} CFD integration in a general FEM environment

1. Product line presentation

2. CFD for product design

3. FEM activities

4. Standard FEM environment

5. FEM environment modifications

6. acuSolve solver characteristics

7. acuSolve solver validations

8. HyperMesh main used features

Philippe GILOTTE
9. HyperView and HyperGraph extensions Plastic Omnium Auto Exterior
01150 Sainte-July, France
10. Computational status

PAGE 1 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration in a general FEM environment

1. CFD interest for product design

z Product line design such as front end module
Front end example
z Energy absorption computation for specification requirements
z Possible interaction with cooling air flow rate
z Introduction of CFD computations for design propositions
Pedestrian safety

2. CFD integration in relation with energy absorption applications

z 2D shell meshing & 3D air volume meshing with HyperMesh
z Solver interface with HyperMesh & HyperView
z CFD Postprocessing options in HyperView & HyperGraph
Air inlet flow example

PAGE 2 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : product line presentation

Bumper with Fender & Front end Tailgate

energy body parts module
absorption

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} CFD integration : CFD for product design
1. Underbody : thermal convection with conduction and radiation transfer
2. External aerodynamic : aerodynamic force reduction for fuel consumption
3. Front end module : cooling air flow optimization for fan power reduction

Underbody : External aerodynamic : Front end module :

Thermal convection of a rear Pressure estimation on for air flow computation
spoiler including conduction tailgate for drag reduction in front cooling modules
and radiation transfers

PAGE 4 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : CFD for underbody optimization
1. Rear floor overheating :
z Thermal radiation : heat shield protection
z Stratified T° field due to air conduction : convection introduction
2. Rear spoiler overheating :
z Thermal radiation : heat shield protection on bumper side
z Conduction in the exhaust pipe finisher : spacer introduction
z Exhaust pipe finisher computation due to convection transfer

Thermal radiation
computation
Thermal radiation for rear spoiler
computation heat shield design
for rear floor
heatshield design
Thermal
Air flow rate computation
computation with convection
for rear floor transfer
cooling design

PAGE 5 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : CFD for external aerodynamic
1. Aerodynamic forces reduction
2. Increasing pressure behind tailgate
3. Controling air flow with sucted flow or pulsed flow

Without suction

Sucted flow

With suction

Velocity and pressure field

PAGE 6 / 2nd HTEC - Strasbourg - 30/09/08
} CFD integration : CFD for front end optimization
1. Increasing cooling air flow through the cooling module
2. Decreasing wakes behind inlet grille

Velocity increase in the lower part of the cooling module

front end
architecture example

Inlet grille in two parts Wake reductions behind the grille bar

PAGE 7 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : CFD for front end optimization
1. Flap integration behind the inlet grille for drag reduction
2. Possible air flow performance reduction due to additional obstruction

CFD computation in Total pressure through P tot = 2400 Pa

standard configuration upper air inlet

P tot = 800 Pa

CFD computation with flap Total pressure through P tot = 2500 Pa P tot = 1100 Pa
obstruction lower air inlet

New pressure balance with inlet flap integration Pressure losses computation due to
flap obstruction

PAGE 8 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : CFD for front end optimization
1. Front end evolution due to energy absorption specifications
2. Air inlet flow rate computation for engine cooling performance
3. Reducing pressure losses and fan power

Power frame integration behind bumper air volume between air inlets and the
for energy absorption specifications. cooling module. Power frame includes
Possible air flow obstruction air guide for air flow optimization

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} CFD integration : FEM activities
1. Surface meshing in Hypermesh
z From neutral fiber surfaces Pedestrian beam
neutral fiber meshing
z From available shell mesh
2. FEM computations
z For modal analysis : Hyperstruct or Abaqus implicit
(Abaqus interface)
z For energy absorption : Radioss or Abaqus explicit
3. Postprocessing in Hyperview & Hypergraph (for all FEM applications)

HyperView : stress values due to leg impact HyperGaph : lower leg acceleration curve

PAGE 10 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : standard FEM environment

Energy absorption
computation with
Radioss

CAD with Shell meshing Post-processing with

CATIA with HyperMesh HyperView and
HyperGraph

HyperMesh : pedestrian
beam neutral fiber meshing
HyperView : stress HyperGaph : lower leg
values due to leg impact acceleration curve

PAGE 11 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : FEM environment modification

Energy absorption
computation with
Radioss

CAD with Shell meshing Postprocessing with

CATIA with HyperMesh HyperView and
HyperGraph

volume meshing Aerodynamic

with HyperMesh with acuSolve

3D Mesh file transfer : CFD files transfer :

HyperMesh : front air
HyperView : velocity or
inlet volume meshing Written in native acuSolve 1 - read in Abaqus format
pressure field
format from HyperMesh 9.0 from HyperView 8.0
2 - read in native acuSolve
format in HyperView 10.0

