the world’s leading cfd magazine october 2008

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To learn more, visit www.hp.com/go/optimize-cae www.cd-adapco.com ENTECHO AZIMUT-BENNETI TURBOMACHINERY WIND ENERGY www.cd-adapco.com Virtual Design Takes Flight Yacht Design Eliminating Heat Stress Flow Simulation © 2008 Hewlett-Packard Development Company ..::REGULARS Events COMING SOON! >> marine SPECIAL REPORT FEATURING • Submarine simulations • Underwater explosions! To receive a copy and register your interest, please email • STAR-CCM+ DFBI models [email protected] now (Don’t miss the boat!) • Ship design including hull validation & propulsion systems www.cd-adapco.com/marinereport/ • Racing yacht design for the America’s Cup • Lifeboat launching • Hurricane resistant offshore platforms • CD-adapco & Classification societies...and more. Contents 10 18 14

Version 2.02 October 2008

Introduction 03 Integrate. Automate. Innovate. Introduction by David Vaughn 30 16 20 05 Product News •STAR-CCM+ V3.04 release •STAR-CD 4.06 release 07 Office News 08 Breaking News •Tecplot •SPT •Computer Games •Felt Racing Global Events •Calendar Competition Automotive 22 24 26 10 Cover Story - Clean, Green & Frighteningly Fast: CD-adapco helps Ford break the land-speed record for fuel-cell powered cars 14 Go kart Analyzing the aerodynamics of a competition kart 16 ING Renault F1 Team: Accelerating Ahead with New CFD Centre Aerospace CD-adapco regularly participates in many global trade shows. To get the chance to talk in person 18 Flying Objects Virtual design enables a revolutionary flying technology to take off 28 32 35 with our experienced and friendly representatives, please make a note of our appearances at Turbomachinery the confirmed shows below. For more information please contact our events staff: 20 The Automated Simulation Process North America: Tara Firenze [email protected] of Combined Thermal, Flow & Stress in Turbine Blade Cooling Analyses Renewables Europe: Marianne Mueller [email protected] 22 Providing Flow Simulation Power For Wind Energy Engineers North America Europe STAR Conferences Industrial Applications SAE Commercial Vehicle Congress SMM 2008 STAR Indian Conference 2008 24 Keeping an Eye on things October 7-9, 2008 September 23-26, 2008 November 3, 2008 Rosemont, IL Hamburg, Germany Bangalore, India Implementing CFD at Overview Printed on Nine Lives recycled paper using vegetable inks. We’re doing our bit, are you? 26 Energy Efficient Radiator Design Reduce your Carbon Footprint today http://www.carbonfootprint.com/ SNAME Maritime Technology Conference & Expo Aachener Kolloquium 2008 STAR French Conference 2008 October 15-17, 2008 October 6-8, 2008 November 8, 2008 Driven by STAR-CCM+ Simulation Houston, TX Aachen, Germany Lyon, France GLOBAL OFFICES - CD-adapco Booth EG 11 Marine Americas Europe Asia-Pacific MAC08 (2008 Mechanical Analysis Conference) STAR European Conference 2009 28 Super Yachts October 22, 2008 LMS simulation Conference March 23 - 24, 2008 Headquarters Headquarters CDAJ Orlando, FL October 8-9, 2008 London, UK The Azimut-Benetti R&D Centre & the CFD design of luxury yachts CD-adapco • New York office CD-adapco • London office Japan Paris, France 60 Broadhollow Road 200 Shepherds Bush Road 37/F Yokohama Landmark Tower Swaglok 3rd Annual Technology Conference 30 Performance Enhancing Canoes Melville, NY 11747, USA London, W6 7NL, UK 2-2-1-1 Minato-Mirai · Nishi-ku October 23-24, 2008 MIRA 2008 CTO & Plastex Paddle to Olympic Glory using CFD Simulation Tel.: (+1) 631 549 2300 Tel.: (+44) 20 7471 6200 Yokohama 220-8137 · JAPAN New Orleans, LA October 22-23, 2008 [email protected] [email protected] Tel: (+81) 45 683 1997 Coventry, UK Regulars www.cd-adapco.com www.cd-adapco.com [email protected] Fuel Cell Seminar www.cdaj.co.jp October 27-30, 2008 PTC User Conference 32 Dr Mesh: DFBI and the art of Duck Hydrodynamics Austin, TX France Tustin, CA Phoenix, AZ November 11-12, 008 Paris office China 34 Training Lebanon, NH Darmstadt, Germany Lyon office CDAJ China NAFEMS 2008 North American Regional Summit Atlanta, GA 35 Global Events [email protected] Beijing office PTC User Conference Cincinnati, OH October 29-31, 2008 [email protected] Detroit, MI Hampton, VA November 13, 2008 EDITORIAL Germany www.cdaj-china.com Seattle, WA Paris, France Nürnberg office Pointwise User Group Meeting 2008 Dynamics welcomes editorial from all users of CD-adapco software or services. Tulsa, OK [email protected] CD-adapco Korea SIMVEC 2008 Houston, TX November 5-6, 2008 To submit an article: Seoul office [email protected] Fort Worth, TX November 26-27, 2008 Email [email protected] Telephone: +44 (0)20 7471 6200 Italy [email protected] Baden-Baden, Germany For S. America - please contact Turin office Power-Gen 2008 Editor Stephen Ferguson [email protected] Melville Office Rome office CD-adapco India December 2-4, 2008 Sub-editors Joel Davison, Dejan Matic [email protected] Bangalore office Orlando, FL Art Direction Resellers [email protected] Brandon Botha SAE Motorsports Engineering Conference Advertising Geri Jackman [email protected] Australia New Zealand South Africa December 2-4, 2008 Multimedia Director Mark Adlington Veta Pty Matrix Applied Computing Ltd. Aerotherm Computational Dynamics Concord, NC [email protected] [email protected] [email protected] Subscriptions Greece Russia Taiwan Dynamics is published approximately three times a year, and distributed internationally. ENEFEL SAROV FLOTREND Corp. To subscribe or unsubscribe, please email [email protected] [email protected] [email protected] [email protected] Telephone +44 (0)207 471 6200 India Turkey CSM Software Pvt Ltd A-Ztech Ltd Media Kit available online at: http://www.cd-adapco.com/press_room [email protected] [email protected] dynamics 2.02 35 ..::INTRODUCTION David Vaughn

The implications of integration with automation “are remarkable - allowing designers and engineers to map the performance of their product over an entire design space. Integrate. Automate. ” Innovate. Introduction by David L. Vaughn

The implications of integration with automation are remarkable - allowing While preparing this introduction, I decided designers and engineers to map the performance of their product over an to take a trip back through history, by entire design space. This will not only provide a more complete picture of how a product actually performs in service, but will free the user from the flicking through the back-issues of mechanics of actually performing the CFD calculations, providing more time for true engineering analysis and thus leading to unprecedented Dynamics magazine, going all the way back innovation. to the Summer of 1994, when we As examples of these automation capabilities, I encourage you to take a published the first ever issue. Obviously, look at a few features in the current and upcoming releases of STAR-CCM+: during that time, the sophistication of the • Dynamic Fluid Body Interaction (DFBI) capability - allows you to simulate the fluid induced motion of a body, requiring little or no simulations undertaken by our users has additional user effort over performing a standard static mesh increased (the first issue included a 2-D calculation (see pages 32 -33 of this magazine). • Mesh Morphing - automatically and robustly adjusts the volume mesh simulation of two trains passing), however to account for bodies in motion or simply changing shapes. Note that this can be used in conjunction with DFBI. what really struck me was the way in • Boundary Layer Transition Modeling - predicts the transition from which CAE (and specifically CFD) has laminar to turbulent boundary layer. • Native CAD Import - allows you to robustly import your native CAD transformed from being a specialist R&D models (NO IGES/STEP TRANSLATION!!!). • Surface Mesh Projection to CAD - maintains the integrity of the mesh tool, to becoming a truly integrated part of by projecting the surface back to the imported analytical geometry. the product design cycle. And these are just a few of the exciting projects we've been working on. As this edition of Dynamics proves, the integration message applies to You may also be interested to know that also in this issue Dr Mesh talks companies across the board, from large multinational corporations such you through his simulation of a floating rubber duck using DFBI. In as Ford, through to the smaller and mid-size companies such as those addition to this, you may also be interested to know that we are currently manufacturing domestic radiator valves or CCTV camera systems. compiling a Marine Special edition of Dynamics, which will contain many articles about practical applications of the DFBI model and lots more. By partnering with these companies, CD-adapco has set the standard for CAE integration. As an example, note that this fall’s release of STAR-CCM+ To register for your copy, visit: www.cd-adapco.com/marinereport version 3.06 will be the first commercially available software that provides fully integrated flow, thermal, and stress simulations with a single mesh Enjoy your read! (finite volume approach).

Thus, as a team (with our loyal customers) we have now made every aspect of CAE integration commonplace, so I sincerely believe that the next logical step is automation. As was the case with integrating CAE processes, CAE (and specifically CFD) automation has been carried out by David L. Vaughn specialists in an R&D setting for several years, but we are now poised to Director Aerospace and Defense bring to fruition fully automated general CAE processes in which multiple CD-adapco CAE calculations will be carried out with minimal user intervention.

 EMAIL [email protected] dynamics 2.02 03 ..::PRODUCT NEWS STAR-CCM+ V3.04

PRODUCT NEWS Just when you thought it was safe to go back in the water: STAR-CCM+ V3.06

