Sequential Multiphysics Coupling: Data transfer and...

© 2011 ANSYS, Inc. November 28, 2014

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Sequential Multiphysics Coupling: Data transfer and interpolation methods

François Chapuis Sadek Cherhabili ANSYS FRANCE


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Agenda

General context • Comprehensive Multiphysics • Method of coupling physics

Mapping status in WB • Overview of existing mapping tools (R13) • New mapping algorithms In R14 • Additional practical tools in R14

“Imported load” functionality – “External data” component • Mechanical/Thermal – Demo1 • Fluid Structure interaction (FSI one-way) – Demo2

Two-way FSI • System coupling (Fluent/ANSYS) in R14


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General context Comprehensive Multiphysics


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Comprehensive Multiphysics

• What is Multiphysics? • Simulation of multiple physics!

• Mulitphysics is not new • Part of core technology for decades

– Thermal Stress – Complex thermoelectric-fluidic calculation

Deformation/Stress increase ~15%

1 Way FSI 2 Way FSI


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DEPTH

BREADTH

MULTIPHYSICS

In-house Solution

ANSYS Multiphysics : Built on a Strong Foundation

Structural

Fluids

Emag

Thermal

CAD Import

Param- terization

Meshing

Workflow

Post-processing

ANSYS’ technical depth and breadth, provides the foundation for true multiphysics simulation.


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ANSYS Multiphysics : Robust, Scalable, Proven

ANSYS Multiphysics Advantages • Highly scalable and robust solutions • Built on proven simulation technology • Single simulation environment • Flexible simulation methods for many applications • Supports parameterization and design optimization • Proven fluid-structure interaction

Thermal

Fluids

Structural

Emag

Multi-Field Solver •Sequential solution •Separate model & mesh •Separation of expertise

Thermal Fluids Emag

Structural

Direct Coupled Field •Element-level coupling •Highly coupled physics •Single model & mesh


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Multiphysics Simulation Portfolio

Product Capabilities ANSYS Multiphysics

ANSYS Mechanical/CFD-Flo

ANSYS Mechanical/Emag

ANSYS Mechanical

ANSYS CFD

Structural • • • • Heat Transfer • • • • • Fluid Flow • • • Low Frequency Electromagnetics

• •

High Frequency Electromagnetics

•

Acoustics • • • • Direct Coupling • • • • Multi-field Solver • • • • ∆

∆ Multi-field solver is available when purchased in conjunction with an ANSYS Mechanical license.


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Methods of Coupling Physics


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Methods of Coupling Physics

Direct Coupling • A single analysis employing a

coupled-field element containing all the necessary DOFs to solve the coupled-field problem.

Load Transfer • Two or more analysis are

coupled by applying results from one analysis as loads in another analysis.

Thermal Fluids Emag

Structural

Direct Coupling •Element-level coupling •Highly coupled physics •Single model & mesh

Thermal

Fluids

Structural

Emag

Load Transfer •Sequential solution •Separate model & mesh •Separation of expertise


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Direct Coupling Options

Continuum Elements • 2-D and 3-D solid elements • General analysis

Discrete Elements • Electromechanical transducer,

thin fluid film elements, discrete circuits

• General analysis • Reduced order modeling

MEMS Switch - actuation voltage, mechanical contact and fluid damping effects are simulated using electro-mechanical transducer and thin fluid film elements.

Silicon Ring Gyroscope – Harmonic response including thermoelastic damping solved with direct coupled-field elements.


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Load Transfer Options

One-way Load Transfer • One-way data exchange sufficient

Two-way Load Transfer • Two-way data exchange required • Implicit sequential coupling

Temperatures


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Mapping status in ANSYS Workbench


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Global mapping options (in release 13)

Data type • conservative data: force, heat flow, heat generation, etc. • non-conservative data: displacement, velocity, temperature, heat flux, force

density, etc.

