From pure CFD applications to coupled solutions: how · PDF fileFrom pure CFD applications to coupled solutions: how can be ... • Oil/Gas and offshore platforms ... AcuSolve is very

Innovation Intelligence®

From pure CFD applications to

coupled solutions: how can be

supported the engineer

Giorgio Cantarutti

Aerospace Senior Consultant

[email protected]

Workshop HPC methods for EngineeringCINECA Milan, 17/19 June 2015

Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Topics

• What doing Altair

• CFD for engineering

• Coupled CFD for real simulations

• How is usable for an engineer


About Us

Staffing Services

EngineeringServices

CAESoftware

PatentedLicensing

Model

HPCSoftware

IndustrialDesign

Services

AnalyticsSoftware

ConceptDesign

Software

CloudSoftware

We help businesses

succeed through the

development and application

simulation technology to

accelerate innovation


We Work with Some of the Best

Automotive Aerospace Heavy Equipment Government

Life/Earth Sciences Energy Architecture

5,000 customers worldwide

Electronics/

Consumer Goods


With a Shared Vision

To radically change the way

organizations design products

and make decisions

James R. Scapa, Chairman & CEO, Altair


Software – At the Core of our Business

Simulation, optimization and analytics technologies that

leverage high performance computing architectures to

to guide faster, more robust decisions to improve

business and product performance.

HyperWorks

solidThinking

PBS Works

Cloud Solutions

Partner Alliance


Value-based Licensing Model to Access Everything

Altair delivers exceptional value to customers. Its

value-based, patented on-demand licensing model

brings together partners and in-the-cloud solutions,

maximizing flexibility and cost efficiency

Patented Unit-based Model

Enables the Entire Enterprise

Access to Everything

40+ Partner Applications

Hosted HyperWorks Units


Services – Not Just Another Software Developer

Product Engineering

Industrial Design

Technical Staffing

HyperWorks Solutions

Analytics Solutions

Altair has grown to become a global product development

consultancy of 700+ designers, engineers, scientists and

creative thinkers. The knowledge of real world product

design and manufacturing has never been lost.


The synergy between our software and services

organizations keeps Altair close to industry challenges and

uniquely positioned as a valued, long-term partner to

support the dynamic needs of our clients.


Topics






HyperWorks

Altair HyperWorks is a modern, open

architecture CAE simulation platform,

offering the best technologies to design and

optimize high performance, weight efficient

and innovative products.

Drive Innovation

Simulate Everything

Interoperate Freely

Access it All


Integration Matters: Flexibility

CAD

ACIS

CATIA V4 / V5

IGES (in)

IGES (out)

JT Precise

Parasolid (in)

Parasolid (out)

Pro/E

SolidWorks

STEP

Tribon

UG/NX

CAE

Adams

Abaqus

Actran

AcuSolve

Ansys

CFD++

Femfat

Fluent

Ls-Dyna

Madymo

Marc

Matlab

Moldflow

Moldex3D

MotionSolve

Nastran

nCode

Permas

Pam-Crash

RADIOSS

OptiStruct

Samcef

Simpack

StarCD

Custom User-defined

InterfacesScripting

Results

Math

Open, adaptable to your environment…


Modeling and Visualization: Pre-Processing

Pre-Processing

HyperMesh

FEA/CFD Modeling,

Customizable to capture

best practices,

Native CAD Support for

better model quality

MotionView

Multi-body modeling,

Parametric modeling,

Solver-neutral data

model,

Highly customizable

Simlab

CAE Pre-Post Processing

Tools to automate and

reduce the simulation time

without compromising

quality


Results Visualization & Validation

Analyze, understand and publish your simulation

results with HyperView and HyperGraph,

HyperWorks’ best-in-class post-processing and

visualization environment for CAE and test data.

