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Role of CFD in Engineering Design
The document provides an introduction to Computational Fluid Dynamics (CFD), explaining its role in engineering design by predicting fluid flows, heat transfer, and mass transfer through mathematical modeling and numerical methods. It outlines the CFD process, including pre-processing, solver techniques, and post-processing to analyze flow characteristics and performance. Additionally, it discusses various applications of CFD in automotive, aerospace, HVAC, and electronics industries, along with a case study on optimizing duct design to minimize pressure drop.
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Role of CFD in Engineering Design
- 1. Introduction to CFD Roleof CFD in Engineering Design Dr. Ganesh Visavale Cofounder & General Manager LearnCAx (Centre for Computational Technologies Pvt. Ltd) Pune: 411007. India March 16, 2014 www.learncax.com Role of CFD in Engineering Design 1 / 31
- 2. Introduction to CFD Fluiddynamics is beautiful ! www.learncax.com Role of CFD in Engineering Design 2 / 31
- 3. Introduction to CFD FDstudy approach www.learncax.com Role of CFD in Engineering Design 3 / 31
- 4. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 5. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 6. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 7. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 8. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 9. Introduction to CFD ComputationalFluid Dynamics Dene CFD ! Computational Fluid Dynamics (CFD) is the science of predicting uid ow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using numerical methods (i.e., on a computer) CFD Capabilities Computational Fluid Dynamics (CFD) provides a qualitative and quantitative prediction of uid ows by means of: mathematical modeling (partial dierential equations) numerical methods (discretization and solution techniques) software tools (solvers, pre- and postprocessing utilities). www.learncax.com Role of CFD in Engineering Design 4 / 31
- 10. Introduction to CFD CFDprocess ow Pre-processing Geometry creation cleanup Mesh generation Boundary conditions Solver Problem specication Additional models (asked by physics) Numerical Computations Post-processing Understanding ow with color, contour etc.. plots Line and contour data Average values (Drag, lift, heat transfer coecient) Report generation www.learncax.com Role of CFD in Engineering Design 5 / 31
- 11. Introduction to CFD CFDprocess ow Pre-processing Geometry creation cleanup Mesh generation Boundary conditions Solver Problem specication Additional models (asked by physics) Numerical Computations Post-processing Understanding ow with color, contour etc.. plots Line and contour data Average values (Drag, lift, heat transfer coecient) Report generation www.learncax.com Role of CFD in Engineering Design 5 / 31
- 12. Introduction to CFD CFDprocess ow Pre-processing Geometry creation cleanup Mesh generation Boundary conditions Solver Problem specication Additional models (asked by physics) Numerical Computations Post-processing Understanding ow with color, contour etc.. plots Line and contour data Average values (Drag, lift, heat transfer coecient) Report generation www.learncax.com Role of CFD in Engineering Design 5 / 31
- 13. Introduction to CFD CFDprocess ow www.learncax.com Role of CFD in Engineering Design 6 / 31
- 14. Introduction to CFD CFDprocess ow www.learncax.com Role of CFD in Engineering Design 6 / 31
- 15. Introduction to CFD CFDprocess ow www.learncax.com Role of CFD in Engineering Design 6 / 31
- 16. Introduction to CFD CFDprocess ow www.learncax.com Role of CFD in Engineering Design 6 / 31
- 17. Introduction to CFD CFDprocess ow www.learncax.com Role of CFD in Engineering Design 7 / 31
- 18. Introduction to CFD Insidethe CFD process www.learncax.com Role of CFD in Engineering Design 8 / 31
- 19. Introduction to CFD Insidethe CFD process www.learncax.com Role of CFD in Engineering Design 9 / 31
- 20. Introduction to CFD Insidethe CFD process www.learncax.com Role of CFD in Engineering Design 10 / 31
- 21. Introduction to CFD Insidethe CFD process www.learncax.com Role of CFD in Engineering Design 11 / 31
