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Topology-Optimization for internal Fluid Flow: TOSCA Fluid
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CFD topology optimization for channel flow
Task: Find a geometrical proposal for a channel within a fluid design space:
Outflow
Inflow
?
For each fluid cell decide:
“Should this cell belong to the channel or not?”
� Each fluid cell is a design variable!
� Millions of design variablespossible
� General optimization schemes
are not feasible...
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� Redesign Rule: Elimination of local
backflow and recirculation by blocking
out of backflow areas
� provides an “optimization” approach
by means of “improvement”
� The Optimality Criterium is to avoid
flow recirculation
OC-based Topology Optimization
� An achieved consequence is (for
many technical flows) a reduction of
pressure drop
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• Meshing “as usual”
Design Space
Topology optimization with TOSCA Fluid
• Define the Design Space (e.g. CAD)
Outflow 1
Outflow 2
Inflow
• Define your Boundary Conditions
• Run the Optimization
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Topology optimization with TOSCA Fluid
Design Space
Outflow 1
Outflow 2
Inflow
Optimized Channel Shape
Prevented Flow
Free Flow
Transition Area
(defining new channel shape)
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� Direct run time communication with
the CFD solver
� Only one single CFD
solver-run for complete optimization process
���� suitable for large real world applications
Topology optimization with TOSCA Fluid
CFD Solver Solution Process
TOSCA Fluid Optimization
Time resp. Iteration
Optimization
and
Flow Result
Shared-Memory
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TOSCA Fluid – Result Reconstruction Methods
Optimization result and
Designspace
STL-Surface
IGES-Cuts CAD-Reconstruction based
on IGES-Cuts
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TOSCA Fluid – Graphical User Interface
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TOSCA Fluid – Example Projects
� EGR-Cooler:
� Pressure Drop Reduction: 20%
� Efficiency Enhancement: 11 %
� Engine Air Intake / Filter System:
� Pressure Drop Reduction: 42%
� Flow Uniformity Enhancement: 56%
� Intercooler Intake Hose:
� Pressure Drop Reduction: 20%
� Commercial Vehicle HVAC Duct:
� Pressure Drop Reduction: 25 %
� Flow Split Enhancement: 6%
� ...
Courtesy Opel
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TOSCA Fluid – Feature Overview
� TOSCA Fluid.topology Version 2.2 features
� Reduction of flow recirculation and vortices by topology optimization of the flow domain
� Reduction of the pressure drop and related phenomena
� Efficient, fast optimization by direct runtime coupling of the
optimization to the CFD solver
� Support of
� STAR-CD V4.0x solver with .ccm / .ccmg databases
� STAR-CCM+ V6 solver
� ANSYS Fluent V12 solver
� Parallel operation support
� GUI and pre/post processing interfaces
� LinuX x86_64 Support
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TOSCA Fluid Key Notes (1)
� New and unique technology for fast and
efficient topology optimization of internal
fluid flow systems
� Simulation driven design, fast and easy design optimization impacting all
development stages
� Use of your favorite CFD-solver and existing models for optimization, no
parameterization necessary
� Unmatched efficiency for large, real world industrial applications
� High innovative strength due to new and potentiality inspiring designs and large
solution spaces
Optimization
process
Resulting design proposal
(60% less pressure drop
compared to a standard design)
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TOSCA Fluid Key Notes (2)
� Based on Daimler Technology
� Technical and support hotline by experienced
CAE and optimization staff
� Easy setup of optimization problems using
the graphical user interface (GUI)
� No model parameterization is required
� Straight forward pressure drop reduction
(noise diminution), flow homogenization and several other optimization tasks
� General reduction of development time and
development cycles which saves your costs
New conceptual
Design, ∆p ↓26 %
initial Design
available Designspace
Optimization
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