Enabling Advanced Vehicle Heat Protection Through the Digital Prototype Frederick J k J. R . Ross Di Director, Gr , Ground nd T Trans nsportation n
Agend nda STAR-C -CCM+ De Designe ned f for V Vehi hicle le H Heat P Protection n Over 25 years of experience STAR-CCM+ Design Focus on VTM Benefit of Siemens Automa mation t n tools ls t to he help lp r reduce t turn-a n-around nd t time me Vsim: Automating Front End Air Flow C2M: Automating Component Modeling Case S Studies
STAR-C -CCM+ F For V Vehi hicle le T The herma mal M l Mana nageme ment nt v2.0 was first enabler using client-server with mesh generation STAR-CCM+ V2: 2006 1 1 1 1 Solv lver T Team m Mesh De h Develo lopme ment nt T Team m Go Goals ls New Client Server Surface Wrapping: Clean Surface 2 2 1 1 Robustne ness 1 1 Job needs to run with minimum Cell Quality Remediation 1 1 2 2 Bring in CAD Tree user interaction. 3 3 Heat Exchanger Models Imprint/Boolean Operations Reduce T Turn A n Around nd 2 2 Automation 2 2 Ease-of-Use Fast S2S Radiation Thin Mesher 3 3 3 3 Quick Modifications Accuracy y 2 2 Shell Conduction 2 2 Parts Based Meshing 3 3 Need to simulate real world test conductions 2 2 Co-Simulation Parallel Trimmer 2 2 Parts Based Profile 2 2 2 2 Concurrent Meshing STAR-CCM+ V11: 2016
Vehi hicle le T The herma mal M l Mana nageme ment nt M Maturity R y Roadma map Level 1 l 1 Level 2 l 2: S : Simu mula lation o n of S Sys ystems ms Level 3 l 3: V : Virtual P l Prototyp ype • Fully automatic • Automating Procedures • Working from CAD to Simulation • Single or Dual Stream • 40-400 Solids + Radiation • Simulating Systems: Solids/Fluid • No Solid Modeling • 4000 + Solids with Radiation & co-sim • Fast turn-around time Full Vehicle Thermal Management • 4000+ solids 5 • Coolant/Oil etc • Drive Cycle Simula?on Exhaust System CHT • 100-400 Solids 3 • Radia?on & CHT • Heat Shield Design/ Placement Brake Cooling • Radia?on & CHT Power Train Cooling 2 • Engine CHT • Rota?ng Parts/Fric?on Hea?ng 4 • Coolant • Op?mize Cooling • Oil, Intake/Exhaust Flows Front End Air Flow 1 • Top Tank Temperature Predic?on 1 1 2 2 3 3 4 4 5 5 Complexity
Ge Gene neration o n of a a Di Digital P l Prototyp ype twin Producing a a d digital t CAD Da D Data F Freeze d define nes d digital p l prototyp ype Damping force F – As with a real prototype, design teams work together to 3000 meet a goal for the design freeze. 2500 Grade 1 2000 1500 Grade 2 – Review board checks, to make sure all components are 1000 500 0 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 Deflection speed v fitted together and data pool is complete. Geometrical Data Functional Data Data Filter: Filters data for simulation – Data needed for simulation is filtered from the overall data pool, and provided for the virtual simulation. • Key component for data transfer – PLM (product lifecycle management) tools enable communication between different tools. Analysis Response – Feeds back into the data pool for design improvement.
