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Cosimulation for Thermal Management and V hi l D i T kVehicle Dynamics Tasks
Klaus Wolf – Fraunhofer SCAI
Overview
• Introduction to Fraunhofer SCAI
M CCI C li E i t• MpCCI CouplingEnvironment
• Automotive Thermal Management Example
• 1D‐3D Fluid Cosimulations
• 1D‐3D for non‐linear Deformations and Multi‐Body Kinematicsy
• FSI Mapping capabilties
• Meta Forming Workflows• Meta Forming Workflows
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de2
Fraunhofer Gesellschaft – Applied Research
Our Mission• Fraunhofer Gesellschaft (http://www.fraunhofer.de) is Europe’s largest application‐oriented research organization. Our research ff d i l l ’ d h l h iefforts are geared entirely to people’s needs: health, security, communication, energy and the environment.
• More than 80 research units, including 60 Fraunhofer Institutes, at different locations in Germany
• More than 20,000 staff – most qualified scientists and engineers
• Fraunhofer Institute for Algorithms and Scientific Computing SCAI g p g(http://www.scai.fraunhofer.de) conducts research in the field of computer simulations and methods
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Fraunhofer SCAI – Neutral Interface Solutions
Our Role
• Independent and neutral developer of advanced software solutions
• Open for co‐operations with interested CAE software partners
• Interface developments realized in close collaborations with most of the leading CAE software providersof the leading CAE software providers
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de4
MpCCI – Multiphysics Interfaces
MpCCI ToolSuite
• MpCCI CouplingEnvironment – Standard Interface for Code Coupling
• MpCCI FSIMapper – File based Mapping for FSI ApplicationsMpCCI FSIMapper File based Mapping for FSI Applications
• MpCCI MetalMapper Fil b d M i f M t l F i W kfl• MpCCI MetalMapper – File based Mapping for Metal Forming Workflows
• MpCCI MapLib – C++ Programming Library for Customised Solutions
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de5
MpCCI – CouplingEnvironment
General Concept• Distributed Architecture
• Open Code Adapter API
• Robust and accurate Mapping
• Flexible Synchronization Schemes
• More than 10 years of experience
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MpCCI – CouplingEnvironment
Supported Code Interfaces Supported Code Interfaces Abaqus 6.10 – 6.12 (6.13)
Ansys 11.0 – 14.0
Fl t 7 6 7 7
Matlab R2007‐2011 (beta)
MSC.Adams V2010, V2011 (beta) Flowmaster 7.6, 7.7
Fluent 12.0 ‐ 14.0
FINE/Hexa 2 11
MSC.Marc 2007r1 – 2011
MD/MSC.Nastran 2010‐2011 FINE/Hexa ‐ 2.11
FINE/Open – 2.11
FINE/Turbo – 8 8 – 8 10
OpenFOAM 1.5‐1.7, 2.0
RadTherm 9.0 – 10.2 FINE/Turbo 8.8 8.10
ICEPAK 13.0, 14.0
JMAG 11
STAR‐CD 4.04 – 4.16
STAR‐CCM 4.04 – 6.06
Open Code adapter API
10Cosimulation for thermal Management and Vehicle Dynamics Tasks
http://www.mpcci.de
Thermal Management for Automotive Vehicles
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de11
Thermal Management for Automotive Vehicles
MpCCI Coupling Scheme
Fl R dTh
TFilmHTCoeff
Fluent RadTherm
TW llTWall
Starting with flow field Tw=const.
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de12
Thermal Management for Automotive Vehicles
Details of Coupled Fluent to RadTherm
Not wetted
Quantity
Fluent RadTherm
frontside
rear side
boundary 1
boundary 2
wetted
y
Example:
Fluent RadTherm
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de13
Thermal Management for Automotive Vehicles
Some Results from BMW (by STARCCM …..)CFD
• …
CFDCFD CFD Figures by courtesy of
BMW AG Munich
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de15
Thermal Management for Automotive Vehicles
Why to use a coupled MpCCI solution?• Fully automatic and fast data transfer over socket connections.
• Easy implementation for repeating data transfer as used for iterative steady or transient simulations.
• Fast and robust data mapping between non‐matching meshes.