Stephen Ferguson, CD-adapco

Dynamic fluid body interaction In June we released STAR-CCM+ V3.04, followed by V3.06 in STAR-CCM+ also includes an automatic wave generator, which is fully October. Central to both releases was the introduction of a integrated into the GUI, allowing users to generate waves using just a few new capability for “Dynamic Fluid Body Interaction”. Unlike simple parameters. The DFBI solver can also be used for marine traditional CFD software, which is typically limited to simulating the applications in which a vessel’s running attitude depends on the pressure motion of a body along some prescribed path, the STAR-CCM+ DFBI field around the hull. Running in steady-state mode the DFBI model will model enables engineers to easily simulate the fluid induced movement calculate the vessels actual position in the water for a given boat speed, of a body, for everything from a tanker listing under heavy seas to an automatically calculating sinkage, heel and trim. aerodynamic body tumbling in free fall. Beyond boats “The significant advantage of our new DFBI model is that it allows the Each new release of STAR-CCM+ contains a raft of new features and fluid induced motion of an object to be predicted in six degrees of enhancements that help to increase productivity while reducing analysis freedom, with no additional effort from the user, compared to performing turnaround times. a simple steady state simulation of flow past the same body,” says Jean–Claude Ercolanelli, CD-adapco’s VP Product Management. In STAR-CCM+ V3.04 we improved the automatic hexahedral mesher, which now has the ability to refine cells in specific directions allowing “The meshing process for a DFBI simulation is identical to that for a greater control of cell count without compromising accuracy, which is simple non-moving calculation and the DFBI model accomplishes its task extremely useful for aerodynamics and free surface simulation. A new without invoking the complex and time consuming re-meshing schemes surface offset tool was added to the Surface Preparation GUI to ease used by other CFD tools.” and speed-up the handling of complex and poor geometry. Indirect topological interfaces for multi-stage turbines may now be modeled where At each inner-iteration, STAR-CCM+ calculates the forces and moments each stage has a different pitch. Multi-band thermal radiation in acting on the body by automatically integrating the pressure and frictional participating media has also been implemented in STAR-CCM+ for the loads before calculating the acceleration, velocity and displacement in six first time, allowing the radiation properties to vary with wavelength. degrees of freedom. Rather than using complex mesh distortion or interpolation across sliding boundaries, the DFBI model works by STAR-CCM+ V3.06 introduces a new capability that will allow users to translating and rotating the entire computational domain in response to perform structural analysis calculations from within the STAR-CCM+ GUI, the fluid induced load. the first time that an integrated process for flow, thermal and stress simulation has been available in a single general-purpose commercial STAR-CCM+ then updates the flow field for the new body position and, finite-volume code. The introduction of a mesh morphing capability iterating this procedure over time, calculates the trajectory of the body. simplifies moving mesh simulations, fluid-structure-interaction Using STAR-CCM+ V3.06 the motion of multiple bodies can be simulated calculations and optimization studies. The process from CAD to CAE using rotating or sliding interfaces within the computational domain. solution is further improved with the introduction of a new selection of native CAD Importers that allow you to robustly import native CAD without A complete tool for marine applications translations, and through the new surface mesh projection capability that DFBI is useful for any simulation in which an unrestrained object moves maintains the integrity of the mesh by projecting the surface back to the in response to fluid excitation. However, it is particularly useful when imported analytical geometry. Finally a new transition model helps to combined with the powerful free surface modeling capability in STAR- predict the transition from laminar to turbulent boundary layer. CCM+, to simulate the behavior of floating vessels such as boats. For large amplitude motions, such as a container ship navigating heavy seas, New versions of STAR-CCM+ are released every four months. For the the DFBI model can be used to simulate wave slamming, capsizing, wave- most up to date information please visit www.cd-adapco.com  piercing, water-entry and green water effects.

 DOWNLOAD https://support.cd-adapco.com dynamics 2.02 05 ..::PRODUCT NEWS STAR-CD V4.06 ..::OFFICE NEWS OFFICE NEWS

Houston

On June 17, CD-adapco officially opened its new-full service office in Houston with an exciting Open House. This event was attended by over 200 engineers, from the Houston area and beyond, who had the opportunity to meet with key CD-adapco personnel, and learn about the tangible benefits of using CD-adapco’s simulation software.

Located at 11000 Richmond Avenue in Houston, the office will provide state of the art computing facilities and dedicated customer areas for training and consultancy technology transfer. PRODUCT NEWS According to Steve MacDonald, providing customers with more access to CD-adapco staff is the key reason for opening the office: “We have always prided ourselves on the quality of our Jean-Claude Ercolanelli, VP of Product Management, CD-adapco people - becoming a CD-adapco customer means more than purchasing world-class software or services; it opens the door to an unrivaled wealth of engineering expertise.”

Address: 11000 Richmond Avenue, Suite 110, Houston, TX 77042 Tel: (+1) 713-334-4311 STAR-CD V4.06 - Mould Breaking CFD Fax: (+1) 713-334-4312

Since its first release 20 years ago, STAR-CD has Users of STAR-CD V4.06 will also benefit from enhancements to Nürnberg established a reputation for its versatility and is today existing capabilities and the addition of a number of key new still unrivaled in its ability to tackle problems involving features: Back in February, CD-adapco closed the door to Nürnberg's HDI complex multiphysics and complicated geometries • Improved treatment of porous media and polyhedral meshes Tower, the place that CD-adapco Germany has called ‘home’ for (using stationary or moving meshes). In the latest release, STAR- • Enhancements to parallel file handling which have significantly more than a decade. CD V4.06 further enhances this reputation with an improved improved the scalability of STAR-CD V4.06 compared to other CFD meshing process and the ability to simulate physics phenomena codes The reason? CD-adapco outgrew its old home and moved to a that have, until now, been beyond the reach of mainstream CFD • Additional options for finite volume stress analysis including; plush purpose built office in the new state-of-the-art Nordostpark technology. orthotropic elastic materials, automatic time step control based on development, located close to Nürnberg airport. The new office plastic strain and improved solution mapping from mesh to mesh occupies 2000 square meters and has the potential to house “More than just a CFD code, STAR-CD V4.06 is an integrated CAE • Improvement of melting and solidification and casting model to well over 100 talented developers, support engineers and platform for performing powerful multi-physics simulations, incorporate FV stress solution, oxide layer tracking and support for consultants, allowing CD-adapco to effectively double the size of including: combustion; multiphase flow; heat transfer; conjugate semi-permeable baffles its German operation over the next few years. heat transfer; melting and solidification; and stress”, explains CD- • Integration of the latest CD-adapco meshing technology adapco President Steve MacDonald. "While other CFD vendors are • Discrete element modeling (DEM) for the study of granular First opened in 1991, with just a single employee, the German content to simply build upon their existing software architecture, transport such as hopper flows, sand blasting and heap formation office has consistently been one of the fastest growing parts of we have achieved our aim of basing all of our product lines on the (available as a beta feature) the CD-adapco empire. In 1998, when CD-adapco moved into the most advanced solver technology available.” HDI Tower, they initially occupied just one-half floor, later Try it out! expanding to take over two full floors of the building. In particular, STAR-CD V4.06 provides benefits for CD-adapco’s STAR-CD V4.06 is now available from CD-adapco’s User Services extensive community of Internal Combustion Engine designers and Site: https://support.cd-adapco.com The new offices also include a large area for visiting customers, engineers. According to VP Product Management, Jean-Claude Or from your local CD-adapco office. state of the art training facilities, and fully equipped meeting Ercolanelli: “We have extensively tested STAR-CD V4.06 against a rooms and demo theatres. range of complex industrial engine simulation examples, and we are now confident that it delivers the same level of accuracy and New address: robustness that our users have come to expect from our products, Nordostpark 3 – 5, 90411 Nürnberg, Germany while providing additional benefits through polyhedral meshing, an Tel: +49 (0) 911 946 43-3 Fax: +49 (0) 911 946 43-99 enhanced physics models and better parallel performance.”

 DOWNLOAD https://support.cd-adapco.com  MORE INFORMATION http://www.cd-adapco.com 06 dynamics 2.02 dynamics 2.02 07 ..::BREAKING NEWS coolstuff ..::BREAKING NEWS Tecplot President, Mike Peery. “Our relationship with CD-adapco is a natural New interface will yield partnership, due to their dedication to technical excellence combined with their focus on customer solutions. Polyhedral performance is becoming Fancy driving a CD-adapco Major productivity increasingly important, and the combined power of our respective applications will yield major productivity gains for users.” branded racing car? gains for users Courtesy Tecplot David Vaughn, Director of Aerospace and Defense for CD-adapco, says, When we announced that CD-adapco’s logo “Tecplot continues to be an invaluable partner for CD-adapco. Their user was going to appear on the ING Renault F1 Tecplot, Inc., developer of Tecplot data focus meshes perfectly with our mission to develop long-term relationships in order to provide maximum benefit for the customer.” Team’s R28 racing car, little did we know visualization and technical plotting that within a few months we’d be driving an solutions, has partnered with CD-adapco will in turn be supporting export of the Tecplot format in the next release of STAR-CCM+. STAR-CCM+ designed entirely CD-adapco branded race-car around CD-adapco to create a new interface Bicycle races to success world famous circuits such as Monaco, Le between Tecplot 360 2008 and STAR-CCM+, Mans and Silverstone. adding support for polyhedral cell in Le Tour, La Giro & the technology. Epsilon Euskadi, the Spanish high performance motor racing technology 2008 Olympics center based in Azkoitia, Spain, has, with the help of EnduRacers Customers of both companies will benefit by being able to combine the (enduracers.com), transformed their ee01 Le Mans series car into a computer comprehensive CFD solutions of STAR-CCM+ with the cutting-edge In Dynamics 27 we reported how Felt Racing model for rFactor, the PC racing simulator from Image Space. The ee01 is a visualization capabilities of Tecplot 360 2008. As a result of the had, with the aid of STAR-CCM+, designed product of the METCA program, a joint graduate degree course in conjunction partnership, Tecplot’s users will be able to read STAR-CCM+’s native file with the University of Mondragon, the Master of Technical Specialization format and CD-adapco’s users will have access to Tecplot 360’s what company founder Jim Felt boldly Masters in Motor Racing Competition (M.E.T.C.A.).  Founded in 1981, privately held Tecplot, Inc. delivers visualization software for engineers publishable quality images and animations. and scientists to analyze, discover, and communicate results. In 1988, the Bellevue, WA-based claimed to be “the most aerodynamic, UCI- Recognizing the contribution CD-adapco software has made to the design of company launched Tecplot, its first software product for the scientific visualization market. A joint announcement of the partnership was made to aerospace the first ever Spanish Le Mans series car, Epsilon Euskadi have generated a Since then, Tecplot, Inc. has been applying and influencing the latest advances in visualization legal frame ever created”. Following a string customers at the 46th AIAA Aerospace Sciences Meeting in Reno, Nevada CD-adapco “skin” for use in the computer game, allowing you to drive a technologies and plotting capabilities. With more than 30,000 users worldwide, Tecplot has during Tecplot’s presentation of the latest release of Tecplot 360. of successful results at some the world’s realistic representation of the car around some of the most famous race become the trusted name in data visualization. best races we’re inclined to agree with them. circuits in the world. The ee01 was also accepted as an entry in this year’s “Being the first to natively support the STAR-CCM+ format shows our CD-adapco calendar completion.  [email protected] www.tecplot.com dedication to both CD-adapco’s customers, as well as our own” says MORE INFORMATION The bicycle in question is the revolutionary Felt DA time trial bicycle, which was designed over two years using extensive CFD modeling: both to determine Be sure to visit the multimedia section on www.cd-adapco.com to see a video which prototype designs were most aerodynamically efficient and to understand of the car racing through the streets of Monaco painted in CD-adapco livery, or the complex aerodynamics interaction between the rider and the individual visit www.rfactor.net and take it for a spin yourself. “CD-adapco is pleased to be able to work with a recognized leader such as bicycle components. Felt Racing provides bicycles to the Garmin/Chipotle-H30 SPT to bring improved practical benefits to engineers involved in flow team (previously known as Slipstream/Chipotle-H30), which is home to leading assurance work, via integrated processes involving an intelligent, judicious riders such as Magnus Bäckstedt, Julian Dean, David Millar, Christian Vande combination of OLGA® and STAR technologies,” said Dennis Nagy, Computational Flow Velde and Dave Zabriskie on its 2008 roster, all of whom ride the Felt DA - CD-adapco’s Vice President of Marketing and Business Development and which bears the CD-adapco logo - during the time-trial stage of major races. Energy Sector Business Director. “As the world’s oil and gas challenges Assurance with SPT Group move to harsher arctic and deep subsea environments, the needs for more Aboard their Felt DAs Slipstream/Chipotle-H3O won the opening 23.6K Team refined insight into the physical behavior of exploration and production Time Trial stage in the Giro d'Italia (the Tour of Italy) beating the all of cycling's & CD-adapco systems and equipment, to ensure optimal operation and avoid failure risks, top teams and propelling Christian Vande Velde into the pink jersey - making can be met by the intelligent use of multi-fidelity simulations such as those him the first American to lead the Giro for over 20 years. This followed on from available from SPT and CD-adapco.” The SPT Group, the leading vendor and another impressive team time trial victory in the Tour Of Georgia - America’s most highly rated professional race - with Slipstream/Chipotle-H3O’s Australian developer of flow assurance software and rider Trent Lowe narrowly missing overall victory by just four seconds. services, and CD-adapco, have launched an These results helped to earn the team - newly rebranded as Garmin/Chiptole- initiative to investigate and grow the H30 - a wildcard invitation to the Tour de France, which is not only the most important cycling race but is also one of the most prestigious sporting events potential integration between SPT’s OLGA® in the world. Following a succession of impressive Time Trial results, and some and CD-adapco’s CFD software. gutsy performances in the mountains, Christian Vande Velde managed to finish  Presenting rFactor, the new racing simulation series from Image in a highly credible fifth place overall in the general classification - arriving in Space Incorporated. After successfully creating over a dozen Paris only three minutes behind the yellow jersey winner. The two companies will work closely with the market to define and products in the past ten years, Image Space takes the next logical implement streamlined processes which use the best features of both step, creating a completely new technology base and development The Felt DA also made an appearance at the 2008 Beijing Olympics, where OLGA® and the STAR solvers to significantly improve the timely, practical process. This new isiMotor 2.0 environment will be the foundation Garmin/Chipotle-H30’s David Zabriskie came a creditable 12th for the US team insight that can be gained by engineers using computational flow assurance on which to build exciting products for many years to come. Courtesy SPT place in the individual time trial. in the oil and gas industry.  MORE INFORMATION http://www.epsiloneuskadi.com  MORE INFORMATION www.feltracing.com http://www.rfactor.net “SPT Group sees the initiative with CD-adapco as an important contribution  SPT Group has, over the years, been successful in turning basic research into profitable www.slipstreamsports.com http://www.enduracers.com to our existing activities. Linking the pre-integrated 3D flow model in OLGA® software products and consulting services to the oil and gas industry. to detailed CFD models for process equipment gives consistent model details and efficient simulations. This yields exciting possibilities and Today SPT Group develops and markets OLGA, Drillbench and MEPO, software products that ultimately gives our customers increased insight and confidence in their support solutions maximizing production and reservoir performance. edpm is a proven dynamic >>2009 Calendar Competition future designs,” says Norbert Hoyer, Executive Vice President of Business online real-time production support system, assisting in the understanding of multiphase flow Calling all CFD ‘Wannabees’! Do you have what it takes to be a REAL CFD Guru? Development in SPT Group. “We are happy to add CD-adapco to our that enables sustained cost effective operations. It is time once again for our International Calendar Competition. Submit your CFD model today. continuously growing list of OLGA Technology Partners” says Bjarte Håtveit  MORE INFORMATION [email protected] www.sptgroup.com The 12 best entries will be published in our exclusive International Desktop Calendar 2008. responsible for the OLGA partner activities. The best design wins our grand prize. Visit the site below for more details. www.cd-adapco.com/calendarcompetition

