface wrapping
• General-purpose
p p CFD packages:
p g Fluent (1983),
( ), STAR-CD ((1987), ), CFX,, •Physical
Physical modeling
Star-ccm+ •Turbulent modeling
•Post processing
•Automatic meshing
•Client-server architecture

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 Development of Commercial CFD Codes How is CFD used in industry?

CFD is used to generate information used in

•Specific purpose/process centric/CAD embed CFD codes
• Flotherm (thermal analysis), Flo/Pack, Flo/PCB • Design
• Flomerics EFD product such as EFD.Pro (ProE), EFD.V5 (CATIA • Development
V5),
) EFD.Labb • Optimization
i i i
• Star-CAD series STAR-CAT5, STAR-NX, STAR-Pro/E, STAR- • Performance characterization
Works • Manufacturing process design
• Easier to use • Installation
• Not versatile or controlled by user • Trouble shooting
• A new trend for design engineers

Users of CFD Users of CFD

Current status of CFD users in industries Future trend of CFD users in industries
• Most CFD users were specialists with graduate degree (PhD in • CFD will be used
most case ) increasingly by less expert
• There
h iis a shortage
h off competent CFD practitioners
ii staff
ff (follow
(f ll theh trendd off
• CFD have been introduced to both undergraduate and graduate other CAE tools, e.g. FE
courses stress analysis)
• CFD users training is provided by commercial software • Depends on CAD embedded,
suppliers specific purpose, or process
• Leaning curves towards the required levels of skill and centric CFD codes
knowledge remains significant
• CFD remains
i iin the
h engineering
i i analysis
l i group or R&D
department

7
 Quality and Reliability CFD in Biomedical field
•A survey shows majority mechanical design engineers (80%) do not use Spiral and non-spiral flow in a human
aortic arch • MRI derived vessel geometry and
CFD because they
— don’t have the necessary expertise and knowledge to use CFD code
flow parameters
— are not aware of what CFD can do for them
• STAR CD analysis
• Easy to use CFD codes for mechanical design engineers can lead to • 400,000 trimmed cells
wrong or unphysical CFD predictions • high Reynolds number k - w
•Knowledge of flow and physics model with hybrid wall
•Appropriate validation techniques functions
•Specialist aerodynamicists and fluids engineers should remain the • 20 hours on a PC (2.7 GHz
important users, interpreters, and reviewers of data generated by CFD CPU and 1.5 GB RAM)
•Matured
Matured CFD models in industry processes can be developed for design
engineers
Qualitative wall shear stress prediction
agrees well with observations and has
Swift CFD Solutions improved the understanding of the
Nilewells Hospital
relationship between hemodynamics and
vascular disease

CFD in Biomedical field CFD in Building Design

Ventilation effect for the new California Academy of Sciences

Flow in human heart

modeled with a
moving mesh

Purpose:
Assist in clinical diagnosis
Serve as a component of virtual surgery
ARUP
Cd-adapco

8
 CFD in Building Design CFD Design of Hydraulic Turbine Tube

Traditional design is based on:

•simplified analytical methods
•model tests
•full-scale
full scale tests
CFD predictions of the flow field in
draft tubes are:
•very challenging
•time consuming
•complex flow features
—turbulence

—unsteadiness

—swirl

—separation

—secondary flow

ARUP
J.G.I. Hellstrom, et al

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 Conclusions

‰ CFD has evolved during the past 30 years

• It has advanced in its ability to handle complex geometry
and its mesh generation, physics modeling, numerical
methods
h d andd post processing
i
• It is being in more industries
• It has become an integral part of the design process
‰ We’ll continue to see CFD evolve
• Faster, better, easier
• Better integration between FEA and CFD
‰ It is also seen that CFD application should be used in caution,
since
i the
th accuracy off the
th simulation
i l ti results lt depends
d d on models
d l
(turbulent modeling and other physics modeling), mesh
qualities, numerical schemes, etc.

Reference:
h //
http://css.engineering.uiowa.edu/~me_160
i i i d / 160

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