SLIDE 1
CAE Custom Tools
SLIDE 2 Introduction
I.
CAE Custom Tools Services
–
Customization of STAR-CCM+ based on client needs.
–
Conversion of standard works to automation.
–
Creation of custom workflows to reduce errors/decrease turn around time.
–
Creation of vertical applications within ST STAR AR-C
M+
–
Support of the customized work, wit ithout ma main intenance ce fees. s.
ü The workflows can extend past STAR-
CCM+ to perform complex multi-step analyses.
ü Custom Tools ensure that best practice
meshing and physics are respected at all steps in the process.
SLIDE 3 CD-adapco’s CAE Custom Tools in Industry
Build ildin ing a clie client base se where re so sophist istica icated analysis lysis needs s to mig migra rate to st standard rd pro roduct ctio ion work. rk.
lients s that are re lo lookin king to push sh analysis lysis clo close ser r to desig sign to sa satisf isfy y busin siness ss re require ireme ments. s.
cing turn rnaro round time imes s thro rough automa matio ion:
icker r re resu sult lts s (4 (4-1
x sp speed up fro rom m CAD AD to re resu sult lts) s)
Error r fre ree re report rtin ing
ility y (Mo (Modif ifica icatio ions s and Comp mpariso risons) s)
OCUS O
ON T THE
HE E
ENGINEER
EERING P
PROBL
BLEM EM
SLIDE 4
“STAR-CCM+ Pipeline”: From Concept to Results
SLIDE 5 STAR-CCM+ Java API
- STAR-CCM+ automation is extensible.
– The JAVA API also allows for external coding for automation
tasks outside of STAR-CCM+.
» Integration with CAD systems (direct downloads without files) » Creation of management ready reports from analysis » Creation of a customized and streamlined GUI – All Java libraries are available through automation within
STAR-CCM+
» Link with other APIs
- Microsoft Office Documents
- Web Based Connectivity
» Everything JAVA can do, STAR-CCM+ can do. » CAE Custom Tools is the World’s Expert in Automation
SLIDE 6
GUI GUI
STAR-CCM+, Automate the entire workflow
Run: Me Mesh sh/So Solve lve/Po Post st Output: Output: Input: Input: Run: Me Mesh sh/So Solve lve/Po Post st “C “Cust stom m Tool” l”
SLIDE 7 Paint Dipping Tool
»
VOF (Volume of Fluid) Multiphase Analysis
»
Transient Mesh Motion
»
Specialized Post Processing
»
Technician-Level Users
SLIDE 8 Paint Dipping Challenges Issues with Dip or Immersion Coating
Can’t drain quick enough Leads to contamination Forms a bubble or void No coating
SLIDE 9 Paint Dipping Workflow – What they wanted….
virtual l pain int dip ip pro roce cess ss
Setup sp specia cial l post st pro roce cessin ssing to visu visualize lize the pro roble lems. ms.
“what-if
” sce scenario rios s wit ith ease se.
SLIDE 10
Paint Dipping Tool – How they got it.
SLIDE 11 Liquid Hold up – 2010 Baseline vs. Modified
Mo Modif ifie ied wit ith Sid Side hole les s Ba Base selin line
SLIDE 12 Water Jacket Design Tool
»
CAD Based Tool. Direct CAD->PPT
»
Excel Driven Routine
»
Ability to create 100s of runs with just Excel or a Text Editor
»
Designer-Level User with Expert-Level switches
SLIDE 13
Water Jacket Design Tool
SLIDE 14 Water Jacket Design Tool
Imp mport rt/Org rganize ize CAD AD
- 1. Import to 3D-CAD
- 2. Imprint all bodies
- 3. Transfer to geometric Parts
- 4. Automatically create regions, boundaries and interfaces
SLIDE 15 Water Jacket Design Tool
Report rtin ing
- Management ready presentation and spreadsheet.
SLIDE 16
Water Jacket Tool Animation
SLIDE 17 Heat Exchanger In-Situ Design Tool
»
Complete CAD -> PPT Workflow
»
GUI-Based Vertical Application with Excel Sheet Data Support
»
Allows Heat Exchanger Designers to run full vehicles with no knowledge of full vehicle CFD
»
Designer-Level User or Expert Level User
SLIDE 18
Vehicle Thermal Management Automation.