Type • Surface-Surface • Volume-Volume

Method • Point-Point (point cloud method) • Point-element (Bucket search) • Element-element (GGI based)


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Overview of available mapping tools (R13)

Point cloud mapping 2D &3D • surface and volumetric • Point-Point

Bucket search based 2D&3D • surface or volume mapping • Point-element

GGI (general grid interface) • 3D surface mapping • Element-element


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Point cloud mapping (triangulation)

Algorithm • Binary search algorithm • creates intermediate triangle(2D) or tetrahedral element on the source

side • use the distance of the target node to source nodes as interpolation

weights Advantages • Robust • no element needed • no element type restrictions Disadvantages • Less accuracy in case of very different node densities between the source

side and target side


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Bucket search based mapping

Algorithm • node to element mapping • linear interpolation

Advantages • Mesh only needed on one side • support more element type than GGI method • suitable for non-conservative data transfer

Disadvantages

• Can not guarantee both profile preserving and global conservation for conservative data (compare with GGI based)


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GGI based 3D surface mapping (exclusive to CFD)

Algorithm • Octree search method • element-element mapping through control surface

Advantages • Robust and accurate • Able to handle non-overlap interpolation • Profile preserving and global conservative for conservative quantities

Disadvantages • Need element information on both sides • complicated and cost more memory and computing times • Mapping information can not directly used for constrain conditions • Very limited element shapes


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New enhancements in Release 14


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New Mapping/interpolation Methods

At R14, we have expanded the weighting options to include: Point Cloud/Triangulation • Works well in many cases. • Can give poor results if target points not found within the source point cloud

-> More options in R14

Kriging (R14) • Regression-based interpolation technique that can give smoother mapping

Distance Based Average (R14) • Simple robust method • give a mapping when other weightings fail


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Mapping onto surface with default settings (R13)


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New triangulation transfer type (R14)

Volumetric • Previously only option available in R13 • Uses tetrahedrons during mapping • Not good for shells and surface mapping

Surface • Uses triangle during mapping • Produces smoother contours when mapping to shells or surfaces


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Surface transfer type effect on mapping nodal temperature

Volumetric mapping (R13)

Surface Transfer (R14)


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Triangulation with projection for outside nodes (R14)

Projection of outside nodes using 8 closest points


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More “Outside” options for Triangulation (R14)

Triangulation weighting • attempts to locate a target point inside tetrahedrons constructed from the source points • Sometimes the target points may lie outside • Several options to handle this situation

Options to handle Outside Points include • “Projection” back into the volume • Use distance weighted average • Ignore outside points

Extrapolation limits can be set


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Kriging (R14)

Regression-based interpolation technique that assigns weights to surrounding source points according to their spatial covariance values


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Example: Kriging vs. Triangulation

Smooth contours

In this example, due to curvature, the nodes fall outside on the ends

R13


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Distance based average mapping (R14)

Using n closest points and use the distance from the target node to the source node(s) to calculate a weighting value

Using 3 point

Using 8 points


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Distance based average for outside nodes (R14)

Increasing the number of points to use for distance based average of nodes found outside improves quality of mapping

Using 1 point

Using 4 points

Using 8 points


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Additional practical tools in R14


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New mapping validation options

Added new tree object (right mouse click on External Load or Imported Thickness and select Insert -> Validation

Reverse Mapping Validation Map results of mapping back onto source and compare to original inputs Distance Based Average Comparison Compare results to distance based average mapping results Source Values Plots the source data which can allow for visual comparison against mapped

data (done in preview 3) Invoked by right mouse click on Validation and select Analyze


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Validation settings

File Identifier • Choose identifier (i.e. variable imported) • Items provided by parent external load or external

thickness object

Type • Reverse Mapping • Distance Based Average Comparison

Output Type • Absolute Difference • Relative Difference


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Validation settings: Graphics Controls

Display • Colored Points (default) or Colored Spheres are drawn using 6

colors based on Display Minimum and Display Maximum inputs • Scaled Spheres are spheres drawn based on Display Minimum

and Display Maximum inputs

Scale • Colored Spheres and Scaled Spheres sizes are controlled by this

input

Display Minimum and Display Maximum • Must be within the range of the Minimum and Maximum

statistics. • Items outside these boundaries will not be drawn

Display In Parent • When On, items will be drawn on the parent object in the tree

(i.e. External Load or External Thickness)

Number Of Items • Currently displayed number of items shown in the graphics

window. This number will change based on the Display Minimum and Display Maximum values


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Validation Example for Reverse Mapping

Validation showing relative difference of reverse mapping back on the source points

Displayed in Parent


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Source Value Validation

New “Source Value” validation draws source load values directly on model.


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Source Value Validation (cont)

“Displaying In Parent” helps show how well mapping performed.


