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LMS Amesim / STAR-CCM+
co-simulation: solid stress
analysis of a gerotor pump
Realize innovation.Unrestricted © Siemens AG 2017
LMS Imagine.Lab Amesim™
A world leading platform for physical
simulation of mechatronic systems
Unrestricted © Siemens AG 2016
2017-01-18Page 2 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivation for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 3 Siemens PLM Software
Simcenter™ Portfolio for Predictive Engineering Analytics
LMS Imagine.Lab
LMS Imagine.Lab Amesim
LMS
Imagine.Lab
System
Synthesis
Unrestricted © Siemens AG 2016
2017-01-18Page 4 Siemens PLM Software
STAR-CCM+
Simcenter™ Portfolio for Predictive Engineering Analytics
STAR-CCM+
Unrestricted © Siemens AG 2016
2017-01-18Page 5 Siemens PLM Software
Cloud
Licensing
flexibility
Simcenter™ Portfolio for Predictive Engineering Analytics
Cornerstones for a future-proof engineering approach
Covering full range of
methods
Analytics, reporting &
exploration
Deployment flexibility
Openness &
Scalability
User experience
Industry &
engineering expertise
Systems approach
Collaboration &
workflow
Multidiscipline
& multiphysics
R
F
L
P
Controls
1D
3D
TEST
CFD
Unrestricted © Siemens AG 2016
2017-01-18Page 6 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivations for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 7 Siemens PLM Software
Presentation of the gerotor pump
• This gerotor pump has 5 internal cells.
• Plate profiles define the inlet and outlet areas to connect to the
suction and delivery ports.
• Designer’s experience and experimental measurements on test
benches are key factors for the successful design of such a type
of pump.
• Tolerance combinations impact the instantaneous flow rate and
associated pressure ripples.
• The mechanical parts directly suffer these variations of pressure,
which has a consequence on their sustainability.
Rotors in the gerotor pump
Unrestricted © Siemens AG 2016
2017-01-18Page 8 Siemens PLM Software
• It’s difficult to measure all variables and most influent parameters to understand the
design sensitivities.
• The historical approach with the trial and error process is expensive and takes time so
it’s no longer compatible with current-day projects, which tend towards a shorter
delivery timeline.
• In some cases, optimal design may involve many real-life iterations until you’ll get the
optimal sets of parameters that are all combined together with cross-influences.
• This study demonstrates the LMS Amesim / STAR-CCM+ co-simulation’s ability to solve
coupled solid mechanical problems with 1D detailed pump models for hydraulics.
• It is focused on the internal/external rotors of a gerotor pump.
• It is built from an existing CAD.
Motivations to go for co-simulation
Pain points
Deliveries
Unrestricted © Siemens AG 2016
2017-01-18Page 9 Siemens PLM Software
Co-simulation of mechanical and hydraulic parts
Rotors in the gerotor pump
 A new approach to simulate both
the fluid and the mechanical parts of
the Gerotor pump is required
LMS Amesim
 Co-simulation brings an alternative to the usual
limitations and offers further new possibilities to
investigate
STAR-CCM+ has a dedicated user interface to connect to
LMS Imagine.Lab Amesim that makes the co-simulation
process easy to set-up.
Unrestricted © Siemens AG 2016
2017-01-18Page 10 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivations for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 11 Siemens PLM Software
1D LMS Amesim model of the gerotor pump
Added-value when co-simulation is used
• Realistic boundary conditions
• Dynamic simulation
• Multi-physics model
Setup of the co-simulation
• The pressure at the inlet and the outlet of the pump
is calculated by LMS Amesim
• Their values are sent to STAR-CCM+ via a TCP/IP
communication
• The behavior of each cell is computed in a
supercomponent
LMS Amesim model
LMS Amesim
Unrestricted © Siemens AG 2016
2017-01-18Page 12 Siemens PLM Software
LMS Amesim results
• There is a 72° phase shift between each cell • Their successive positions at the inlet or the outlet
generates fluctuations in the cumulative flow rate
Flow rates in the gerotor pump
Volume of each cell
Characteristics of each cell during a cycle LMS Amesim
Unrestricted © Siemens AG 2016
2017-01-18Page 13 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivations for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 14 Siemens PLM Software
Setup of the 3D model
Boundary conditions
• Pressures on :
 The inlet of the pump (in blue)
 The outlet of the pump (in red)
Numerical model
• Implicit unsteady
• 3D solid domain
• Finite element solid stress
• Linear isotropic elastic behavior
Meshing
• Swept quadrilateral mesh
Boundary conditions
Finite element mesh
Unrestricted © Siemens AG 2016
2017-01-18Page 15 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivation for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 16 Siemens PLM Software
The pressure fluctuations computed within the LMS
Amesim model are applied to the STAR-CCM+
mechanical parts (rotor and stator).
The usual stress, strain and displacement results are
computed within STAR-CCM+.
