Fan System simulation with HyperMesh and AcuSolve solutions

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Fan System simulation with HyperMesh and AcuSolve solutions

  1. 1. Fan System simulation with HyperMeshand AcuSolve solutions6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, ItalyManuel Henner, Bruno Demory, Serge Mondon, Ming Ma, Elias TannouryValeo Thermal Systems, FranceYoussef BEDDADICFD EngineerVALEO Thermal System, Franceyoussef.beddadi@valeo.com
  2. 2. IApril 2013 | 2Fan System developments driven by numerical simulation Shorten development cycle by virtual prototyping Offer engineers a reliable tool for design and analysis Detailed simulation with actual geometry Willing to develop multi-physics and multi-objectives studiesStandard Valeo Single Fan SystemThermal - MechanicsAerodynamics - AcousticsRheologyElectronicsIndustrial BackgroundAn automotive engine cooling fan system6th European ATC - April 22-24th, 2013 - Turin, ItalyStartEnd of the project
  3. 3. IApril 2013 | 3Fan system simulation with ALTAIR PlatformMotivations and Objectives6th European ATC - April 22-24th, 2013 - Turin, ItalyMotivations Replace current highly integrated numerical methods by ALTAIR methodologies Communalize tools for several kind of numerical applications (CFD, FEA, etc…) Reduce license fees with common tools between various R&D teamsObjectives Investigate solutions offered by ALTAIR for CFD (HyperMesh, HyperView,AcuSolve) Test and assess benefit of the platform to implement automation Evaluate openness of the platform (OpenFoam)OTHER CFD Softwares….AUTO
  4. 4. IApril 2013 | 4OutlineAutomated process with ALTAIR Platform Standard fan simulation process and alternativesAutomation : Batch and scripting Automated meshing process (HyperMesh) Pre-processing (Acuconsolve) and solvier (AcuSolve) automation Automated process for post-processing (HyperView)Numerical simulations for Fan Systems Simulation set-up Comparison between CFD and experimental results1236th European ATC - April 22-24th, 2013 - Turin, Italy
  5. 5. Automated processwith ALTAIR Platform6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
  6. 6. IApril 2013 | 6 6th European ATC - April 22-24th, 2013 - Turin, ItalyAutomated process with ALTAIR PlatformStandard fan simulation process and alternativeStandard Automated ProcessCATIA AcuConsole AcuSolve HyperViewHyperMesh OpenFoam ParaViewAlternative Automated process
  7. 7. Automation :Batch and Scripting6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
  8. 8. IApril 2013 | 8Batch and scripting in ALTAIR Platform6th European ATC - April 22-24th, 2013 - Turin, ItalyCATIAModel.nasHyperMeshMesh.inpAcuConsoleAcuSolveHyperViewPerformancePredictionOpenFoam…Script TCLScript PYBatchAutomated process for test rig fan simulation
  9. 9. IApril 2013 | 9Easy scripting and automated volume mesh Under HyperMesh graphical user interface, activity is recorded in the "command.cmf" file All the commands recorded and transferred in TCL (Tool Command Language) Commands can be used without GUI to generate meshes for other geometries with thesame meshing strategy (same grid density, same wall treatment, same volume meshdomains…)Batch and ScriptingAutomated meshing process (HyperMesh)6th European ATC - April 22-24th, 2013 - Turin, ItalyHyperMesh MeshNumber oftetrahedron87,763,903Element in INLET 7,133,234Element in MRF 64,499,930Element inOUTLET16,130,739Mesh Size (standard parameters tokeep the mesh density constant)Automated cells extrusions for boundary layer(same wall treatment for all simulations)
  10. 10. IApril 2013 | 10Volume mesh parameters Thickness of the first layer, the growth ratiobetween 2 tetrahedral layers and the number ofboundary layer.Openness and automated export Several types of format possible, including AcuSolve Easy change for switching solvers, and benchmark differentsolutions.Batch and ScriptingPre-processing (AcuConsole) and solving (AcuSolve)6th European ATC - April 22-24th, 2013 - Turin, Italy
  11. 11. IApril 2013 | 11Automation process in AcuSolve AcuSolve commands scripted in Python language Easy process with only 3 functions: "usrRunInput“ : Import HyperMesh file "usrRunHeliceProblem“ : Set the boundary conditions in AcuSolve, solverparameters, numerical models… "usrRunAcuSolve" : set the number of processor, generate input file andlaunch AcuSolve.Automation process in HyperView Same process as HyperMesh with recorded operation6th European ATC - April 22-24th, 2013 - Turin, ItalyBatch and ScriptingAutomated process for post-processing (HyperView)
  12. 12. Numerical simulations forFan System6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
  13. 13. IApril 2013 | 13Domain of simulation Coarse and fine mesh (10 Mo. and 87 Mo. Cells) K-Omega SA and SST (Menter) turbulence model HyperMesh and AcuConsole mesh for AcuSolve RANS simulation6th European ATC - April 22-24th, 2013 - Turin, ItalyNumerical Simulation for Fan SystemSimulation set-upFull outlet domain foratmospheric conditionsTest rig facility with torque-meter Plenum (mass flow imposed)
  14. 14. IApril 2013 | 14No simplification for tiny details (underhub ribs, tipclearance, connecting radius)Cell extrusion at wall boundary (anysotropic layer)Densification in region of interest6th European ATC - April 22-24th, 2013 - Turin, ItalyNumerical Simulation for Fan SystemMeshing strategy with HyperMesh
  15. 15. IApril 2013 | 15Numerical Simulation for Fan SystemMeshing strategy with HyperMesh
  16. 16. IApril 2013 | 16Numerical Simulation for Fan SystemAcuSolve simulationFlow Rate = 2797 m3/hFlow Rate = 3996 m3/h800 m3/h 2800 m3/h 4000 m3/h 5200 m3/hTurbomachinery post-processing
  17. 17. IApril 2013 | 17 6th European ATC - April 22-24th, 2013 - Turin, ItalyNumerical Simulation for Fan SystemOpen Foam simulation
  18. 18. IApril 2013 | 18Numerical Simulation for Fan SystemAcuSolve and Open Foam simulation (Coarse mesh)8,5 millions of tetrahedronkw SST for turbulence modelMeshing available for different softwares Good prediction for both solvers Some improvement to bring at low flow rateAcuSolve OpenFoam Experiment
  19. 19. IApril 2013 | 19Numerical Simulation for Fan SystemAcuSolve with AcuConsole or HyperMeshAcuSolve_Hy permesh AcuSolve_AcuConsole Experiment87,7 millions of tetrahedronkw SST for turbulence model Excellent prediction on torque Improvement on pressure rise, difference underinvestigationEquivalent results for different mesh types
  20. 20. Conclusions andperspectives6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
  21. 21. IApril 2013 | 21 6th European ATC - April 22-24th, 2013 - Turin, ItalyConclusions and PerspectivesAchievements Fan system simulation tested with ALTAIR numerical tools, and afully automated process was quickly implemented HM and HV successfully used for CFD (as for other physics :mechanics and rheology). Possibility to share common toolsbetween different R&D teams Platform easily customizable for connection with other software(OpenFoam for instance), and comparisons between differentnumerical processes has been doneAUTO
  22. 22. IApril 2013 | 22 6th European ATC - April 22-24th, 2013 - Turin, ItalyConclusions and PerspectivesStill on progress Improve meshing process withinsmall gaps (see tip clearance) Generalyse best practice forCFD mesh, with small growthrate ratio Further tests to be conductedwith AcuSolve for unsteadysimulation and aeroacousticpurpose
  23. 23. Thank you for your attention

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