08 dynamics 2.02 competition 09 ..::FEATURE ARTICLE Automotive ..::FEATURE ARTICLE Automotive Clean, Green & Frighteningly Fast: CD-adapco helps Ford break the land-speed record for fuel-cell powered cars

Tim O’Brien, Ford Motor Company. Dejan Matic, CD-adapco.

This record breaking vehicle has a serious message: to horizons with fuel cell powered vehicles. The collaboration with demonstrate that sustainability can be achieved without Ohio State University also affords us an opportunity to work compromising drivability. In practical terms, sustainability means closely with a prestigious university, which provides out-of-the- companies taking into account not just financial outcomes, but box thinking from student engineers and helps us recruit  also environmental and social performance. Ford Motor talented young people to work at Ford Motor Company." Ford is becoming smaller, Company takes a no-compromise approach towards integrating leaner, more globally integrated and sustainability into all aspects of its business strategy: The Ford Fusion Hydrogen 999 is a collaborative effort among more focused on meeting customers' "Sustainability is about making people's lives better," said Tim Ford, Roush, Ballard Power Systems and Ohio State University. needs and wants. O'Brien, Ford’s deputy chief of staff, executive operations and The car was designed by Ford engineers while Roush provided It is also a company with sustainability. "That's the essence of any successful product, motorsport expertise and a workshop in which the car was sustainability at the heart of its whether you are talking about an iPod, an automobile or a taco." constructed. The team of Ohio State’s University students business. Our vision for the 21st provided the design of a 770 hp electric motor, giving the century is to provide sustainable Ford's strategy for alternative fuels is built around multiple opportunity to Ford to recruit talented young people from a transportation that is affordable in technologies, including hydrogen fuel cells. This flexible prestigious university. every sense of the word: socially, approach allows the company to meet goals for customer environmentally and economically. needs, environmental impact and shareholder interests. The Given that aerodynamic drag increases with velocity squared, it Alan R. Mulally strategy does not focus on a one catch-all solution, but includes takes an enormous amount of power to run any vehicle at over President and Chief Executive Officer a flexible array of options, including hybrids, E85 ethanol, clean 200 mph, especially for what is essentially a modified diesels, bio-diesels, advanced engine and transmission production vehicle. Roush engineers therefore dedicated special technologies as well as hydrogen fuel cells. While developing attention to drag reduction, since for a given engine output the sustainable vehicles, maintaining drivability key: drag of the vehicle essentially determines its maximum speed. (contd.) "The point is, people often drive the vehicle they think they have The drag optimization was performed numerically using CD- to drive even though they'd really like to drive something else. Traveling at 207mph, without consuming an ounce of gasoline and leaving nothing But we are working on designing vehicles that not only support but a trail of water-vapor, Ford’s record breaking Fusion Hydrogen 999 recently the sustainability agenda, but are exciting vehicles that people want to drive," says O’Brien. demonstrated that “Clean and Green” doesn’t have to come at the expense of Racing is part of Ford Motor drivability. Named after an early 1900's vehicle that reached speeds near 100mph, the The Ford Fusion 999 also reflects the company’s proud heritage of involvement in motorsports: "Racing is part of Ford Motor Company's DNA so it seemed only Ford Fusion Hydrogen 999 is powered by the latest fuel-cell technology and designed using Company's DNA so it seemed only natural for us to build a fuel cell race car that runs on hydrogen, a fuel that could some day “natural for us to build a fuel cell race cutting-edge Computational Fluid Dynamic simulation. It has replicated the success of its play a key role in meeting the energy needs of the transportation famous namesake, by becoming the first production based fuel cell powered car to travel sector," said Gerhard Schmidt, Vice President, Research & car that runs on hydrogen Advanced Engineering for Ford Motor Company. "Our goal in at over 200mph. attempting this record is to further expand our technological Gerhard Schmidt, Vice President, Research & Advanced Engineering for Ford” Motor Company 10 dynamics 2.02 dynamics 2.02 11 ..::FEATURE ARTICLE Automotive > St. Eval Wind Farm - Cornwall Turbines: 16 • STAR-CCM+ • STAR-CAD Series • STAR-CD Power capacity: 9.6 MW Homes equivalent: 5368 Developer: National Wind Power Ltd

The Ford Fusion Hydrogen 999 car's number is rooted in Ford's land speed history. The triple-nine was used on several of Henry Ford's early racers, most notably one that set a record in 1903 with an average speed of 91.32 mph over frozen Lake St. Clair. That vehicle has since been restored and is on display at the Henry Ford Museum.

adapco’s STAR-CCM+ Computational Fluid Dynamics software, which allowed DC/AC inverter and an induction motor. The fuel cell system developed by Roush engineers to rapidly examine the impact of multiple design config- Ballard chemically changes hydrogen atoms into electrical current with heat urations from the comfort of their desktop computers, including the analyses and water as by-products. It delivers DC current to an inverter, which converts of different underbody and rear-wing configurations, all of which were current to AC and drives a 3 phase 770 hp induction motor. In order to benchmarked against the original car. As well as reducing drag, STAR-CCM+ maximize fuel cell power delivery, it was decided not to use ambient air for the also helped increase the high-speed stability of the vehicle, by demonstrating catalytic process, but to carry all oxygen required for the speed record that the addition of a rear spoiler significantly reduced the body generated lift. attempt. The oxygen is stored in tanks as a Heliox mix which contains 60% Helium and 40% Oxygen. For the purpose of reducing aerodynamic drag, the "Drag reduction of the Ford Fusion 999 was a key element of the successful front of the car is closed to airflow so the only cooling provided for the fuel world record attempt. By taking advantage of CFD analysis, physical test times cells is ice cold water stored in a 400-litre tank. could be reduced and multiple configurations of the vehicle studied. Other benefits included insights such as adding a rear spoiler for stability,” The culmination of the project occurred on August 15, 2007 at the Bonneville John W. Zaleski, Program Manager, Roush Industries. “Through several design Salt Flats in Utah, a location synonymous with speed having seen the world iteration we managed to reduce the drag coefficient of the vehicle from 0.34 land speed record broken no fewer than 18 times. It was here that the Ford to 0.21, helping the Fusion to become the first fuel cell powered car to pass Motor Company became the first automaker to set a land speed record for a the 200 mph barrier. Our partnership with CD-adapco in our use of production-based fuel cell car when Ford Fusion Hydrogen 999 raced to STAR-CCM+, allowed us to draw from a great pool of expertise spanning both 207.297 mph. With this latest environmental innovation and a historic run at CFD and vehicle aerodynamics." Bonneville, Ford is looking to further expand the company’s technological horizons with fuel cell powered vehicles. They are hoping that lessons learned The engineering effort expended designing, testing and manufacturing the Ford from this project will feed future fuel cell vehicle development with a goal of Fusion Hydrogen 999 is nothing short of exceptional. The fuel and power plant reducing vehicle complexity and cost, while making the designs more efficient, Visit us at: system consist of two Heliox tanks, one Hydrogen tank, the fuel cell system, a and by joint venturing the production of the fastest and cleanest speed record Power-Gen ‘08 vehicle ever designed, CD-adapco continues to actively participate in providing Booth 5208  MORE INFORMATION www.ford.com ecologically viable industrial development.  December 2-4, 2008 Orlando, FL Ford’s History of Alternative Fuel Innovations

Ford’s involvement in the development of alternative fuel vehicles has a long history, beginning with its founder, Henry Ford. Besides being an industrialist, Ford was a conservationist who preferred harnessing nature as an energy source and using zero- emission hydroelectric energy. Today, Ford Motor Company is deeply involved in research and development of alternative fuels for the future, including plug-in hybrids, hydrogen and hydrogen fuel cells. The company devotes a significant percentage of its Flow, Thermal & Stress scientific research budget to environmental efforts toward a world where motorized transportation is cleaner, more fuel efficient and generally less harmful to the natural environment. Simulation for Renewable Energy

 Productivity Accuracy Flexibility Expertise

What do you expect from your Engineering Simulation Software?