- 22. Introduction to CFD Insidethe CFD process The CFD Process Analysis begins with a mathematical model of a physical problem. Conservation of mass, momentum, and energy must be satised throughout the region of interest. Simplifying assumptions are made in order to make the problem tractable (e.g., steady-state, incompressible, inviscid, two-dimensional). Provide appropriate boundary and initial conditions for the problem www.learncax.com Role of CFD in Engineering Design 12 / 31
- 23. Introduction to CFD Insidethe CFD process Meshing your way into it CFD applies numerical methods (called discretization) to develop algebraic equations to approximate the governing dierential equations of uid mechanics in the domain to be studied. Entire domain should be divided into small cells or volume The collection of cells is called the grid or mesh. The equations are solved for each such grid or mesh volume www.learncax.com Role of CFD in Engineering Design 13 / 31
- 24. Introduction to CFD Insidethe CFD process Solver The system of algebraic equations are solved numerically (on a computer) for the ow eld variables at each node or cell System of equations are solved (usually through iterations) to provide solution ρφv · dA = Γφ φ · dA + V SφdV (1) Nfaces f ρf Vf φf · Af = Nfaces f Γφ( φ)n · Af + SφV (2) www.learncax.com Role of CFD in Engineering Design 14 / 31
- 25. Introduction to CFD Insidethe CFD process Post-processing The nal solution is post-processed to extract quantities of interest Example: lift, drag, heat transfer, separation points, pressure loss, etc.) www.learncax.com Role of CFD in Engineering Design 15 / 31
- 26. Introduction to CFD CFDwithin Design Cycle Problem denition Dimensional reduction Experimental design Management of CFD simulations Data analysis Design phase Performance testing Issue resolution www.learncax.com Role of CFD in Engineering Design 16 / 31
- 27. Introduction to CFD CFDwithin Design Cycle Advances in computational technology Continuous eort by CFD providers to implement comprehensive physical models Advances in numerical methods 1 1 Image from: Future Trends for Computational Fluid Dynamics in Process Industry, Ahmad H. Haidari Brent Matthews www.learncax.com Role of CFD in Engineering Design 17 / 31
- 28. Introduction to CFD CommercialSimulation packages 1 ANSYS Provides wide range of established commercial packages from tools of geometry cleanup, mesh generation, solver and postprocessing FLUENT CFX ICEM CFD 2 The STAR-CCM+ solver provides one of the most eective numerical methodologies available in an industrial CFD code with the high level of accuracy needed for complex unstructured meshes 3 COMSOL Multiphysics is a modeling package for the simulation of any physical process you can describe with partial dierential equations (PDEs) 4 OpenFOAM, FLOW3D www.learncax.com Role of CFD in Engineering Design 18 / 31
- 29. Introduction to CFD SomeApplications of CFD: Automobiles Air handling systems Engine cooling Intake and exhaust manifolds External aerodynamics Motor sports Power train Oil lters Combustion chamber www.learncax.com Role of CFD in Engineering Design 19 / 31
- 30. Introduction to CFD SomeApplications of CFD: Automobiles Air handling systems Engine cooling Intake and exhaust manifolds External aerodynamics Motor sports Power train Oil lters Combustion chamber www.learncax.com Role of CFD in Engineering Design 19 / 31
- 31. Introduction to CFD SomeApplications of CFD: Automobiles Air handling systems Engine cooling Intake and exhaust manifolds External aerodynamics Motor sports Power train Oil lters Combustion chamber www.learncax.com Role of CFD in Engineering Design 19 / 31
- 32. Introduction to CFD SomeApplications of CFD: Automobiles Air handling systems Engine cooling Intake and exhaust manifolds External aerodynamics Motor sports Power train Oil lters Combustion chamber www.learncax.com Role of CFD in Engineering Design 19 / 31
- 33. Introduction to CFD SomeApplications of CFD: Electronics Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 20 / 31
- 34. Introduction to CFD SomeApplications of CFD: Electronics Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 20 / 31
- 35. Introduction to CFD SomeApplications of CFD: Electronics Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 20 / 31
- 36. Introduction to CFD SomeApplications of CFD: Electronics Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 20 / 31