Results Visualization

Powerful Reporting

Math Functions

Engineering Analytics


Modeling and Visualization: Post-Processing

Post-Processing and Data Analysis

HyperView

Result Visualization,

High performance

architecture,

Advanced reporting

functionality,

Solver independent

HyperGraph

Data analysis with automatic

plot generation

Mathematical library for

advanced analyses

3D Result plotting

HyperMath

General purpose

numerical computing

Allows to easily develop

and perform custom

mathematical operations


Modeling and Visualization: Altair HyperView

Finite Element Analysis & Multi-Body Dynamics Post-Processor

World Class

Visualization and

Animation, with Video

Animation Overlay

Multi-Solver

Interface

Architecture for

Results Visualization

Advanced Query

and User Defined

Results Math

Capabilities

Fully Customizable

via Template and

Tcl/Tk Scripting

Languages


Modeling and Visualization: HyperGraph

Powerful data analysis and plotting tool for all types of CAE data.

Minimizes the manual

effort and time to

generate plots

Plot macros capture

and automate

common math

expressions

Fully customizable

interface to fit any

engineering

environment

Comprehensive and

customizable library

of mathematical

functions


HyperMath enables:

• Efficient custom math modeling

• Seamless pre and post

processing of CAE data

Modeling and Visualization:HyperMath

Numerical computing environment:

• High-level scripting language

• Extensive math libraries

• Comprehensive set of interactive

development tools


Analysis: HyperWorks Solver Technology

Multiphysics Analysis and Optimization

Structural

Analysis

Manufacturing

Simulation

Systems

SimulationFluid

Dynamics

Thermal

Analysis

Crash, Safety,

Impact &

Blast

Electro-

Magnetics


HyperWorks Solvers

Thermal

and CFD

Highly Non-Linear

Crash

Safety

Forming

Statics

NVH

Thermal

Non-Linear

Multi-body

Dynamics

OptiStruct RADIOSS MotionSolve AcuSolve

Optimization

Smart Multiphysics

FEKO

Electro-

Magnetics


Design Exploration: Altair HyperStudy

Multi Disciplinary design exploration, study and optimization software

Perform what-if studies

Calibrate simulation models

to match with test results

Design better performing

products

Increase the reliability of the

designs

Find robust designs that are

less sensitive to variations

Increase the return on CAE

investments

+17% in reliabilityBefore After


AcuSolve – Better Technology, Better Solution

Multiphysics Analysis and Optimization

Fluid-

Structure

Interaction

Thermal

ManagementComputational

Aero-acoustics

Non-

Newtonian

Flow

Simulation

Electronic

CoolingAerodynamics


Background

• AcuSolve• Leading finite element based CFD product and solutions

• Capabilities

• Transient/Steady State

• Turbulence models (Spalart Allmaras, SST, DDES, LES, DNS)

• AcuSolve Product Suite• Pre-processing - AcuConsole

• CFD Solver Engine - AcuSolve

• Post-processing – AcuFieldView, AcuTrace, AcuReport, etc.


AcuSolve Overview

• Markets using AcuSolve:

• Automotive

• Train aerodynamics

• Renewable Energy

• Boat design

• Electronic cooling

• Chemical mixing

• Home Appliances

• Medical and medical equipment

• Oil/Gas and offshore platforms

• Universities

• National labs

• Etc. . .

A.37


AcuSolve - Overview

• AcuSolve Key Points

• General purpose, 3-dimensional, unstructured flow solver

• Based on finite element method

• Foundation is the Galerkin least squares method• Rich history in academia (25 years)• Further refined by ACUSIM Software, Inc. for industrial applications

• Differentiation• Robustness

• Most problems solved on first attempt, no parameter tuning/knob turning required!

• Speed• Architected for massively parallel applications

• Accuracy• Highly accurate in space and time


HyperWorks Desktop

• HyperView and HyperGraph

• Visual Data Interactively

• Standardize Post-Processing

• Results in H3D or EnSight file

AcuFieldView

• OEM version of FieldView based on FV 13

• Included with AcuSolve V12 product suite

• Functions only with AcuSolve generated

results data

• Supports all features of FieldView

• Runs in true batch mode

• client/remote server access

Using HyperWorks for CFD Analysis – CFD Post-Processing


CFD Optimization – What?

