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Integration of Mixed Reality to CFD in Industry 4.0: A Manufacturing Design

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Article in Procedia CIRP · January 2022

DOI: 10.1016/j.procir.2022.05.122

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Integration of Mixed Reality to CFD in Industry 4.0:
A55th CIRP Conference on Manufacturing Systems
Manufacturing Design Paradigm
Integration of Mixed Reality to CFD in Industry 4.0:
28th CIRP Design a,*Conference, May 2018, aNantes,, NikosFrance
A Manufacturing
Dimitris Mourtzis Design
, John Angelopoulos Paradigm Panopoulosa

A new methodology to Mourtzis

analyzea,*,the functional and physical architecture of
Laboratory for Manufacturing Systems and Automation (LMS), Department of Mechanical Engineering and Aeronautics, University of Patras, Rio Patras
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Dimitris John
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address: mourtzis@lms.mech.upatras.gr
of Mechanical Engineering and Aeronautics, identification
of Patras, Rio Patras
26504, Greece
Paul Stief fax:
* Corresponding author. Tel.: +30-2610-910-160; *, Jean-Yves Dantan,
+30-2610-997-314. Alain
E-mail address: Etienne, Ali Siadat
mourtzis@lms.mech.upatras.gr
Abstract
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Simulation, as a pillar technology of Industry 4.0, is a key tool for improving manufacturing processes. Simulation is an indispensable set of
*Abstract
technological
Correspondingtools and
author. methods
Tel.: for37the
+33 3 87 54successful
30; E-mail implementation of digital manufacturing, since it allows for the experimentation and validation
address: paul.stief@ensam.eu
of product, process, and system design and configuration. The value of simulation is evident, especially in today's volatile manufacturing
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identification
1. Introduction most widely used method for designing and analyzing
manufacturing systems. Additionally, simulation is heavily
The term Industry 4.0 (also known as the fourth industrial used in Industry 4.0 to support the development and
1.1. Introduction
Introduction
revolution) was coined as part of a German government-led most
of widelyof range
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Cyber-Physical and/or
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strategy to promote digitalization in manufacturing. It refers to manufacturing
assembled in systems.
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In this context, simulation
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challenge in
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Due term
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and digitally managed process, also known as cyber-physical facing It refers
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to be able toReality
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and Virtual
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design, operation, and optimization of factory processes Reality (VR),
products to Smart
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10.1016/j.procir.2022.05.122
 Dimitris Mourtzis et al. / Procedia CIRP 107 (2022) 1144–1149
2 Mourtzis et al. / Procedia CIRP 00 (2019) 000–000
operating costs. Over the last few decades, digital technologies
like Cloud, Fog, and Edge Computing, Extended Reality (XR
– including Augmented, Mixed, and Virtual Reality), and the
Internet of Things (IoT) have enabled engineers to monitor the
status of manufacturing equipment and formalize data in
databases, especially during Industry 4.0 [6]. CFD simulation
can also help engineers gain a competitive advantage due to its
low cost, low risk, and ability to provide meaningful insights.
Users can use CFD tools to create precise simulations, as well
as interactive design and analysis tools. From a cognitive
standpoint, fluid flow behavior is also a difficult problem to
interpret and visualize. Engineers or technicians should
visualize the behavior of the desired flow field to improve their
cognitive ability in problem-solving. To address these issues,
this paper proposes an Industrial Internet of Things (IIoT)
framework for simulation and visualization of selected
monitored values based on Mixed Reality (MR) and
Computational Fluid Dynamics (CFD) in a cloud-computing
environment for intuitive data visualization on smart devices.
To that end, this review paper identifies the gaps in current
CFD and AR practices, and future trends and challenges to be
met on this field. The contribution of the research work is
extended to a workflow for the integration of Mixed Reality
(MR) to the CFD simulation, in an attempt to create simulation
