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www.comsol.com 2016
FROM STUDENTS
TO ENTREPRENEURS
University at Buffalo
PAGE 32
Rocket System
Combustion Instability
Modeling at NASA
PAGE 8
COMSOL .COM 1
CONTENTS
I'd like to thank all of the COMSOL users who contributed their
stories for sharing their expertise and striving for excellence in
their work. PRODUCT SAFETY & QUALITY
Enjoy your reading. 12 Giving Furniture Testing a Leg Up
ELECTRONICS COOLING
14 Increasing Productivity and
Valerio Marra Revenue with Computational
Technical Marketing Manager
COMSOL, Inc.
Applications
ENERGY TECHNOLOGIES
INTERACT WITH THE COMSOL COMMUNITY
18 Improving Gas Pipeline
Squeeze-Off Standards with
Numerical Simulation
COMSOL, Inc. COMSOL Multiphysics @COMSOL_Inc google.com/+comsol
BLOG comsol.com/blogs
FORUM comsol.com/community/forums
COMSOL
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are either registered trademarks or trademarks of COMSOL AB. All other
ON THE COVER
trademarks are the property of their respective owners, and COMSOL AB and
The Atlas V rocket launching from Space Launch
NEWS
its subsidiaries and products are not affiliated with, endorsed by, sponsored
by, or supported by those trademark owners. For a list of such trademark
Complex 41 at Cape Canaveral Air Force
owners, see www.comsol.com/trademarks. Station in Florida, USA. Image Credit: NASA/
Bill Ingalls.
The IN logo is a registered trademark or trademark of LinkedIn Corporation
2016 and its affiliates in the United States and/or other countries. The 'f' logo is a The National Aeronautics and Space
Administration (NASA) does not endorse the
registered trademark of Facebook, Inc. The bird logo is a registered trademark
of Twitter, Inc. The G+ logo is a trademark of Google, Inc. COMSOL Multiphysics software.
BUILDING PHYSICS
24 Shake, Rattle, and Roll
8
Structural Integrity in High
Performance Nuclear Fusion
Machines for Power Generation
TECHNOLOGY ENTREPRENEURSHIP
32 Promoting Industrial Innovation
with Custom Simulation Apps
35
BUILDING PHYSICS
Multiphysics Analysis Helps
Preserve the Past
4 32
ELECTRONIC PACKAGING
38 Thermal Characterization of an
Electronic Device with a Custom App
GUEST EDITORIAL
40
18
COMSOL Multiphysics Brings
Innovation to Academia and
Industry
COMSOL .COM 3
ABB CRC, SWEDEN
by LEXI CARVER
F
or everything from cooking Among this equipment are power But transformers come with noise,
to charging our phones, we transformers for increasing and often manifested as a faint humming
rely every day on the electrical decreasing voltage levels in power lines or buzzing that can be heard when
grid that powers buildings like that carry alternating current (see Figure walking nearby. Although it is
homes, businesses, and schools. This 1). Power transfer with higher voltages impossible to completely silence them,
complex network includes stations results in lower losses and so is more regulations require adherence to safe
generating electric power, high-voltage desirable for transporting power long sound levels, and good product design
transmission lines that carry electricity distances. However, such high voltage can minimize these acoustic effects.
across large distances, distribution lines levels would pose a safety hazard at One of the biggest manufacturers
that deliver power to individual homes either end of the lines, so transformers of transformers used around the
and neighborhoods, and the related are used to increase voltage levels at the world, ABB (headquartered in Zrich,
hardware used for power flow control power feed-in point and decrease them Switzerland), has used numerical
and protection. close to neighborhoods and buildings. analyses and computational applications
through the windings of one coil creates CRC) in Vsters, Sweden needed to
a magnetic flux that induces current in understand the inner workings of their
an adjacent coil. The voltage adjustment transformers in order to optimize their
is achieved through different numbers designs for minimal transformer hum.
of coil turns.
Because the core is made of steel, COUPLING ACOUSTIC,
a magnetostrictive material, these MECHANICAL, AND
magnetic fluxes which alternate ELECTROMAGNETIC
direction cause mechanical strains. EFFECTS ALL IN ONE
This generates vibrations from the quick We chose to work with
growing and shrinking of the metal. COMSOL Multiphysics because it
FIGURE 1. Photo of transformer equipment
These vibrations travel to the tank allows us to easily couple a number
for high-voltage power lines.
walls through the oil and the clamping of different physics, said Mustafa
points that hold the inner core in place, Kavasoglu, scientist at ABB CRC. Since
creating an audible hum known as core this project required us to model
in order to predict and minimize the noise (see Figure 2, bottom). electromagnetics, acoustics, and
noise levels in their transformers. In addition to the core noise, the mechanics, COMSOL software was
Through the COMSOL Multiphysics alternating current in the coil produces the best option out there to solve
simulation software and its Application Lorentz forces in the individual for these three physics in one
Builder, they have run virtual design windings, causing vibrations known as single environment.
checks, tested different configurations, load noise that add to the mechanical Kavasoglu; Dr. Anders Daneryd,
and deployed their simulation results energy transferred to the tank. principal scientist; and Dr. Romain
through customized user interfaces built With these multiple sources Haettel, principal engineer, form
around their models. of noise and the interconnected the ABB CRC team working with
electromagnetic, acoustic, and transformer acoustics. Their objective
SILENCING SOUND FROM mechanical factors at play, engineers at was to create a series of simulations
SEVERAL SOURCES the ABB Corporate Research Center (ABB and computational apps to calculate
Transformer noise often comes from
several sources, such as vibrations in the
transformer core or auxiliary fans and
pumps used in the cooling system. Each
of these sources needs to be addressed
differently to reduce noise.
ABBs transformers comprise a metal
core with coils of wire wound around
different sections, an enclosure or tank
to protect these components, and an
insulating oil inside the tank (see Figure
2, top). Passing alternating current
FIGURE 2. Top left: CAD model of the active part of a three-phase transformer with windings mounted around the core. Top right: The active part of a
power transformer that is placed in a tank filled with oil. Bottom: The energy conversion chain for core noise and load noise generation (magnetostriction
in the core and Lorentz forces in windings).
COMSOL .COM 5
CUSTOM APPLICATIONS | POWER TECHNOLOGY
FIGURE 4. Left: COMSOL software results showing levels of magnetic flux in the steel. Right:
Results showing the resonance of the core. Deformations are exaggerated for visibility.
FIGURE 3. Simulation results showing the
magnetic flux density (left) and Lorentz forces
(right) in the transformer coil windings.
These simulation applications simplify
these apps. testing and verification for the designers
Oracle and Java are registered trademarks of Oracle and/or its affiliates. COMSOL .COM 7
NASA, AL, USA
MULTIPHYSICS SOFTWARE
MODELS MEAN FLOW-AUGMENTED
ACOUSTICS IN ROCKET SYSTEMS
Combustion instability in solid rocket motors and liquid engines is a complication that continues to
challenge designers and engineers. The adoption of a higher-fidelity modeling approach supported by
multiphysics analysis provides greater insight and predictive ability.
by SEAN R. FISCHBACH
M
any rocket systems experience violent fluctuations in
pressure, velocity, and temperature originating from
the complex interactions between the combustion
process and gas dynamics. During severe cases of combustion
instability, fluctuation amplitudes can reach values equal
to or greater than the average chamber pressure. Large
amplitude oscillations lead to damaged injectors, loss of
rocket performance, damaged payloads, and, in some cases,
breach of case or loss of mission.
Historic difficulties in modeling by Sigman and Zinn3 by solving the COMSOL finite element framework to
and predicting combustion instability acoustic velocity potential equation model the steady flow-field parameters
have reduced most instances of rocket (AVPE) formulated by perturbing the of a generic liquid engine using the
systems experiencing instability to a Euler equations4. High Mach Number Laminar Flow
costly fix through testing (see Figure 1), Determining eigenvalues of the physics interface, which makes use of
or to scrapping of the system entirely. AVPE, where is the complex acoustic the fully compressible Navier-Stokes
potential, the complex eigenvalues, equations for an ideal gas together
depiction
A more complete
of
c the speed of sound, and M the
Mach vector,
with conservation of energy and
mass equations.
