CFD With HyperWorks

March 2015
Rishi Patil

Innovation Intelligence
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HyperWorks Solver Technology

Crash Safety,
Structural Thermal Fluid Systems Manufacturing
Impact
Analysis Analysis Dynamics Simulation Simulation
& Blast

Multiphysics Analysis and Optimization

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HyperWorks Solvers

OptiStruct RADIOSS MotionSolve AcuSolve

Statics Highly Non-Linear

NVH Crash Multi-Body CFD

Safety Dynamics Thermal
Thermal Forming
Blast
Non-Linear

Optimization

Smart Multiphysics
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AcuSolve Better Technology, Better Solution

Fluid- Non-
Structure Thermal Computational Newtonian Electronic
Aerodynamics
Interaction Management Aero-acoustics Flow Cooling
Simulation

Multiphysics Analysis and Optimization

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Background
AcuSolve
Leading finite element based CFD product and solutions

AcuSolve Product Suite

Pre-processing - AcuConsole
CFD Solver Engine - AcuSolve
Post-processing AcuFieldView, AcuTrace, AcuReport, etc.
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Using HyperWorks for CFD Analysis AcuSolve

Comparison of base discretization technologies:

Finite Volume (FV) Finite Element (FE)

Conservative In general more accurate than FV

Strong for high flow speeds (viscous effects Strong for viscous dominated flows (e.g. low
are not dominant), because conservation is speed flows), because diffusion operator is
important math. Optimum in FEM

Faster than FEM More mathematical theory available

In general less accurate In general not conservative

AcuSolves differentiation:
Conservation of all relevant quantities in all cases
Including conditions of nonlinear enthalpy, variable time step, radiation, ALE, free surface,
FSI, sliding interfaces etc.

Typically faster and more robust than FV Codes

Due to a novel proprietary iterative linear solver technology which allows fast and
robust solution of the coupled system
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Using HyperWorks for CFD Analysis AcuSolve

Advantages over FV-based codes:

Robustness
Most cases solved on first attempt
Convergence under nearly all conditions
Speed
Efficient parallel scalability
Superior steady state convergence
Superior transient time stepping
Accuracy
2nd order for all problems & elements
Features
Unmatched stability/accuracy
Almost no Element quality requirements
Single solver for all flow regimes

Best in class capabilities for FSI,

Thermal Analysis & Optimization
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AcuSolve Element Quality

AcuSolve is very forgiving of poor element quality

Requires significantly less manual meshing work to obtain suitable
quality when compared to FV schemes

Reduced to 25%
inflow outflow

Max. vol skew 0.9997 0.95 (remeshed, tetra in BL) 0.95 (remeshed, penta in BL)
Delta_p [Pa] 2.63 2.63 2.63
X-traction [N] 3.13e-3 3.13e-3 3.12e-3
Iterations 20 21 25
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AcuSolve Overview

Markets using AcuSolve:

Automotive
Train aerodynamics
Renewable Energy
Boat design
Electronic cooling
Chemical mixing
Home Appliances
Medical and medical equipment
Oil/Gas and offshore platforms
Universities
National labs
Etc. . .

A.11
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AcuSolve - Overview

AcuSolve Key Points

General purpose, 3-dimensional, unstructured flow solver
Based on finite element method
Foundation is the Galerkin least squares method
Rich history in academia (25 years)
Further refined by ACUSIM Software, Inc. for industrial applications
Differentiation
Robustness
Most problems solved on first attempt, no parameter tuning/knob turning required!
Speed
Architected for massively parallel applications
Accuracy
Highly accurate in space and time
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Using HyperWorks for CFD Analysis CFD Post-Processing

HyperWorks Desktop

HyperView and HyperGraph

Visual Data Interactively
Standardize Post-Processing
Results in H3D or EnSight file

AcuFieldView

OEM version of FieldView based on FV 13

Included with AcuSolve V12 product suite
Functions only with AcuSolve generated
results data
Supports all features of FieldView
Runs in true batch mode
client/remote server access
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Using HyperWorks for CFD Analysis DOE & Optimization

HyperStudy and HyperMorph

Parameterize models easily using Morphing in HyperMesh

HyperMorph changes the shape of a mesh in useful, logical, and
intuitive ways
Creates shapes which can be used in HyperStudy
Tightly integrated with HyperStudy
HyperStudy for DOE, Optimization, and Stochastic Studies
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Summary HyperWorks Solvers