Skin Cooling Module Excel file Custom GUI
SLIDE 19
One place to put all of the data…
Dual-st l-stre ream m heat exch xchanger r mo model: l:
SLIDE 20 Ø Detail il GUI Deve velo lopme ment
§ Me Mesh sh Se Setup GUI § Condese ser r Se Setup GUI § Interco rcoole ler r Se Setup GUI § Radia iator r Se Setup GUI § Fan Se Setup GUI § Po Post st-p
roce cessin ssing (N (No Me Menu) )
Additional GUI Development to Support the Input
SLIDE 21 § Me Mesh sh le leve vel l se setup for r use ser r § Ve Vehicle icle skin skin me mesh sh size size § Coolin ling mo module le me mesh sh size size
Mesh Setup GUI
Leve vel l 1 Gro roup Leve vel l 2 Gro roup CAD AD Pa Part rt List ist Leve vel l 3 Gro roup Leve vel l 4 Gro roup
SLIDE 22
Heat Exchanger In-Situ Custom Tool Animation
SLIDE 23
Ø Code Va Valid lidatio ion
§ Ve Vehicle icle in inclu cludin ing in interco rcoole ler r è è Ve Vehicle icle: XX XX
Results: Validation
SLIDE 24 Intake Port Modeler Tool
CAD CFD
…
»
CAD Based Tool. Direct CAD->PPT
»
Sophisticated Vertical Application
»
Specialized Multi-step workflow
»
Designer-Level User
SLIDE 25 Intake Runner and Port Development
Example
Intake Manifold Mass flow rate (g/s):
Baseline
Tumble index:
Baseline Iteration 1 Iteration 11 Iteration 6 Iteration 5
The CFD auto-t
l allo llows s the desig signer r to ru run the analysis lysis and re revie view the re resu sult lts s ve very ry quickly ickly (< (< 1/2 day) y)
CAD CFD
… Goal: Maximize flow with acceptable level of mixture motion
SLIDE 26 Mesh Solve Calculate Data and Create Images Output to Excel & PPT Move Valve CAD Import CAD Surfaces Create Rig Geometry Visualize flow field in plots to understand design changes
The Port Flow CFD Analysis Workflow
SLIDE 27
Customized Port Flow Analysis Tool
SLIDE 28
Intake ke Po Port rt Tool l An Anima imatio ion
SLIDE 29 Fuel Rod Analysis Tool
»
Automatic Handling of CAD Geometry
»
Dramatically Reduces Click-Intensive Workflow
»
Allows Atomic Level Detail on Rods and Spacer Grids
- Individual Rod Selection
- Intra-Rod Selection via “Banding”
»
Automatically Apply Reports to any Level of Detail
»
Turnaround Time Reduction from Weeks to Only Days
SLIDE 30 Fuel Rod Fretting Challenges
- Flow Induced Vibration (FIV) “Fretting”
Causes Damage to the Fuel Rods
- Difficult to Predict Where This Will Happen.
- Fuel Bundle Can Be 9x9 or More.
– Many Rods, Long Axial Distances
- To Find the Position of FIV, One Needs Many
Data Points, and Many Reports.
- CAD Data is not Typically Setup for this Type
- f Analysis
– Many Times, the Fuel Bundle is One Body
- Need an Automated Process to Split CAD
and Make Many Slices or “Bands” of Each Fuel Rod.
SLIDE 31 Fuel Bundle Needs to be Split Automatically
reate a simp simple le GUI to Input Data Ab About the Fuel l Bu Bundle le
Automa mated Tool l will ill Sp Split lit the Fuel l Rods s Individ ividually lly wit ith no Use ser r Intera ract ctio ion.
SLIDE 32 “Super Bands” are Needed to Cut Through the Fuel Bundle
ser r Defin ines s “Su “Super r Ba Bands” s” that Cut the Fuel l Rods s in into Sp Specia cial l Gro roups. s.
mber r of Ba Bands s ca can be Use ser r Determin rmined.
se ca can be use ser r cu cust stomize mized base sed on the Sp Space cer r Grid rid lo loca catio ions s
SLIDE 33 “Selection Sets” are Defined for Reports
ser r Defin ines s Se Sele lect ctio ion Se Sets s Ba Base sed
l Rod Grid rid, Su Super r Ba Band Loca catio ion, and Individ ividual l Ba Band Loca catio ion.
ser-F r-Frie riendly ly Name mes s are re Ap Applie lied to these se Se Sele lect ctio ion Se Sets. s.
Sele lect ctio ion Se Sets s will ill be use sed for r Report rts s
SLIDE 34 “Selection Sets” are Defined for Reports
rts s are re Genera rated Usin sing Se Sele lect ctio ion Se Sets s Inst stead of CAD AD Bo Boundarie ries. s.
Any y Report rt ca can be Use sed (F (Force rce Report rt, Near-R r-Rod Ve Velo locit city, y, etc. c.) )
SLIDE 35
Fuel Rod Analysis Animation
SLIDE 36 Summary
- Custom Tools builds GUIs and batch tools to workflow
specifications.
- Clients see turnaround times reduce 4-10x.
- Repeatable and Consistent Results.
- Focuses the general functionality of STAR-CCM+ into a
documented, verified, and experimentally valid tool.
- CAE Custom Tools has a Proven Track Record in
Industry and is growing at 56% 2011 - 2012
SLIDE 37
Yo Your r Pa Part rtner r For r Su Succe ccess ss