In order to account for the injection
combustion instability of hot gas due to the burning
oscillations is propellant, the injector face plate is
modeled with a uniform inward flow of
achieved when a combusted propellant gas (see Figure 2).
global energy-based is considerably more complex than the All other solid boundaries are modeled
assessment is used. traditionally used pressure-based with the slip boundary condition, and
wave equation, the exit plane is modeled with the
During the early development of hybrid outflow condition, which means
rocket propulsion technology scientists that both subsonic and supersonic flows
and engineers were cued to the and requires numerical approximations are supported.
underlying physics at play through the of the chamber flow field and Results from the mean flow analysis
measurement of vibrating test stands, eigenvalues. are reviewed to ensure a valid and
observation of fluctuating exhaust converged solution. Mean flow
plumes, and, most notably, the audible parameters such as pressure, density,
tones accompanying instabilities. These
MODELING CHAMBER velocity, and speed of sound are needed
observations lead the pioneers of
GAS DYNAMICS to model the AVPE. The values of the
combustion instability research to focus The latest theoretical models for mean flow in the converging section of
their modeling efforts on the acoustic oscillatory disturbances in high-speed the nozzle, near the sonic choke plane,
waves inside combustion chambers. flows require a precise determination are of considerable interest. The sonic
This focus on acoustics is quite logical of the chamber acoustic eigenmodes. plane, where the Mach number is equal
given that the measured frequency But first, a simulation of the mean flow to 1, creates an acoustic barrier in the
of oscillation often closely matches properties of the combustion chamber flow. In order to create an accurate
the normal acoustic modes of the must be performed. geometry for the acoustic analysis, the
combustion chamber. But this narrow COMSOL Multiphysics software sonic plane (pictured in magenta in
focus misses contributions made by provides a numerical platform for Figure 3) is extracted from the mean
rotational and thermal waves that are a conveniently and accurately simulating flow analysis.
direct result of, or closely coupled with,
the acoustic wave. A more complete MODELING CHAMBER
depiction of combustion instability ACOUSTICS
oscillations is achieved when a global The Coefficient Form PDE (Partial
energy-based assessment is used. Differential Equation) mathematics
Recent advances in energy-based interface of COMSOL Multiphysics
modeling of combustion instabilities is used to determine the complex
require an accurate determination eigenvalues of the AVPE. Mean flow
of acoustic frequencies and mode terms in the AVPE are supplied by the
shapes. Of particular interest are the solution from the mean flow analysis.
acoustic mean flow interactions within Gas dynamics within the combustion
the converging section of a rocket chamber play a key role in defining the
nozzle, where gradients of pressure, FIGURE 1. Pressure trace of a stable (red) boundary conditions for the acoustic
density, and velocity become large. The and unstable (blue) solid rocket motor1.
analysis. Within the converging and
expulsion of unsteady energy through diverging section of the rocket nozzle,
the nozzle of a rocket is identified as gradients of chamber pressure, velocity,
the predominate source of acoustic both the chamber gas dynamics and and density grow theoretically infinite
damping for most rocket systems. internal acoustics. This finite element at the sonic plane where the Mach
Recently, an approach to address software package provides many number is equal to 1. Downstream of
nozzle damping with mean flow effects predefined physics along with a the sonic plane, acoustic disturbances
was implemented by French2. This new generalized mathematics interface. are convected with the mean flow at
approach extends the work originated The present study employs the speeds greater than the speed of sound.
Originally published in the December 2015 edition of NASA Tech Briefs magazine. COMSOL .COM 9
COMBUSTION INSTABILITY | ROCKET PROPULSION
Mach 1 surface
FIGURE 3. Velocity streamlines plotted over chamber pressure. The Mach 1 surface is conditions, can now be more accurately
plotted in magenta.
modeled before testing.
PREDICT
THE BEST WAY TO
THE FUTURE
...IS TO
CREATE IT. ABRAHAM LINCOLN
Revolutionary Design
P R I N C I P A L S P O N S O R S C A T E G O R Y P R I Z E
S P O N S O R S S P O N S O R S
COMSOL .COM 11
CONTINUUM BLUE, UK
Giving Furniture
Testing a Leg Up
In the furniture world, quality standards rule. Chairs that pass a physical
test are permitted to be sold on shelves, while a failed prototype means
its back to the drawing board for the engineers who designed the chair.
by LEXI CARVER
FIGURE 1. Setup of the chair test. Overlaid,
geometry of the Continuum Blue chair model.
B
ehind every consumer product for testing different chairs. This would Permanent Cracking
that hits the market is an iterative allow them to virtually predict whether deformation along edges
& bending
process of designing, redesigning, a chair design would pass or fail prior to
prototyping, and testing that points to the physical testing stage.
the work of researchers, engineers, and Our customer wanted to explore
specialists ensuring that an object is whether they could develop simulation
ready for retail. To meet requirements applications for their test services,
Permanent
for safety and quality, manufacturers explained Dr. Mark Yeoman, director of deformation
must pass an assessment to verify that Continuum Blue. Their clients would be Surface cracking & excessive
Cracking where bending
their product can be sold in stores. able to log in remotely, upload various legs meet base
For a chair to be allowed on the chair designs, and virtually test each
shelves, this rigorous process involves one. Only once they were confident that FIGURE 2. Schematic showing crucial points in
the chair where failure typically occurs.
confirming that it will hold a persons a chair passed the virtual test would
weight, retain its shape, and not buckle they manufacture the design and send a
under certain conditions. A chair must sample to the test house.
survive thousands of cycles of repeated Such a test app would require a It must survive a lifetime without
loading over a lifetime and cannot diverse range of functionality. It would breaking, endure continued use with
suffer cracking, breaking, or bowing. have to incorporate the quality criteria, no cracking, and the legs should not
be intuitive and usable for engineers bend, splay apart, or bow too much. If
TEST HOUSES LIGHTEN and designers at all stages of the cracking occurs in the corners where the
THE LOAD FOR DESIGNERS development process, and be flexible legs meet the base, the chair will fail.
Because this testing process can be enough to test different chair models,
costly and time consuming for clients shapes, and materials. MEASURING UP TO THE
needing certification, an independent TESTING CRITERIA
assessment organization (a test SIMULATION PAVES The first part of the test is a Static
house) is striving to lessen the burden THE WAY TO QUICKER Load Test to see if the chair can hold
on companies involved in chair FURNITURE ASSESSMENT a certain maximum load, Yeoman
production. They test hundreds of Yeoman developed a numerical model explained. The test loads the chair over
different chairs every year, and each using COMSOL Multiphysics software a 20-second period, initially loading
design that fails to meet the European that would predict a chairs response to the base and then the back, to mimic
and American quality standards (EN, a standard loading test. His simulation a large person sitting down and then
BS, ISO, and ANSI standards) results in included the chair geometry, floor, leaning back. The second part involves
disappointment for chair producers and blocks to hold the legs in place, and a fatigue evaluation, where the chair is
thousands of dollars in design changes loading plates for the back and base to repeatedly loaded and unloaded over
and re-testing. mimic the physical test (see Figure 1). thousands of cycles. This is equivalent to
To reduce the burden on Ultimately, the question the the chair being used over many years.