All the 3D results can be displayed in STAR-CCM+.
All the 1D results can be displayed in LMS Amesim.
Results of the stress analysis
Unrestricted © Siemens AG 2016
2017-01-18Page 17 Siemens PLM Software
Results of the stress analysis
The distribution of Von Mises Stress underlines the critical mechanical points
Unrestricted © Siemens AG 2016
2017-01-18Page 18 Siemens PLM Software
Table of contents
• Introduction to the product portfolio
• Motivation for this co-simulation study
• Setup the 1D LMS Amesim model
• Setup the 3D STAR-CCM+ model
• Results of the LMS Amesim / STAR-CCM+ co-simulation
• Going further
Unrestricted © Siemens AG 2016
2017-01-18Page 19 Siemens PLM Software
STAR-CCM+ / LMS Amesim co-simulation user guide in LMS Amehelp
Unrestricted © Siemens AG 2016
2017-01-18Page 20 Siemens PLM Software
Systems-Driven Product Development
Predictive Engineering Analytics
Role in Systems-Driven Product Development
Predictive Engineering AnalyticsSystem Mockup
Managed in PLM Context - Multi-Domain Traceability, Change and Configuration
TEST
Digital
Twin
1D
CFD
Exploration - Analytics - Reporting
3D
Unrestricted © Siemens AG 2016
2017-01-18Page 21 Siemens PLM Software
3D SIMULATION
CFD SIMULATION
1D SIMULATION
From disconnected models and data …
Customer Usage data
Simulation data
Test data TEST MODELING
Historical data
CONTROLS
Unrestricted © Siemens AG 2016
2017-01-18Page 22 Siemens PLM Software
…to a performance Digital Twin
3D SIMULATION
CFD SIMULATION
1D SIMULATION
Customer Usage data
Simulation data
Test data TEST MODELING
Historical data
CONTROLS
Unrestricted © Siemens AG 2016
2017-01-18Page 23 Siemens PLM Software
Contact
Karim NASSAR & Stéphane NEYRAT | LMS Amesim Platform
Peter MENDOZA & Joe OSMAN | CD-adapco
Siemens Industry Software S.A.S.
Digital Factory Division
Product Lifecycle Management
Simulation & Test Solutions
DF PL STS CAE 1D | CD-adapco
siemens.com

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LMS Imagine.Lab Amesim/STAR-CCM+ co-simulation: solid stress analysis of a gerotor pump

  • 1. LMS Amesim / STAR-CCM+ co-simulation: solid stress analysis of a gerotor pump Realize innovation.Unrestricted © Siemens AG 2017 LMS Imagine.Lab Amesim™ A world leading platform for physical simulation of mechatronic systems
  • 2. Unrestricted © Siemens AG 2016 2017-01-18Page 2 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivation for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 3. Unrestricted © Siemens AG 2016 2017-01-18Page 3 Siemens PLM Software Simcenter™ Portfolio for Predictive Engineering Analytics LMS Imagine.Lab LMS Imagine.Lab Amesim LMS Imagine.Lab System Synthesis
  • 4. Unrestricted © Siemens AG 2016 2017-01-18Page 4 Siemens PLM Software STAR-CCM+ Simcenter™ Portfolio for Predictive Engineering Analytics STAR-CCM+
  • 5. Unrestricted © Siemens AG 2016 2017-01-18Page 5 Siemens PLM Software Cloud Licensing flexibility Simcenter™ Portfolio for Predictive Engineering Analytics Cornerstones for a future-proof engineering approach Covering full range of methods Analytics, reporting & exploration Deployment flexibility Openness & Scalability User experience Industry & engineering expertise Systems approach Collaboration & workflow Multidiscipline & multiphysics R F L P Controls 1D 3D TEST CFD
  • 6. Unrestricted © Siemens AG 2016 2017-01-18Page 6 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivations for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 7. Unrestricted © Siemens AG 2016 2017-01-18Page 7 Siemens PLM Software Presentation of the gerotor pump • This gerotor pump has 5 internal cells. • Plate profiles define the inlet and outlet areas to connect to the suction and delivery ports. • Designer’s experience and experimental measurements on test benches are key factors for the successful design of such a type of pump. • Tolerance combinations impact the instantaneous flow rate and associated pressure ripples. • The mechanical parts directly suffer these variations of pressure, which has a consequence on their sustainability. Rotors in the gerotor pump
  • 8. Unrestricted © Siemens AG 2016 2017-01-18Page 8 Siemens PLM Software • It’s difficult to measure all variables and most influent parameters to understand the design sensitivities. • The historical approach with the trial and error process is expensive and takes time so it’s no longer compatible with current-day projects, which tend towards a shorter delivery timeline. • In some cases, optimal design may involve many real-life iterations until you’ll get the optimal sets of parameters that are all combined together with cross-influences. • This study demonstrates the LMS Amesim / STAR-CCM+ co-simulation’s ability to solve coupled solid mechanical problems with 1D detailed pump models for hydraulics. • It is focused on the internal/external rotors of a gerotor pump. • It is built from an existing CAD. Motivations to go for co-simulation Pain points Deliveries
  • 9. Unrestricted © Siemens AG 2016 2017-01-18Page 9 Siemens PLM Software Co-simulation of mechanical and hydraulic parts Rotors in the gerotor pump  A new approach to simulate both the fluid and the mechanical parts of the Gerotor pump is required LMS Amesim  Co-simulation brings an alternative to the usual limitations and offers further new possibilities to investigate STAR-CCM+ has a dedicated user interface to connect to LMS Imagine.Lab Amesim that makes the co-simulation process easy to set-up.