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External data Component


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Importing External Load into Mechanical

1 2 3

Edit

Edit


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External Load - Details


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3D Face & Body Temperature Mapping

1

2

3D Face

3D Body


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2D Edge & Body Temperature Mapping

2D Bodies

2D Edge

1

2


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3D Face Pressure Mapping

1

2

1

Using Magnitude & Normal

Using X Y Z Components


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2D Edge Pressure Mapping

Using Magnitude & Normal

Using X Y Z Components

1

2


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Convection Load Mapping – 3D Face

1


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Mapping 2D Results onto 3D Model

2D Results

2D Results Mapped on 3D Model using cylindrical coordinate system


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Thermal-Stress Analysis (Dissimilar Mesh)

Temperature distribution bleed across the body boundary with “All” bodies selected

With “Manual” option user can choose the body using material IDs to produce more accurate results


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Multiple File Mapping

Often users need to map multiple sets of data • WB must provide a way for users to easily setup whether mapping 1 file or

a 100

External Data now supports • Ability to handle multiple files • Multi-edit to specify file formatting • Ability to designate “Master File” to re-use XYZ data(leads to much faster

mapping)


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Multi File Mapping : multiple select

By Multiselecting the files, properties for all files can be set at once

Columns can be sorted for more efficient editing

Multi row specification can be set at once

Data Identifiers can be copied into Mechanical


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Multiple File Mapping: Example

• Source results taken from two separate analyses • Geometry is oriented on arbitrary coordinate system • Results from each analysis are generated in separate files and added to a single External Data System • Transformations are applied to get source data into target system


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Multiple File Mapping: Example (cont)

Identifiers are available for each file contained in upstream External Data system.

Multiple imported loads can be inserted to correspond with files from External Data System.

Target Geometry

Imported Loads from each file


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Multiple File Mapping with Master

Transient results exported to separate files. Each file contains all nodes with results at different time points.

Master file selected. Nodes from all other files will not be read.

Single connection from External Data to Mechanical


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Multiple File Mapping with Master (cont)

Single Imported Load from External Data. Since master file is selected, nodes will be read only once reducing memory footprint and much quicker mapping

Multiple loads can be imported and applied at different time steps.


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Activation/Deactivation Support for Imported Loads

Ability to allow activation or deactivation of Imported Loads per load step. This allows the user to turn “off” an imported load in a subsequent load step.

• User can choose to activate/deactivate the loads using the RMB option that is available in the timeline (Graph) and tabular data

• Available for all imported loads


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Imported Data “Export” Functionality

New “Export” option allows writing tab delimited data to a file. Accessible from Imported Loads and Imported Thicknesses.

Nodal Data

Element Centroid Data


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Demonstration


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External Data For FSI one-way


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One-way Data Transfer (R13)

• In Workbench both thermal and structural loads can be transferred from CFX/Fluent to ANSYS

– Temperature • Either as a surface or a body load

– Wall Heat Transfer Coefficient • As a surface convection coefficient

– Pressure • Surface load which includes both normal (Pressure) and tangential (Shear)

components • In fact, force data that comes directly from the solution of the momentum equations is

used

• The data is interpolated in the background using CFD-Post


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Pressure/temperature/HTC Transfer to Mechanical Systems (R13)

• Mechanical/thermal nodal values are transferred by linear interpolation from the surrounding CFD nodes

• If interpolation process cannot find a face to map to, then closest point is chosen

• Mapping can be slow for large cases

• Octree mapper or”external data” can be used instead, discussed later


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CHT Mesh

One-way data: Integrated Process in Workbench (R13)

CFD CHT Solution Geometry

Thermal Loads Pressure Loads Thermal Stress Solution

Example Project Schematic


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New Octree mapping CFD-Post (R14)

1-way FSI (β) • New Octree mapping method

– Significantly faster algorithm – Improved handling of nodes outside selected

region – Need to set Option in CFD-Post

• 1-way FSI in ANSYS Workbench uses CFD-Post ‘under-the-hood’ – Will use mapping option set by user in CFD-Post

(which is stored in user preferences) – Status message with diagnostics report will

indicate use of new mapping method is being used


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Allows pressure, temperature and heat transfer coefficient to be imported into ANSYS Mechanical from an external ASCII file