manufacturers, a test house turned to simulation needed to answer for many Yeomans model analyzed the
Continuum Blue, a COMSOL Certified different designs was, will this chair fail deformation during a person sitting
Consultant helping companies develop under the required load? down, the mechanical stress, and the
numerical simulation apps, to create a A chair has to hold up to scrutiny in earliest and likeliest points of failure
tool the test house could offer clients quite a few areas, Yeoman remarked. (see Figure 2). The model also assessed
the contact pressure between the chair, contact problem: four points of contact regions of the chair will be highlighted
loading plates, and floor, and predicted between the chair legs and the floor, to let the user know that the chair is
number of cycles to failure (see Figure 3). then points between the seat and the yielding. If the stress rises above the
Setting up most of the model bottom loading plate, and the chair tensile strength of the material, then
was straightforward, he added. back and the back loading plate, the chair has some form of catastrophic
The structural mechanics, material he continued. We use the material material failure, such as cracking and
properties, and load parameters stiffness, yield stress, and coefficient of fracturing, Yeoman said. The app will
were relatively quick to implement in friction to help us accurately define the automatically show a pop-up window
COMSOL software. Many mechanical contact parameters. announcing that stress levels have gone
factors influence the pass or failure of above the material tensile strength and
a chair test, but the contact study was MAKING VIRTUAL the chair has failed.
the tricky part, as Yeoman explained: TESTING QUICK AND EASY This was exactly what the test house
Contact analysis is inherently complex; After completing and validating the had been looking for, an application
it is highly dependent on the material COMSOL model, the Continuum Blue that allows chair manufacturers and
properties of the contact surfaces, the team went on to build the customized designers to import their own chair
coefficients of friction, and is highly user interface, or application, that geometry, select materials, define
nonlinear in nature. would allow a user to quickly run virtual contact and loading conditions, and
There are several points of contact tests on chair designs by changing check the results against the test
that make this an inherently unstable certain inputs and parameters related to requirements to immediately see
geometry, load conditions, and whether the design would pass or fail
material properties. (see Figure 4).
We used the Application Builder Through a local installation of the
in COMSOL Multiphysics, Yeoman COMSOL Server product, Yeoman
commented. The Application Builder
allows the app designer to arrange
entry fields, results tables, buttons, This will give them
drop-down options, and graphics. the ability to virtually
The resulting app runs the full
simulation, but the user who may
assess dozens of
have no background in engineering or designs before
multiphysics modeling has access to deciding on a single
only the chosen inputs, not the model,
physics, or analysis underneath.
successful design to
For the test application we built prototype and test.
for our client, we wanted the user
FIGURE 3. Simulation showing deformation to be able to define various options, MARK YEOMAN, DIRECTOR AT
(left), stress (center), and contact pressure CONTINUUM BLUE
like nonlinear materials.
(right) for a single chair during loading. We parameterized all the
model features so that they was also able to distribute the app to
were fully linked, and when different users, allowing them to log in
someone changed one to a database and launch specific apps.
parameter the simulation The test house, in turn, intends to use
would update accordingly. COMSOL Server in the future for sharing
When the chair is loaded, test apps with their own clients all
stress levels are assessed over the world.
against the yield and tensile These apps will make it much
strength of the material. If it simpler for designers and test engineers
goes into permanent plastic to easily assess a chairs performance
deformation, the relevant before production and physical testing,
Yeoman said. This will give them the
ability to virtually assess dozens of
designs before deciding on a single
successful design to prototype and
test, knowing with confidence that it
will meet the test requirements of the
quality standards, reducing the time
FIGURE 4. The Continuum Blue app showing mesh and cost spent on building and testing
and input fields for a client to adjust according to their Mark Yeoman, Director at physical prototypes. v
design needs. Continuum Blue.
COMSOL .COM 13
ALTASIM, OH, USA
by JENNIFER SEGUI
COMSOL .COM 15
CUSTOM APPLICATIONS | ELECTRONICS COOLING
b c d
FIGURE 4. Log into COMSOL Server product using a browser. Then run HeatSinkSim from COMSOL Server in a separate browser tab or
window (a). Through the simulation application in (b), you specify the geometry, materials, and operating conditions. The app offers two levels of
analysis. Results from a Level 1 analysis (c) indicate that a Level 2 analysis (d) is recommended, which entails a full 3D conjugate heat transfer study.
customized functionality in easier since more people can run have or intend to have simulation
Java code methods that are run in simulations through an app. specialists on staff, you still have the
response to user input. If you recognize that you can option of outsourcing the model
Results from the HeatSinkSim app develop simulation apps that are and app development to COMSOL
are shown in Figure 4, demonstrating predictive and represent real-world Certified Consultants, such as AltaSim,
the two different levels of analysis that situations with real dimensions and or purchasing access to an existing
are available. A Level 1 heat transfer operational characteristics, then you can simulation app HeatSinkSim is just
analysis solves the conjugate heat also look at the number of potential one example.
transfer problem and includes fluid users that could benefit from simulation With simulation apps available to
flow with conduction, convection, and apps, says Crompton. There are an you and your colleagues, you can
radiation. Results are shown in one- estimated 80 million scientists and rely on highly accurate multiphysics
dimensional line plots of temperature engineers around the world that are models to predict the real-world
vs. design parameters, such as the potential users of computational apps, performance of your product or process.
number of fins in the heat sink. A Level compared to just 750 thousand that By improving your understanding and
2 analysis performs a more detailed heat are currently using computer-aided reducing the time and cost associated
transfer simulation for a more accurate engineering (CAE) tools." with prototyping, you can get your
three-dimensional solution, but takes Instead of running all of the innovative solution to market first.
longer to run. If temperatures reach the analyses themselves, which can create Returning to the example of heat
user-defined operating limits during an a workflow bottleneck, simulation sink design optimization for power
initial Level 1 analysis, a Level 2 analysis applications can help your simulation electronics, using HeatSinkSim offers
is recommended to the user specialists make time to develop a competitive advantage by improving
by HeatSinkSim. new tools and features that require access to simulation capabilities that
In planning your simulation-driven their expertise. In case you do not help to ensure that safe operating
workflow, it is important to consider
logistics such as who will set up and
validate the initial multiphysics model, There are an estimated 80 million scientists and
design the simulation app based on that
model, and ultimately perform design
engineers around the world that are potential
evaluation and optimization using the users of computational apps, compared to just 750
app. The ability to create an app based thousand that are currently using computer-aided
on a multiphysics model adds flexibility
and makes planning your workflow engineering (CAE) tools.
16 COMSOL NEWS 2016 Oracle and Java are registered trademarks of Oracle and/or its affiliates.
ELECTRONICS COOLING | CUSTOM APPLICATIONS
temperatures are maintained, and complexity, and desired solution time are HeatSinkSim, and then pay for the
consequently, continuous all factors to consider. If you would like features and time that they use. By
manufacturing operations. results as fast as possible, but without developing simulation apps, not only
the responsibility of managing hardware can you expand access to highly accurate
DISTRIBUTION AND or the related security concerns, a multiphysics modeling capabilities, but
REVENUE supercomputing center may be an pay-per-use access to apps can open
Providing the means to access and attractive option. up a new revenue stream for your
run simulation applications is just as To provide access to HeatSinkSim, organization as well.
important as deciding who will be AltaSim partners with AweSim, an
developing and using them to achieve organization that aims to strengthen A BETTER, FLEXIBLE
your design goals. Through a local economic competitiveness by PRODUCT DESIGN
installation of the COMSOL Server providing simulation-driven design WORKFLOW
product, your colleagues or customers capabilities to small and midsized The HeatSinkSim app by AltaSim is
can readily access simulation apps manufacturers. Behind AweSim is the not only an example of a solution to
through a COMSOL client or web Ohio Supercomputing Center (OSC), meet your design goals, but is also a
browser. Figure 4a shows a web browser which operates three major systems. product itself, developed and validated
with the Application Library for the HeatSinkSim runs on a node on the by experienced simulation specialists.