  • 10. Unrestricted © Siemens AG 2016 2017-01-18Page 10 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivations for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 11. Unrestricted © Siemens AG 2016 2017-01-18Page 11 Siemens PLM Software 1D LMS Amesim model of the gerotor pump Added-value when co-simulation is used • Realistic boundary conditions • Dynamic simulation • Multi-physics model Setup of the co-simulation • The pressure at the inlet and the outlet of the pump is calculated by LMS Amesim • Their values are sent to STAR-CCM+ via a TCP/IP communication • The behavior of each cell is computed in a supercomponent LMS Amesim model LMS Amesim
  • 12. Unrestricted © Siemens AG 2016 2017-01-18Page 12 Siemens PLM Software LMS Amesim results • There is a 72° phase shift between each cell • Their successive positions at the inlet or the outlet generates fluctuations in the cumulative flow rate Flow rates in the gerotor pump Volume of each cell Characteristics of each cell during a cycle LMS Amesim
  • 13. Unrestricted © Siemens AG 2016 2017-01-18Page 13 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivations for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 14. Unrestricted © Siemens AG 2016 2017-01-18Page 14 Siemens PLM Software Setup of the 3D model Boundary conditions • Pressures on :  The inlet of the pump (in blue)  The outlet of the pump (in red) Numerical model • Implicit unsteady • 3D solid domain • Finite element solid stress • Linear isotropic elastic behavior Meshing • Swept quadrilateral mesh Boundary conditions Finite element mesh
  • 15. Unrestricted © Siemens AG 2016 2017-01-18Page 15 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivation for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 16. Unrestricted © Siemens AG 2016 2017-01-18Page 16 Siemens PLM Software The pressure fluctuations computed within the LMS Amesim model are applied to the STAR-CCM+ mechanical parts (rotor and stator). The usual stress, strain and displacement results are computed within STAR-CCM+. All the 3D results can be displayed in STAR-CCM+. All the 1D results can be displayed in LMS Amesim. Results of the stress analysis
  • 17. Unrestricted © Siemens AG 2016 2017-01-18Page 17 Siemens PLM Software Results of the stress analysis The distribution of Von Mises Stress underlines the critical mechanical points
  • 18. Unrestricted © Siemens AG 2016 2017-01-18Page 18 Siemens PLM Software Table of contents • Introduction to the product portfolio • Motivation for this co-simulation study • Setup the 1D LMS Amesim model • Setup the 3D STAR-CCM+ model • Results of the LMS Amesim / STAR-CCM+ co-simulation • Going further
  • 19. Unrestricted © Siemens AG 2016 2017-01-18Page 19 Siemens PLM Software STAR-CCM+ / LMS Amesim co-simulation user guide in LMS Amehelp
  • 20. Unrestricted © Siemens AG 2016 2017-01-18Page 20 Siemens PLM Software Systems-Driven Product Development Predictive Engineering Analytics Role in Systems-Driven Product Development Predictive Engineering AnalyticsSystem Mockup Managed in PLM Context - Multi-Domain Traceability, Change and Configuration TEST Digital Twin 1D CFD Exploration - Analytics - Reporting 3D
  • 21. Unrestricted © Siemens AG 2016 2017-01-18Page 21 Siemens PLM Software 3D SIMULATION CFD SIMULATION 1D SIMULATION From disconnected models and data … Customer Usage data Simulation data Test data TEST MODELING Historical data CONTROLS
  • 22. Unrestricted © Siemens AG 2016 2017-01-18Page 22 Siemens PLM Software …to a performance Digital Twin 3D SIMULATION CFD SIMULATION 1D SIMULATION Customer Usage data Simulation data Test data TEST MODELING Historical data CONTROLS
  • 23. Unrestricted © Siemens AG 2016 2017-01-18Page 23 Siemens PLM Software Contact Karim NASSAR & Stéphane NEYRAT | LMS Amesim Platform Peter MENDOZA & Joe OSMAN | CD-adapco Siemens Industry Software S.A.S. Digital Factory Division Product Lifecycle Management Simulation & Test Solutions DF PL STS CAE 1D | CD-adapco siemens.com