 Ford through the years

Ë FACTS For more information: [email protected] www.cd-adapco.com 12 dynamics 2.02 ..::FEATURE ARTICLE Automotive ..::FEATURE ARTICLE Automotive

Go Karting Trivia Go Karting is a popular sport across Europe, but it actually originates from America. Art Ingels is thought to have built the world's first Go Kart in 1956 in California. Go Karting quickly caught on with facilities in many towns and cities across the USA. The initial enthusiasm lasted until a lack of finances towards the end of the 1960s meant that Go Karting facilities began to disappear. By the 1990s, changes in design and the introduction of the first few regulatory bodies helped Go Karting to find its place as the first step for aspiring racing drivers. Nowadays, the vast majority of racing drivers in Formula 1 have started  Fig:02 out on the Go Karting circuit. The Kart, ready for action. Ë FACTS

 Fig:03a  Fig:03b  Fig:03c

Once complete, the model was imported into STAR-CCM+ with a The results (shown in Figure 3) immediately demonstrated that  Fig:03a-c bounding aerodynamic box. Boundary conditions were set up and the modified front bumper and faring immediately have a Streamlines showing the Analyzing the Aerodynamics the model re-surfaced ready for generation of a polyhedral significant effect on the pressure field around the kart: improved heat exchange of volume mesh generated containing approximately 2 million cells. • Less force is generated over the helmet of the driver due both radiators, thanks to the The automated nature of the STAR-CCM+ meshing was to the deflection of the air due to the new faring. good quality of air flowing particularly important in this study as multiple configurations • This masking action also shows an overall reduction in through them. of a Competition Kart were analyzed, with proximity refinement heavily used to ensure pressure on the drivers body, something likely to make suitable mesh density in areas of small clearance e.g. low driving easier at higher speeds. Giorgio Pagliara, Giuseppe Ganio & Daniele Camatte - Polytechnic of Turin ground clearances of the tubular frame. • Less influence of the airflow of the front and rear wheels again due to the deflection of airflow by the front bumper The steady state flowfield around driver/kart geometry was and re-designed side pods. Viewed from trackside, kart racing shares absolutely none of the glamour analyzed with a 90kph inlet velocity and ground and wheel associated with the multi-million dollar world of Formula 1. However, with movement to match. The standard k-ε model was used The modified radiator design for configuration 3b shows an throughout with the radiators on the kart modeled using the improvement in the “quality” of air through the two radiators due the fastest karts capable of attaining speeds in excess of 160mph porous media formulation. to the ducting and their higher position.  The Politecnico is a research university and, if you are a PhD (250kph), when viewed from a kart seat located just a few inches from the Three different configurations were simulated with modifications Figure 3c demonstrates that both new configurations cause a student or a young researcher, you made to side-pod protection and radiator position in line with slight increase in drag; this is specifically due to increased will find state-of-the-art facilities ground the racing is every bit as competitive. Kart racing is often seen as CIK-FIA regulations (Commission International de Karting - airflow (and hence drag) through the radiators, over the engine here, to learn how to “research”. the first step on the ladder of a motor racing career, with almost all top F1 Federation International de l’Automobile). The first configuration and the brakes. It is also seen that a significant increase in Big multinational companies have analyzed was the existing, commercially available model with two downforce is seen on the newer configurations, indeed it is already decided to bring their drivers, from Michael Schumacher to Lewis Hamilton, having graduated from modified versions, type 08a, which has a traditional radiator almost doubled in the ‘a’ configuration. laboratories within the competition karting in the early stages of their careers. positioning, but at a shallower angle to the flow and type 08b, Politecnico, thus creating, besides which has two smaller radiators positioned either side of the Conclusions an effective flux and exchange of The Kart driver, each with an inlet duct. Slight modifications to the faring, Although an increase in drag was seen in the new configurations, knowledge and abilities, also an From an engineering point of view, F1 is dominated front bumper and side pods are also implemented on type 08a this is offset by the improved downforce and better cooling of the important job market for the great by cutting edge technology with aerodynamics being The kart in question is a regular small competition kart with a and 08b. engine and brakes. It is clear that, although an improvement is number of Master and PhD a key consideration in producing a championship typically high power to weight ratio. It is equipped with a water winning car; the F1 industry was an early adopter of cooled engine mounted on a tubular chassis and is connected seen in the new configuration, it is not yet optimized. students that study and work Results today at the Politecnico. CFD technology, and the needs of the industry continue to play to the wheels via a chain with no differential or suspension. A a key role in the development of CAE tools. typical kart track contains many tight bends, but despite this, A key indicator for success in the study was an overall decrease Significant design changes have yet to be carried out on the the average speed of a race is 90kph with a top speed of in drag, increase in down-force (vital for the tight twisting tracks bumpers which have been developed to conform to international Obviously, by its very nature, a small open wheeled kart around 130kph. seen in karting), improved radiator efficiency and finally better regulations which are open to interpretation. This means that the constructed largely from steel tubing is never going to be the cooling of the brake system. design of such karts is constantly changing and evolving year on most aerodynamic of vehicles. However the authors of the In keeping with the “rough and ready” nature of the sport, the year.  current study were confident that, using CFD simulation, they kart itself had no original CAD drawings, so a series of digital would be able to better optimize the configuration of the kart images of the kart were taken including measurement and help to squeeze the extra couple of hundredths of a references and were then imported into CATIA and scaled second that could ultimately be the difference between winning accordingly. Finally, a mannequin representing the driver was  MORE INFORMATION ON POLYTECHNIC OF TURIN http://www.polito.it/ and losing a race. inserted into the seat of the kart to complete the assembly. 14 dynamics 2.02 dynamics 2.02 15 ..::FEATURE ARTICLE Automotive F1 Trivia ..::FEATURE ARTICLE Automotive Did you know?: Renault introduced the turbo engine to Formula One when they debuted their first car, the Renault RS01 at Silverstone in 1977. ING Renault F1 Team: Ë FACTS Accelerating Ahead with New CFD Centre

In August 2008 the ING Renault F1 Team will formally open a new Computational Fluid Dynamics (CFD) centre at its technical centre in Enstone. Those three letters represent the future when it comes to Formula 1 - as well as having direct relevance to road cars, and the world at large. Here’s why…

CFD and Formula 1 Commonly referred to as a ‘wind tunnel in a computer’, CFD is a technology enjoying rapid growth thanks to the exponential development of computing capacity. Using enormous computing  Present in 118 countries, Renault capacity and sophisticated software, it allows engineers to model and simulate the is a multi-brand volume carmaker. It has interaction between an object and the surrounding fluid. In F1 terms, that primarily achieved a global dimension through: its means aerodynamics, and how the car manages airflow around its surface to Alliance with Nissan, its acquisition of generate down-force. But it can also be applied to areas such as modeling gas the Romanian manufacturer Dacia, the flow through the exhausts, or simulating combustion within the engine: creation of Renault Samsung Motors in “CFD gives us access to a huge range of information,” explains Technical Director South Korea. Bob Bell. “Where wind tunnel testing allows us to measure forces on the car, CFD Renault’s workforce of nearly 130,000 opens up much more detailed information about airflow around the car, and even employees conceives, designs, allows us to simulate how parts of the car deform under load. It’s the way of the manufactures and markets attractive, future.” safe, environmentally-friendly vehicles. Its sales financing subsidiaries offer a A cutting-edge resource In recent years, the trend in Formula 1 has been towards comprehensive line of financing and expensive second wind tunnels, requiring significant capital expenditure – and service packages. whose limits are already well-known. The Renault Commitment 2009 plan Currently, CFD is viewed as an ‘answer tool’ in F1 circles, used to confirm or expresses Renault’s ambition to make predict the results of solid-state model testing. The new Renault F1 Team CFD and sustain Renault as the most Centre aims to transform the technology into an ‘ideas tool’. “As we saw our rivals profitable European volume car investing in second wind tunnels, we asked ourselves: why spend millions in that company. area, when an investment in new technology could bring us better results at half the cost?” explains Bob Bell. The new facility will allow the team to exploit the new rules limiting CFD usage to their maximum, and will rank among the top 100 global computing facilities. What’s more, its potential to contribute to future road car development prevents any potential redundancy that might be incurred under rules changes in the year ahead.

The CFD centre will primarily be used to run simulations using CD-adapco’s industry leading CFD A society-relevant technology In harmony with the environment tools STAR-CCM+ and STAR-CD. CD-adapco is the exclusive provider of CFD software to the ING The potential applications of CFD stretch far beyond Formula 1, or Cutting-edge technology is not just housed within the building: the Renault F1 Team, and has been a partner of the Team since its inception. STAR-CD and STAR-CCM+ even the automotive industry. CFD has been applied to product new CFD Centre embodies the latest standards in construction have been used extensively in the design of all the Team’s cars including the R28 and the World design fields as diverse as jumbo jet and heart valves, and its and environmental responsibility. The Centre has been sited below Championship winning R25 and R26. The R28 carries the CD-adapco logo on both sides of the rear applications continue to expand as development of the technology ground level to minimize its impact on the Sites of Special attenuator. accelerates. For example, a recent CFD project conducted jointly Scientific Interest located around the Enstone site. Its modular by Renault F1 Team and Boeing could potentially lead to a 2% to construction has contributed to an exceptionally rapid construction The road cars of tomorrow 3% drag reduction on transonic aircraft in coming years. Formula 1 phase. Furthermore, the facility will be powered by renewable The $50 million investment in future technology represents a firm sign of Renault’s commitment to a has a proven capacity to adopt new technologies and drive their energy, in line with the entire site. Environmental priorities form an competitive future in Formula 1. But the new CFD Centre symbolizes much more for the Renault- development, for use both within the automotive industry and on-going development path for the team, and the team achieved Nissan Alliance. “We will be working on the cutting-edge of technology in this new facility,” elaborates beyond. “This approach is much more society-relevant than the Kyoto target of a 12.5% reduction in emissions in 2005. The Bell. “This will allow us to develop CFD techniques superior to those available in the marketplace, constructing additional wind tunnels,” concludes Bob Bell. “This is new facility is due to come on-stream during the second half of which will then be available to the Renault-Nissan Alliance. Formula 1 will make a concrete something that the FIA is very keen on Formula 1 doing, using its 2008, allowing it to make a contribution to the final development contribution to helping develop the road cars of tomorrow.” Improved CFD techniques and processes technological leadership to derive benefits for society at large. phase of the R28 – and to play a key role in the 2009 design and can make a decisive contribution to developing more efficient, environmentally-friendly vehicles and Here is a perfect example of how we are doing that.” development programme. power trains in the years to come. Furthermore, the size of the facility will provide the Alliance with a permanent, additional CFD resource for road car development.  MORE INFORMATION ON PROS3 http://www.ing-renaultf1.com/en/ 16 dynamics 2.02 dynamics 2.02 17 ..::FEATURE ARTICLE Aerospace ..::FEATURE ARTICLE Aerospace

During the same design loop, the yaw control surfaces capabilities can be evaluated in order to complete the range of information needed for the flight controls systems. Mesh size and setup parameters have been  Entecho was formed for the optimized to allow at least one configuration to be run overnight. This purpose of commercializing the unique stage closes the aerodynamic design loop, as shape and dynamic loads flight technology that founder Kim are then known for the CAD/FEM team to finalize the model. Schlunke developed. Benefits and Achievements Kim’s dream was to make the world a The STAR-CCM+ simulation process is fully integrated into the virtual better place, ultimately by producing a design process and interacts strongly with the CAD design and software flying vehicle that could partially development for the control system. The design loads predicted by the replace road travel, thereby reducing CFD analysis make the choice of the composite materials in the craft’s  Fig:02 congestion and pollution. structure much easier, leading to significant weight reductions and Momentum model, tilted flight further improvements in the payload and endurance capabilities of the flight platform.