COMSOL Server installation, through Oakley cluster, which is an HP Intel By using the multiphysics modeling,
which you can launch the HeatSinkSim Xeon machine with more than 8300 application design, and distribution
app. AltaSim uses the dashboard to cores for parallel computation. By capabilities of COMSOL Multiphysics
manage app access and submitting a request to AweSim to use and COMSOL Server throughout the
feature availability. HeatSinkSim, you are provided with an product development cycle, you can
COMSOL Server is a product designed account at OSC, enabling you to log in bring simulation to everyone, adding
to run on anything from a standard remotely from a web browser on your flexibility to your workflow that can
laptop or desktop computer, to state-of- own computer to run the app on their improve quality and reduce risks and
the-art supercomputing clusters. When supercomputing clusters. costs, while delivering your best
choosing hardware that meets your Through the AweSim distribution possible product to market in a
specific needs, cost, availability, model method, users can first try out competitive timeframe. v
Executive Summary
Intel and Xeon are trademarks of Intel Corporation in the U.S. and/or other countries. COMSOL .COM 17
GAS TECHNOLOGY INSTITUTE, IL, USA
by BRIANNE COSTA
FIGURE 2. A simulation showing the total displacement (mm) of a pipe squeeze-off (left) and the
full simulation of the squeeze-off process (right).
COMSOL .COM 19
NONLINEAR STRUCTURAL MECHANICS | ENERGY TECHNOLOGIES
Since current oil spill cleanup and containment methods are often costly and operate
with only limited success, engineers at Amphos 21 have devised a numerical simulation
app for testing new cleanup techniques using hydrophobic meshes.
by LEXI CARVER
O
il spills are notorious
for being urgent and
unexpected, known for
the villainous damage they
cause to aquatic environments and
marine life, and must be contained
swiftly before they cause long-term
disaster. Techniques for containing
and recovering spilled oil are readily
available in the form of booms and
skimmers that collect it, but these rarely
fully rectify the problem. FIGURE 1. Concept of a hydrophobic mesh operation.
Booms are used to curb the spread
of oil into wider areas and keep the oil
from reaching sensitive coastlines. Some results in even more pumping after the capabilities available for the engineers,
designs absorb oil in an effort to remove cleanup attempts, in order to access the researchers, and cleanup crews seeking
it, while skimming techniques are also original amounts of oil. the appropriate response for a given oil
used to clear oil away. In other cases, In response to the need for cleanup spill scenario as they race against the
controlled fires burn oil off of the methods that prevent ecological disaster clock to stave off destruction.
water though this creates another and oil waste, Amphos 21, a consultant
pollutant or chemical dispersants are group specializing in environmental POTENTIAL FOR NEW OIL
added to the water to accelerate the technology, has developed numerical RECOVERY METHOD
breakdown of the oil components. models of hydrophobic meshes, a The meshes being studied at Amphos 21
These methods, while helpful, are concept for collecting spilled oil that are usually made of steel or copper and
not able to collect much of the oil is being studied by scientists and coated with a hydrophobic polymer to
during cleanup and are only effective if technologists. Their goal? An answer to repel water and attract oil. They act like
deployed very quickly to the site of the this quandary that would be fast, easy filters; water remains on one side, while
accident. Much of the oil sinks to the to use, and environmentally friendly. oil passes through (see Figure 1). The
seafloor. For instance, cleanup efforts After conceptualizing the rates of oil flux through the holes of the
after the 1989 Exxon Valdez oil spill hydrophobic mesh as a porous medium, mesh depend on the water depth, oil
off the Alaskan coast were unable to they developed computer simulations properties (which can vary depending
recover most of the oil. and custom applications to distribute on where the oil is pumped), and the
What is collected is often an oil-water to people in product development, coating on the metal.
mixture that is only partially usable. This disaster response, and environmental In addition to being an effective
means that in addition to the obvious organizations. Through simulation apps, option for clearing oil from the water,
environmental concerns, the wasted oil they intend to make virtual testing this offers the possibility of recycling
COMSOL .COM 21
CUSTOM APPLICATIONS | ENVIRONMENTAL ENGINEERING
FIGURE 3. COMSOL software results showing how oil flux through the mesh (left) and fractional water flow (center) vary with wire radius and
water depth. Pore analysis showing the relationship between fluid height, pore radius, and oil flux (right).
COMSOL .COM 23
NGI, NORWAY
Shake, Rattle,
and Roll
Norwegian researchers are tracking how
low-frequency sound waves travel within
buildings so that they can recommend
design adjustments to alleviate
annoying vibrations.
by JENNIFER HAND
A
nyone who has slept near an airport will know the
sensation an early morning flight wakes you We have never achieved
from sleep, not only because the engine is noisy but this level of agreement
also because everything around you seems to be with real-life testing
shaking. Likewise, people living near wind turbines, military before and it is all down
sites, or hospitals with helicopter landing pads often complain to how we were able
that windows rattle and everyday objects buzz when there is to model the different
external noise. More puzzling for them is the fact that even structural elements in
when they can discern no sound, they may still notice
COMSOL Multiphysics.
irritating vibrations.
If the response of the sound is 20 vibrations per second FINN LVHOLT, NGI
(20 Hz) or less, it is described as infrasound, meaning that
the original sound is not usually audible to the human ear. persists for longer distances. The amount of sound transmitted
The effects, however, are very easy to detect. As waves hit from the outside to the inside of buildings is greater. We are
windows, spread to the floor, and affect internal walls, they interested in what happens at the threshold of hearing,
induce a noticeable indoor vibration. Low-frequency sound explains Lvholt. We want to understand how sounds
waves are notorious for their potential to create from external sources interact with buildings and generate
annoying disturbances. vibration that is perceived by people. We can then recommend
countermeasures to prevent vibration and may be able to
LOW-FREQUENCY SOUND WAVES propose standard units that recognize the need to account for
IN BUILDINGS the annoyance factor.
Noise is part of modern life and there are formal standards
that use sound pressure level measurements to recognize SIMULATING THE SPREAD OF
high-frequency sound waves at levels of sensitivity, intrusion, SOUND WAVES
and danger for humans. According to Finn Lvholt of the Lvholt and his colleagues decided to create a computer
Norwegian Geotechnical Institute (NGI), the generation of model that would allow them to pick apart the mechanism
building vibration due to infrasound is an area of research of low-frequency sound waves hitting and penetrating a
that has not been explored extensively. For this reason, NGI, building. They used the COMSOL Multiphysics software to
an international center for research and consulting within simulate a wooden structure with two rooms separated by
the geosciences, has been running investigative programs for a wall (see Figure 1, top), closely mimicking the laboratory
several years on behalf of the Norwegian Defence experiment setup. Within the model, they assigned a
Estate Agency. loudspeaker to one room, a microphone to the other, and
Low-frequency sound encounters less absorption as it placed various probes around the structure in order to monitor
travels through the air than higher-frequency sound, so it sound pressure levels and vibrations. Every component was
explains that the motion of the wall and the sound pressure
level are the main quantities measured and results show very
close correlation to the COMSOL Multiphysics model (see
Figure 2). The response of the real wall is very clear and the
model mimics it almost perfectly. This is the most
spectacular aspect.
The model shows that the transmission of sound within
a building is governed by the way in which low-frequency
waves interact with the fundamental modes of the building
components, the dimensions of the room, and the way in
which air leaks from the building envelope. Vibrations in
ceilings and walls seem to be the dominant source of
low-frequency indoor sound, with floor vibration driven
by sound pressure inside the room.
COMSOL .COM 25
ORNL, TN, USA
Nuclear-Safety-Related SQA
Procedure Automation with
Custom Applications
Nuclear-safety-related procedures are rigorous for good reason. Small design mistakes can quickly turn
into unwanted failures. Researchers at Oak Ridge National Laboratory worked with COMSOL to define a
simulation app that automates the software quality assurance (SQA) verification process and provides
results in less than 24 hours.
by NATALIA SWITALA
S
oftware updates can feel like an old friend surprising
you with insufficient notice that they will be coming
to visit. You are equally excited and frantic. You hope
everything will go smoothly, that the update is backward
compatible with the version you are currently running, and
that it passes all of the software quality assurance (SQA)
requirements. This scenario is even more exaggerated when
the software is used in a highly regulated environment,
such as a nuclear research reactor operated for the U.S.
Department of Energy (DOE).
Test
selection
Model
selection
Test
status
FIGURE 2. Model Tester app that will run a suite of models and compare results, such as temperature and electric potential, against the values
provided in the product documentation. The user receives an automated report once the test is complete.