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} CFD integration : acuSolve solver

z Numerical characteristics : mean square Galerkin solver

z Galerkin formulation :
- Resolution of a variational equation
- Velocity projected on shape function
- Quadratic solution in space and time
z Least square operator :
- Stabilizes Galerkin formulation
- Satisfies exact solution
- Convergence robustness

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} CFD integration : acuSolve solver

z Application characteristics :
z Cover current computation needs
- Steady or transient computations (LES) for pulsed flow
- Multiple reference frame or sliding mesh for fan computation
- Thermal radiation computation for exhaust temperature computation
z Anable to share computations with other FEM application
- FEM formulation well adapted to automatic tetrahedron meshing
- Robustness and precision of the solutions
- Speed of convergence in agreement with other FEM computations
- Transfer via native format or Abaqus interface

CFD with thermal radiation Transient computation

MRF computation
PAGE 14 / 2nd HTEC - Strasbourg - 30/09/08
} CFD integration : acuSolve solver
z CFD Validation : Polhausen flow case
z Analytical description of turbulent boundary layer
z Polynomial expression of the velocity in the boundary region
z Boundary layer can be captured in a fine tetrahedral mesh
z Enable to capture flow frictions for cooling module air gap & drag coefficient

velocity profile in the direction normal to a plane

0,014
velocity profile
0,012
canal thickness [m]

0,01
0,008 Boundary layer thickness of 6 mm
0,006 for a inlet velocity of 5m/s
0,004
0,002
0
0 1 2 3 4 5 6
velocity [m/s]

Air gap thickness of 10 mm : flow rates and

Computed velocity profile corresponds to a boundary layers are computed with cell thickness
Polhausen description with cell thickness of 2 mm of 2 mm (6 nodes in the cross direction)

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} CFD integration : acuSolve solver
z CFD Validation : external aerodynamic on Ahmed body
z Comparison with published 2D results from Renault (Research dept) - IMFT
z Vortex description behind the base of a Ahmed body in square extruded surface
z Good agreement on average total pressure coefficients and streamlines

Average results for total pressure coefficient and Average results for total pressure coefficient
streamline from Renault – IMFT publication and streamlines from acuSolve simulation

PAGE 16 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : acuSolve solver
z CFD Validation : tangential fan performances
z Computed pressure and flow rate in concordance with EBM PAST figures
z Steady state simulation realized with multiple reference frames (MRF)
z rotating velocity of 1500 rpm

Tangential fan
optimization for
rear flow control

Tangential flow performance Velocity of 30 m/s (with

in open air inlet pressure suction of 150 Pa)

-50 Pa

Scroll housing
optimization

Flow representation from Flow and pressure result after scroll

EBM PAPST optimization in a confined environment
PAGE 17 / 2nd HTEC - Strasbourg - 30/09/08
} CFD integration : HyperMesh main used features
1. Geometry :
z overlapping surface (edge edit)
z available shell mesh (surface from FE)
z air gap closing (surface)
2. Surface meshing : 2D automesh
z 100% Triangular cells (no pyramid cells)
Surface mesh closing for 3D air meshing
z Cell size control on air gap cross sections
3. Volumic meshing : 3D tetramesh
z With fixed and free triangular shell mesh
z User control meshing : growth rate=1
4. acuSolve export in CFD panel Air gap control on surface mesh
crossing and tetrahedron cell growth

PAGE 18 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : HyperView & HyperGraph extension
1. Mesh and result loading :
pyramid & surface cells (in Abaqus format)
Streamlines, &
pressure coefficient
2. Velocity vector representation :
cutting slice & uniform grille option
3. Field operations :
z relative velocity (MRF)
z pressure coefficient
Velocity vector
z vorticity (curl U) or gradient representation and
surface pressure loading
4. Velocity or pressure profiles :
depending on x,y,z
velocity profile in the direction normal to a plane
0,014

0,012
velocity profile

canal thickness [m]

5. Surface integrated values :
0,01

0,008

0,006

flow rate & drag coefficient 0,004

0,002

6. Streamlines
0 1 2 velocity 3[m/s] 4 5 6

Velocity or pressure profiles

PAGE 19 / 2nd HTEC - Strasbourg - 30/09/08

} CFD integration : computational status
1. Model preparations : HyperMesh
z Geometry, 2D and 3D features enable to mesh air volume
z Geometry and 2D meshing tasks can be shared in a CAE team
z 3D meshing remains easy for air volume meshing
Air volume meshing

2. CFD Average values : HyperView

z Enable to represent pressure and scalar velocity fields
z Vector velocity field for symmetric boundary conditions (Y0 plane)
Velocity vector field for Y0

3. CFD instantaneous values : HyperView and HyperGraph

z Pressure or velocity profiles depending of time
z Quick visualization of instantaneous pressure or velocity fields
Instantaneous velocity field

4. Feature extensions in HyperView & HyperGraph ?

PAGE 20 / 2nd HTEC - Strasbourg - 30/09/08