The flight control system CFD analysis has proven to be a powerful tool. One of its most important outputs is the data that is fed into a flight simulator that delivers realistic attitude response and lift characteristics. It has also made it possible to identify, quantify and address an unusual ground effect response and therefore avoided putting the prototype craft or personnel at risk.

Once the CFD calculations of aerodynamic performance and attitude control met the prerequisite targets, a prototype flight platform was constructed.

The successful test flights of this “MuPod” UAV (unmanned aerial vehicle) has confirmed the value of CD-adapco products in providing accurate flight characteristics early in the development process. It was very rewarding to witness the technology at work as the prototype took Virtual Design Enables a off for the first time and behaved as predicted by the flight simulator. Evolution The virtual design environment approach has provided an early and Revolutionary Flying thorough understanding of the potential and capabilities of this innovative flight technology. The number of hardware variants selected for construction has been reduced significantly by using the right tools and the right techniques and significant savings in time and cost have been realized as a result. We are currently updating the implementation Technology to Take off  MORE INFORMATION http://www.entecho.com.au methodology to use STAR-CCM+ with very promising results so far. 

 Fig:03 David Lasserre, ENTECHO, Australia MFR method, flow through the rotor The challenge of designing a next generation compact Vertical Take Off and Landing (VTOL) craft has been addressed with the combination of a novel radial fan technology and the use of unique lifting and control surfaces.

CFD Techniques The mesh generation and model setup is controlled by a The design process started with a searching script that implements the CD-adapco automatic meshing aerodynamic analysis in order to establish the feature when running a series of cases at different control best interaction between the lifting surfaces and surface configurations and flight orientations. to set the parameters of the propulsion system that satisfy the lift requirements. During the concept creation stage, no The flight control system analysis has proved essential in the prototype was built, and the geometry development relied only optimization of the performance of the attitude control on the CFD results. To ensure a high turnover of results for system. For example, the flight performance of the manned  Fig:01 each configuration, automation scripts were written to create, platform in particular required detailed analysis of its Using an axis symmetric mesh mesh and run a matrix of geometries and boundary behavior in ground effect. This flight control system analysis provides the best compromise of conditions. returns accurate aerodynamic forces and pitch, roll and yaw quality, density and size torque inputs to the flight controls system lookup tables, with In the next step where the flight mechanics and stability are up to four configurations being run daily on the solving cluster. analyzed, all surfaces relevant to the control of the craft are modeled in detail. However, to reduce the complexity, rotor Simultaneously, the propulsion system and lifting surfaces and stator blades are simulated through a momentum are analyzed in greater detail. Sector meshes are set up for generator, using the user subroutines capability of the Moving Reference Frame (MFR) method to analyze the STAR-CCM+. The radial momentum added to the system propulsion turbo machinery. Special attention is paid to the converges on the value of the power input needed to hover in rotor and stator interactions with the blades optimized to each case. An additional swirl can also be added to satisfy the dual requirements of efficient lift generation and accurately simulate any residual tangential flow. rotor torque cancellation. 18 dynamics 2.02 dynamics 2.02 19 ..::FEATURE ARTICLE Turbomachinery ..::FEATURE ARTICLE Turbomachinery

 Wood Group Light Industrial Turbines  Fig:01 is the world-leading independent provider of CAD representation of the example shrouded-blade integrated maintenance solutions, and repair and overhaul services for industrial gas turbines, used for power generation, compression and transmission in the oil and gas and power-generation industries.

The Automated  Fig:04 Conformal Polyhedral Mesh showing primary gas path in grey, blade in blue and cooling path in brown

Simulation Process  Fig:03 Surface triangulation around the root area  Fig:07 of Combined Thermal, Flow & Stress Internal streamlines through the cooling passage colored by temperature in Turbine Blade Cooling Analyses

Joel B Davison, Stephen Ferguson, Fred G Mendonça and Adam F Peck - CD-adapco Allan Thomson - Wood Group LIT  Fig:06 Temperature through the blade, external and internal cooling paths Production turbine blade designs are geometrically very complex. Dealing with details in and around the hub, shroud,  Fig:05 squealer, tip clearances, internal cooling passages containing Memory usage of different structural solver types ribs and pedestals, and transpiration/film cooling holes continues to pose a major challenge in respect of geometry definition, manipulation and meshing. For practical reasons, many simplifications with respect to geometry and boundary conditions between the flow and thermal parts are sought.

These simplifications lead to separate analyses being performed The framework is exemplified here on a shrouded-blade production geometry on the external and internal flow paths, blade metal and surface (see Figure 1), that originates from the Tornado engine, a 5-7MW power- heat transfer. It creates the need to iterate many times between generation unit from Siemens (formally Ruston Gas Turbines), which would the separate analyses, updating boundary conditions up to a point now typically be undergoing overhaul. The blade contains a curvilinear  Fig:08  Fig:09  Fig:10a  Fig:10b where the interdependency between them converges. Often, simplifications to internal cooling path exiting at the shroud. Details such as dust holes need Shroud damage (left) compared to the undamaged blade (right) Temperature distribution in the turbine blade Effective stress (left) and displacement (right) geometries are so extreme that experimental correlations are needed so as to be represented faithfully (see Figure 2). This engine is maintained by Wood within the blade to force validity of simplified modeling. Group light industrial turbines. WORKFLOW The Finite Volume Method for Stress Analysis Indeed, if the cooling passage flow is plotted in isolation, it is seen that This article describes an optimized workflow that allows engineers to work The finite volume methodology is more commonly used for the solution of the fluid increases to full temperature within a very short distance of with actual geometries and to combine flow, thermal and ultimately stress Meshing Strategy the Navier-Stokes equations of fluid flow and heat transfer, and is common entering at the bottom of the blade. analysis into a single model. in many commercial codes. Commercial Finite Volume (FV) solver A combination of surface wrapping and surface re-meshing techniques were techniques for steady-state flows are frequently solved fully implicitly and Stress Analysis used to repair flaws in CAD surface representation. At the same time, feature therefore have no stability restriction on the time step size, unlike explicit The current turbine, overhauled by Wood Group LIT, underwent thorough detail such as film cooling holes and high curvature are retained. The CAD finite element analysis (FEA). The finite volume approach presented here examination and testing to identify long term areas of weakness of the was exported in IGES format and read into STAR-CCM+ for meshing and employs a segregated iterative solver and has been validated for well- structure. Such weaknesses can lead through minor changes in shape to analysis. In this example, over 600,000 errors in the IGES tessellation were known test scenarios and also evaluated for consistency between different inefficiencies or worse, to catastrophic failures in such turbines. found, ranging from unclosed surfaces to excessively large aspect ratios in mesh types, including polyhedra. the triangulation. It can be seen in Figure 8 that damage has been caused to shroud region, The FV method holds some significant advantages over its FEA counterpart specifically resulting in a deformation affecting the external primary gas The final volume mesh ready geometry was produced automatically using the as it has far more in common with CFD solvers than structural solvers and path. Figure 9 illustrates that this matches with a region of high surface wrapper technology. Surfaces were then automatically split, through therefore requires similarly low memory usage for a comparable number of temperature (circled). This gives a first, though not conclusive, indication of topology detection, into three distinct domains; the primary and internal gas cells. It benefits from full parallel scalability. One seeming disadvantage is locations of potential damage. Other indicators are of the transient heating paths and the blade solid. The detection process identifies interfaces that FV stress solution requires more cells than FEA higher-order elements or cooling rate change in engine load. Though performed here, transient (surfaces common to one or more domains) and prepares them in to properly describe bending stresses in thin members, though if combined conjugate analysis is now made possible through this process. anticipation of continuous multi-domain volume meshing further downstream compared in terms of FEA nodes, the parity is retained. in the process. The effective stress, Figure 10a resulting mainly from rotational and Flow and Thermal Fields thermal loading, supports the inference of high loading and consequent With a high quality surface mesh in place and the three distinct regions, two Slices of temperature throughout blade and fluid are shown although small deformation at the same corner of the end-plate. Figure 10b illustrates the fluid and one solid, a polyhedral volume mesh was generated. The some cool-down is achieved by the cooling passages (see Fig:06) radial displacement resulting from the thermal field.  automation is faithful to the requirement for contiguous meshing between  Fig:02 Transparency showing dust hole and internal detail fluid and solid domains, and also able to perform a finite volume stress analysis to sufficient accuracy.  MORE INFORMATION [email protected] www.wglit.com 20 dynamics 2.02 dynamics 2.02 21 ..::FEATURE ARTICLE Renewable Energy ..::FEATURE ARTICLE Renewable Energy

Providing Flow Simulation Power for Wind Energy Engineers

16,818 megawatts (MW) of wind power plants were in place in the  Turbine simulations with shroud. U.S. at the end of 2007, serving the equivalent of 4.5 million average households. By the end of 2008, AWEA expects that number to jump to over 22,000 MW, which can serve the equivalent of over 5.5 million average households. Ë FACTS

Providing Flow Simulation Courtesy Wingring Power for Wind Energy Engineers

Stephen Ferguson, CD-adapco

Keeping turbines in a clean airflow at onshore wind farms significantly increases their power output and longevity. STAR-CCM+ has been used to simulate the airflow over a potential site and turbine configurations to enable wind farm developers to visualize complex wind patterns, identify areas of high wind speeds or turbulence and optimize turbine positioning.