holograms on the user’s field of view.
The remainder of this paper is structured as follows. In the
next Section 2, the literature review methodology is presented
in the field of CFD historical evolution, frameworks, and AR
applications. Then, in Section 3 the proposed IIoT framework
is presented and discussed in detail. Finally, Section 4
concludes the paper and future research directions are
discussed.
2. State-of-the-Art
The literature review is based on academic peer-reviewed
publications that use Computational Fluid Dynamics (CFD)
simulation in manufacturing applications in general, in
conjunction with the Augmented Reality (AR) cutting edge
digital technology over a period of twenty-one (21) years, from
2000 to 2021. The review focuses mainly on CFD simulation
methods and AR applications and tools as described in the
abstract and was carried out in three stages:
1. Search in scientific databases (Scopus, Science Direct
and Google Scholar) with relevant keywords
2. Abstract reading to identify relevant papers
3. Full-text reading and grouping into research topics
The relevant keywords utilized were a) Industry 4.0, b) Fourth
Industrial Revolution, c) Computational Fluid Dynamics, d)
CFD, e) Simulation, f) Augmented Reality, g) AR, h) Mixed
Reality, and i) MR.
As a result, the literature was organized using keywords,
allowing academic papers to be separated into relevant and
irrelevant topics following the review methodology presented
in [1]. The Search Query concluded the most relevant results
(23) is presented as follows:
“TITLE-ABS-KEY (CFD, AND computational AND fluid
AND dynamics, AND industry 4.0) AND PUBYEAR > 1999”
1145
Fig. 1. Number of Scopus publications related to CFD and Augmented
Reality in Industry 4.0.
Simulation and AR, as pillar technologies of Industry 4.0
[7], are critical in many smart factory applications [8]. There
are several engineering and manufacturing applications that use
fluid dynamics and CFD as a simulation and visualization tool,
such as:
1. building heating, ventilation, and air conditioning
2. combustion in boilers or propulsion systems
3. interaction of various objects with the surrounding air-
water or air-particles mixture or separation
4. complex flows in heat exchangers and chemical
reactors
Additionally, fluid flow behaviour is a difficult problem to
interpret and visualize cognitively. As such,
engineers/technicians should visualize the behaviour of the
desired flow field in order to improve their cognitive ability in
problem-solving and decision-making.
Based on the abovementioned challenges and on the authors
knowledge, there is no available publication in literature that
proposes a framework to integrate the results obtained from
CFD tools (e.g., ANSYS Fluent) with Mixed Reality (MR)
technology. Therefore, the novelty of this review paper lies in
the fact that it presents an Industrial Internet of Things (IIoT)
framework for simulation and visualization of selected
monitored values based on Mixed Reality (MR) and
Computational Fluid Dynamics (CFD) in a cloud-computing
environment for intuitive data visualization on smart devices.
The proposed framework can be considered as a tool to
improve virtual learning and training in smart factories.
2.1 Brief History of CFD
The analysis of fluid flows using numerical solution
methods is known as computational fluid dynamics (CFD).
CFD can be used to solve complicated problems involving
fluid-fluid, fluid-solid, or fluid-gas interactions. Aerodynamics
and hydrodynamics are two engineering fields where CFD
analyses are frequently used to obtain quantities such as lift and
drag, as well as field properties such as pressures and velocities.
Physical laws in the form of partial differential equations are
used in fluid dynamics. These laws are transformed into
algebraical equations by sophisticated CFD solvers, which can
1146 Dimitris Mourtzis et al. / Procedia CIRP 107 (2022) 1144–1149
Mourtzis et al. / Procedia CIRP 00 (2019) 000–000
then be numerically solved. The fundamental basis of almost
all CFD problems is the Navier–Stokes equations, which define
many single-phase (gas or liquid, but not both) fluid flows.
These equations can be simplified by removing terms
describing viscous actions to yield the Euler equations [9].
Further simplification, by removing terms describing vorticity
yields the full potential equations. Finally, for small
perturbations in subsonic and supersonic flows (not transonic
or hypersonic) these equations can be linearized to yield the
linearized potential equations [10].
CFD techniques have been refined over time through trial
and error, refinement, and numerous validation and assessment
procedures. In 1973, Imperial College's CFD group began work