• Parameters (mass flow, temperature, …)

Common design targets:

• Pressure drop / rise

• Flow uniformity / turb. intensities

• Flow rate / balance

• Flow separation control

• Force (Drag/Lift) / Torque

• Shape change of flow guiding structure (baffles, pipes, blades …)

no geometrical changes


CFD Optimization with HyperWorks: Morphing


CFD Optimization with HyperWorks

Parameterize models easily using Morphing in HyperMesh

• Create morph volumes/domains to localize the shape changes

• Handles are moved to move the nodes of associated volumes/domains

• If satisfied with the morph, save node perturbations as a shape

• Tightly integrated with HyperStudy



Change the shape of the mesh with HyperMorph

• Create single shapes for each parameter variation as shape changes are

automatically superposed during the optimization

Example: Cooling Fan optimization of a rotary hammer

• Allowed shape changes:

• Inner/Outer Height (a/b)

• Length (c)

• Thickness (d)

• Angle (e)

• Curvature (f)



After morph volumes have been created, define the shapes by moving handles:



The created shapes and the element quality can be reviewed in HyperMesh:



The nodes of the volume elements can move accordingly to the surface nodes



Advantages of AcuSolve w.r.t. CFD optimization:

AcuSolve is very forgiving of poor element quality

most robust CFD solver to mesh deformations

Reduced to 25%inflow outflow

Max. vol skew 0.9997 0.95 (remeshed, tetra in BL) 0.95 (remeshed, penta in BL)

Delta_p [Pa] 2.63 2.63 2.63

X-traction [N] 3.13e-3 3.13e-3 3.12e-3

Iterations 20 21 25



General workflow of a CFD shape optimization with HyperWorks:

Node

coordinatesSolver setup(batch mode)

CFD solver(batch mode)

Result-File

Input setup

(AcuConsole)

HyperStudy

Shape-File

(HyperMorph)



Optimization strategy:

• Ideally, the problem formulation should have as many independent design

variables as possible.

• However, the number of simulations needed in any study type is a function

of the number of design variables.

• Start optimization with a DOE, which are used to investigate the sensitivity

of system responses to the changes in the design variables

Example:

• 5 design variables

• 2 Levels (0 or 1)

• Full Factorial

• 2^5 simulations



• After evaluation of the DOE results, the relevant design variables can be

identified, the rest can be omitted from further studies to reduce #simulations

2 Shapes have much more impact than the rest


Case Study : Optimization of an exhaust tube

in

out

g : +12% Dp: -16%

optimizedinitial

initial

optimized

Flow velocity

Case: Exhaust system, catalytic converterObjective: uniform flow, min. pressure dropResult: uniformity +12%,

pressure drop -16%


Case Study Uniform Flow

g : +4%

Dp: -6%

Original Optimized

inflow

outflow

Flow velocity

Case: Evaporator, HVAC systemObjective: uniform flow, min. pressure dropResult: uniformity +5.6%, pressure drop -7%


Working with VWT: Virtual Wind Tunnel

• Process Overview

Watertight

Surface

Mesh

Nastran

Format

PDF

Report

Virtual

Wind Tunel

AcuSolve

AcuField

View

AcuConsole


VWT is for engineers:


Topics






Terminology

“Fluid–structure interaction (FSI) is the interaction of some movable or deformable

structure with an internal or surrounding fluid flow. Fluid–structure interactions can

be stable or oscillatory. In oscillatory interactions, the strain induced in the solid

structure causes it to move such that the source of strain is reduced, and the

structure returns to its former state only for the process to repeat.”

- Bungartz, Schäfer (2006). Fluid-structure Interaction: Modelling, Simulation, Optimization.

62-Videos “courtesy” of YouTube


AcuSolve’s FSI Capabilities - PFSI

63

• Practical Fluid/Structure Interaction (P-FSI)• Structural displacement computed by AcuSolve

• Based on modal superposition• Limited to linear structural displacements• No run-time coupling



• Step 1: Solid Model

• Solve an Eigenvalue problem using OptiStruct, Abaqus, Ansys, Nastran,

etc.

• Step 2: Projection

• Project the Eigenvectors onto the AcuSolve mesh

• Built-in tools to extract & project directly from OP2, ODB, etc.