A combination of atmospheric boundary-layer inflow conditions and coupling to meteorological codes ensures accurate representation of the local weather conditions. In order to meet the world’s energy demands in a sustainable manner, engineers Extreme Conditions As well as predicting how a given turbine design will perform under standard need to deliver robust innovative technology. For 25 years, CD-adapco has enabled operating conditions, CD-adapco's CFD solutions are routinely used to If the simulations had energy engineers to do just that in the ‘traditional’ energy sectors. understand how a turbine will react upon in extreme loading. This technology allows engineers to optimize the aerodynamic efficiency of the turbine and been carried out before understand the range of conditions under which safe operation can be assured. Now we’re routinely applying our technology and expertise in the renewable energy The biggest advantage of CFD is that its rapid turn-around time helps to break “the prototype stage, sector as well. the dependence of wind turbine design on pre-existing design codes. Although design wind conditions are a useful starting condition for analysis, CFD millions of dollars could CD-adapco’s Proven Pedigree simulation allows designers to more easily pursue multiple “what if?” can be interpreted directly and do not have to undergo scaling, a scenarios. Once a CFD model for a turbine is set up, it is relatively simple to have been saved... CFD can be used to simultaneously simulate the efficiency process that can introduce a significant uncertainty, especially for repeat the calculation for multiple loading scenarios. of a wind turbine while calculating the structural loading transient phenomena such as the impact of an extreme gust event. upon it. Hans Grassmann - University di Udine Aerodynamics and Structural Loading A further advantage is that, instead of being restricted to retrieving data from a few experimental monitoring probes, data is available at every point on the A wind turbine is essentially a very large, inverse fan. Instead of using During the design of wind turbines, designers aim to simultaneously turbine, at every discrete time interval for which the simulation is performed. electricity to produce a small breeze, the wind pressure acting on the increase a turbine’s power output over the full range of operating The simulation results can be viewed from any angle, and the instantaneous ” blades of the turbine turns a rotor which, via a gearing mechanism conditions, while improving durability. In a recent project, wind turbine forces acting on any part of the structure can be calculated. drives an electricity generator. The challenge for wind turbine designers design company RingWing used STAR-CCM+ to improve the design of is to extract the maximum amount of energy, in the widest range of their innovative shrouded turbine. The simulations provided detailed Data from CFD calculations can also be used to assist other types of analysis, conditions, at the least cost. Obviously no wind turbine is able to insight into the aerodynamics of the turbine as well as the force for example, the forces acting on a turbine can be exported to a stress-analysis extract all the energy from the wind (operating at a theoretical 100% loading on it, enabling engineers to quantify the effect of design software package. In extreme cases, where fluid forces cause large deflections efficiency); if one did so the air behind the turbine would be perfectly changes. of turbine blades, the CFD simulation can be coupled directly with the stress still, even in the windiest conditions, preventing new air from passing analysis tool and both stress and fluid simulations can be performed through the blades of the turbine. Upfront design investigation can have a big impact on a project’s simultaneously, each simulation feeding new boundary conditions to the other. profitability. In another wind turbine design study, this time by the In order to maximize their efficiency, most current wind turbines were University di Udine, Italy, the business benefit of early understanding of Offshore Wind Farms designed using extensive experimental model testing. Although designs, prior to prototyping, was recognized. Having compared various Coping with higher wind-speeds, corrosion and wave impacts, the challenges of experimental analysis provides considerable insight into the designs using STAR-CCM+, they gained a level of insight that had producing durable, cost-effective offshore wind farms are great, but far from performance of a particular design, physical prototypes are expensive otherwise been unattainable. University di Udine’s Hans Grassmann insurmountable. One example where 3D flow simulation is having a significant Courtesy Wingring and time consuming to construct. states CFD’s impact on the bottom line. impact is in modeling wave loading. The loading on the turbine-supporting structure can be determined for different wave heights, sea-states or wind Unlike testing of physical prototypes, CFD simulations are typically “If the simulations had been carried out before the prototype stage, speeds, at full-scale and without the expense of manufacturing prototypes or  Turbine simulations without shroud. carried out at full scale (the computer model has the same dimensions millions of dollars could have been saved with obvious benefits to the physical testing. Technology that’s been routinely used in the marine industry as the actual production wind turbine rather than those of a smaller project profitability and overall success. But the success did not stop for years is now being applied to reduce the impact of the harsh offshore  MORE INFORMATION [email protected] experimental model). This has the considerable advantage that results there. STAR-CCM+ was able to assist in finding a solution.” environment on wind turbines.  22 dynamics 2.02 dynamics 2.02 23 ..::FEATURE ARTICLE Industrial Applications ..::FEATURE ARTICLE Industrial Applications

CFD simulation was able to save the company between £1000 - £1500 (US $2000 - $3000) per day.

 Fig:03  Fig:05  Fig:04 Motor temperatures inside the new dome Incident solar radiation on the internal of the CCTV dome External heating of the CCTV enclosure Implementing CFD caused by incident Solar radiation Increasing the complexity the ambient environment on conditions within the dome and With the basic tests carried out, the CFD analysis was how these conditions can affect (adversely or otherwise) the extended to a full analysis of the newest product in the electronic systems inside. One of the key advantages of  Overview Limited is a British at Overview Overview range - the Sparkle dome. This newly developed STAR-CCM+ over the other codes evaluated was the solar Company, located in Wandsworth, Alex Pope, Overview Ltd. CCTV enclosure is Overview’s most technically sophisticated radiation modeling. As the domes are usually placed outside South West London, specialising in the product, and so the implementation of CFD into the design and may be exposed to direct sunlight in the height of design and manufacture of CCTV process would be key to a successful deployment of the final summer, this can lead to significant heating of the system as dome mechanisms and associated The increased accessibility of CFD, provided in part by innovative products such as product. a whole. electronics for OEM supply. STAR-CCM+, has led to the adoption of simulation technology at many companies that have Within the relatively small enclosed space of the dome there Solar radiation are stepper motors for camera control, as well as the camera The aim of this solar radiation modeling was to both analyze little previous experience of Computational Fluid Dynamics. In this article, Alex Pope, of itself and all of the control electronics, which combined the effect of high intensity direct sunlight on the dome and Overview Limited, explains the challenges and rewards of introducing Computational Fluid produce significant amounts of heat: potentially posing the system within it, as well as to investigate possible ways problems in component performance and ultimately reducing of “shielding” the enclosure from the sun. This solar shielding Dynamics into an organization for the first time. product lifespan. Early designs of the Sparkle dome had could be accomplished either by constructing a physical shown that glue used within the assembly was failing and barrier to shade the dome from the sun, or by using reflective First steps along the road to CFD Overview Limited is a London based British company causing the system to malfunction. The glue itself located on coatings. Both these scenarios, as well as the un-shielded that specializes in the design and manufacture of CCTV In common with many companies that have taken the first step the central shaft was rated only to a specific temperature and case, were easily run in STAR-CCM+, with simple (closed circuit television) camera dome mechanisms towards integrating CFD simulation into their design process, the so the first analyses concentrated on discovering the modifications to solar properties able to provide quick “what- and associated technology. The story of CAE integration management and design engineers at Overview needed to be conditions in the area of the shaft that were responsible for if” studies of the different configurations, and again provide at Overview has followed a fairly typical route: mirroring the convinced of the technology’s usefulness and accuracy. Although causing this failure. previously unavailable insight. development of computational techniques for design, test and the benefits of CFD may be apparent to experienced users in larger manufacture using CAD and FEA structural and thermal analysis, OEMs, for smaller companies the (apparently) relatively high cost The first step in the analysis process was to build a suitable Conclusions and resulted in the first implementation of CFD technology within of the software (compared to CAD programs for example) must be geometry for study. This involved taking the original CAD The implementation of CFD simulation technology at Overview SMILE - YOU’RE ON CCTV! Overview’s design process. justified. configuration and simplifying it to a level whereby run times Ltd has, over the course of the past year, proven to be of  Fig:01 The UK has more CCTV cameras would be reduced to reasonable timescales without overly increasing benefit to the design and analysis process across A traditional CCTV Dome per head of population than ANY From a thermal perspective, the analysis of CCTV domes presents After an extensive evaluation process, STAR-CCM+ was chosen for compromising accuracy. Once complete, the CAD model was a range of products at both a system and component level. produced by Overview Ltd a significant challenge. A large number of power hungry our applications. We successfully validated the software using a other country. About one camera for imported and meshed in STAR-CCM+ using polyhedral cells, The first step along this road to full integration was for CFD to every 14 people… components are enclosed in a small space, which is sealed in range of simple components, which gave us confidence in the which we considered to offer the best compromise between “prove itself” to the company at large, and to justify the order to avoid water ingress. This small sealed space is then accuracy of the code and helped us to establish a set of best accuracy and simulation time. Results from the simulation investment in the software technology. Indeed with the London's Metropolitan Police subjected to extreme environmental conditions from long hot practices for the types of simulations that would be carried out in identified a “hot spot” in the enclosure in which the design implementation of solar radiation modeling, a tangible benefit, Force have approximately 200,000 summer days to cold winter weather with high winds, snow and future. The idea of these initial tests was to start simple then temperature of the glue was exceeded. Immediately, CFD had both financially and in engineering terms, was gained as CFD cameras installed around the rain. steadily increase complexity, to the point of modeling and illustrated its value in the engineering process by helping to simulation was able to save the company between £1000- capital validating a full system. These initial simulations included: identify a critical mechanism for failure that was easily £1500 (US $2000-$3000) per day in solar testing, as well as The largest CCTV system in the As with any electrical component, temperature is a limiting factor •Modeling a heat sink to validate pressure drop and heat transfer. resolved by adopting a new adhesive rated above the cutting down on turnaround time and allowing the study of World is in Australia, the New South and without proper ventilation and cooling, failure may occur. This •Measurement of single component heating and cooling identified peak temperature, ensuring that future system many different configurations, quickly and easily. The presents a problem. Because the unit is sealed, ambient air may within a simplified enclosure. Wales City Rail system has over malfunctions will be prevented. technology has since been used across a wider range of 7,000 fully networked cameras! not be drawn through the enclosure. Traditionally, this would not applications throughout Overview and more engineers have  Fig:02 have been an issue for Overview enclosures, but an expanding For each of the initial tests, experimental results were gathered Radiation modeling been exposed to its benefits. The software is now being used Almost every bank cash machine The internal electronics of product line, which incorporates larger cameras and more powerful and compared to the computational data, with good agreement A key additional step when looking at the modeling of further upfront in the design process allowing analysis results in the UK uses CCTV to record the Sparkle dome motors means that the enclosures are subjected to increasingly shown. Once the results were presented to fellow engineers and Overview’s CCTV enclosures was understanding the effect of to drive the design and not the other way round.  customers making transactions large thermal loads. management and confidence in the accuracy and applicability of CFD simulation had been established, the range of simulations  MORE INFORMATION [email protected] http://www.overview.co.uk/ Ë FACTS carried out could be extended to more complex situations. 24 dynamics 2.02 dynamics 2.02 25 ..::FEATURE ARTICLE Industrial Applications ..::FEATURE ARTICLE Industrial Applications

M Fig:01 Typical 1-pipe system (left) and thermal image of radiator (right) with closed valve and no backflow restrictor M Fig:04 M Fig:02 Chart showing CFD (red) and test results (black) CFD model used for buoyancy effect simulations

Valve Inlet

Radiator Bypass

M Fig:03 Plane section (blue) used to monitor the convergence Outlet criteria of stable net heat flux

Restrictor

STAR-CCM+ Simulation

Drives Energy Efficient Radiator Design  Fig:05  Fig:06  Fig:07 Restrictor placed horizontal Restrictor pointing downwards Restrictor pointing upwards