on an ambitious and appealing program to predict simple shear
flows, free and confined jet flows. The work was done in a very
intuitive manner, with attempts to predict flow patterns using
two and then three-dimensional flow configurations. These
mainly concern simple parabolic flow with no recirculation and
the use of the stream function –vorticity solution algorithm,
which resulted in some non-measurable flow characteristics,
making the application difficult to compare to real engineering
problems. Using various forms of the Imperial College and
Spalding's basic concept, many industrial applications and
models of furnaces and combustion chambers have been
successfully carried out. The following were the major issues
confronting the CFD at that period:
• Mainframe computational limitations
• Slow convergence and numerical diffusion
• Difficulty carrying out three-dimensional complex
geometries with a simple orthogonal grid
• Time-dependent calculations
Fig. 2. Hierarchy of Fluid Flow Models (Adapted from [11, 12]).
Simulation became easier with the introduction of personal
computers with increasing memory capacities. The software
developers had succeeded in making more durable and user-
friendly programs with detailed operation manuals. The
general trajectory of the evolution of CFD towards higher
fidelity models and more complex geometries between 1970
and the next sixty years is illustrated in Figure 2 [11, 12].
2.2 CFD Simulation in smart factories
In the literature, there are several examples of CFD
simulations used to investigate ventilation and conditioning
inside a factory. In order to reduce particle contamination in
3
automatic machinery, CFD was used in [13] to simulate airflow
in a clean room for hard disk drive factories. The simulation
depicts airflow in each area of the production line, allowing for
the most efficient machine configuration. The authors then
used CFD to investigate the performance of factory ventilation
in complex layouts and predicted the flow field and particle
distributions. In terms of temperature distribution in the work
environment and the quality of inhaled air, simulations for air
conditioning prediction are critical for operators' health. [14,
15].
In the period of unprovoked disturbances such as the
COVID-19 pandemic, CFD can also be used to mitigate and
reduce virus transmission in industrial facilities, laboratories,
pharmaceutical plants, and office environments. The impact of
pressure suction on COVID-19 dispersion [16], as well as the
airborne dispersion of particles ejected due to different
respiratory mechanisms, such as coughing, sneezing, normal
talking, and loud talking [17], has been investigated by
simulating operational conditions such as ventilation air flows
and people distribution. Finally, in the chemical or petroleum
industries, CFD analysis is used to investigate the fluid
characteristics and behavior of complex mixture flows [18, 19].
2.3 CFD Operation Principles
CFD analysis can be realized as a complex process, which
requires careful planning and selection of solver parameters.
Consequently, in order to successfully perform a series of
experiments, a big data set must be created prior the execution
of the analysis/simulation. In an attempt to model the workflow
of the CFD solver, the process is discretized in four layers, in
particular the pre-processing layer, the solution layer, the post-
processing layer, and the validation layer. Each of the layers
consists of individual processes, as illustrated in Figure 3. More
specifically, as regards, the layers and the processes involved
are discussed below in detail.
Pre-processing
The problem statement is transformed into an idealized and
discretized computer model during this phase. The type of flow
to be modelled (viscous / inviscid, compressible /
incompressible, steady / non steady) is predetermined. Mesh
generation and the application of initial- and boundary
conditions are two other processes that are involved.
Solving
The solver oversees the actual computations, and
computational power is required during this phase. There are a
variety of solvers available, each with a different level of
efficiency and capability for solving specific physical
phenomena.
Post-processing
In the post-processing phase, the obtained results are
visualized and analyzed. At this point, the analyst can double-
check the findings and draw conclusions based on them. Static
or moving pictures, graphs, and tables are all examples of ways
to present the results.
Validation
This layer involves the process of comparing the results
obtained from the simulation versus the results/data gathered
from the physical experiments.
 Dimitris Mourtzis et al. / Procedia CIRP 107 (2022) 1144–1149 1147
4 Mourtzis et al. / Procedia CIRP 00 (2019) 000–000

