Using Star-CCM+ within a students project for an ... · Using Star-CCM+ within a students project...
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Using Star-CCM+ within a students project for an industrial application in electroplating systems Tilman Botsch Georg Simon Ohm University of Applied Sciences Nuremberg Faculty of Process Engineering Alexandra Schmid, Wolfgang Harleß, Uli Girschele, Paul Leibham, Jonathan Brendle – Behnisch, Florian Kluger, Stefan Schindhelm, Reinhold Breckner, Lukas Absalon, Sven Stumpmeier, Michael Grubmüller Supervision: Prof. Dr.-Ing. Tilman Botsch Industrial partner:
Transcript of Using Star-CCM+ within a students project for an ... · Using Star-CCM+ within a students project...
Using Star-CCM+ within a students project
for an industrial application
in electroplating systems
Tilman Botsch
Georg Simon Ohm University of Applied Sciences Nuremberg
Faculty of Process Engineering
Alexandra Schmid, Wolfgang Harleß, Uli Girschele, Paul Leibham,
Jonathan Brendle – Behnisch, Florian Kluger, Stefan Schindhelm,
Reinhold Breckner, Lukas Absalon, Sven Stumpmeier, Michael Grubmüller
Supervision: Prof. Dr.-Ing. Tilman Botsch
Industrial partner:
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Using Star-CCM+ within a students project
for an industrial application
in electroplating systems
Projects in the degree course scheme
why? when? how with CFD?
Electroplating process
Specific tasks
Results and benefits
AG
EN
DA
page 3
mehrere Folien zur Hochschuldidaktik
• Curriculum VT
• Umfang Projekt
• Sinn Projekt
• Nutzen Projekt
Curriculum
Bachelor in Process Engineering
engineering mathematics
informatics programming simulation
electrical engineering process control instrumentation
material sciences
chemistry chemical engineering
engineering mechanics design engineering, CAD
languages
thermodynamics thermodynamics thermal process engineering
fluid mechanics powder engineering
heat and mass transfer envir. process engineering
plant engineeringplant engineering
project I project II
thesis
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Students Project
in final semester
application of knowledge on a real industrial task
in cooperation with an industrial partner
training of soft skills (team work, presentation, organisation, …)
6 ECTS-credits (approx. 1 day a week)
11 students, 5 different tasks
meetings on Fridays from 2 to 7 p.m.
arrangement of mile stones
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Students Project – schedule from Oct to Dec 2008
1. Friday: training course STAR-CCM+
2. Friday: visit of industrial partner, assignment of tasks
3. Friday: training course STAR-CCM+
model build up, meshing, simulation, first results
7. Friday: meeting with industrial partner
10. Friday: in-house presentation
12. Friday: presentation with reception of industrial partner
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Flow in an electroplating system
Evaluation of special "injector nozzles"
Tasks
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Electroplating
cathode anode
work piece
electrolyte
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Electroplating plant
modular electroplating systems
decorative or functional coatings
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Geometry
anodes
work pieces
carrier
(modelled
as porous region)
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inlet by 20 holes in two tubes outlet by bottom valve and overflow
Scheme of electroplating system
bottom valve
overflow
Task: Optimal ratio between flow through bottom valve and overflow for
homogeneous flow conditions around the work parts and
few dead zones at any place in the system
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number of cells: 1 081 328
inlets
bottom outlet
outlet overflow
Parameters
inlet velocity: 3,1 m/s (volume of reservoir to be
exchanged 5 times per hour)
ratio bottom valve / overflow
0% overflow
20% overflow
50% overflow
80% overflow
100% overflow
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Comparison: section through inlets
section through
inlet tubes
20%
overflow
80%
overflow
100%
overflow
50%
overflow
0%
overflow
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0%
overflow
20%
overflow
100%
overflow
50%
overflow
80%
overflow
cross section
Comparison: cross section
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Comparison: central section
100%
overflow
20%
overflow
80%
overflow
0%
overflow
50%
overflow
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Result
Flow field independent of location of outlet
Internal circulation dominates
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tube with holes tube with 2 ejector nozzles
Special "ejector nozzle"
"quadruples the flow rate!"
How much fluid is dragged along with the
inlet jet?
height over inlet / m
flo
w r
ate
in
je
t /
inle
t fl
ow
ra
te
ejector nozzle
hole
Examination of a special nozzle
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Technical Results
Internal circulation dominates
Flow field in the system does not depend on the location of the outlet
Ejector nozzles are not adequate for electroplating systems
Flow field is more homogeneous when tubes with holes
are used as injecting system
Ejector nozzle does not quadruple the flow rate
nozzleejectorholeswithtubes inlet
stream
inlet
stream
V
V
V
V
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Summary
Good technical results, very valuable for industrial partner
Practical education with evident industrial relevance
Motivated students
High learning outcome
Satisfied professor
Use of STAR-CCM+ is possible with undergraduate students
Supervision and coaching is essential
Scepticism and criticism versus simulation results
had to be and could be inspired
Conversion of CAD-files may cause problems
CFD is a good tool for students projects