Can be used as an alternative to the standard 1-way mapping • Export a data file from CFD-Post, then import via External Data

External Data Component for FSI (R14)


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External Data Component for FSI R14 (cont)

Consider using External Data when: • You want to map a non-standard variable, e.g. a transient average

• You want to use lower resolution data from CFD results instead of mapping every node – Create a Point Cloud in CFD-Post then export data

• Fluid and structural geometries are in different coordinate frames – Export data using a local coordinate frame in CFD-Post

• A workflow based on a single project is not convenient – E.g. fluid and structural groups

• You don’t have a CFD-Post license available when importing the data into Mechanical

• The interpolation is too slow using the standard approach – Could also use the Point Cloud method to speed up


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External Data Component (cont)

• The main disadvantage of using External Data is that the workflow is disconnected – no automatic data updates


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Demonstration

Standard transfer WB

External Data

CFD Solution


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System Coupling 14.0 – Two-way FSI with FLUENT and Mechanical


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Fluid-structure interaction problems encompass a wide range of applications in many different industries.

Aerospace, automotive, power generation, biomedical, etc.

Fluid-Structure Interaction Applications


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• The solution to two-way fluid-structure interaction requires co-simulation between computational fluid dynamics and structural mechanics.

• Applications such as air foil flutter, flow induced vibration from wind loading, membrane valves, pumps, elastic artery modeling and fuel tank sloshing require a two-way fluid-structure interaction solution to accurately predict the behavior of the design.

Fluid-Structure Interaction


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Iterative Coupling*

• A transient 2-way FSI simulation has three levels of iterations:

The transient loop – each loop/step moves forward in time, as in a standard CFD or

FEA transient simulation.

Loads / displacements are updated between the FEA

and CFD solvers.

The usual inner loop, used to converge the field(s) within a solver – named

Coefficient Loops in CFD and Equilibrium Iterations in FEA.

Time Loop

End Time Loop

End Coupling / Stagger Loop

End Field Loop

Coupling / Stagger Loop

Field Loop

• Existing for ANSYS CFX since R11 • Now for ANSYS FLUENT with System Coupling (R14)


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• Facilitates simulations that require tightly integrated couplings of analysis systems in the ANSYS portfolio

• Extensible architecture for range of coupling scenarios (one-, two- & n-way, static data, co-simulation…)

• ANSYS Workbench user environment and workflow • Standard execution management and data interfaces

System Coupling 14.0


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• Two-way surface force/displacement coupling with ANSYS Fluent and ANSYS Mechanical – Steady/static and transient two-way FSI

• Workbench based setup and execution – Windows and Linux

• Execution from command line outside of Workbench including cross-platform execution

• Integrated post-processing with ANSYS CFD-Post • Parallel processing for both CFD and structural solutions with ANSYS

HPC • Restarts for fluid-structure interaction • Parameterization, design exploration and optimization

System Coupling 14.0 – A Broad Range of Features


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System Coupling Schematic Setup


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• Solution update can ONLY be done via System Coupling • System Coupling ensures that the time duration and

time step settings are consistent across all participant solvers

System Coupling Controls the Participant Solvers for Transient and Steady/Static Solutions


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Setup Transient Structural Model

Setup transient structural solution, structural boundary conditions and Fluid Solid Interface


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Setup Fluid Flow (FLUENT) Model

Setup transient fluid solution, fluid boundary conditions and specify System Coupling Dynamic Mesh Zone for fluid-structure interaction motion


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• System Coupling motion identifies zones that may participate in System Coupling

• Allows user-defined motion to be combined with System Coupling motion

• Defaults to stationary motion type when not connected to System Coupling

System Coupling Motion Type


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• State of System Coupling setup cell will be – Upstream data is now available for SC Setup

Update Setup Cells for Transient Structural and Fluid Flow (FLUENT)


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System Coupling Setup GUI

Solution Information Text Monitors

Chart Monitors

Outline

Details


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• Coupling End Time • Coupling Step Size • Minimum Number of Iterations

per Coupling Step • Maximum Number of Iterations

per Coupling Step

System Coupling Analysis Settings


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• Region and variable information is generated automatically via Update when analysis systems are first connected to System Coupling

• For FLUENT, all regions of type Wall are shown in SC Setup

• For Mechanical, all regions of type Fluid Solid Interface are shown in SC Setup