- 37. Introduction to CFD SomeApplications of CFD: HVAC Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 21 / 31
- 38. Introduction to CFD SomeApplications of CFD: HVAC Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 21 / 31
- 39. Introduction to CFD SomeApplications of CFD: HVAC Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 21 / 31
- 40. Introduction to CFD SomeApplications of CFD: HVAC Component level ow and cooling Telecommunication equipment Engine and transmission controllers Magnetic storage devices www.learncax.com Role of CFD in Engineering Design 21 / 31
- 41. Introduction to CFD SomeApplications of CFD: Aerospace Combustor External aerodynamics Fire suppression Inlets and nozzles instrumentation Missile systems Propulsion Pumps Rotor-airframe interaction www.learncax.com Role of CFD in Engineering Design 22 / 31
- 42. Introduction to CFD SomeApplications of CFD: Aerospace Combustor External aerodynamics Fire suppression Inlets and nozzles instrumentation Missile systems Propulsion Pumps Rotor-airframe interaction www.learncax.com Role of CFD in Engineering Design 22 / 31
- 43. Introduction to CFD SomeApplications of CFD: Aerospace Combustor External aerodynamics Fire suppression Inlets and nozzles instrumentation Missile systems Propulsion Pumps Rotor-airframe interaction www.learncax.com Role of CFD in Engineering Design 22 / 31
- 44. Introduction to CFD SomeApplications of CFD: Aerospace Combustor External aerodynamics Fire suppression Inlets and nozzles instrumentation Missile systems Propulsion Pumps Rotor-airframe interaction www.learncax.com Role of CFD in Engineering Design 22 / 31
- 45. Introduction to CFD CaseStudy: Boiler outlet duct design Flow through the ducts Important to analyze ow physics as it induces resistance to the ow. Essential to design it in such way that the duct oer less resistance to the ow. www.learncax.com Role of CFD in Engineering Design 23 / 31
- 46. Introduction to CFD CaseStudy: CFD Approach 1 What is the objective statement for CFD? Minimize the pressure drop across the ducts 2 What is the physics ? Incompressible, steady, single phase, turbulent 3 What is CFD domain and BCs? No solid, only uid domain modeled. Mass ow rate at inlet 4 Geometry? Domain I need, Simplications I can make, Parts necessary for physics, symmetries 5 Mesh? Type of mesh, Possible all hex mesh, Some parts too complex while some are simple. www.learncax.com Role of CFD in Engineering Design 24 / 31
- 47. Introduction to CFD Boileroutlet duct system design Objective We need to optimize the design to ensure minimum pressure drop for the given ow through duct to the ow. CFD Solver Incompressible - steady ow - Pressure based solver Realizable K-e turbulence modeled Imbalances in the domain : Less than 1 Convergence 1 × 10−03 Second order upwind www.learncax.com Role of CFD in Engineering Design 25 / 31
- 48. Introduction to CFD Meshgeneration A hexahedral mesh is created using structured Multi-block technique in ANSYS ICEMCFD www.learncax.com Role of CFD in Engineering Design 26 / 31
- 49. Introduction to CFD results TypicalPressure contour Typical Velocity contour Flow pathlines www.learncax.com Role of CFD in Engineering Design 27 / 31
- 50. Introduction to CFD DesignIterations Existing design Design Iteration 1 Design Iteration 2 Design Iteration 3 Design Iteration 4 Iterative design process using CFD simulation results the overall pressure drop within the ducting system by about 80% www.learncax.com Role of CFD in Engineering Design 28 / 31
- 51. Introduction to CFD results TypicalPressure contour Typical Velocity contour Flow pathlines www.learncax.com Role of CFD in Engineering Design 29 / 31
- 52. Introduction to CFD CFDLearning Path What a fresher Engineer should learn in order to get into CFD analysis ? Fundamentals of Fluid dynamics and Thermal sciences Fundamentals of CFD How to use CFD software ? How is CFD used in Design ? What should a fresh engineer expect from CFD eld ? How to make sense of CFD results ? How to make design decisions based on CFD results ? www.learncax.com Role of CFD in Engineering Design 30 / 31
- 53. Introduction to CFD Thanks...! LearnCAx Inspire| Educate | Mentor CCTech - Pune 1 Akshay Residency, 50 Anand Park, Aundh, Pune-411007. India. ganesh@learncax.com, www.learncax.com www.learncax.com Role of CFD in Engineering Design 31 / 31