SQA efforts into two categories: verification the results provided in the software documentation. The
and validation (V&V). number of chosen applications can be large and every output
Compliance with the validation requirements can be the variable reported in the results is required to be documented,
most difficult to meet since the ideal situation is to have resulting in significant resources needed to complete the
experimental, test, or operational data to directly compare verification procedures.
and measure the code accuracy. For some codes, particularly Jim says that with the reporting requirements, qualifying
codes such as COMSOL Multiphysics that are new to the a new version of COMSOL used to take around one to three
nuclear industry, the best approach, and the one that ORNL months to complete, because we had to compare the results
intends to carry out for COMSOL Multiphysics, is to produce a from several simulations by hand against the documentation
standalone validation report that demonstrates valid results provided by COMSOL.
for a number of simulations directly related to their research.
Alternatively, the validation task is included as part of the STREAMLINING THE SQA PROCESS
formal nuclear-safety-related calculation process, as controlled This all changed when COMSOL introduced the Application
and governed by a separate procedure. Builder, and Michael W. Crowell (Mike) joined the ORNL
While compliance with verification requirements is more team as a nuclear safety and experiment analyst and saw
straightforward, it can be very time-consuming without the the opportunity to automate part of the SQA process.
appropriate software tools. DOE requires the team to produce The Application Builder allows simulation specialists using
a report that compares the results of a chosen set of COMSOL COMSOL Multiphysics for their physics-based analyses to build
software applications run by ORNL and included in the a custom user interface for their models. This means that
Application Library shipped with COMSOL Multiphysics against everyone on the team can access a COMSOL model and reap
the benefits of the specialists' work without needing to have Library) and receive an automated report once the test is
coding experience specific to COMSOL. In addition to being complete (see Figure 2).
able to easily build a custom interface, simulation specialists
can extend their models with methods written in Java code AUTOMATED REPORTS UNLOCK
that allow them to implement custom commands and link to PRODUCTIVITY
legacy programs. This is exactly what the ORNL team needed. Customers will be able to run models in the Application
The verification procedures require the researchers to Library according to their COMSOL Multiphysics license, with
demonstrate that the software has installed correctly on the flexibility to select which of the models they want to
specific computers and produces the results intended by the include in their own installation tests. Once the simulations
COMSOL Multiphysics developers. Mike was looking for a have been run, the test app will tell the customers which
solution that would allow the team to test whether they of the models passed and which have failed, including the
would get the same simulation results on different computers values where a failure occurred, and present the user with an
using different operating systems and mathematical libraries. automated report. The pass/fail criteria is set by default but
Because of the differences in machine architecture and may be changed to meet the customers needs. Customers can
libraries, along with the limitations of machine precision, we also extend the tests with their own models and by entering
their own reference values for the numerical solution.
The automated report has Customers can use the app to compare the results from
the previous installation to clearly understand the impact
provided us with newfound of the possible product updates in a new installation, says
time, as well as increased Ed. For example, if COMSOL changes a mesh algorithm or a
turbulence model, you will be able to check how the results
accuracy and reliability. from your own models and from COMSOLs Application
JIM FREELS, SENIOR RESEARCH STAFF Library are influenced by the updates.
MEMBER, ORNL Upon testing a preliminary version of the test app, Mike
exclaimed, We were able to complete the entire verification
dont expect the included and local results to be identical process in about 24 hours!
to the final decimal point, but we expect them to be close Jim added that The automated report has provided
enough, Mike explains. The reason behind any discrepancies us with newfound time, as well as increased accuracy and
may be due to, for example, how solvers and meshing reliability. That allows us to direct our efforts on the work
algorithms are locally created and compiled, which could needed to convert the HFIR fuel from a high-performance
affect the final results. HEU to an LEU fuel. v
Prior to the release of the COMSOL-developed Application
Builder Model Tester, Mike had developed a custom
MATLAB software program that automated the verification
process in a similar manner by selecting a subset of models
from the Application Library that came with the COMSOL
software to run locally and extract and compare the results.
This development was documented in a recent paper
published through the COMSOL Conference 2015 Boston. The
MATLAB software program that Mike developed compares
the results in the models and documentation provided by
COMSOL against the locally generated results, and then
reports the variance and highlights any out-of-bounds cases.
Using Mikes new approach, ORNL was able to reduce the time
needed for verification from months to days.
Jim was eager to share Mikes accomplishments with
COMSOL, as well as with other facilities working on DOE
projects. This shared knowledge led to a conversation with
Ed Fontes, CTO of COMSOL, about developing an application
to be included in the Application Library for all customers to
easily verify a COMSOL Multiphysics installation. Ed explained
that these kinds of verification tests are done during the
development of COMSOL Multiphysics with several hundred
models tested every night. He happily agreed to kick off the
project and explained that the app will allow customers to
run a suite of models and compare several physics results, Top: The High Flux Isotope Reactor Site at Oak Ridge National Laboratory.
such as temperature and electric potential, against the values Bottom: The core COMSOL group within the Research Reactors Division of
ORNL, from left to right: Christopher J. Hurt, Franklin G. Curtis, Prashant
provided in the product documentation (and Application
K. Jain, Michael W. Crowell, James D. Freels, and Emilian L. Popov.
28 COMSOL NEWS 2016 Oracle and Java are registered trademarks of Oracle and/or its affiliates.
MIT, MA, USA
by JENNIFER SEGUI
COMSOL .COM 29
VACUUM VESSEL DESIGN | MAGNETIC FUSION ENERGY
simulation in COMSOL Multiphysics magnetic model of the ADX, including 1.5 million amperes of current, stops
software to predict the magnetic fields, the vessel, plasma, and poloidal moving after 10 milliseconds, and loses
eddy currents, and Lorentz forces magnetic coils, which are needed to all of its current in a single millisecond.
resulting from a plasma disruption, hold the plasma in its Rapidly changing magnetic fields
explains Doody. The calculated loads equilibrium position. surrounding the disruptive plasma
are then applied to a separate structural A worst-case scenario exists produce eddy currents in the vacuum
model of the vessel in order to predict for plasma disruptions in vertical vessel shell. Lorentz forces are exerted
stress and displacement. Figure 3 shows displacement events (VDE), where on the vessel when the eddy currents
the geometry for a cyclic symmetry the plasma drifts upward carrying cross both the poloidal magnetic fields,
and the stronger toroidal magnetic
fields of the tokamak that confine
the plasma.
During a VDE, eddy currents are
larger in magnitude because of how
close the plasma gets to the vessel wall,
and VDE is therefore the test case of
choice in the computational model
of the ADX. Figure 3 shows the eddy
current distribution calculated from the
numerical model. A second model was
developed to determine the Lorentz
forces due to the toroidal magnetic
fields of the tokamak, where only
poloidal fields were included in the first
model of the ADX.
STRENGTHENING THE
ADX VACUUM VESSEL
Plasma disruptions result in strong
Lorentz forces that act on the walls of
the ADX, particularly in the upper and
lower pockets of the vacuum vessel
during a VDE. In a structural model
of the ADX vessel, shown in Figure 4,
the top and bottom boundaries are
FIGURE 4. At top, the geometry for the structural model of the ADX shows purple boundaries attached to the vessel cover and cannot
where the structure is fixed. Stress and displacement simulation results indicate the design be displaced during simulation. Loads
requires reinforcement. At bottom, the model geometry shows an additional fixed boundary corresponding to the Lorentz force
corresponding to a support block added to the ADX design. exerted on the vessel are applied to the
relevant boundaries. In this test case, approaching the yield value, and the newest fusion machine to serve as
the Lorentz force was determined for causing 1-centimeter deflections in an R&D platform to test the divertor
a tokamak operating with a 1.5 million the structure. To stabilize the vacuum concepts required for a fusion reactor. v
ampere plasma current and 6.5 Tesla vessel wall, a support block is added
toroidal field strength. to immobilize an additional boundary
The modular vessel components are as shown in the bottom row in Figure
made from Inconel 625, a strong nickel- 4. Simulation results, obtained for the
based alloy that is also highly resistive case with the support block in place,
to current flow, keeping eddy currents demonstrate significantly reduced stress
to a minimum. The yield stress for the and displacement of the vessel wall,
material is 460 MPa, however the design indicating that the stabilized vacuum
criteria for the ADX stipulates that vessel can survive a plasma disruption
the vessel walls should not experience and support ADX operation.
stresses exceeding 306 MPa, which is
two-thirds of the yield stress value. NEXT-STAGE NUCLEAR
Numerical simulation shows that, FUSION AND BEYOND
Jeffrey Doody is a mechanical engineer at the
without any design modifications, Simulation-led design of the ADX MIT Plasma Science and Fusion Center, pictured
the Lorentz force due to a VDE will help ensure its safe, successful here at the COMSOL Conference 2015 Boston
leads to large stresses in the vessel operation at PSFC, where it will become where he won an award for his simulation work.
