The release of STAR-CCM+ v6.04 includes many new features across the simulation workflow with a focus on multiphase modeling. Key additions include enhancements to Eulerian and Lagrangian multiphase simulations, new fluid film modeling, discrete element method particle bonding, and improved vortex core detection. The release also expands application areas through new combustion and RELAP5-3D coupling models.

1. June 2011 p. 1
STAR-CCM+ v6.04 –June 2011 release
This release of STAR-CCM+ has a range of new features across the entire simulation workflow. Many
new physics models are introduced that expand the application scope of STAR-CCM+ with particular
focus given to multiphase modeling. The ability to extract meaningful engineering results is improved
with automatic vortex core detection and geometry preparation has been pipelined to aid
automation and ease of use. To enhance STAR-CCM+’s CAD and PLM offering, a new client for
Autodesk Inventor is deployed in this release.
STAR-CCM+ v6.04 most important new features are:
1. Eulerian Multiphase Enhancements
 A range of enhancements to the Eulerian multiphase framework including heat and mass transfer allowing the
simulation of a wider range of applications
2. Fluid Film Modeling
 New enhanced model to simulate deposition, transport and stripping of thin fluid films opening new application
areas for STAR-CCM+
3. Discrete Element method (DEM)
 New features to broaden the application scope of the DEM model with particle bonding, breaking and lattice
injection
4. Lagrangian Multiphase Enhancements
 Enhancements to many areas of lagrangian multiphase including a new injector type, track animation and the
simulation of the effect of electric fields on particles
5. Combustion
 A new combustion model to better predict emissions in computationally efficient manner
6. RELAP5-3D Coupling
 Expanding STAR-CCM+ application coverage by adding in a new co-simulation option with the leading nuclear 1D
code
7. Parallel Meshing
 Fully parallel polyhedral meshing technology allowing quick and efficient generation of ever larger meshes on
distributed computing platforms
8. STAR-Inventor
 New CAD client bringing the power of STAR-CCM+ to the users of Autodesk Inventor
9. Vortex Core Detection
 New post-processing feature enabling the rapid assessment of vortex strength and location
10. Geometry Operations
 A pipelined approach to geometry preparation with automatic fluid extraction, hole filling and Boolean
operations
The STAR-CCM+ Competitive Advantages are:
o Cutting edge CAD & PLM integration
 Integration within the CAD & PLM environment with the CAD Clients
 A complete choice of native, transmit and neutral formats for reading
o Unrivaled meshing technology
 The most advanced meshing toolset on the market today
 Flexible surface preparation and revolutionary volume meshing
o A unique and intuitive simulation user environment
 Easy to learn, use and remember
 A unique single integrated environment easily automated and deployed
o True multi-disciplinary solution capability
 A wealth of physics models for complete application coverage
 Flow, thermal & stress modeling, multiphase flows, electromagnetics, DEM…
o Engineering analysis for meaningful results
 A complete range of tools for turning raw simulation data into engineering insight
 Powerful visualization tools for effective communication of analysis
o A flexible approach to hardware deployment
 A client server architecture to ensure efficient use of hardware resources and remote processing
 Flexible licensing to help make the most of HPC and cloud computing facilities
o Seamless integration with other CAE software
 Working in conjunction with our partners for complete application coverage
 Solutions for 1D & 3D co-simulation and code to code mapping
o A product focused on customer satisfaction
 Development driven by customer feedback
 A four month release cycle to ensure timely exposure of new features.

