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The Return on Investment of Computational Fluid Dynamics


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Measuring the ROI of Fast and Reliable Computational

Fluid Dynamics (CFD) is not always straightforward. In this presentation, we are demonstrating the positive ROI of CFD using different point of views.

(1) Advantages and cost-savings of using CFD simulation both early and often during the development.
(2) Avoiding costly downtime or product failures.
(3) The ROI of CFD simulation to optimize product performance.
(4) The cost of choosing the wrong simulation tool.
(5) Some tips for you to answer the questions: “Would I benefit from using fast and reliable CFD?”.

For more information on ANSYS Fluid Dynamics Software ROI, you can read the white paper

Published in: Engineering, Technology
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The Return on Investment of Computational Fluid Dynamics

  1. 1. © 2012 ANSYS, Inc.1 Computational Fluid Dynamics ROI: Benefiting from Fast and Reliable CFD Gilles Eggenspieler, Ph.D. ANSYS, Inc
  2. 2. © 2012 ANSYS, Inc.2 Simulate early and often Assess your CFD ROI Optimize your design Avoid product failure and downtime Predict product performance accurately Key ROI of Computational Fluid Dynamic
  3. 3. © 2012 ANSYS, Inc.3 Simulate Early and Often Simulate early to not run into “surprises” when physical testing are performed •Even before a prototype is built •Gain insight into the product performance as the first drawings are done Simulate often to design a high performance and robust product •Study different product configurations •Analyze the entire operating condition envelope
  4. 4. © 2012 ANSYS, Inc.4 Simulate Early and Often Concept Design Detail Design Prototyping Evaluation Production Ramp-Up Full Production 1 X 10 X 100 X 1,000 X 20,000+ X Development Phase Number of Problems Resolution Cost/Resolution Design Change Cost Design Change Cost Design Change Cost CDF & Simulation CAD and Traditional Analysis Prototyping Testing Only Source: Aberdeen Group: The Impact of Strategic Simulation on Product Profitability
  5. 5. © 2012 ANSYS, Inc.5 Saving 6+ months over built-and-test methods Problem Select the best boiler design Solution ANSYS Fluent Result 6+ months saved over a traditional built-and-test approach Weil McLain was looking at 2 designs with very different heat transfer performance. The company applied ANSYS FLUENT simulation software to guide its selection of a final set of design, arriving at one that was the most efficient and economical design. Weil-McLain
  6. 6. © 2012 ANSYS, Inc.6 Reducing Prototyping Expenses by $150,000 Problem Unexpected flow patterns leading to inefficiency Solution ANSYS Fluent and impeller housing simulations Result 6+ months and $150,000 saved over a traditional built-and-test approach AcoustiFLO’s original fan impeller housing showed significant areas of flow recirculation. The improved design, evaluated using CFD, showed much higher efficiency. Using ANSYS FLUENT to perform CFD simulation, engineers discovered unexpected interactions between the diffuser and the impeller, which would have been diffi cult to assess with physical testing only. AcoustiFLO
  7. 7. © 2012 ANSYS, Inc.7 FSI Makes for Cool Gas Turbine Blades Problem Cool turbine blades with minimum impact on gas turbine performances Solution ANSYS Advanced CFD and FSI capabilities Result Improved cooling efficiency This allowed the Wood Group Industrial Turbines to replace costly experiments by virtual prototyping Wood Group Heavy Industrial Turbines, AG, Switzerland Courtesy of Wood Group Heavy Industrial Turbines
  8. 8. © 2012 ANSYS, Inc.8 The Cost of Product Failure and Downtime Consequences of a product failure can mount-up • Loss of profits • Repair/recall costs • Wasted fixed costs • Brand reputation damage The cost of equipment downtime can also be very high
  9. 9. © 2012 ANSYS, Inc.9 Maintaining Power Problem Too much erosion in a boiler ANSYS CFD Solution ANSYS CFD Turbulence, Multiphase and Combustion ANSYS CFD Value Decreased Maintenance Downtime Without the insight provided by ANSYS CFX software, Tractebel would have been limited to trial-and-error testing to identify and mitigate the cause of the undesirably high erosion. Tractebel was able to determine the erosion pattern and make informed and cost-effective decisions regarding the operation of the burner and, consequently, the plant Tractebel EnergiaCourtesy of ESSS and Tracteble
  10. 10. © 2012 ANSYS, Inc.10 Warranty Costs Go Down Problem Increasing warranty costs Solution Using CFD to upgrade the design Result Better design in a few weeks instead of 12 months CFD simulation made it possible to quickly upgrade the turbine bypass valve in a few weeks, compared to the six to 12 months that would have been required using conventional methods. Control Components Inc.Courtesy Control Components Inc.
  11. 11. © 2012 ANSYS, Inc.11 Today, even simple design must be optimized • Gain a competitive advantage • Reduce operating costs of your products Yesterday, CFD was used to validate a given design Today, CFD is used to optimize a given design – tens or hundreds of CFD simulations can be performed to identify the best design CFD optimization can be connected to optimization tools like 6-Sigma, DoE, etc. The ROI of Design Optimization