MODEL DEMONSTRATIONS
Want to learn about modeling specific physics phenomena? Model
demonstrations take you through all the steps necessary to simulate them,
including electromagnetics, structural mechanics, non-isothermal flow,
acoustics, chemical reactions, MEMS, microfluidics, and more. These
videos will give you a feel for how to create models in COMSOL Multiphysics
software and how to turn them into custom applications featuring a
user-friendly interface for everyone to run by connecting to
COMSOL Server product.
KEYNOTES
Hear from fellow engineers and scientists about how they are using numerical
simulation in their industries. Each year at events worldwide, COMSOL users
present their work, showcasing best practices and innovative designs. Watch
this collection of presentations from the comfort of your desk.
COMSOL .COM 31
UNIVERSITY AT BUFFALO, NY, USA
PROMOTING INDUSTRIAL
INNOVATION WITH CUSTOM
SIMULATION APPS
A research group at the University at Buffalo is sharing simulation expertise across a wide
variety of industries through custom simulation applications. These apps allow an end user to perform
the desired analyses without needing the understanding and expertise that is required to
develop the underlying computational model.
by BRIDGET CUNNINGHAM
L
ook at any industry today, from models to analyze and design materials
automotive design to consumer and devices for industrial purposes.
electronics, and you will find Now, the potential for the team to
a common thread that binds them extend the reach of their expertise FIGURE 1. The geometry of an EDLC and a
together: the demand for more to a broader range of industries is plot indicating the predicted capacitance.
innovative technology. The latest and growing, thanks to the ability to create
greatest technologies are continuously customized simulation apps using
surpassed by even more complex and COMSOL Multiphysics software.
intricate devices that offer advanced COMSOL software models with the
features and functionality. BRINGING MODELING goal of helping industries continue on
Numerical simulation tools are a EXPERTISE TO MANY the path of innovation and growth.
viable solution to the challenge of INDUSTRIES When it comes to energy storage, for
creating more elaborate devices quickly, For Furlani, multiphysics modeling has example, electrochemical-based devices
delivering results with real-world always been an important element in like electric double-layer capacitors
accuracy without the need for building day-to-day work. As a research scientist (EDLCs) are becoming more and more
prototypes for each design modification. at Eastman Kodak, he performed common. Favored over traditional
Some organizations, however, may not modeling in support of material and capacitors for their significantly
have the resources to bring a simulation device development for commercial greater capacitance, these devices offer
expert on board to help create and products, including inkjet systems and potential for new operating scenarios
modify models. This is where simulation myriad digital imaging technologies. that require several rapid charge/
applications come in. These customized Furlani also developed models for a discharge cycles. In the capacitors, ions
user interfaces are built around range of industry needs, from photonics separate and accumulate on the surface
numerical simulations of physics-based and microfluidics to applied magnetics of the oppositely charged electrodes
systems and allow an end user to run and microsystems technology. In his in response to an applied voltage. By
multiphysics analyses set up for them by current role as a professor at UB, Furlani developing models, Furlanis group,
simulation specialists. incorporates multiphysics software into in collaboration with Professor Gang
With over 30 years of modeling the classroom to further help students Wu at UB, has been able to predict
experience in the industrial sector, learn and develop their engineering ion transport and equilibrium charge
Edward Furlani, a professor in the skills in an interactive way using accumulation within the devices, as well
School of Engineering and Applied computational tools. as their capacitance, to foster a better
Sciences at University at Buffalo (UB) The focus of Furlanis group at UB understanding of their behavior and
SUNY with joint appointments in the is highly interdisciplinary and reflects how to optimize their designs
Departments of Chemical and Biological industrial and academic research. (see Figure 1).
Engineering and Electrical Engineering, His graduate students develop Membrane technology is another
saw an opportunity to bring numerical multiphysics computational models popular point of interest in the
simulation to a greater number of for the development of products with industrial community, with uses
organizations. His idea: Organize functionality engineered all the way ranging from seawater desalination
a university group that could work from the nanoscale to the macroscale. to CO2 removal from natural gas.
together to develop mathematical His group has created a number of Designing thin-film composite (TFC)
THE BUSINESS OF
BUILDING CUSTOMIZED
SIMULATION APPS
The group has also been involved in
simulation activities for the startup
world. At Vader Systems, a startup
company in Buffalo, NY, founders
Zachary and Scott Vader have developed
an innovative process known as
FIGURE 2. Cropped screenshot of an app for EDLC analysis. liquid metal jet printing (LMJP).
Designed to mimic inkjet printing,
this technology, which is based on
magnetohydrodynamics (MHD),
membranes with high selectivity is the COMSOL Server product on a involves liquefying a solid metal feed
key to extending the use of membrane computing cluster through the and ejecting molten metal droplets via
systems, keeping costs and the overall university's Center for Computational a pulsed electromagnetic field. This
footprint at a minimum. The team at Research (CCR) a supercomputing enables the printing of highly complex
UB developed 3D models to see how facility that supports scientific 3D metal objects. As they commercialize
layer thickness, selectivity, and porosity computing, software engineering, and printers based on LMJP, Furlanis group
impact membrane performance. The parallel computing. This setup creates a has developed COMSOL apps to better
models, which have been validated high-performance and high-throughput understand the printing process and
experimentally by Professor Haiqing computing environment for running enhance its capabilities.
Lin at UB, provide greater insight into
how to further optimize these energy-
efficient systems and pave the way for
additional uses.
Furlani began turning these and
other complex models into easy-to-use
apps, as shown in Figure 2. Using the
Application Builder available in
COMSOL Multiphysics, he and his
students were able to build a simplified
interface on top of each model,
customized to meet the specific needs
of different companies, and empower
a larger group of people to run their
own simulation tests. "With custom
applications, you have all of the power
of COMSOL Multiphysics at your
disposal without needing the expertise
required to develop the underlying
model," Furlani said. "Users can study
details that are difficult to measure
and can greatly expedite their product
development life cycle by reducing
costly and time-consuming
trial-and-error engineering."
FIGURE 3. A simulation of an inductive coil coupling in a moving vehicle. The analysis examines
To further promote economic the impact of steel belts in a moving tire on coil inductance (a) and the magnetic field distribution
development via mathematical with a tire moving above an inductive coil (b). The vehicle axle motion is shown (c), as well as a 3D
modeling, the team is running computational domain for simulating the detection of the axle (d).
COMSOL .COM 33
CUSTOM APPLICATIONS | TECHNOLOGY ENTREPRENEURSHIP
by GARY DAGASTINE
FIGURE 1. From left to right, the images show different scales of structures of interest to the
built environment, from large land areas down to the materials used in a window.