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New feature and improvements in STAR-CCM+ v6.04
CAD Integration
 STAR-Inventor
o Provides the same access to STAR-CCM+ as the existing CAD Clients
o Uses a native ribbon in Autodesk Inventor for the STAR-CCM+
functions
 Updated compatibility with CAD versions
o STAR-CAT5: CATIA versions R19 and R20
o STAR-NX: NX versions 7.0 and 7.5
o STAR-Pro/E: Pro/Engineer Wildfire 5.0
o STAR-Works: SolidWorks 2010 and 2011
o STAR-Inventor: Inventor 2011
 New option in STAR-Pro/E to select a point for moving reference frame
definition
 Velocity vectors now displayed on boundaries in STAR-NX and STAR-Pro/E
 Default boundaries are no longer highlighted in any CAD package. This will improve speed of rendering for large models
CAE Integration
 New co-simulation coupling between STAR-CCM+ and RELAP5-3D
o RELAP5-3D models the coupled behavior of a reactor coolant system and the core for loss-of-coolant accidents and
operational transients
o Socket communication used between codes
o A parallel server of STAR-CCM+ can communicate with a single RELAP5-3D process through the master process
 Data mappers can now automatically calculate temperature values for unmapped face targets (based on surrounding faces)
User Environment
 New option to specify LM_PROJECT variable for Power-On-Demand at start/load of sim file
o Improves ease of use for Power-On-Demand customers
o No need to manually set environmental variables
 New java option to call Turbo Wizard
o Allows the use of the Turbo Wizard as part of an automated process
 Command line option -info now shows iteration count in addition to previous sim file information
 Pressure reference location may now be highlighted in a scene
Geometry
 3D-CAD
o Extended design parameter usage
 Linear and circular pattern settings
 Translation vectors
 Rotation and rotation axis
 Mirror plane quantities
o Constraints in sketches may be created referencing non
sketch entities
 Used to align sketch entities to other bodies or
sketches not present in the active sketch
o Fillets and chamfers may now be created by selecting faces
 Selecting 2 or more faces creates the feature on
the common edges
 Selecting 1 face creates the feature on all face
edges
o Loft with guide curves to enable more complex shapes to be created through lofting
o Extrusions may now be done in local coordinate systems
o New pierce constraint to ensure guide curves and sketches are coincident
 Geometry operations
o Option at the parts level allow common preparation options to be setup and executed
o Allows pipelined geometry preparation with operations re-executed when geometry is modified or replaced
o Result of operations creates a new geometry part for transfer to meshing
o Currently available operations:
 Extract Volume/ Fill Holes/ Boolean Unite, Intersect and Subtract
 Meta data now available on part surfaces as well as parts
 Option to automatically merge vertices at PLMXML import
 Option to assign all part surfaces within a composite part to a single boundary

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Surface Preparation & Meshing
 Surface preparation
o Multi-part imprinter
 Now allows for edges to be imprinted as well as faces
 Conformal face match option where adjacent parts have
coincident faces and vertices, but no part contact data
 Parts can be imprinted more than once (with manual
selection)
 Display of imprint number to show which part has been
imprinted
o Vertex projection
 No longer requires prior selection of any entity
 Picking of vertices may be done interactively in the
scene to improve ease of use
 New project to line option allows pick of start, end and
intermediate vertices with intermediate vertices projected to line
between start and end
o New toolbar button to launch surface repair directly
 Gives the option for which parts or regions to work on from a drop
down menu
 Surface diagnostics now launched from within surface repair and not at startup
o New options for geometric range thresholds:
 Radius around a point, box around a point and closest entity
o Option to select faces by CAD associativity
o Invert selection option
o Improved performance of split by topology operations
 Surface remesher
o Compatibility refinement:
 Option that controls the relative sizing of faces across gaps to ensure that a large disparity in face sizes does
not occur
 Improves quality for thin meshing
o Several improvements made to the scope and quality of aligned
meshes
 Surface wrapper
o Contact prevention sets may now be highlighted in a scene
 Prism mesher
o New Hyperbolic tangent option for prism layer stretching
 Trimmed cell mesher
o New custom growth rate option for the trimmer
 Allows users to specify number of layers for each
growth level
o Option for anisotropic wake refinement with different cell size
distribution in each direction
 Parallel Polyhedral mesher
o First instance of Parallel meshing in STAR-CCM+
 Full meshing process parallelized including prism layer mesher and cell optimization
 Uses fully distributed memory approach to best utilize clusters and sure no node is overloaded
 Mesh redistributed when complete to ensure optimal load balancing for solving
Physics
 Eulerian multiphase
o Phase coupled fluid energy model
 Allows the solution of the energy equation for Eulerian
Multiphase flow
 User control of whether enthalpy or temperature are
solved
o New phase interaction models:
 Interphase energy transfer by thermal diffusion
 Interphase mass transfer
o New options for interaction length scale
 Kurul-Podowski for bulk boiling flows
 Constant
 User defined
o Interaction area density
 Spherical particle
 Symmetric
 User-defined

