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Cosimulation for Thermal Management and V hi l D i T kVehicle Dynamics Tasks

Klaus Wolf – Fraunhofer SCAI

Overview

• Introduction to Fraunhofer SCAI

M CCI C li E i t• MpCCI CouplingEnvironment

• Automotive Thermal Management Example

• 1D‐3D Fluid Cosimulations

• 1D‐3D for non‐linear Deformations and Multi‐Body Kinematicsy

• FSI Mapping capabilties

• Meta Forming Workflows• Meta Forming Workflows

Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de2

Fraunhofer Gesellschaft – Applied Research

Our Mission• Fraunhofer Gesellschaft (http://www.fraunhofer.de) is Europe’s largest application‐oriented research organization. Our research ff d i l l ’ d h l h iefforts are geared entirely to people’s needs: health, security, communication, energy and the environment.

• More than 80 research units, including 60 Fraunhofer Institutes, at different locations in Germany

• More than 20,000 staff – most qualified scientists and engineers

• Fraunhofer Institute for Algorithms and Scientific Computing SCAI g p g(http://www.scai.fraunhofer.de) conducts research in the field of computer simulations and methods


Fraunhofer SCAI – Neutral Interface Solutions

Our Role

• Independent and neutral developer of advanced software solutions

• Open for co‐operations with interested CAE software partners

• Interface developments realized in close collaborations with most of the leading CAE software providersof the leading CAE software providers


MpCCI – Multiphysics Interfaces

MpCCI ToolSuite

• MpCCI CouplingEnvironment – Standard Interface for Code Coupling

• MpCCI FSIMapper – File based Mapping for FSI ApplicationsMpCCI FSIMapper File based Mapping for FSI Applications

• MpCCI MetalMapper Fil b d M i f M t l F i W kfl• MpCCI MetalMapper – File based Mapping for Metal Forming Workflows

• MpCCI MapLib – C++ Programming Library for Customised Solutions


MpCCI – CouplingEnvironment

General Concept• Distributed Architecture

• Open Code Adapter API

• Robust and accurate Mapping

• Flexible Synchronization Schemes

• More than 10 years of experience


MpCCI – CouplingEnvironment

Supported Code Interfaces Supported Code Interfaces Abaqus 6.10 – 6.12 (6.13)

Ansys 11.0 – 14.0

Fl t 7 6 7 7

Matlab R2007‐2011 (beta)

MSC.Adams V2010, V2011 (beta) Flowmaster 7.6, 7.7

Fluent 12.0 ‐ 14.0

FINE/Hexa 2 11

MSC.Marc 2007r1 – 2011

MD/MSC.Nastran 2010‐2011 FINE/Hexa ‐ 2.11

FINE/Open – 2.11

FINE/Turbo – 8 8 – 8 10

OpenFOAM 1.5‐1.7, 2.0

RadTherm 9.0 – 10.2 FINE/Turbo 8.8 8.10

ICEPAK 13.0, 14.0

JMAG 11

STAR‐CD 4.04 – 4.16

STAR‐CCM 4.04 – 6.06

Open Code adapter API

10Cosimulation for thermal Management and Vehicle Dynamics Tasks

http://www.mpcci.de

Thermal Management for Automotive Vehicles



MpCCI Coupling Scheme

Fl R dTh

TFilmHTCoeff

Fluent RadTherm

TW llTWall

Starting with flow field Tw=const.



Details of Coupled Fluent to RadTherm

Not wetted

Quantity

Fluent RadTherm

frontside

rear side

boundary 1

boundary 2

wetted

y

Example:

Fluent RadTherm



Some Results from BMW (by STARCCM …..)CFD

• …

CFDCFD CFD Figures by courtesy of

BMW AG Munich



Why to use a coupled MpCCI solution?• Fully automatic and fast data transfer over socket connections.

• Easy implementation for repeating data transfer as used for iterative steady or transient simulations.

• Fast and robust data mapping between non‐matching meshes.

• Data inter‐ and extrapolation on geometrical irregularities like partially non‐matching geometries.p y g g

• Flexible steering of simulation procedure for instance with subcycling, time‐step sharingsubcycling, time step sharing


Coupled 1D‐3D Fluid Simulations

Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de

Coupled 1D‐3D Fluid Simulations

MpCCI 1D‐3D co‐simulation is the coupling between• a 1D model component (integration point)

• a surface of the 3D CFD application

3D CFD Model 1D ModelCFD connection

1D ModelCFD connection

CFD connection

1D ModelCFD connection

CFD connection


Coupled 1D‐3D Fluid Simulations ‐Manifold

Manifold and Exhaust System• Flowmaster

• FLUENT

• Steady State Heat Transfer Simulation

• Quantities exchanged:Quantities exchanged:– Mass Flow Rate

– Mass Flux RateMass Flux Rate

– Total Pressure

– Temperaturep

Cosimulation for thermal Management and Vehicle Dynamics Taskshttp://www.mpcci.de


Co‐simulation components in 1D Flowmaster• Flow source for a CFD pressure boundary

• Pressure source for a CFD flow boundary

Activate the External Model Boundary propertyActivate the External Model Boundary property• Allow the component to perform co‐simulation