T
here's always room for improvement in the expertise in advanced mathematics and computational tools,
things we humans create, and nowhere is and the ability to perform complex numerical experiments to
this more true than in the so-called built create innovative designs and optimize their performance.
environment, the term for human-made physical As a consultant and professor, van Schijndel often needs to
surroundings in which we live, work, and play. think of ways to make complex ideas accessible to his clients
The built environment encompasses everything from large who are not simulation experts or to students who are still
metropolitan areas to individual buildings, parks, roadways, learning about modeling and simulation work. As a
and the infrastructure with which we interact over the course COMSOL Multiphysics software user, he takes advantage of its
of our lives. Although it may not always seem dynamic, it is Application Builder, which enables him to build intuitive user
continually impacted by a myriad of physics-based processes, interfaces powered by a COMSOL software model. This allows
such as heat transfer, air flow, and moisture transport, which him, as a simulation expert, to efficiently collaborate with
take place on many different scales (see Figure 1). clients and colleagues in other organizations and departments.
The ability to model and
simulate these processes APPS FACILITATE THE USE OF
accurately can lead to significant NUMERICAL SIMULATION
improvements in many important Using COMSOL apps To his corporate clients, van Schijndel offers
areas such as energy efficiency, first gives students numerical analysis and testing capabilities through
health and safety, operating costs, these customized user interfaces, or applications,
durability, and notably,
an entry point into built from COMSOL models. These apps make
historic preservation. numerical analysis it easy for an end user who has never used the
Deeply immersed in this work and physics systems simulation software before, or who doesnt have
is Jos van Schijndel, founder of before they continue the technical background to create a model, to run
Netherlands-based consulting virtual tests on different design changes based on
firm CompuToolAble and assistant
on to building their their specific needs.
professor at Eindhoven University own models from In the university setting, he uses the same
of Technology, Netherlands, where scratch. software to introduce students to multiphysics
he specializes in the mathematical simulation and application design. Using COMSOL
modeling of building physics. apps first gives students an entry point into
What gives me joy and energy is to work on projects that numerical analysis and physics systems before they continue
not only incorporate leading-edge research, but which are on to building their own models from scratch. Once they
relevant to society and can also inspire my students, van are familiar enough with the concepts and the modeling
Schijndel said. I formed CompuToolAble to offer clients our techniques, they can eventually create their own apps using
FIGURE 2. At left, Amerongen Castle is one example of an historic structure that is subject to the potentially FIGURE 3. App users can explore
damaging effects of heat- and moisture-driven stress and strain over time. This applies both to the building a variety of designs and operating
itself, and to the treasures the castle contains, such as the cabinet door at right (source: Rijksmuseum scenarios, e.g., different geometry
Amsterdam). parameters and material properties.
the Application Builder, further expanding their knowledge to more effective preservation efforts.
and the reach of their collective analysis capabilities. Van Schijndel has created and overseen the creation of
Application Builder is very important to me in two distinct many COMSOL models related to the preservation of historic
ways, van Schijndel said. At the university, its an ongoing buildings and items in close collaboration with colleague Henk
challenge to motivate students to use their creativity and Schellen, associate professor in Physics of Monuments. For
ingenuity before they dive too deeply into mathematical example, one of their PhD students, Zara Huijbregts, used the
modeling. But now, I can easily build engaging simulation Heat Transfer Module, an add-on to COMSOL Multiphysics,
apps with just the characteristics I want my students to to model how sunlight streaming through windows would
explore. Then, only after theyve had a chance to play with the heat the floor and walls of a room at different times over the
apps to analyze the physics involved and to understand the course of a day (see Figure 4).
effects when various changes are made, do we get into more The simulation combined
detailed work. conductive heat transfer
On the corporate side, van Schijndel continued, often through the building envelope,
there are people who need to use numerical simulations convective heat transfer and
so that they can see and understand the impacts of physics measured indoor air, and
processes on their products, but dont have enough radiant heat transfer. The model
experience or interest in building models themselves. Using included different surfaces of
the Application Builder I am able to create a specialized user
interface based on advanced numerical models and provide
them with only the parameters that they are interested in.
This also ensures no errors are introduced, because we are
all working from the same reference point. An app can be
deployed for use by everyone who needs access to it, through
either a web browser or a downloadable client and letting
them connect to COMSOL Server product (as shown in a
cropped screenshot of the app in Figure 3).
FIGURE 5. To understand the moisture transport, which can cause damage like that pictured above (left), van Schijndel created a COMSOL model that
accurately couples heat and moisture transport through a wall (right).
the room and the building faades, and also accounted for Historic structures are facing unprecedented threats to
the cooling effects of outdoor shade. their integrity from climate change, increased urbanization,
The results predicted the temperature on each wall at and other factors. At the same time, the regulations
different times of day, indicating the best locations for governing their preservation have never been stricter, because
protecting sensitive objects from sunlight and heat damage. it is a societal benefit to preserve the legacy of the past. The
It is extremely important to know such precise temperature ability to use sophisticated modeling and simulation tools such
distributions so that, for example, paintings can be hung in as COMSOL is an important part of the toolkit that helps us
locations where they will be less affected by solar heating, meet those requirements, said van Schijndel. v
van Schijndel said.
Moisture damage is another major issue that can damage
walls, buildings, roofs, and the contents of a room. Because
in older structures it isnt always clear where the moisture
enters a building or room, van Schijndel sometimes uses
COMSOL Multiphysics as an investigative tool.
The idea is to deduce how moisture might be entering by
running multiphysics simulations that include measurements
of relative humidity at many different locations. Areas of
high relative humidity give clues as to how the mass transport
of moisture occurs, and we couple this information with
heat transfer simulations because heat drives the moisture
distribution, he said.
Van Schijndel developed a COMSOL model of moisture
transport in a wall with visible leakage damages near the FIGURE 6. Both images show COMSOL simulations of a cross section
window. His model enabled him to deduce where the of a wall on which a painting is hanging. The left image shows the
moisture was coming from (see Figure 5). He and his students temperature distribution in the wall and painting at a given point in
time, while the image on the right shows the rate of change of relative
used this technique to model thermal bridges using different
humidity in the wall and the painting at that same point in time. This
materials, analyze how the positioning of insulation influences model can help predict stress and strain, which impacts historic buildings
heat transfer from the inside to the outside of a building, and artifacts, giving experts the information needed to take appropriate
and to understand how moisture travels through different damage mitigation actions.
building materials such as concrete, stone, and insulation
(see Figure 5).
Given that temperature and humidity are major drivers of
stress and strain on precious objects such as historic paintings,
the ability to accurately couple these together in a model can
lead to better predictions of potential damage. Van Schijndels
model calculates the temperature distribution throughout the From left to right: Henk
wall and painting, as well as the relative changes in humidity Schellen, Zara Huijbregts,
(see Figure 6). and Jos van Schijndel.
COMSOL .COM 37
BE CAE, ITALY
THERMAL CHARACTERIZATION
OF AN ELECTRONIC DEVICE
WITH A CUSTOM APP
By distributing high-fidelity multiphysics models as custom simulation apps,
engineers at BE CAE & Test leverage their expertise and streamline the consulting process.
by GIUSEPPE PETRONE
S
imulation consultants are using THERMAL
custom applications as an CHARACTERIZATION OF A
effective way to communicate SURFACE-MOUNT DEVICE
their work to clients. Instead Whether devices use or convert energy,
of delivering a static report, they can they must properly manage heat so
now deploy a product that contains the that they continue to operate in a
intricacy of an unabridged mathematical designated temperature range. An SMD
model, with the clarity and usability is an example of one electronic system
of an app. This lets clients run their that clients ask us to model. We make
simulations independently. At BE CAE use of COMSOL Multiphysics software
& Test, we have created such an app to to investigate these systems due to the
simulate a surface-mount device (SMD). wide range of physics that can be taken FIGURE 1. Top: Geometric details and
into account and the ease with which materials used in the SMD. Bottom: Side view
SIMULATION one can couple them. of the frame, die, solder, pin, and ribbon.