System Coupling Participants are Transient Structural and Fluid Flow (FLUENT)


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• Use Ctrl key to select a FLUENT and Mechanical region pair and select Create Data Transfer from right-click pop-up menu

• Automatically fills in the details for the data transfer region

• Data transfers can be one-way (i.e. only transfer force or only transfer displacement) or two-way

Recommended Way to Create Data Transfer Regions


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Create Data Transfers


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• Participant • Region • Variable • Transfer At

– Start of Iteration only • Under Relaxation Factor • Convergence Target

Data Transfer Defines the Details for the Source, Target and Data Transfer Controls


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• Co-Simulation Sequence – Transient or Static Structural will

always be first in the co-simulation sequence

• Debug Output – Different levels of debug output for

analysis and data transfers

• Intermediate Results File Output – Controls the intervals for writing

restart file information

Execution Control


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Executing System Coupling


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• From schematic select Update using right-click menu on System Coupling solution cell

• Solution progress (% complete) can be monitored using View Progress menu

Alternative Method for Executing System Coupling


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• Build information • Complete summary of coupling

service input file • Analysis details • Participant summaries • Data transfer details • Mapping diagnostics • Time step and iteration summary • Solver field equation

convergence summary • Data transfer convergence

summary • FLUENT/MAPDL solver output

Solution Information


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Chart Monitors

Default chart monitors show convergence history for all data transfers.

X-axis can be coupling time, step or iteration.


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• Add charts by selecting Create Convergence Chart • Variables can be added or removed from charts

– Data transfers, CFD and structural convergence norms

• Chart properties are editable in same manner as other charts within ANSYS Workbench

Adding Charts and Variables


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• Transient Structural or Fluid Flow (FLUENT) Results cell for solver-specific post-processing

• Add a Results System (ANSYS CFD-Post) for unified post-processing of structural and fluid results

Post Processing System Coupling


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• Oscillating Plate Verification – Excellent correlation between

System Coupling, published data and MFX solver

Post Processing System Coupling


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• Conservative • CFX GGI technology. Locally and globally conservative and preserves profiles.

Should be used when sending flows (Heat Flows, Total Force)

• Profile Preserving • Used for non-conservative data and fluxes (Displacement, Temperature, Wall Heat Flux)

• The appropriate option is automatically chosen • If defining your own data to send need to pick the appropriate option

Data Transfer Type


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System Coupling – Examples


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Fuel Tank Sloshing

Transient free surface flow in a fuel tank with internal baffles.


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Mitral Valve

Transient blood flow through a three leaf mitral valve, non-Newtonian fluid and anisotropic hyperelastic tissue. Solution includes re-meshing of the fluid domain and nonlinear contact.


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Reed Valve

Transient response of reed valve opening and closing. Solution includes re-meshing of the fluid domain, large deformations and nonlinear contact.


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Vibrating Rod

Transient response of vibrating rod including vortex shedding.


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Summary

In Release 14:

• More options/enhancements for existing mapping methods

• New mapping/interpolation methods

• Extension to CFD users for FSI (Surface and Volume loads - One-way coupling)

• System Coupling for two-way FSI for CFD user’s


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Questions and Answers


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Appendix A1 More on mapping


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Mapping Diagnostics: Named Selection Creation

• Option to create nodal based named selections for mapped nodes, unmapped nodes, and outside nodes.

• Can help the user better understand the mapping.


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Source Point Morphing

Users desire to “morph” the locations of the source points. This allows more precise mapping between dissimilar geometries.

External Data now exposes “Morphing”

Can be done in X/Y/Z or R/th/Z.

Default is no morphing(i.e. x=x)

Morphing supports a number of intrinsic functions for moving nodal locations. Below is a list of supported functions:

sin(arg) asin(arg) sinh(arg)cos(arg) acos(arg) cosh(arg)tan(arg) atan2(arg1,arg2) tanh(arg) atan(arg) exp(arg) log10(arg) log(arg) loge(arg)max(arg list) min(arg list) nint(arg) int(arg) abs(arg) fabs(arg) pow(value, exponent) sqrt(arg)sign(arg) floor(arg) ceil(arg) round(arg) PI, pi – constant E, e – constant


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Source Point Morphing (using constants)

External Data Morphing Inputs

Unmorphed nodes

Morphed nodes

Source Results(cylinder)

Target Model (ellipse)


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Source Point Morphing (using functions)

Original nodes in XY Plane Nodes morphed using function on ‘z’ coordinate


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Imported Thickness From External Data

• An Imported Thickness group is created for each External Data system linked to the Model cell under Geometry

• Support for 3D Shells and 2D Planar • Additional Imported Thickness objects can be added to the

group via the context-menu • Mapping is performed to calculate the thickness on the mesh.