Sieme mens ns P PLM S Software + + C CD-a D-adapco: : Market L Leader i in S n Sys ystems ms Dr Driven P n Product De Develo lopme ment nt The he c cle lear le leader a amo mong ngst P PLM s solu lution p n providers i in s n simu mula lation a n and nd t test s software, a , and nd a associated s services. . § Computational Fluid Dynamics (CFD), Computational Solid STAR-C -CCM+ Mechanics (CSM), heat transfer, particle dynamics, reacting flow, HEEDS DS electrochemistry, acoustics and rheology. Optima mate § Multidisciplinary optimization and design space exploration SPEED D § Electric machine simulation and design BDS DS § Behavioral simulation: 1D cross-discipline simulation, like mechanical Virtual.L l.Lab and electrics, e.g. fuel economy & range simulation for hybrid vehicles Samt mtech h § 3D mechanical simulation: e.g. stiffness, noise, vibration § Testing: Solutions for prototype testing (stationary & mobile) Ima Imagine ne.L .Lab Test.L .Lab § Streamlines and accelerates the product development process in a NX C X CAD D collaborative environment NX C X CAE § Includes a modern, multi-discipline CAE environment Nastran n Teamc mcent nter Tecno noma matix
Ge Gene neration o n of a a Di Digital P l Prototyp ype twin Producing a a d digital t TeamC mCent nter Damping force F Allows user to sort throw CAD, pick assemblies to be modelled 3000 Export PLMXML data with JtOpen 2500 Grade 1 2000 1500 Coarse/Medium/Fine Tesselation Grade 2 1000 500 0 Brep: Passing geometry 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 Deflection speed v Material Properties linked to parts Geometrical Data Functional Data AmeSim 1D tool for modeling cooling circuit Helps predicting top tank temperature STAR-CCM+ Read CAD and prepare mesh for simulation Simulate 3D flow field Post results
STAR-C -CCM+ W Workf kflo low Computational Process & Tools • Parasolid Files • Team Center Interface • STL Data CAD Import exhaust coolant oil • Setup air stream through engine compartment • Define zones for heat exchangers/fans Front End Air • Connect to 1D tools for coolant circuit if needed convection Flow conduction • CAD cleanup • Build Interfaces between parts • Concurrent meshing Solid CHT radiation • Parallel Surface-2-Surface RadiaPon • Solids run full thermal transient driving cycle 1D thermal network Co- • Fluid either steady or transient simulaPon So Source rce: M. M. Disch isch ( (upco comin ming Ph Ph.D thesis sis, FKF KFS) S) 8 8
Front End Air Flow Workflow Import CAD Separate region for fan/heat exchangers Underhood Regions: Group surfaces for underhood region Separate by mesh and physics size: Set prevent contact for important gaps Close large holes? Use gap closure/anti seed point to prevent leakage into main cabin Wrap Region Setup heat exchanger/fans: Create interfaces for sub-regions Wrap fan region, if needed. Just remesh heat exchangers Create physics continua (including material properties) Create all reports, monitors, plots for monitoring convergence Use parallel trimmer to reduce mesh generation time. Page 9 April 3, 2014
2 Solid Conjugate Heat Transfer Model Goal Go l Predict lo local c l compone nent nt t temperature Typ ypical A l Appli lications ns Components Surrounding Exhaust Brake Cooling Important Im nt P Phys ysics Convection Conduction Radiation Solu lutions ns Convection: Vsim Conduction: Parts Based Meshing Framework C2M: Cad to Mesh Tool Radiation: Parallel Surface-to-Surface
Solid Conjugate Heat Transfer Workflow Import CAD Check CAD Check fit and completeness multiple components per leaf-level part and split into separate parts Check for duplicate parts and tag / delete Repair CAD problems Extrude parts without thickness Clean CAD surface errors (pierced faces, free edges, non-manifold) Replace or fix gross non-fitting CAD Wrap poor quality parts Boolean subtract all intersecting components Split part surfaces at special internal BC locations Create physics continua Apply physics to regions Set material properties for each region Apply all radiative surface properties to boundaries Create all reports, monitors, and plots for monitoring convergence Mesh using parts based meshing to allow multiple pipelines Enable concurrent meshing to reduce meshing time April 3, 2014
Agend nda STAR-C -CCM+ De Designe ned f for V Vehi hicle le H Heat P Protection n Over 20 years of experience Focus of STAR-CCM+ since version 2.0 Benefit of Siemens Automation tools to help reduce turn-around time Vsim: Automating Front End Air Flow C2M: Automating Component Modeling Note: Case S Studies The automaPon tools can be provided by CD-adapco as examples for clients to use. They are maintained for each release, and as long as they are maintained, clients can get updated.
VS VSim: A : Aero/The herma mal A l Automa mation n 1 1 STAR-CCM+ reading setup information directly from excel Automa mated P Process f from C m CAD t D to R Report Reads CAD from subdirectory Spreadsheet Contains Settings • CAD Grouping to CFD Boundaries • Heat Exchanger/Fan Information • Thermal Boundary Conditions Input: Cad/Exce Excel l Run: Me Run: Me Mesh Mesh sh/So sh/So Solve Solve lve/Po lve/Po Post Post st st Output: Po PowerPo rPoin int
VS VSim: A : Aero/The herma mal A l Automa mation n 1 1 STAR-CCM+ reading setup information directly from excel • OperaPng CondiPons 1 • Group CAD to Boundaries 2 • Mesh SeYngs 3 • Fan/Heat Exchanger ProperPes 4 • Monitors and Post Processing 5
2 Automa mation: C n: C2M T Toolb lbox Che hecks ks S Surface f for e errors Repair p parts w with s h severe e errors Move into surface repair Alternatively wrap/replace part Gene Ge nerate V Volu lume me me mesh h Sets up parts based meshing tree Find nd a and nd Ge Gene nerate Int Interfaces b between n compone nent nts
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