• Step 3: Run AcuSolve

• Solve the coupled flow and linear deformation

• At each step, AcuSolve

• Computes fluid forces on the wetted surface

• Projects the forces onto the Eigensystem

• Advances the modal response

• Computes the new mesh position

• Solves the fluid and other equations on the deformed mesh

64



• Benefits of P-FSI

• Extremely fast

• Little or no cost associated with the

structure

• Some cost associated with ALE, however

• Extremely robust

• No run-time coupling to an external code

• All calculations performed internal to

AcuSolve

• Flexible

• Can utilize input from any structural solver

• Requires a simple translator script

65

Drawbacks of P-FSI• Only accurate for “small” displacements

• Limited to linear structural materials

• Very limited contact model

• No direct visualization of stresses


FSI Applications

• Automotive – Notional F1 Front Wing

• P-FSI example

• Drag in transient simulation reduced by 3%

66


AcuSolve’s FSI Capabilities - DC-FSI

• Directly Coupled Fluid/Structure Interaction (DC-FSI)• Codes communicate at run time

• Loads/displacements exchanged multiple times per step• Supported with RADIOSS, Abaqus


AcuSolve’s FSI Capabilities – DC-FSI

• Step 1: Construct Fluid Model

• Build appropriate model for the fluid domain which contains the wetted

surfaces of the structure

• Identify the wetted surfaces as “EXTERNAL_CODE_SURFACE”

• Step 2: Construct Structural Model

• Build the structural model and identify appropriate wetted surfaces for

communication with AcuSolve

• Step 3: Run both codes in tandem

• Codes connect via TCP socket (default)

• At each step, AcuSolve

• Passes the fluid forces to the structure

• Waits for displacements to return

• Updates mesh position

• Solves the fluid and other equations on the deformed mesh

68


Critical FSI Technology

• Mesh Motion

69

• Arbitrary Lagrange-Eulerian Mesh Motion• Arbitrary motion/deformation of the mesh

• Free surface modeling• Moving Bodies• Requires hyperelasticity equation

• Specified mesh motion• User defines how the mesh moves

• Useful for simpler motions• Very fast computationally

• Non-conformal mesh interfaces• Rotating/sliding interfaces


Critical FSI Technology

• Mesh Motion

70

• Most CFD codes are VERY sensitive to element quality • AcuSolve handles highly distorted meshes with ease• Some of our competitors “give up” and disable elements when they

become distorted!


FSI Applications

• Off-shore oil industry

• Non-linear soil/pipe interactions

• Non-linear bending

• “Linearized” non-linear bending

71


• “Linearized” non-linear bending of oil platform riser pipe

• Large/unsteady deformations caused by flow forces

• 1500:1 L/D ratios

FSI Applications


FSI Applications

• Flow restriction devices

• Linear/non-linear deformations

• Linear/non-linear materials

• Flow being “pinched”

73


FSI Applications

• Consumer goods


• Linear/non-linear material models

74


FSI Applications

• Chemical Mixing



75


FSI Applications

• Automotive



76

• Medical



• Very tightly coupled


Introduction – CFD/MBD Co-Simulation

• The CFD and MBD solvers send and receive information via TCP socket

communication during simulation runtime

• Allows cross platform communication

• CFD simulation runs on HPC, while MBD runs locally

• Middleware application communicates information between the solvers

• Forces and moments from the CFD model to the MBD model

• Displacements and rotations from the MBD model to the CFD model

• Information is exchanged at the CFD time increment

• Middleware manages runtime and licensing

CFD

Fx

Fy

Fz

Mx

My

Mz

MBD

Δx

Δy

Δz

θx

θy

θz

Interface


Introduction – CFD/MBD Co-Simulation

Simulate MBD rigid motion in MotionSolve while directly

coupling with the CFD solver AcuSolve to better model reality

Purpose:

Use Cases:

Loosely Coupled

Actuating rigid bodies

that have an effect on the

surrounding fluid

Tightly Coupled

Rigid bodies are forced to

actuate due to the

surrounding flow field


Proof of Concept: Bicycle Rider’s Legs

• Perform simulation studies to identify

environment effects on the rider

• Rider strategies for performances


Sloshing Tanker Truck

• Simplified vehicle chassis traveling at

constant velocity changes lanes

• Tank is filled with water to 33% of capacity

• Two loading cases investigated

• Full two-way coupling (fluid forces are dynamic

based on the sloshing within the tank)

