fan system simulation with hypermesh and acusolve solutions
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Fan System simulation with HyperMesh and AcuSolve solutions
6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
Manuel Henner, Bruno Demory, Serge Mondon, Ming Ma, Elias Tannoury
Valeo Thermal Systems, France
Youssef BEDDADI
CFD Engineer
VALEO Thermal System, France
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Fan System developments driven by numerical simulation
Shorten development cycle by virtual prototyping
Offer engineers a reliable tool for design and analysis
Detailed simulation with actual geometry
Willing to develop multi-physics and multi-objectives studies
Standard Valeo Single Fan System
Thermal - Mechanics
Aerodynamics - Acoustics
Rheology
Electronics
Industrial Background An automotive engine cooling fan system
6th European ATC - April 22-24th, 2013 - Turin, Italy
Start
End of the project
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Fan system simulation with ALTAIR Platform Motivations and Objectives
6th European ATC - April 22-24th, 2013 - Turin, Italy
Motivations
Replace current highly integrated numerical methods by ALTAIR methodologies
Communalize tools for several kind of numerical applications (CFD, FEA, etc…)
Reduce license fees with common tools between various R&D teams
Objectives
Investigate solutions offered by ALTAIR for CFD (HyperMesh, HyperView,
AcuSolve)
Test and assess benefit of the platform to implement automation
Evaluate openness of the platform (OpenFoam)
OTHER CFD Softwares
…. AUTO
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Outline
Automated process with ALTAIR Platform
Standard fan simulation process and alternatives
Automation : Batch and scripting
Automated meshing process (HyperMesh)
Pre-processing (Acuconsolve) and solvier (AcuSolve) automation
Automated process for post-processing (HyperView)
Numerical simulations for Fan Systems
Simulation set-up
Comparison between CFD and experimental results
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2
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6th European ATC - April 22-24th, 2013 - Turin, Italy
Automated process
with ALTAIR Platform
6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
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Automated process with ALTAIR Platform Standard fan simulation process and alternative
Standard Automated Process
CATIA AcuConsole AcuSolve HyperView
HyperMesh OpenFoam ParaView
Alternative Automated process
Automation :
Batch and Scripting
6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
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Batch and scripting in ALTAIR Platform
6th European ATC - April 22-24th, 2013 - Turin, Italy
CATIA
Model.nas
HyperMesh
Mesh.inp
AcuConsole
AcuSolve
HyperView
Performance Prediction
OpenFoam …
Script TCL
Script PY
Batch
Automated process for test rig fan simulation
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Easy scripting and automated volume mesh
Under HyperMesh graphical user interface, activity is recorded in the "command.cmf" file
All the commands recorded and transferred in TCL (Tool Command Language)
Commands can be used without GUI to generate meshes for other geometries with the
same meshing strategy (same grid density, same wall treatment, same volume mesh
domains…)
Batch and Scripting Automated meshing process (HyperMesh)
6th European ATC - April 22-24th, 2013 - Turin, Italy
HyperMesh Mesh
Number of
tetrahedron
87,763,903
Element in INLET 7,133,234
Element in MRF 64,499,930
Element in
OUTLET
16,130,739
Mesh Size (standard parameters to
keep the mesh density constant)
Automated cells extrusions for boundary layer
(same wall treatment for all simulations)
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Volume mesh parameters
Thickness of the first layer, the growth ratio
between 2 tetrahedral layers and the number of
boundary layer.
Openness and automated export
Several types of format possible, including AcuSolve
Easy change for switching solvers, and benchmark different
solutions.
Batch and Scripting Pre-processing (AcuConsole) and solving (AcuSolve)
6th European ATC - April 22-24th, 2013 - Turin, Italy
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Automation process in AcuSolve
AcuSolve commands scripted in Python language
Easy process with only 3 functions:
"usrRunInput“ : Import HyperMesh file
"usrRunHeliceProblem“ : Set the boundary conditions in AcuSolve, solver
parameters, numerical models…
"usrRunAcuSolve" : set the number of processor, generate input file and
launch AcuSolve.
Automation process in HyperView
Same process as HyperMesh with recorded operation
6th European ATC - April 22-24th, 2013 - Turin, Italy
Batch and Scripting Automated process for post-processing (HyperView)
Numerical simulations for
Fan System
6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
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Domain of simulation
Coarse and fine mesh (10 Mo. and 87 Mo. Cells)
K-Omega SA and SST (Menter) turbulence model
HyperMesh and AcuConsole mesh for AcuSolve
RANS simulation
6th European ATC - April 22-24th, 2013 - Turin, Italy
Numerical Simulation for Fan System Simulation set-up
Full outlet domain for
atmospheric conditions
Test rig facility with torque-meter Plenum (mass flow imposed)
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No simplification for tiny details (underhub ribs, tip
clearance, connecting radius)
Cell extrusion at wall boundary (anysotropic layer)
Densification in region of interest
6th European ATC - April 22-24th, 2013 - Turin, Italy
Numerical Simulation for Fan System Meshing strategy with HyperMesh
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Numerical Simulation for Fan System AcuSolve simulation
Flow Rate = 2797 m3/h
Flow Rate = 3996 m3/h
800 m3/h 2800 m3/h 4000 m3/h 5200 m3/h
Turbomachinery post-processing
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Numerical Simulation for Fan System Open Foam simulation
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Numerical Simulation for Fan System AcuSolve and Open Foam simulation (Coarse mesh)
8,5 millions of tetrahedron
kw SST for turbulence model
Meshing available for different softwares
Good prediction for both solvers
Some improvement to bring at low flow rate
AcuSolve OpenFoam Experiment
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Numerical Simulation for Fan System AcuSolve with AcuConsole or HyperMesh
AcuSolve_Hy permesh AcuSolve_AcuConsole Experiment
87,7 millions of tetrahedron
kw SST for turbulence model
Excellent prediction on torque
Improvement on pressure rise, difference under
investigation
Equivalent results for different mesh types
Conclusions and
perspectives
6th European ALTAIR Technology Conference - April 22-24th, 2013 - Turin, Italy
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Conclusions and Perspectives
Achievements
Fan system simulation tested with ALTAIR numerical tools, and a
fully automated process was quickly implemented
HM and HV successfully used for CFD (as for other physics :
mechanics and rheology). Possibility to share common tools
between different R&D teams
Platform easily customizable for connection with other software
(OpenFoam for instance), and comparisons between different
numerical processes has been done
AUTO
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Conclusions and Perspectives
Still on progress
Improve meshing process within
small gaps (see tip clearance)
Generalyse best practice for
CFD mesh, with small growth
rate ratio
Further tests to be conducted
with AcuSolve for unsteady
simulation and aeroacoustic
purpose