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o Drag Laws
 Bozzano drag law for bubbly liquid gas systems including surface tension effects
 Symmetric drag law across phase inversion
o New option for phase permeable walls
 Allows for the simulation of de-gassing and particle deposition (soiling/icing)
 Fluid film modeling
o New model to model the deposition and transport of thin films on
walls
o Models conservation of mass and momentum, with an assumed
parabolic velocity profile
o New shell region structure to handle films
o Includes options for deposition, initialization and wave based
stripping
 Lagrangian multi-phase
o New hollow cone injector type
 Specifically targeted at turbomachinery applications
where this injector is used in combustion chambers
o Coulomb force model
 Used in conjunction with the Electrostatic Potential
model
 Simulates the force on particles due to an electric field
o Injectors may now re-randomize every time step
o Option to adjust the default parameters of the Bai-Gosman wall impingement model
 DEM
o Particle bonding model
 Allows for the simulation of bonding, breaking and flexing of particle clumps
o Option to initialize DEM flows with lattices
 Simple cubic lattice
 Body centered cubic lattice
 Face centered lattice
 VOF
o Surface tension model now extended to specify phase-wise surface tension
 Carman-Kozeny Mushy permeability model added for partially solidified flows
o Allows the simulation of binary alloys with partially solidified melt in between liquidus and solidus temperatures
 Battery simulation module
o Possibility to use different Cartesian meshes for the electrical and
CFD models with automatic mapping of fields between the two
enabled
o Improvements have been made to the speed of the circuit solver
o Detailed electrochemistry data can be exported for distributed
battery models
 Combustion modeling
o New progress variable model (PVM)
o Change in the default relaxation factor for CFM combustion to 0.9
 Aeroacoustics
o Steady model for FW-H tonal noise prediction
o FW-H now compatible with rigid body motion
 Harmonic balance
o Non-reflecting boundary condition now works on unstructured meshes
 Porous media
o Momentum fluxes may be explicitly excluded
 Thermal Comfort Management (TCM) model now extended to handle increased number of regions
 Additional options for passive scalar transport
o Convection and diffusion
o Convection only
o Diffusion only
o No convection or diffusion
 Material property definition
o Acentric factor added for the Peng-Robinson real gas model
o Selected material properties can be set using a table in T (temperature)
o Entropy coefficient added for thermodynamic polynomial data
o Multi-component diffusion now available for non-reacting mixtures
Performance
 Changes to AMG solver defaults for pressure correction to improve scalability
o F-cycle now V cycle
o CG acceleration turned on
o No additional boundary sweeps

5. June 2011 p. 5
Analysis and Post-processing
 Plots
o Entities in graph legends may now be renamed
o User control of width of lines and appearance of symbols in
legend can now follow main plot
 New vortex core derived part
o Option to detect and visualize vortex cores based on the vector
field
o May be used to seed streamlines and other derived parts
 VRML scene export
o Scenes may now be exported as a 3D VRML file for
visualization in 3D
o May be used to send results to 3D printers
 Lagrangian particle track animation
o Particle tracks may now be used in streamline displayers and
animated accordingly
 Auto range option for displayers
o Allows users to choose the method of automatic range detection allowing consistency of scalar display
o Options are:
 Displayer parts
 Displayer regions (input regions of the displayer parts)
 All regions (in the simulation)
 Direct method for plotting accumulated force
o Macros no longer required with ability to create an accumulated force table
o Table plots both accumulated force and also geometric profile of the sample points
 SGS field function to aid visualization of turbulent scales with LES
 Regions and boundary now consistently ordered alphabetically in reports
 New constant tip size option for vectors
 Symmetric transforms may now plot different scalar fields on each side
Documentation
 Refactoring of existing material
o New top level heading, “Defining the Simulation Topology”. This covers geometry parts to regions assignment, as well as
manipulations on regions and boundaries
o Ongoing improvements to structure in “Modeling Geometry” and “Generating Mesh”
 New tutorials
o Abaqus co-simulation mechanical coupling
o Fluid film down a vertical wall
o Coherent Flame Model tutorial
o Adiabatic PCFM (Partially Premixed Coherent Flame Model) tutorial