• MBD only (fluid force is considered as point

load)

• Design criteria investigated

• Transient forces & moments

• Suspension response

− Vehicle roll, pitch, yaw, suspension displacement

15.0m

3.5

m

24.6m


Sloshing Tanker Truck – Contours of Velocity, Shear

Stress Vectors, Steering Performance

• Vehicle stability

verification

• Load investigation

• Driver strategies for

manouvers

• Accident

reconstruction


Usage: Aerodynamic Drag Calculations On Vehicles

Accurate loads prediction via MotionSolve-AcuSolve coupling

Direct co-simulation with AcuSolve allows for bi-directional coupling.

MotionSolve calculates displacements and velocities while AcuSolve predicts

accurate forces and moments


Matthew N. Godo, Ph.D.FieldView Product Manager

Member AIAA

David CorsonSenior Analyst, Altair.

Member AIAA

Steve M. LegenskyGeneral Manager

Senior Member AIAA

Usage 2: Aerodynamic study of bicycle wheel performance


Smart Multiphysics

Static and

NVH

Static and

NVH

Optimization

Non-

linear

(implicit)

Non-

linear

(implicit)

Non-

linear

(explicit)

Non-

linear

(Explicit)

Thermal

and CFD

Thermal

and CFD

Thermal

and CFD

Multi-

body

dynamics

Others

(Partners)

Others

(Partners)

Non-

linear

(implicit)

Thermal

and CFD

Multi-

body

dynamics

Others

(Partners)

Le

ve

l o

f In

teg

ratio

n


APA Altair Partner Aliance JMAG

86

Copper loss, iron loss, magnet eddy

current loss, stray loss can be

transferred as heat sources

Temperature

Loss

AcuSolve

Temperature

distribution

Magnetic flux

density distribution Efficiency mapSpeed distribution

Heat transfer

coefficient

Coupling for Motor


Topics






Access It All: Flexible High Value Licensing

Software

As-a-Service

Simulation

Data

Management

Broad Alliance

of Partners

Drive

Innovation

Access

It All

Simulate

Everything


Software As-a-Service

HyperWorks delivers exceptional value to customers. Its value-based, patented

on-demand licensing model brings together partners and in-the-cloud

solutions, maximizing flexibility and cost efficiency


PBS Works Suite – Altair Knows HPC

PBS Works is the trusted leader in high-performance

computing (HPC) workload management, with integrated

solutions for intelligent job scheduling, Web-based

submission and analytics, and remote visualization.

Workload Management / Scheduling

Green Provisioning™

EAL3+ security

GPU/co-processor scheduling

Integrated management portals


Altair's cloud solutions simplify access to scalable

on-premise and remote simulation and infrastructure

resources to model, explore, analyze, organize,

manage and collaborate across the enterprise.

Cloud Solutions for Compute-intensive Simulation

Simulation Cloud Suite

HyperWorks On-Demand

HyperWorks Unlimited

Hosted HyperWorks Units


AcuSolve: Scalability


AcuSolve: Scalability


Broad Alliance of Partners

Altair provides a value-based solution with the broadest

community of partners. The Altair Partner Alliance

effectively extend the HyperWorks offering to over

50 applications at absolutely no incremental cost.

Complementary technologies

Reduce IT / admin costs

Evaluate new software risk-free

On-demand access


Compute Manager

Run, Monitor CAE Jobs

Simulation

Manager

Manage CAE Data,

Projects & KPIs

Process Manager

Capture and Automate

Enterprise Processes

Display Manager

Remote Display Big

Data

HW Collaboration

Tools

Explore, Organize,

Connect & Automate

Database PDM 3rd Party AppsPBS

ProfessionalHyperWorks

Simulation Cloud Suite

Altair Enterprise Foundation – ProfessionalData Management, Access Management, Results Visualization, Remote Visualization, Job Management, Unified Data Model


HyperWorks: Performance Enhancing Software Suite

Documents

From pure CFD applications to coupled solutions: how · PDF fileFrom pure CFD applications to coupled solutions: how can be ... • Oil/Gas and offshore platforms ... AcuSolve is very