2.2 CFD Main Solvers – State of the Market

Computational fluid dynamics (CFD) software allows
testing flow and fluid effects on surfaces and make sure your
design or product meets all safety and structural integrity
standards by testing, simulating, and solving your problems
and equations. Based on the State-of-the-Market survey, a list
of the top Computational Fluid Dynamics (CFD) Software are
presented in Table 1.
2.3 AR in Industry 4.0
Under the framework of Industry 4.0 visualization
technologies have become more important for the enhancement
of user perception, user experience, training and guidance etc..
All these technologies fall under the field of Extended Reality
(XR). The categorization of these technologies and techniques
is based on aspects such as user immersion and user interaction.
Consequently, Virtual Reality (VR) can be realized as the
technology to fully immerse the user in computer generated
virtual environment. By extension, advanced user interaction is
highly required in order to assist users become part of the
virtual environment.
On the other hand, Augmented Reality (AR) and Mixed
Reality (MR), are two similar technologies, based on the partial
user immersion. Essentially, with the use of dedicated
equipment, such as smart devices and goggles the user’s
physical environment is enriched by digital, no-existing,
information. By taking advantage of the above-mentioned Fig. 3. CFD numerical methodology flow chart.
opportunities, engineers under the framework of Industry 4.0
are designing and developing frameworks for providing remote Indeed in the literature there can be found interesting
assistance/guidance, and training to shop-floor technicians. integrations of XR to CFD. However, in the presented research
further to that, several research works have focused on work, the proposed method is based on the utilization ANSYS
improving the collaboration between engineers. CFD solver since an educational license was readily available.
Considering the findings from the literature reviewed, it is Furthermore, from preliminary developments it has been
obvious that there is lack of frameworks and applications aimed concluded that the connection between ANSYS and Unity 3D
at assisting CFD simulation software. Current implementations can be successfully interfaced through the ParaView
entail the setup and visualization of CFD simulations using middleware. So far, Siemens offers Virtual Reality
traditional computer-based methods. Furthermore, there are visualization of CFD results which is differentiated from the
several limitations in the understanding of experiment proposed framework. Our contribution mainly focuses on the
parameters as well as the representation of CFD models, visualization from results computed from data gathered from
limiting the education of young engineers in the field of CFD. the physical installation. The contribution of this research work
As a result, the boundary conditions, the control volumes extends to the setup of new fluid networks (plumbing) which
and the meshes, and by extension the CFD results could be can be performed and tested (virtually) in the physical
presented in a more robust way with the utilization of Extended environment of the installation.
Reality applications for training or up-skilling purposes.
Table 1. Top Computational Fluid Dynamics (CFD) Software
CFD Software Description
Businesses use this CFD and simulation software product in manufacturing, cosmetics, appliances, aerospace, scientific
COMSOL Multiphysics [21]
research, engineering, gaming, and higher education
Businesses use the program in industries such as architecture, real estate, manufacturing, engineering, construction, and
Autodesk CFD [22]
natural resources.
IVRESS is a simulation software product that offers users an integrated virtual reality
IVRESS [23]
environment. It's an object-oriented VR toolkit that's designed to enable developers to create immersive interactive worlds.
Businesses use Altair Hyperworks in various industries such as aerospace, engineering, automotive manufacturing,
Altair Hyperworks [24]
financial services, healthcare, insurance, scientific research, and agriculture.
This simulation and CFD software product is used by businesses in industries such as aerospace, manufacturing,
SimulationX (ESI Group) [25]
machinery, travel, natural resources, mining, energy, and automotive production.
PIPESIM is used by businesses and other organizations in a variety of industries worldwide, such as construction, oil and
PIPESIM [26]
gas production, transport, mining, engineering, manufacturing, geochemistry, and geology.
1148 Dimitris Mourtzis et al. / Procedia CIRP 107 (2022) 1144–1149
Mourtzis et al. / Procedia CIRP 00 (2019) 000–000 5

CFD Software Description

Various organizations use the CFD product in aviation, industrial engineering, scientific research, design, government
OpenFOAM [27]
services, education, and natural resources.
PowerFLOW (Dassault Systems) The simulation software product is used by businesses that operate primarily in the transportation, mobility, aerospace,
[28] defense, automotive, engineering, manufacturing, and scientific research industries.
The CFD product is used by organizations in biotechnology, education, mechanical engineering, manufacturing,
ANSYS Fluids [29]
machinery, architecture, research, and design.
Businesses use the product in industries such as manufacturing, natural resources, biotechnology, aerospace, maritime
FLOW-3D [30]
production, and scientific research.

