LMS Amesim/STAR-CCM+ co-simulation: Fluid-thermal analysis of a water-jacket

Unrestricted © Siemens AG 2017

Siemens PLM Software

LMS Amesim / STAR-CCM+

co-simulationFluid-thermal analysis of a water-jacket

Realize innovation.Unrestricted © Siemens AG 2017



Agenda

• Introduction to the product portfolio

• Motivations for this co-simulation study

• Setup of the 1D LMS Amesim model

• Setup of the 3D STAR-CCM+ model

• Results of the LMS Amesim / STAR-CCM+ co-simulation

• Going further



Simcenter™ Portfolio for Predictive Engineering Analytics

LMS Imagine.Lab

LMS Imagine.Lab Amesim

LMS

Imagine.Lab

System

Synthesis




STAR-CCM+

STAR-CCM+




Cornerstones for a future-proof engineering approach

Cloud

Licensing

flexibility

Covering full range of

methods

Analytics, reporting &

exploration

Deployment flexibilityOpenness &

ScalabilityUser experience

Industry &

engineering expertiseSystems approach

Collaboration &

workflow

Multidiscipline

& multiphysics

R

F

L

P

Controls

1D

3D

TEST

CFD



Agenda






• Going further



Engine cooling system

ENGINEHEATER

CORE

RADIATOR

THERMOSTAT

AIR FLOW

TANK

Engine cooling

system

Engine water

jacket

PUMP

• Global system overview



Local water jacket phenomena are determinant

An accurate water jacket

pressure drop computation and

local heat exchanges are

required for computing the

coolant temperature evolution



Motivations for co-simulation

Engine cylinder head

Water-jacket geometry

• Strong coupling between the local coolant flow and heat exchanges to

the engine thermal masses

• Coolant flow streamlines impact the global water jacket pressure drop

• Optimal design requires multiple iterations

• A valued approach improving both 1D and 3D CFD results

• Modelling of system interactions

• Realistic boundary conditions

• Possibility for multiple design iterations.

Pain points:

Solution: co-simulation



Presentation of the co-simulation case

• This study demonstrates the ability of LMS Amesim

and STAR-CCM+ to co-simulate complex flow analysis

along with complete dynamics of the system which is

represented using 1D LMS Amesim models

• Aim: to simulate a complete engine thermal

management system with local zooming on the water

jacket

• This type of study enables the exploration of design

space of water jacket geometry

STAR-CCM+ has a dedicated user interface to

connect to LMS Imagine.Lab Amesim that makes

the co-simulation process easy to set-up.



Agenda






• Going further



1D LMS Amesim model

Engine thermal management

Fuel economy and performance

Passenger comfort

Vehicle integration analysis

LMS Amesim is a world-leading platform for

simulating multiphysics systems



Engine thermal model

• Thermal model of engine

• Represents engine combustion and friction,

engine thermal mass, heat exchange with

underhood, water-jacket and oil-lubrication

system

• Representation of engine thermal masses

• Engine split into thermal lumped masses:

• Engine block: inner block side, piston, external

block side, lower block

• Cylinder head: intake side, exhaust side,

cover with camshaft box

Engine thermal lumped masses



Agenda






• Going further



• Extraction of water-jacket using CAD2AME

• Based on an existing CAD model

• CAD cleaning and surface repair in

STAR-CCM+

3D STAR-CCM+ model

CAD

• 3D polyhedral unstructured mesh

• ≈1M cells for co-simulation case

• y+≈5

Mesh



3D STAR-CCM+ model

• Ethylen Glycol (50%), Water (50%)

• Incompressible

• Fluid properties at 1bar and 80 degC

• Segregated solver

• Implicit unsteady

• 𝑘 − 𝜖 turbulence model

Fluid properties

Numerical model

Temperature Contours



Agenda






• Going further



Co-simulation model

LM

S A

me

sim

to

STA

R-C

CM

+

STA

R-C

CM

+ to

LM

S A

me

sim

Cylinder head wall temp

Engine block wall temp

Inlet pressure

Inlet temperature

Outlet 𝑚Cylinder head heat fluxes

Engine block heat fluxes

Outlet pressure

Outlet temperature

Inlet 𝑚

Co-simulation

Cylinder head

exhaust side

Cylinder head

intake side

Engine inner

block side

Engine outer

block side



Co-simulation results

• Unsteady simulation is done by following NEDC

driving cycle

NEDC cycle speed and vehicle speedParticle tracks (steady simulation using

STAR-CCM+ 𝒎 = 𝟎, 𝟓 𝒌𝒈𝒔−𝟏)

LMS Amesim

STAR-CCM+




Engine temperature evolution

along the cycle

LMS Amesim

STAR-CCM+

STAR-CCM+




• Complete detailed coolant behavior during start-up phase

in the water jacket: pressure drop and heat exchange

prediction

• Using 1D models LMS Amesim represents complete

dynamics of the system including:

• Engine thermal model with metal masses, oil circuit and

external heat exchanges

• Vehicle fuel economy and performances in interaction

with the gearbox and the alternator

• Possibility to carry out multiple design studies and

optimize water jacket heat transfer and pressure loss

Mass flow rates for coolant

LMS Amesim




Heat fluxHeat flux (co-simulation)

• Realistic boundary conditions

• Dynamic simulation

• Multi-physics model

Added value provided by

co-simulation

Pressure time evolution

LMS Amesim LMS AmesimSTAR-CCM+



Agenda






• Going further



STAR-CCM+ / LMS Amesim co-simulation user guide in LMS

Amehelp



Systems-Driven Product Development

Predictive Engineering Analytics

Role in Systems-Driven Product Development

Predictive Engineering AnalyticsSystem Mockup

Managed in PLM Context - Multi-Domain Traceability, Change and Configuration

TEST

Digital

Twin

1D

CFD

Exploration - Analytics - Reporting

3D



3D SIMULATION

CFD SIMULATION

1D SIMULATION

From disconnected models and data …

Customer Usage data

Simulation data

Test data TEST MODELING

Historical data

CONTROLS



…to a performance Digital Twin

3D SIMULATION

CFD SIMULATION

1D SIMULATION

Customer Usage data

Simulation data

Test data TEST MODELING

Historical data

CONTROLS



Contact

Karim NASSAR & Stéphane NEYRAT | LMS Amesim Platform

Romain GONARD | LMS Amesim Powertrain subsystems

Joe OSMAN | STAR-CCM+

Siemens Industry Software S.A.S.

Digital Factory Division

Product Lifecycle Management

Simulation & Test Solutions

DF PL STS CAE 1D

siemens.com

LMS Amesim/STAR-CCM+ co-simulation: Fluid-thermal analysis of a water-jacket

Technology

Transcript of LMS Amesim/STAR-CCM+ co-simulation: Fluid-thermal analysis of a water-jacket