  12. 12. © 2012 ANSYS, Inc.12 An Optimized Fan Problem Need multiple design options to boost fan performance Solution ANSYS FLUENT enabled 10X design variation analysis Result 250% improvement over original design Dyson Air Multiplier™ Fan “The team investigated 200 different design iterations using simulation, which was 10 times the number that would have been possible if physical prototyping had been the primary design tool. With critical acclaim from many reviewers, the Dyson Air Multiplier fan has been a resounding success in the marketplace.” Richard Mason Research Design & Development Manager Dyson Courtesy of Dyson
  13. 13. © 2012 ANSYS, Inc.13 New Valves Swing into Action Problem Optimize the shape of a valve ANSYS CFD Solution ANSYS CFD and DesignXplorer ANSYS CFD Value Generate results in hours instead of weeks The flow performance curve for a wide range of feed conditions was generated for each of the 50 valves, providing solutions in hours rather than weeks. Cameron, IncCourtesy of Cameron
  14. 14. © 2012 ANSYS, Inc.14 Solid Suspensions Get a Lift Problem Design an optimized hydrofoil for mixing equipment ANSYS CFD Solution ANSYS CFD and moving reference frames ANSYS CFD Value Dramatic performance improvement The solid concentration variance was improved by 48.5% and the pumping effectiveness increased by 410.2% Universidade Estadual de CampinasCourtesy of ESSS and UNICAMP
  15. 15. © 2012 ANSYS, Inc.15 Better Steam Turbines Problem Improving performance Solution CFD for turbomachinery Result Gain insight impossible to obtain using physical testing Engineers used CFD to acquire insight into the flow parameters; a task that would have been impossible without simulation tools Bharat Heavy Electricals LimitedCourtesy BHEL
  16. 16. © 2012 ANSYS, Inc.16 Problem Quickly design and analyze parts to enhance car performance Solution ANSYS FLUENT for Aerodynamic CFD simulation Result Reliable, accurate analysis in record time; won 2010 and 2011 Formula 1 Drivers’ and Constructors’ Championship Victories for Red Bull “ANSYS [CFD] simulation software is incredibly reliable and accurate. Simulation enables us to drastically reduce lead times and get solutions to the circuit much quicker, so we are more competitive race to race.” Steve Nevey Business Development Manager Red Bull Technology
  17. 17. © 2012 ANSYS, Inc.17 Problem Design the best performing boat both from the aerodynamic (sails) and hydrodynamic (boat haul and keel) Solution ANSYS CFD multiphase capabilities and HPC speed-up Result Evaluate quickly different design and find the best performing one Wining the Americas' Cup Emirates Team New Zealand won the 2007 Louis Vuitton Cup and Team Alinghi won the 2007 America’s cup Alinghi, BMW ORACLE Racing Emirates Team New Zealand Team Shosholoza Courtesy of Team Shosholoza Courtesy of BMW Oracle Racing Courtesy of Emirates Team New Zealand Courtesy of Emirates Team New Zealand
  18. 18. © 2012 ANSYS, Inc.18 Only accurate CFD is Computational Fluid Dynamics Inaccurate CFD is “Colorful” Fluid Dynamics What you need: • Thoroughly validated CFD Software • Knowledgeable technical support teams The Cost of Inaccuracy
  19. 19. © 2012 ANSYS, Inc.19 Gasing Up with Coal Problem Study the complex phenomena of gasification Solution ANSYS advanced chemistry modeling and dense particles modeling Result Ability to gain more insight into the gasifier performance After carefully validating the simulation tool with experimental data, CFD can be used to gain more insight into the gasifier performance National Energy Technology LabCourtesy of NETL
  20. 20. © 2012 ANSYS, Inc.20 The actual ROI depends on your company practices and workflows • How expensive are your physical prototyping? How much could you save by reducing their numbers by 2? • What are the savings of reducing your development time by 5%? 10% 25%? • What are the savings of improving your engineers productivity? • Can your warranty provisions reduced? • What would a product recall cost you? Assessing your CFD Simulation ROI
  21. 21. © 2012 ANSYS, Inc.21 CFD Brings a Breadth of Fresh Air Problem Develop respiratory drugs is very expensive Solution CFD of real pulmonary network Result Possibility for huge reduction in development costs and time The cost of developing a respiratory therapy drug for asthma is estimated at more than $1 billion; the process can take up to 14 years and involve thousands of patients in clinical studies. The impact of CFD on development costs and time could be stunning. FluidDA (Belgium)Courtesy FluidDA
  22. 22. © 2012 ANSYS, Inc.22 A Quieter Train Ride Problem Develop new quiter fans Solution ANSYS CFD and multi-design evaluation Result Prototype costs reduced by 2/3 In Germany, Voith Turbo used CFD to develop quieter fans by simulating a complete railcar cooling system Voith reduced its prototype costs by two-thirds. Voith Turbo (Germany)Courtesy of Voith Turbo
  23. 23. © 2012 ANSYS, Inc.23 CFD helps reduce both development times and development costs CFD allows you to optimize your design CFD reduces warranty costs CFD helps reduce the probability of critical failure CFD reduces equipment downtime Chose your CFD partner wisely Conclusions