Per Adamsen, Danfoss Heating Controls

Faced with the twin threats of energy security and global warming, building services engineers hence the buoyancy source term was modeled using the Boussinesq horizontal mode, the influence of the bend does not seem to have a approximation, where body forces are a function of temperature alone. significant effect on the backflow. This was also not expected as the are increasingly required to demonstrate the sustainability of heating and ventilation schemes design of the restrictor was meant to inhibit the flow by using the To obtain a converged solution the coupled steady-state solver was density differences in the fluid caused by the temperature changes. in both commercial and residential buildings. In attempting to reduce the energy signature of used for initialization of the flow, while the segregated transient solver heating system, every component is candidate for redesign and optimization in an attempt to was used after a few hundred iterations to obtain the final steady- Rotating the restrictor 90 degrees, however, shows a more dramatic state results. The net heat flux across the plane section combining effect as the hot (and thus less dense) water coming from the right- improve efficiency and to reduce wasteful heat loss. Danfoss Heating Division, take the the heat sink with the rest of the model was used to monitor if a hand side is blocked by a layer of relatively cold (and denser) water in challenge of sustainability very seriously. In this article, they describe how CFD has been converged solution had been reached based on engineering data (see the bottom of the restrictor. As a result, two recirculation zones Figure 3). emerge with a very low heat transfer in between. used to reduce unwanted heat loss from radiator systems. Discussion of results The last configuration is better in terms of minimizing the net heat A common problem with 1-pipe heating systems is Computational setup The results from the CFD simulations have been compared to flux. Although the temperature of the “exhaust” fluid is almost the the unwanted heating of the radiator when the Using the efficient STAR-CCM+ pre-processing tool, a simple laboratory tests using the same restrictor geometry and, although same in the two cases, using the restrictor in downward configuration thermostat is in the minimum position and the valve model was quickly created enabling an easy study of the design there were quantitative differences, the major flow features were well results in average velocities almost 60% higher in the “cold” pipe is closed. Unlike 2-pipe systems there is a constant proposal. It was decided, after some trial simulations, not to predicted. While the laboratory tests were carried using a complete section due to the longer path over which the fluid can be accelerated.  Danfoss Heating Division flow of hot water running past the radiator via a bypass, which model the entire radiator for two reasons; radiator setup (see Figure 1), the CFD model was only a small part of With the restrictor pointing upwards, the same type of acceleration is offers components and solutions means that very close to the radiator there will always be both 1) modeling the entire radiator heat transfer (i.e. heat transfer the entire geometry, which would explains the differences in results seen, but since this occurs on the “hot” side of the restrictor, the for generation, distribution and fluid and solids at temperatures as high as 95oC. from water -> solid -> air) would require a detailed model of shown in Figure 4. added momentum does not have an effect on the net heat flux out of use of heat for comfort and the entire system to catch the buoyant features and the restrictor on the “cold” side. Therefore, the most efficient way of energy savings in residential The construction of a 1-pipe system therefore has the 2) only the backflow restrictor’s influence on the heat transfer When comparing the CFD simulations to experiment, all restrictor installing a backflow restrictor would be with the bend facing upwards, buildings. Our six business units disadvantage of hot water being able to travel in the wrong path is of interest. results were compared to the net heat flux from a setup where the as the laboratory tests also showed. are market leading within heat direction after passing through the bypass and slowly circulate restrictor was replaced with a straight pipe. As expected, there is not pumps, floor heating, district inside the radiator due to buoyancy effects. This slow circulation Based on the trial runs a major part of the supply piping was much difference in the net heat flux when the restrictor is horizontally Conclusion heating, comfort controls, water of water is termed “backflow” and is undesirable since it adds removed and the radiator was replaced with a 300 mm fluid aligned as this would be the same as adding extra pipe length to the A series of simulations have been carried out in order to investigate controls and burner components. to the heating bill of the consumer even during a closed valve section acting as a heat sink: cooling down the pipe “exhaust” existing setup. However, positioning the restrictor with the bend what effect a backflow restrictor would have on net heat flux going into Our divisional headquarter is period. flow to ambient temperatures (see Figure 2). pointing up- or downwards shows a dramatic drop in the net heat flux the radiator system. The simplified model showed similarities to real situated in Nordborg, Denmark, but more interestingly the efficiency of the restrictor is higher with the laboratory tests and the trends found were also replicated in the CFD with manufacturing facilities and Using computational fluid dynamics (CFD), a simplified version of The solid parts were prescribed a convective heat transfer of 5 bend pointing upwards. results, although no direct numerical comparison could be made. With sales organizations located a 1-pipe system with a bypass was investigated with special W/m2-K @ 20oC ambient temperature, while the pipe end the CFD results it was possible to get a better understanding of the around the world. Altogether, we attention paid to the recirculating flow and the effect of furthest from the heat sink was maintained at a constant To explain these findings, a sequence of plots showing streamlines localized flow patterns in different configurations and thus give a are approx. 5,200 people connecting a restriction in the bottom of the radiator. The CFD temperature of 95oC. The heat sink was prescribed a constant and velocity magnitude for the three different positions of the backflow better recommendation on how to use the restrictor in a real worldwide and with revenues of results, which have been verified against laboratory tests, have temperature equal to the ambient temperature. For the restrictor is shown in Figure 5 through Figure 7. With the restrictor in installation.  more than DKK 5.5 billion. been used to gain knowledge about the flow through the simulation of buoyancy, the model assumed steady-state, suggested restrictor when buoyancy is the dominant effect. incompressible and laminar flow. A density was specified and  MORE INFORMATION ON DANFOSS http://www.danfoss.com 26 dynamics 2.02 dynamics 2.02 27 ..::FEATURE ARTICLE Marine Before purchasing CFD software Azimut-Benetti undertook an ..::FEATURE ARTICLE Marine exhaustive evaluation process. For hydrodynamic simulation, we chose STAR-CCM+ because of its ability to: 1. Perform bi-phase calculations in air and water 2. Automatically construct a calculation grid that adapts to the  The Benetti shipyard, based in Viareggio had been owned by the physics of the problem Benetti family since its foundation in 1873 and in 1985 was taken over 3. Calculate the equilibrium position of a planing hull. by Azimut. The yard had earned an exceptional reputation as the boats builder in classical lines, fitted out with luxury interiors. For aerodynamic simulation, we needed to be able to work  Fig:04 Unsurpassed in producing top class boats based on traditional effectively with CAD data to extract a single wetted surface, craftsmanship, Benetti were revolutionary on account of being the first to often starting from a CAD that contains superfluous details that introduce and develop the modern concept of “motoryachts”, quoting interfere with the fluid volume meshing software; a final one example the: “delfino” line. requirement therefore is: 4. The ability to automatically clean CAD surfaces (surface wrapper).

 Fig:03

Similarly, although CFD simulations with a single-phase fluid hexahedrons that are subsequently “trimmed” to the CAD model have been used elsewhere to provide information on surfaces. A very important detail is the treatment of the The Azimut-Benetti R&D the resistance of immersed parts, this does not represent layer of cells near the solid walls: layers of prismatic cells an acceptable approximation for solving our issues. are used that automatically fit the CAD geometry.

Historically the process of hydrodynamic design relied Fig:03 illustrates the emerged part of a yacht and the Centre & the CFD Design heavily on the analytical data provided by multiple towing relevant aerodynamic calculation. In this case, the use of tank tests, which are both expensive and time consuming the surface wrapper outlined above was fundamental - the Global demand for private luxury to perform: a single tank test typically costs many task of the wrapper is to produce a surface totally free of yachts has been increasing steadily of Luxury Yachts thousands of Euros. Nowadays we adopt a “Virtual connectivity defects, which can then be used as an input over the last five years. Marinas are Prototyping” approach in which we try to reduce physical datum for the volume mesher. In the case of external at saturation point in many parts of hydrodynamics testing to just a single model in a tank; aerodynamics, given the large quantity of objects present in the Mediterranean, as well as the Simone Bruckner, Francesco Serra, Azimut-Benetti, R&D Centre in Varazze (SV) validating the design that we have found to be the best the original CAD, the surface wrapper has allowed entire Caribbean. This growth is due to following numerous "virtual" tank tests using STAR-CCM+. days to be saved that would otherwise have been dedicated the largest demand for leisure to an activity (CAD cleaning) with no added value for an R&D includes the brands Azimut Yachts, Atlantis and Benetti Yachts - each aimed at boats ever seen with recreational Azimut-Benetti has been at the top of the The Azimut-Benetti Group develops and produces about five Centre. a distinct segment of the boating market - as well as Fraser Yachts, a leading boat ownership a $25 billion new yachts a year. Using STAR-CCM+ we can carry out very world "mega-yacht" industry for over ten brand in the service sector. international industry and sales many tests on different hulls configurations under a wide Fig:04, finally, illustrates the calculation grid for the external years: owning over 10% of the global market, variety of operating conditions. We can compare numerous aerodynamics. In this case, Azimut-Benetti has opted for growing annually at 5-10%. Within the Azimut Benetti group Computational Fluid Dynamics simulation is According to Showboats deployed for many purposes: tests even with designs that are not finalized. Thus we are polyhedral grids which guarantee automatic setting but and nearly 30% of the domestic market; the International, a publication that • internal environment conditioning; able to virtually optimize the hull in all its details. The final perform better than the tetrahedrons. Italian company is the world boating • aerodynamics; production vessel is therefore fully optimized, reducing tracks vessel construction, in 1993 the world had fewer than 700 industry’s largest private group, producing • thermal analysis of engine rooms; experimentation costs and time to market and providing a Azimut-Benetti maintains its market leadership thanks to a • exhaust gas flow analysis; better overall product. technological leadership such as, for example, the use of private owners with boats over 24 over €800 million worth of yachts every year. • resistance calculation for fixed trim hulls; accurate and dedicated CFD software. This is put into metres (79 feet). Today, there are • calculating the hydrodynamic characteristics, including flow resistance, of In 2007 Azimut-Benetti developed, in partnership with practice by working alongside key players on the CAE scene an estimated 7000 yachts over 24 Dedicated to delivering the highest standards in both performance planing hulls, with fixed and free trim (2 degrees of freedom). CD-adapco, a proprietary method that uses STAR-CCM+ as such as CD-adapco and by making significant contributions metres (79 feet) in use. and quality, Azimut-Benetti have adopted STAR-CCM+ as a standard a fluid dynamic simulation "engine". This method calculates to improving the products, with a long term spin-off for the  Ë FACTS CFD tool for the aerodynamic, hydrodynamic, and thermodynamic Of these calculations the most complex and valuable is the hydrodynamic the running attitude of the vessel in 2 degrees of freedom entire nautical sector. design of their yachts. Using STAR-CCM+ Azimut-Benetti have analysis of planing hulls. It is necessary to consider the hull as a three- ("sink" and "trim"). In order to represent the full complex managed to optimize the performance of their yachts, while dimensional body that interacts with two immiscible fluids (air and water), geometry of the hull, and to provide appropriate resolution simultaneously reducing development costs and time to market. simultaneously accounting for the manner in which the fluids interact with each at the free-surface waterline, Azimut-Benetti opted for the other at the free-surface and for the way in which the trim of the boat is trimmed cell calculation method available in STAR-CCM+. Azimut-Benetti conducts structural and hydrodynamic research and influenced through the interaction with both mediums. Simple static The method prescribes a Cartesian base grid with perfect development at a dedicated facility in Varazze (SV), where innovative solutions simulations (in which the boats running attitude is not determined by the are developed and later deployed across the entire Azimut-Benetti group, which simulation) are not generally sufficient for our purpose.  MORE INFORMATION ON AZIMUT-BENNETI VISIT: http://www.azimutyachts.com 28 dynamics 2.02 dynamics 2.02 29 ..::FEATURE ARTICLE Marine ..::FEATURE ARTICLE Marine

For this reason, the experimental research was widely supported with extensive CFD simulation, which is more suited to a detailed comparison of the influence of flow properties such as wave elevation and pressure distribution on the hull for different designs.