Broad analysis capabilities

significant additions in HyperWorks 12.0

Optimization enabled
robust, fast and accurate

Extensive Multiphysics capabilities

solve real world applications efficiently
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Unlock the
power of your
HyperWorks Units
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Altair Partner Alliance (APA)

NVH Composites Thermal Analysis

Process Structure Casting

Interaction

HyperWorks platformInjection
Ergonomics
has Molding
been opened to Partner applications.
Durability Complexity
MBD Management Tolerance
Customers have gained on-demand access to third-party technology,
Impact Analysis

Systems
using their existing
EMS pool of HyperWorks Units.
Stress Project
Management
Materials
CFD t
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APA Altair Partner Aliance RadTherm

RadTherm standalone or coupled with CFD

ThermoAnalytics Human Comfort Module

Battery Analysis for Vehicles

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APA Altair Partner Aliance JMAG

Coupling for Motor

Copper loss, iron loss, magnet eddy

current loss, stray loss can be
transferred as heat sources

AcuSolve

Loss Temperature
distribution

Temperature

Magnetic flux Heat transfer

density distribution Efficiency map coefficient
Speed distribution
20
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SC/TETRA for CFD

Application Fields
Automotive
Mechanical and Heavy Manufacturing
Electrical and Electronics
Chemical Reaction
Overset mesh
Robust auto-mesh generator enables Arbitrary Lagrangian-Eulerian (ALE)
Dynamical motion of element
capturing complex geometry Heat radiation / Solar radiation
Best-in-class memory saving and Fan model
Diffusion / Chemical reaction, Combustion
computation speed Multiphase flow / Free surface flow
Aerodynamische Berechnung mit
Virtual Wind Tunnel (VWT)
SimLab for CFD-Cleanup

Simon Zwingert
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Problems with Input FE Data:

Penetration Overlap

Close Proximity (1.5 mm gap) Self Intersection

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Connect Parts - Work Flow

Find overlapping or
close proximity parts

Flush overlaps /
gaps

Connect Parts:
Boolean +
automatic local
remesh
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Wrapper:

Local Wrapper
Performs wrapper locally only to connect parts at connection
Preserve edges everywhere else
One click operation

Essentials:
Need to have all bodies clean (no intersections) and watertight (no free edges)

Not Connected Connected using Local Wrap

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Wrapper:

Tight Wrapper
Has capabilities to preserve all features based on wrapping size
Possibility to create feature edges manually for each body
Can extract bodies
Quick solution for thousand of intersections to perform initial run

Not Connected STL mesh Connected using Tight Wrap

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Advanced mesh manipulation

Patching parts
Close gaps between different
parts

before

after
 Virtual Wind Tunnel
Efficient external aerodynamics

Innovation Intelligence
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Motivation

Field of application
Drag, Lift and Cross Coefficient

2 ,
=
2 (1.225 /3 )

Oscillation of components (Fluid-Structure-Interaction)

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Requirements & Goals

Preprocessing
Clean surface geometry
Surface mesh size ~ 4 7 Mio. elements
Volume mesh size ~ 70 150 Mio. Elements
1st boundary layer height ~ 1e-4m (y+ ~10)
5-10 boundary layers
Solver
100-400 cores
Transient run time up to 24h for 1-6 sec. physical time
Steady state run up to 10h
Postprocessing
Large data size up to 100GB and more
Batch process
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Working with VWT

Process Overview
Watertight
Surface Nastran Virtual
Format
Mesh Wind Tunel

AcuConsole

AcuSolve

AcuField PDF
View Report
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Working with VWT

Graphic User Interface

Drop down menus

Toolbar

Browser area

Unit system
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Fluid-Structure-interaction of a rear wing

Spoiler oscillation, FSI

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Fluid-Structure-interaction of a rear wing

monitor point
FSI analysis
Generic model of an automotive rear wing
Soft plastic material, thickness of 2mm
20 & 100 eigenmodes computed with OptiStruct

fixed

4%

Displacement of monitor point Down force for rigid and elastic

(20 & 100 eigenmodes)
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Fluid-Structure-interaction of a rear wing

monitor point
FSI analysis
Generic model of an automotive rear wing
Soft plastic material, thickness of 2mm
20 & 100 eigenmodes computed with OptiStruct

fixed

Structural deformation (vel. contour) Structural deformation (vel. contour)