• Data inter‐ and extrapolation on geometrical irregularities like partially non‐matching geometries.p y g g
• Flexible steering of simulation procedure for instance with subcycling, time‐step sharingsubcycling, time step sharing
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de16
Coupled 1D‐3D Fluid Simulations
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de
Coupled 1D‐3D Fluid Simulations
MpCCI 1D‐3D co‐simulation is the coupling between• a 1D model component (integration point)
• a surface of the 3D CFD application
3D CFD Model 1D ModelCFD connection
1D ModelCFD connection
CFD connection
1D ModelCFD connection
CFD connection
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de18
Coupled 1D‐3D Fluid Simulations ‐Manifold
Manifold and Exhaust System• Flowmaster
• FLUENT
• Steady State Heat Transfer Simulation
• Quantities exchanged:Quantities exchanged:– Mass Flow Rate
– Mass Flux RateMass Flux Rate
– Total Pressure
– Temperaturep
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de
Coupled 1D‐3D Fluid Simulations ‐Manifold
Co‐simulation components in 1D Flowmaster• Flow source for a CFD pressure boundary
• Pressure source for a CFD flow boundary
Activate the External Model Boundary propertyActivate the External Model Boundary property• Allow the component to perform co‐simulation
Create a MpCCI Link File from the report menup p• Contains the definition of the External Model Boundary
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Coupled 1D‐3D Fluid Simulations ‐Manifold
Coupled 1D‐3D Fluid Simulations ‐Manifold
Model Setup in FLUENT 3D• Standard K‐Epsilon turbulence model
• Mass Flow specification Method
• for the inlets: Mass Flux
• Default temperature at the inlets: 300KDefault temperature at the inlets: 300K
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Coupled 1D‐3D Fluid Simulations ‐Manifold
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Coupled 1D‐3D Fluid Simulations – Aircraft ECSLarge Aircraft Cabin ECS System in Flowmaster V7Large Aircraft Cabin ECS System in Flowmaster V7
Partial CFD Model of Cabin in Fluent
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Coupled 1D‐3D Fluid Simulations – Aircraft ECS
1D – Air Distribution System Modeling• Analyze large aircraft air distribution• Analyze large aircraft air distribution• Evaluate duct re‐routing scenarios• Study mixing of fresh and re‐circulated air
Mass Flow Results (kg s‐1)
• Study mixing of fresh and re‐circulated air• Conduct “what if” scenarios on duct sizing• Fast to set up and very quick to analyze Mass Flow Results (kg s 1)Fast to set up and very quick to analyze
EnablingEnabling• Understand system interactions• Help meet passenger flow rate requirements
System Pressures (N m‐2)
Help meet passenger flow rate requirements• Help guarantee proper temperature
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de25
Coupled 1D‐3D Fluid Simulations – Aircraft ECS
ll dWell Designed System
ECS thermal failure
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Non‐Linear Tire Deformations and Suspension System
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Non‐Linear Tire Deformations and Suspension System
General MpCCI Coupling Concept• Fast solution for rigid body system (MSC.Adams)
• Detailed analysis for FEM‐Components (FEA)
• Co‐Simulation is more realistic
• Reuse of existing modelsReuse of existing models
• Exchanged Quantities– Position of the wheel hub is send by MSC Adams and received by FEA– Position of the wheel hub is send by MSC.Adams and received by FEA
– Reaction Force on the wheel hub is send by FEA and received by MSC.Adams
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Non‐Linear Tire Deformations and Suspension System
Chassis of the rigid body car (MSC.Adams tutorial)Chassis of the rigid body car (MSC.Adams tutorial) with applied GFORGE element (red arrow)
Detailed Tire Model in FEA
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Non‐Linear Tire Deformations and Suspension System
Tested Road Surface and Dynamic Tire Deformations
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Tested Road Surface and Dynamic Tire Deformations
Further MpCCI Multiphysics Examples
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Fluid‐Structure for Hydraulic Axial Pumps
PWK‐pump with a cam‐driven t ti itcommutation unit
• Constant displacement pump with very good performance
• Working pressure up to 55 Mpa
• Efficiency of 94%
• Good power densityGood power density
• Abaqus – MpCCI ‐Fluent
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Heat‐Loss Calculations in Electrical Devices
3‐Phase‐Busbar Systems• Magneto‐thermal coupled problem
• Three‐phase current
• RMS current 1600A at 60 Hz
• Simple Test‐CaseSimple Test Case
• JMAG – MpCCI ‐ FLUENT
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Heat‐Loss Calculations in Electrical Devices
3‐Phase‐Busbar Systems• Electromagnetic calculation of power losses (JMAG)
– Eddy currents
– Temperature dependent resistivity
• Thermal calulation (FLEUNT)– Heat conduction fluid and solid
– Heat convection incl. buoyancy effects
– Laminar flow
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de34
MpCCI – FSIMapper
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de35
MpCCI – FSIMapper
EnSight FSIPlugin
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de36
MpCCI – FSIMapper
EnSight FSIPlugin
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MpCCI – FSIMapper
EnSight FSIPlugin ‐ Supported File Formats
• Source Data: Adina CFD, ACUSOLVE, .., CFD++, CFD‐ACE+, CFD‐, , , , ,Fastran, CFX, ..., FINE/AERO, FINE/TURBO, ..., Flow3D, Fluent, OpenFOAM, PAM‐FLOW, PowerFlow, ..., SC/Tetra, STAR‐CCM+, ..., Vectis, ... http://www.ensight.com/CFD‐Interfaces/cfd‐interfaces.html
• Target Data: Abaqus *.inp, Nastran *bdf, Ansys (under g q p, , y (development), EnSight Gold
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MpCCI – FSIMapper
Cooling Flows and Thermal Stresses in Electronic Devices
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MpCCI – MetalMapper
Forming to Crash Simulation Workflows• Transfer of manufacturing simulation results
• Automatic handling of non‐matching model positions
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MpCCI – MetalMapper
Process Chains in Automotive Design• Metal forming (PAM‐Stamp, AutoForm)
• Assembly (SYSWELD)
• Paint Bath (CADFEM VPS/DRY)
• Crash (PAM‐Crash)Crash (PAM Crash)
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de41
Conclusion
MpCCI – Multiphysics Interfaces from a neutral andindependent providerindependent provider
• MpCCI CouplingEnvironment – The Standard InterfaceMpCCI CouplingEnvironment The Standard Interface for Code Coupling
• MpCCI FSIMapper – File based Mapping for FSIMpCCI FSIMapper File based Mapping for FSI Applications
• MpCCI MetalMapper – File based Mapping for MetalMpCCI MetalMapper File based Mapping for MetalForming Workflows
• MpCCI MapLib – C++ Programming Library forMpCCI MapLib C Programming Library forCustomised Solutions
Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de42