Create a MpCCI Link File from the report menup p• Contains the definition of the External Model Boundary



Model Setup in FLUENT 3D• Standard K‐Epsilon turbulence model

• Mass Flow specification Method

• for the inlets: Mass Flux

• Default temperature at the inlets: 300KDefault temperature at the inlets: 300K



Cosimulation for thermal Management and Vehicle Dynamics Tasks23

Coupled 1D‐3D Fluid Simulations – Aircraft ECSLarge Aircraft Cabin ECS System in Flowmaster V7Large Aircraft Cabin ECS System in Flowmaster V7

Partial CFD Model of Cabin in Fluent


Coupled 1D‐3D Fluid Simulations – Aircraft ECS

1D – Air Distribution System Modeling• Analyze large aircraft air distribution• Analyze large aircraft air distribution• Evaluate duct re‐routing scenarios• Study mixing of fresh and re‐circulated air

Mass Flow Results (kg s‐1)

• Study mixing of fresh and re‐circulated air• Conduct “what if” scenarios on duct sizing• Fast to set up and very quick to analyze Mass Flow Results (kg s 1)Fast to set up and very quick to analyze

EnablingEnabling• Understand system interactions• Help meet passenger flow rate requirements

System Pressures (N m‐2)

Help meet passenger flow rate requirements• Help guarantee proper temperature


Coupled 1D‐3D Fluid Simulations – Aircraft ECS

ll dWell Designed System

ECS thermal failure


Non‐Linear Tire Deformations and Suspension System



General MpCCI Coupling Concept• Fast solution for rigid body system (MSC.Adams)

• Detailed analysis for FEM‐Components (FEA)

• Co‐Simulation is more realistic

• Reuse of existing modelsReuse of existing models

• Exchanged Quantities– Position of the wheel hub is send by MSC Adams and received by FEA– Position of the wheel hub is send by MSC.Adams and received by FEA

– Reaction Force on the wheel hub is send by FEA and received by MSC.Adams



Chassis of the rigid body car (MSC.Adams tutorial)Chassis of the rigid body car (MSC.Adams tutorial) with applied GFORGE element (red arrow)

Detailed Tire Model in FEA



Tested Road Surface and Dynamic Tire Deformations


Tested Road Surface and Dynamic Tire Deformations

Further MpCCI Multiphysics Examples


Fluid‐Structure for Hydraulic Axial Pumps

PWK‐pump with a cam‐driven t ti itcommutation unit

• Constant displacement pump with very good performance

• Working pressure up to 55 Mpa

• Efficiency of 94%

• Good power densityGood power density

• Abaqus – MpCCI ‐Fluent


Heat‐Loss Calculations in Electrical Devices

3‐Phase‐Busbar Systems• Magneto‐thermal coupled problem

• Three‐phase current

• RMS current 1600A at 60 Hz

• Simple Test‐CaseSimple Test Case

• JMAG – MpCCI ‐ FLUENT


Heat‐Loss Calculations in Electrical Devices

3‐Phase‐Busbar Systems• Electromagnetic calculation of power losses (JMAG)

– Eddy currents

– Temperature dependent resistivity

• Thermal calulation (FLEUNT)– Heat conduction fluid and solid

– Heat convection incl. buoyancy effects

– Laminar flow


MpCCI – FSIMapper


MpCCI – FSIMapper

EnSight FSIPlugin


MpCCI – FSIMapper

EnSight FSIPlugin ‐ Supported File Formats

• Source Data: Adina CFD, ACUSOLVE, .., CFD++, CFD‐ACE+, CFD‐, , , , ,Fastran, CFX, ..., FINE/AERO, FINE/TURBO, ..., Flow3D, Fluent, OpenFOAM, PAM‐FLOW, PowerFlow, ..., SC/Tetra, STAR‐CCM+, ..., Vectis, ... http://www.ensight.com/CFD‐Interfaces/cfd‐interfaces.html

• Target Data: Abaqus *.inp, Nastran *bdf, Ansys (under g q p, , y (development), EnSight Gold


MpCCI – FSIMapper

Cooling Flows and Thermal Stresses in Electronic Devices


MpCCI – MetalMapper

Forming to Crash Simulation Workflows• Transfer of manufacturing simulation results

• Automatic handling of non‐matching model positions

Cosimulation for thermal Management and Vehicle Dynamics Tasks40

MpCCI – MetalMapper

Process Chains in Automotive Design• Metal forming (PAM‐Stamp, AutoForm)

• Assembly (SYSWELD)

• Paint Bath (CADFEM VPS/DRY)

• Crash (PAM‐Crash)Crash (PAM Crash)


Conclusion

MpCCI – Multiphysics Interfaces from a neutral andindependent providerindependent provider

• MpCCI CouplingEnvironment – The Standard InterfaceMpCCI CouplingEnvironment The Standard Interface for Code Coupling

• MpCCI FSIMapper – File based Mapping for FSIMpCCI FSIMapper File based Mapping for FSI Applications

• MpCCI MetalMapper – File based Mapping for MetalMpCCI MetalMapper File based Mapping for MetalForming Workflows

• MpCCI MapLib – C++ Programming Library forMpCCI MapLib C Programming Library forCustomised Solutions


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