3. Proposed workflow for AR integration suitable, since the data can be processed in near real-time, thus
the AR visualizations can be adjusted accordingly.
The contribution of this research work is to highlight the
challenges and opportunities towards the integration of AR
technology to CFD tools. Furthermore, the contribution
extends to the data modelling of the experiment and the solver
properties, along with the proposition of a feasible workflow.
In Figure 4 the conventional workflow of a CFD solver is
illustrated. The proposal for the integration of AR involves the
visualization during the setup of the experiment. During this
step the user has to import the 3D geometries as well as to
define the fluid control volume. With the use of AR
visualizations, the users can setup the control volume on a
real/existing component. Afterwards, the solver parameters
must be set. In a similar fashion, through interactive AR
Graphical User Interfaces (GUIs) the users can select the fluid
and its parameters set the flow parameters. In continuation,
these data, along with the control volume must be passed to the
solver software, in order to run the simulation. Therefore, with
the utilization of a Cloud database, the data can be formalized
and distributed accordingly. Then, the third step involves the
exporting of the results, the plots, and the 3D representations.
Similar to the second step, the results are classified in the Cloud
Database. Therefore, the data are automatically imported in an
XML file, prior being downloaded from the AR application. As Fig. 4. Architecture of the proposed system architecture
regards the visualization of the simulation results on the real
From a development point of view, the first approach is
environment two approaches can be utilized. The first approach
easier to accomplish, as the developing engineer is required to
involves the use of a middleware, such as ParaView, in order
download the 3D objects from the Cloud Database and import
to export the simulation results in the form of 3D objects, which
them in the AR scene. On the contrary, the second approach is
can then be easily imported in the AR scenes and overlaid on
more resource intensive since the visualization generator is
the real environment. The second approach is based on the post
responsible for processing the data as they are fetched from the
processing of the results by the AR application. Consequently,
Cloud Database. In addition to that, new 3D geometries have
this approach can be realized as more dynamic versus the first
to be created and animated on-the-spot.
approach, since the data can be downloaded and processed in
Taking into consideration of the 7V’s of Big Data, (i.e.
near real-time by the AR devices. Therefore, the visualization
Volume, Velocity, Variety, Variability, Veracity,
of the results can be setup on-the-go by the user. Furthermore,
Visualization, Value), there are certain challenges regarding
the implementation of a result processing algorithm, denoted as
the adoption of the proposed method. On the one hand Volume
visualization generator, is necessary.
is a key property of Big Data, which (as it is commonly known)
Taking into consideration the specifications of each
is measured in GB (Gigabytes), Terabytes (TB), up to
visualization approach it can be concluded that the two
Yottabytes (YB, equal to 1.21e+24 Bytes). As the Things on
approaches are valid solutions, depending on the
Internet are increasing the volumes of data produced by the
responsiveness to simulation setup changes, as required by the
Things require the design and integration of new infrastructure
application. more specifically, the first approach is more
to properly handle and distribute the large volumes of data.
suitable for training and education purposes, which do not
However, it has been concluded by relevant research works that
require immediate response. Consequently, with the utilization
in most cases these volumes of data often include trash (non-
of the above-mentioned middleware, the CFD results are
usable data – Value). On the other hand, taking into
overlaid on the users’ field of view. On the other hand, in
consideration that Variety, Variability and Veracity, are
applications, where the simulation setup is constantly changing
adequate, there are also challenges regarding Velocity and
adapting to the system operation, the second approach is more
Visualization. By integrating the proposed method, and by
 Dimitris Mourtzis et al. / Procedia CIRP 107 (2022) 1144–1149
6 Mourtzis et al. / Procedia CIRP 00 (2019) 000–000
extension utilizing new digital technologies such as Extended
Reality (XR), visualization of data is addressed. Therefore, in
order to ensure that the data are efficiently processed Artificial
Intelligence (AI) and Machine Learning (ML) algorithms are
required for cleaning data and organizing them properly in
relational/non-relational databases. In a research we have
recently published (not online yet) we have examined the
possibility of reducing the data traffic by implementing an
Edge-Computing architecture. In its essence the architecture is
based on the implementation of MPUs (Micro-Processor Units)
for preprocessing and cleaning the data prior the upload to a
Cloud Database for further utilization. Besides that, in order to
ensure the reliable and fast transmission of data (Velocity) the
utilization of 5G networks is mandatory.
4. Conclusions and Outlook
As discussed in the previous paragraphs, the contribution of
this research work is focused on investigating the challenges
and opportunities arising from the integration of XR to CFD
simulations. Based on the discussion of the literature presented
in the previous paragraphs, the lack of research in the field of
XR and CFD is evident. In an attempt to extend the contribution
of this manuscript beyond the identification of the challenges
and opportunities from the combination of the two above-
mentioned pillar Industry 4.0 technologies, a framework is
proposed. In the presented research work, two approaches have
been presented, which are classified based on the
computational power needed as well as the user involvement,
i.e. developing engineer, required. Last but not least, it has to
be mentioned that the integration of digital tools to the design
and development stages of a product/process lifecycle,
contributes to the reduction of the CO2 emissions of the design
and development stages, due to the need for the construction of
less real-life prototypes for laboratory testing. Consequently,
future research work will be directed towards the development
of the proposed frameworks, the implementation in real
industrial case studies as well as on the comparison of the two
approaches. Moreover, in an attempt to bridge the gap between
advanced visualization and Digital Twins, the proposed
framework could be realized as the foundation towards the
connection between Digital Twin, CFD, and XR. Thus, the
engineers will be capable of visualizing CFD results, based on
near real-time data and visualize them on the real environment.
In addition to that, the investigation of Edge Computing for
offloading the central processing system, thus enabling the
distribution of bigger volumes of data is also necessary.
Acknowledgements
This work has been partially supported by the funded project
“SPARE – Sensor-based Product monitoring system to support
Augmented Reality remote maintenancE” (GA No: 80765
ΔΕΡ5-0020271).
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