• Thickness value is mapped from imported data to each node on the scoped surface body/face.

• For a 2D analysis, an average thickness per element is calculated from the nodes which is sent to the solver as real constant for every element.

• User can modify final thickness via the Scale and Offset entries.

• Applied thickness = (Imported values * Scale) + Offset • Shell Offset is only available for 3D Shell models only

File containing point cloud data of thickness at various XYZ locations


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Visualization of Imported Thickness(3D)

Select Mesh node in the tree to visualize Thickness on the Mesh

Select Imported Thickness node in the tree to visualize contours

Note variation


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Imported Thickness(2D Planar)

Note 2D Geometry

Contour on Imported Thickness Object

Verify correct solve via user defined result(NMISC1 on PLANE182)


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Shell thickness and offset when mapping data to shells

Shell Thickness Factor property allows you to account for the offset and thickness at each target node (surface bodies) when mapping data from an upstream External Data system

This value is multiplied by each target node’s physical thickness and used along with the node’s offset to determine the top and bottom location of each target node. A positive value uses the top location of each node during mapping, while a negative value uses the bottom location of each node.

Target geometry overlay with source points

Target shell elements overlay with source points top

bottom

All target nodes projected to top and then mapped

All target nodes projected to bottom and then mapped

All target nodes mapped at default surface body location

Offset Type - Middle


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User input thickness value for all unmapped nodes

A thickness value can be applied to target nodes that fall outside the threshold of the mapping settings and cannot be mapped.

Unmapped nodes that will get default value 1.5e-2 (m)

Source points are from model with larger hole radius


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User input thickness value for all unmapped nodes

Contour plot of imported thickness

Mesh shell thickness plot using imported thickness (nodes along hole are using 1.5e-2 (m) default thickness value)


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Appendix A2: More Examples/illustrations


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Solution comparison between 3D shells and 2D Plane Stress Elements

2d plane stress analysis provides almost same solution as 3d shells with same imported thickness with in plane loading

3D Shells

3D Shells

2D Planar

2D Planar

Equivalent Stress

Total Deformation


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Input file for Imported thickness

Global thickness Imported thickness

Sending global thickness per body


Overriding global thickness by sending imported thickness per element



sending imported nodal thickness table

Overriding global thickness by sending imported nodal thickness table

2D Plane Stress

3D Shell M

odel


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Imported thickness restrictions for a 2D plane stress analysis:

Imported thickness can be applied in a 2d analysis for a plane stress model only. It will be marked under defined if 2d behavior is not set to plane stress. Solving such an analysis will throw an error:

Imported thickness values for all nodes should be positive.

If imported data has negative values, then user may use appropriate offset so that imported thickness is positive.

Importing non positive values will throw an error:

User is not allowed to apply force load on an edge which is being shared by the scoping of an imported thickness. Solving such an analysis will throw an error:


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Example: Triangulation with Projection

Projection

Results in smoother mapping as compared to V13


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Thermal results on curved surface to be used in mapping

Thermal result to be transferred to Structural mesh

Results are only on surface


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Reverse mapping validation

Absolute difference using Volumetric transfer type

0.04 C to 0.209 C

• Absolute difference using Surface transfer type

• 0.04 C to 0.068 C


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Reverse mapping validation

• Relative difference using Volumetric transfer type

• 1.0e-2% to 7.9e-2%

• Relative difference using Surface transfer type

• 1.0e-2% to 2.6e-2%


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Distance based average comparison

Absolute Difference Volumetric transfer type • Absolute Difference

Surface transfer type


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Distance based average comparison

Relative Difference Volumetric transfer type • Relative Difference

Surface transfer type


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Multiple File Mapping with Master (cont)

Imported loads at 1, 3, and 5 seconds.

Sequential Multiphysics Coupling: Data transfer and...

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