topology-optimization for internal fluid flow: tosca fluid · 2012-08-21 · tosca fluid –...

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Topology-Optimization for internal Fluid Flow: TOSCA Fluid



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CFD topology optimization for channel flow

Task: Find a geometrical proposal for a channel within a fluid design space:

Outflow

Inflow

?

For each fluid cell decide:

“Should this cell belong to the channel or not?”

� Each fluid cell is a design variable!

� Millions of design variablespossible

� General optimization schemes

are not feasible...



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� Redesign Rule: Elimination of local

backflow and recirculation by blocking

out of backflow areas

� provides an “optimization” approach

by means of “improvement”

� The Optimality Criterium is to avoid

flow recirculation

OC-based Topology Optimization

� An achieved consequence is (for

many technical flows) a reduction of

pressure drop



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• Meshing “as usual”

Design Space

Topology optimization with TOSCA Fluid

• Define the Design Space (e.g. CAD)

Outflow 1

Outflow 2

Inflow

• Define your Boundary Conditions

• Run the Optimization



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Design Space

Outflow 1

Outflow 2

Inflow

Optimized Channel Shape

Prevented Flow

Free Flow

Transition Area

(defining new channel shape)



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� Direct run time communication with

the CFD solver

� Only one single CFD

solver-run for complete optimization process

�� suitable for large real world applications


CFD Solver Solution Process

TOSCA Fluid Optimization

Time resp. Iteration

Optimization

and

Flow Result

Shared-Memory



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TOSCA Fluid – Result Reconstruction Methods

Optimization result and

Designspace

STL-Surface

IGES-Cuts CAD-Reconstruction based

on IGES-Cuts



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TOSCA Fluid – Graphical User Interface



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TOSCA Fluid – Example Projects

� EGR-Cooler:

� Pressure Drop Reduction: 20%

� Efficiency Enhancement: 11 %

� Engine Air Intake / Filter System:


� Flow Uniformity Enhancement: 56%

� Intercooler Intake Hose:


� Commercial Vehicle HVAC Duct:

� Pressure Drop Reduction: 25 %

� Flow Split Enhancement: 6%

� ...

Courtesy Opel



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TOSCA Fluid – Feature Overview

� TOSCA Fluid.topology Version 2.2 features

� Reduction of flow recirculation and vortices by topology optimization of the flow domain

� Reduction of the pressure drop and related phenomena

� Efficient, fast optimization by direct runtime coupling of the

optimization to the CFD solver

� Support of

� STAR-CD V4.0x solver with .ccm / .ccmg databases

� STAR-CCM+ V6 solver

� ANSYS Fluent V12 solver

� Parallel operation support

� GUI and pre/post processing interfaces

� LinuX x86_64 Support



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TOSCA Fluid Key Notes (1)

� New and unique technology for fast and

efficient topology optimization of internal

fluid flow systems

� Simulation driven design, fast and easy design optimization impacting all

development stages

� Use of your favorite CFD-solver and existing models for optimization, no

parameterization necessary

� Unmatched efficiency for large, real world industrial applications

� High innovative strength due to new and potentiality inspiring designs and large

solution spaces

Optimization

process

Resulting design proposal

(60% less pressure drop

compared to a standard design)



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TOSCA Fluid Key Notes (2)

� Based on Daimler Technology

� Technical and support hotline by experienced

CAE and optimization staff

� Easy setup of optimization problems using

the graphical user interface (GUI)

� No model parameterization is required

� Straight forward pressure drop reduction

(noise diminution), flow homogenization and several other optimization tasks

� General reduction of development time and

development cycles which saves your costs

New conceptual

Design, ∆p ↓26 %

initial Design

available Designspace

Optimization

topology-optimization for internal fluid flow: tosca fluid · 2012-08-21 · tosca fluid –...

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