APPLICATIONS FOR In our SMD model, the parts we're
ENHANCED ENGINEERING mainly interested in are the copper
COMMUNICATION frame, lead-free solder layer, and the
In simulation consulting, apps silicon die (see Figure 1).
are the next step in engineering The material of the solder layer and
communication: They're a streamlined silicon die, the thickness of the solder
way to communicate and work with layer, and the dissipated thermal power
clients. With a custom application, a each have the potential to impact the
client can access a complete simulation maximum junction temperatures and
through a user-friendly interface. junction-to-case thermal resistance. In
Using an app is advantageous for our model, we investigate the effect FIGURE 2. Highlighted regions of the SMD
both the simulation specialist and of varying these parameters on heat depicting the boundary conditions used in the
the client, as the client receives an distribution, as it ultimately affects the multiphysics model.
easy-to-use tool with which they can
independently investigate their system,
and the numerical expert is able to
dedicate more time to the detail of
the simulation rather than running
computations for the client.
In this example, which describes the
characterization of an SMD, the client
has access to the numerical model
through the app and can modify a few FIGURE 3. From left to right: 3D geometry, mesh, and simulation results from
parameters and material choices. COMSOL Multiphysics software.
IMPROVING ENGINEERING
COMMUNICATION
In our experience of creating simulation
apps, clients have been pleased to be
FIGURE 4. The Surface-Mount Device Thermal Model app, created with the Application provided with an interactive tool with
Builder available in COMSOL Multiphysics software. The user can change factors such as the which they can investigate their system.
solder thickness, operating conditions, and materials in order to analyze the thermal behavior Previously, after providing clients with
of different SMD designs. the outputs of simulations, there would
be requests for further computational
modeling with different parameters.
proper functioning of the SMD. In our created with the functionality available Now, it is possible for the simulation
test simulation run, the heat source is in the COMSOL Application Builder. expert to deploy a custom application
15 W, the initial frame temperature is As the application user progresses with which the client can investigate all
set to 25C, and the remaining parts are through the steps of the simulation, of their remaining uncertainties. This is
thermally insulated. graphical output is displayed: first optimal for the simulation expert as well
With COMSOL Multiphysics, it is the geometry of the SMD, then its as clients the time spent on repeating
straightforward to model heat transfer mesh, and finally the computed simulations with different parameters is
through the device, as all modeling temperature distribution. Thus, the better spent adding complexity to the
steps are carried out in the same interactive, dynamic nature of the simulation and app.
environment. We were able to quickly model is preserved in the app. When Now, with simulation apps, upon
build the geometry; add materials; the app user modifies a parameter, all receiving a request for parametric
use the Heat Transfer in Solids physics visualizations are easily regenerated. simulations, we can say, Let us provide
interface to set up boundary conditions; The final result is a clear and you with a COMSOL custom application,
mesh; solve; and postprocess the results easy-to-use application that relies on and you will be able to inspect your
with the expressions we defined, such as the accuracy and predictive power of product yourself. v
the junction-to-case thermal resistance. the mathematical model defined by
BUILDING A CUSTOM
SIMULATION APP FROM A step
In simulation consulting, apps are the next
in engineering communication: They're a
NUMERICAL MODEL
Once the COMSOL Multiphysics model
streamlined way to communicate and work
is complete (see Figures 2 and 3), it can with clients.
be wrapped in a user-friendly interface
with the Application Builder tool. As
the experts in the physics at hand, we
ABOUT THE GUEST AUTHOR
consider both our mathematical model Giuseppe Petrone is a cofounder and the sole administrator of
and our client's specifications in order BE CAE & Test, a COMSOL Certified Consultant. He received his
to choose the parameters that the app masters degree in mechanical engineering from the University of
user can access and modify within an Catania in Italy and later earned his PhD in energetic and process
acceptable range (see Figure 4). engineering from the Universit Paris-Est in France. Before starting
The app user can see the geometry BE CAE & Test, Petrone devoted his time to academic research
of the SMD, adjust the solder thickness, ventures, which included exploiting numerical methods in fluid
generate a mesh, launch the simulation, dynamics and thermal analyses. He has been a user of the
return to default settings, and generate COMSOL Multiphysics software since 2005.
a report. These features are easily
COMSOL .COM 39
GUEST EDITORIAL COMSOL
NEWS
COMSOL Multiphysics Brings Innovation
to Academia and Industry
by CARL D. MEINHART
I use COMSOL Multiphysics software in both academia and I founded Numerical Design, Inc. in 2012 and since its
industry to solve complex multidisciplinary problems. The inception, it has been a COMSOL Certified Consultant
reason is simple: What would previously require a custom company. We serve a variety of industries in technical fields
numerical algorithm, from advanced multiphysics applications such as microfluidics, electromagnetics, chemical engineering,
to optimization analysis, can be easily solved by and many others.
COMSOL software. We work on many microfluidics applications occurring
At the University of California, Santa Barbara, COMSOL has on length scales ranging from tens of nanometers to
been incorporated into several graduate and undergraduate tens of microns, and time scales on the order of a few
classes. For example, in the Introduction to Multiphysics microseconds. Because of the small length scales and short
Simulation class, we teach predominately mechanical time scales, it is often very difficult to instrument devices
engineering seniors and graduate students. This course for experimental performance characterization. Fortunately,
provides seniors with the necessary skills to use COMSOL COMSOL Multiphysics allows us to simulate these devices and
for the design and optimization of their year-long capstone numerically design them for optimal performance.
We routinely design microfluidics devices that would be
With COMSOL, we are able to impossible to create by instrumenting hardware prototypes.
Furthermore, the microfabrication process for many
quickly simulate and analyze many microfluidic devices can cost tens of thousands of dollars
design concepts, and optimize per microfabrication run and may take, say, six months to
complete. This large cost in both time and money can make
the designs, before committing to multiple design iterations impractical. With COMSOL, we
actual hardware fabrication. are able to quickly simulate and analyze many design
concepts and optimize them, before committing to
projects. It allows students to iterate through a variety of actual hardware fabrication.
design ideas in the fall quarter of senior year, before they ever There are many optimization tools available commercially.
build hardware. This process saves significant time and energy, However, for multiphysics-based shape optimization, COMSOL
and teaches students modern industrial design practices. is the ideal tool for the design of complex structures that
Were also planning to use custom applications created with cannot be engineered strictly from first principles. In one
the Application Builder. Apps will most likely first be used industrial example, we recently conducted a 10-parameter
to teach undergraduate laboratory classes. Students can use optimization of a nonlinear multiphysics problem. If all
pre-built applications to simulate physical experiments and possible parametric combinations were studied and each
predict the expected results before actually performing them parameter was swept with, say, 10 steps, the result would
in the lab. During the analysis stage, students will compare be 1010 simulations. Assuming each nonlinear sweep
simulation and experimental results to understand the physics took approximately 30 minutes to solve, it would take
as well as experimental and numerical errors. approximately 570,000 years to complete. By using COMSOL,
Many projects are multidisciplinary in nature, spanning we can optimize the problem within approximately one day.
the fields of engineering, chemistry, physics, and biology. The resulting geometric structure is non-intuitive and could
One unique advantage of COMSOL is that vastly different not have been predicted a priori.
physics can be easily coupled to solve research problems or
to answer scientific questions that previously required years
of developing dedicated numerical algorithms. This flexibility ABOUT THE AUTHOR
allows researchers to spend more time thinking about the
physics and less time worrying about the numerics. Dr. Carl Meinhart is a professor of Mechanical
One example is in the field of microfluidics, where AC Engineering at the University of California, Santa
Barbara. He earned his PhD from the University of
electrothermal flow can be used to drive heterogeneous
Illinois in 1994. Since coming to UCSB in 1996, his
chemical reactions. These models require us to consider research has focused on developing microfluidic
electrostatics, heat transfer, fluid flow, and chemical reactions. devices and investigating their fundamental
To further increase the high fidelity of our numerical transport mechanisms. Dr. Meinhart is also founder
simulations, our mathematical models also take into account and CEO of Numerical Design, Inc., which is a
the fact that material properties are temperature-dependent. COMSOL Certified Consultant company based in
Santa Barbara, CA. Dr. Meinhart is a fellow of the
The models allow the physics to be fully coupled and interact
American Physical Society.
exactly as they do in the real world.