Each CFD simulation considered a canoe hull towed at constant speed through calm water. The computational analyses yielded numerical data, such as hull resistance, as well as allowing the design team to visualize the flow field around the hulls, thereby helping them identify the mechanisms behind variations in physical performance, e.g. bow and stern wave height or wave interaction. After testing the existing boats, the best design was chosen based on analysis results and work on new designs began. By  K1, K2 and K4 canoes - free surface elevation. implementing CFD into the design process, timescales and costs have been significantly reduced. The viability of each new design was first tested numerically, so that only a small number of optimized designs were selected for manufacturing and testing in the model basin. Final tests were carried out in real conditions - with the professional competitor rowing along the basin.

The simulations were carried out using the Volume Of Fluid (VOF) model for multiphase flows and the RNG k-epsilon turbulence model using specially constructed 1.5 million cell hexahedral meshes. The surface models of the existing canoes were obtained by digitally scanning the hulls, carried out using an ATOS II optical scanner and a TRIPOD photogrammetric system provided by GOM GmbH.

Due to the fact that the Olympic canoes travel at relatively high speed (of the order of 6m/s), it is absolutely necessary to take into account the dynamic trim and sinkage of the hull in the numerical analysis of the flow around it, requiring either experiment data, or if not available, adjusting the hull position during the CFD simulation CTO & Plastex Paddle until force and moment equilibrium is reached. Although this can be done iteratively, based on the hull hydrostatics, CTO uses an in- house, automated procedure for coupling the flow solver to the hull  The canoe hull in its static (above) and dynamic motion equations, allowing for accurate evaluation of the canoe’s position in the flow. to Olympic Glory using CFD position. The computational mesh in this approach remains rigid, it moves together with the hull without relative motion of the nodes, which proved to be sufficiently accurate, robust and very simple, no re-meshing is required when the hull changes its position.  Example of the hull dynamics analysis. Wigley hull in waves. Simulation Tomasz Bugalski, Ph.D and Marek Kraskowski - Centrum Techniki Okrêtowej At present, the CFD analyses and model tests of the canoe’s performance are limited to steady-state analyses - the hull is towed For most of the competitors at the 2008 Beijing Olympic Games, the possibility of mounting with constant speed and fixed centre of mass. Such a simplified the podium to claim an Olympic medal represents the very pinnacle of sporting achievement: approach allowed for effective optimization of the hull shapes based upon resistance with an identified 1% reduction, which could usually the payoff of many years of blood, sweat and tears. However, in 2008, being the best easily be the difference between Olympic Glory and ignominious defeat. The use of CFD methods allowed reduction in costs by athlete is not longer necessarily enough: in most events the Gold Medal winner will also have limiting the number of designs tested and so reducing the need to had the aid of the very best sporting equipment. manufacture many hull shapes. Further to this, identification of the flow phenomena by CFD allowed optimization to be carried out far For this reason, the battle for Gold begun long out of 81 medals were won by competitors using Plastex quicker than previously possible. ago in the offices and testing facilities of research boats. The boats themselves are designed by the company’s centres, where the sports equipment used by the owner, Ryszard Seruga, in cooperation with Tomasz Bugalski, It is very likely that the present shapes of the Olympic canoes are  Plastex Composite is producer and competitors in the Beijing Olympics has been Ph.D, from the Ship Design and Research Centre (CTO) S.A. - already very close to the absolute minimum resistance obtainable exporter of boats and paddles of the constantly optimized and improved. Canoeing is one of the Poland. in steady flow. In the future, significant further development will only highest quality for canoeing and rowing. fields where extensive research has been performed into occur by optimizing the dynamic behaviour of the hull, which means They have a track history that far exceeds minimizing hull resistance using state of the art In the spring of 2007, Plastex and CTO began to work on the taking into account all the phenomena encountered during a race, any of their competitors as far as sporting measurement and experimental techniques, backed shape of new canoes for the Olympic Games in Beijing. motion of the competitor, and unsteady forces exerted on the hull.  Final tests were carried out with a  Example of the computational mesh. medals go, their athletes have simply extensively by Computational Fluid Dynamics simulation Optimization of the new design started with extensive For that reason, the next step for CTO is to study 6 degrees of professional rower. won far more using their products. using CD-adapco software. investigation of the existing hull shapes in CTO’s model freedom (6-DOF) analyses to help aid hull optimization and to try to basin, with the principal aim of determining the dependency adjust the shape so as to minimize the loss of energy due to the Olympic Classification: Since 1998 Plastex has begun - in The Polish company, Plastex Composite, recognized of the canoe’s performance on the basic design parameters hull motion and interaction with other canoes. CTO have already Kayak: K1 - single seat kayak Canoe: C1 - single kneeling canoe cooperation with the Institute of worldwide as one of the leading producers of competition and initial trim. Although such experiments provide a large performed a trial simulation of the Wigley hull in head waves. In this K2 - double seated kayak C2 - double kneeling canoe Hydrodynamics - the research of more canoes, has provided state-of-the-art equipment for Olympic amount of reliable data in a short timescale, they do not simulation, the hull was free to pitch and heave (2-DOF motion), K4 - 4 seated kayak C4 - 4 person kneeling canoe effective models of kayaks and canoes Games and World Championships for many years. In 2005, always illuminate the physical mechanisms that affect the while sailing with constant speed and fixed zero drift angle results Ë based on the application of CFD. during the 1st World Canoe Championships in Poznań, 56 performance of the hull. revealed good accuracy and robustness of the method.  FACTS 30 dynamics 2.02 dynamics 2.02 31 ..::REGULARS Dr Mesh ..::REGULARS Dr Mesh The Practical Application of Duck Hydrodynamics In the world of Oceanography, as in my bathtub, the rubber duck is king... First things first... On January 10, 1992 three 40 foot containers were Start off by placing your moving object (be it a small Finally, before finding out just how seaworthy our duck is, we need dislodged from a cargo ship during stormy weather, yellow toy or a large rusty supertanker) into a box, and to set up the waves for him to bobble about on (nothing is more releasing a flotilla of 30,000 Chinese made plastic bath creating your volume mesh in the normal way. Next we dull than simulating a duck in still water). In the tools folder there toys into the Pacific ocean. While two thirds of the ducks need to set up our models to study how our flow field affects the is a new option for VOF waves where you can setup automatically were soon washed onto the beaches of Indonesia, body of interest: in this case my duck! The dynamic fluid body generated flat or first order waves, just right click on the folder, Australia, and South America, the remaining 10,000 set interaction feature of STAR-CCM+ is under the name “6-DOF”, select the wave type you want and fill in its properties. off on what, for many, would prove to be a 16 year chosen to reflect the 6 degrees of freedom a free moving body odyssey around the oceans of the world, tracked by has. As with any other physics model, simply select the“6-DOF” delighted oceanographers who have used their progress option in the STAR-CCM+ continua panel (under the motion to validate models of the ocean currents. selection box).

Chief among the duck spotters is oceanographer Curt In this case we are simulating my duck floating on water and so Ebbesmeyer, who successfully predicted that some of the we also need to turn on multi-phase mixture (VOF) modeling, but ducks would, after being swept by wind and currents you can also simulate objects flying, falling through the air or through the Bering Straits and become frozen in the Artic indeed any situation where the fluid surrounding a body Icepack. Ebbesmeyer suggested that, moving at a rate of influences its motion. a single mile per day, that the ducks would take five or six years to reach the North Atlantic and thaw, before being With our continua set up, we first need to specify the properties  Fig04 washed up on American beaches in 2003. of my duck: this is done in the 6-DOF bodies folder. Just right Setting up a wave click on the folder and select “New”. You will notice now that when the wave is set up, you will have Don’t fancy simulating a duck? Ebbesmeyer has tracked some field functions that have been automatically created with the progress of other accidently spilled cargo including: “VOF Wave x” in the name. These are then used to set up the 100,000 toy cars and balloons, 30,000 ice hockey boundary conditions and initialization of your domain. gloves, five million pieces of Lego and 3,000 accidentally  Fig01 spilled Nike running shoes. There are also a range of new reports to help you determine just The new 6-DOF Bodies node in STAR-CCM+ how your duck is performing. These all start with “6-DOF” and Ë FACTS If you click on your new body, you will see options for all the can be turned into monitors and plots to study the acceleration, various physical properties that are will ultimately determine the velocity, force, moment, orientation, and translation of the body body’s movement in response to fluid excitation, specifically through time. things such as: mass, moment of inertia, centre of mass and so on. Dr Mesh: DFBI and the Art of Duck

 Fig05 Hydrodynamics The angle of my Duck through time  Fig02 What do you do in the bath? Images courtesy of Joel Davison & Dejan Matic. My duck’s properties So with everything set up, all you need to do is press “run” and Jumping In... “Eureka!” see how your duck behaves. Hopefully a little better than mine, In this case we want our duck to be moved freely by the water so To have a look at my duck trying to stay afloat visit Rumor has it that, when a naked Archimedes leapt screaming from his bathtub, his famous we select “Free Motion”. This gives a further node where we can http://www.cd-adapco.com/media/ specify in which ways our duck can move. I am just going to let exclamation was less about having found a convenient way of calculating the volume of an him move up and down (z motion) and rock forwards and Now if you’ll excuse me, my bath water is beginning to get a little object and more to do with the fact that his rubber duck had just flown across the room and backwards (x rotation) (two degrees of freedom). tepid. landed in the toilet. Best Regards

Now, if Archimedes had used STAR-CCM+ he would have been able to work out that, by Dr. Mesh entering his bath a little more slowly, his faithful yellow companion would have stayed Dr Mesh happily in the tub for the remainder of his bath-time (he would also have been able to easily calculate the volume of any object using STAR-CCM+ report). So, in the spirit of historical,  Fig03 Motion properties and factual, inaccuracy we are going to have a look at what happens to my bath toys when I get in for a soak!  MORE INFORMATION [email protected] 32 dynamics 2.02 dynamics 2.02 33 ..::REGULARS Training

Training at CD-adapco

We regularly hold CD-adapco product training sessions at our offices in: London, Detroit, Seattle, Nürnberg, Paris and Turin and around the world. Other courses as listed on our website can be scheduled to suit your requirements and information can be requested from our training administrators (see below).

To Register for a Course: Use the online form, or request a faxable form from your training administrator:

USA: [email protected] (+1) 631 549 2300 x129 UK: [email protected] (+44) 020 7471 6200 Germany: [email protected] (+49) 911 946433 France: [email protected] (+33) 141 837560 Italy: [email protected] (+39) 011 562 2194

Choose from Courses Including: • STAR-CD Basic • Advanced STAR-CCM+ • Advanced Modeling • STAR-CCM+ • Advanced STAR-CD • User Subroutines • pro-STAR advanced meshing • Advanced Meshing • Spray & Combustion • STAR-Design • Moving Mesh • E2P

New Course A new foundation level Introduction to CFD course is now being offered at CD-adapco for those with little or no training in Fluid Mechanics. The course is aimed at introducing new users, or non-users who encounter CFD, to the fundamentals of the subject. Please contact your local office for more information.

Note: In most situations it will be possible to register trainees on the course of their choice. However, if requests for places on courses are received too close to the course date, this may not be possible. Availability of places can be obtained by contacting your local office. See our website for most up to date schedules. 34 dynamics 2.02