Module 2

Lecture 1

Module 2 - Lecture 1 1
 Roadmap

1. CFD simulation workflow

Module 2 - Lecture 1 2
 CFD simulation workflow

Geometry description

Mesh generation
Visualization

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CFD simulation workflow

GEOMETRY

UP TO 70% OF USER TIME

THIS IS THE BOTTLENECK

MESHING

CASE SETUP UP TO 10% OF USER TIME

VISUALIZATION UP TO 20% OF USER TIME

The percentages shownModule

are based on 1my personal experience.
2 - Lecture 4
CFD simulation workflow

GEOMETRY

MESH

SOLVER CO-PROCESSING

PARAMETRIZATION
OPTIMIZATION

VISUALIZATION

Parametric or optimization
Module 2 -approach
Lecture 1 Simulation loop 5
 CFD simulation workflow
PARALLEL ASYNCHRONOUS OR CONCURRENT DRIVER
MULTIDIMENSIONAL OR PARAMETRIC STUDY
DESIGN OF EXPERIMENTS
SENSITIVITY ANALYSIS
OPTIMIZATION STUDY
UNCERTAINTY QUANTIFICATION
ROBUST DESIGN AND OPTIMIZATION UNDER UNCERTAINTY
MULTIOBJECTIVE OPTIMIZATION
SURROGATE BASED OPTIMIZATION

HUMAN DECISION MAKER

DECISION MATRIX OR
GEOMETRY GEOMETRY GEOMETRY

MESH MESH MESH

SOLVER CO-PROCESSING SOLVER CO-PROCESSING SOLVER CO-PROCESSING

PARAMETRIZATION PARAMETRIZATION PARAMETRIZATION

OPTIMIZATION OPTIMIZATION OPTIMIZATION

VISUALIZATION VISUALIZATION VISUALIZATION

CASE 1 CASE 2 CASE N

AUTOMATIC POST-PROCESSING

Concurrent approach
Module 2- Simulation
Lecture 1 nested loop 6
 CFD simulation workflow

CASE SETUP POST

GEOMETRY MESHING
AND SOLVER PROCESSING

Salome blockMesh OpenFOAM (FVM) paraView

Blender snappyHexMesh Code Saturne (FVM) VISIT
Free-CAD Salome SU2 (FVM) gnuplot
Sketch-Up Engrid Overture (FDM) scilab
pythonOCC GMSH ELMER (FEM-DG) grace
Openscad TETGEN Fenics (FEM) Python
OpenVSP Calculix OpenLB (LBM) R computational
statistics
Onshape cfMesh Palabos (LBM)

This list does not enumerate all the open source applications available. It only shows those applications that I like
to use or I feel confortable with. Module 2 - Lecture 1 7
Module 2
Lecture 2

Module 2 - Lecture 2 1
 Roadmap

1. Geometry generation using open source

tools - Preliminaries

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Geometry generation using open source tools

The best way to learn how to use the geometry generation tools is by doing.
Hereafter we are going to show you how to get started with the geometry
generation tools. The rest is on you.
There are many video tutorials available on internet for each specific tool, so
feel free to surf the web.
There are always many ways to accomplish a task when creating a
geometry, this give you the freedom to work in a way that is comfortable to
you. Hereafter we are going to show you our way.
There is no wrong or right way to generate a geometry. The only rule you
should keep in mind is that by the end of the day you should get a unique
clean and watertight geometry.
Remember, the quality of the mesh and hence of the solution,
greatly depends on the geometry. So always do your best when
creating the geometry.

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Geometry generation using open source tools
Potential geometry issues
Missing faces. Cracks.
Small faces. Gaps.
Misaligned faces. Free faces, edges, nodes.
Overlapping faces. Hard edges.
Sliver faces (high aspect-ratio). Small edges.
Repeated faces. Sharp angles.
Several surfaces connected to a single Repeated edges.
surface. High curvature NURBS.
among others

These issues must be fixed in order to create a smooth, clean, watertight body and to
prevent meshing issues
In general, when generating the geometry and by using good geometry generation
practices, we should not experience these geometry issues.
At the end of the day we are interested in getting a smooth, clean, watertight body.
Usually, we find these issues when importing or exporting the geometry from/to different
formats.

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Geometry generation using open source tools
So, how do we prepare the geometry for mesh generation?

Delete hard edges.

Delete small edges/faces.
Fill holes.
Split surfaces with high curvature.
Sew faces.
Remove sliver faces.
Connect/disconnected edges/faces.
Delete sharp edges.
Remove unnecessary details (defeaturing). This includes points, edges and
faces.
Boolean operations among bodies.
Decompose geometry into meshable sections.

Let us take a look at a corrupt or incomplete geometry

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Geometry repair/cleanup

To improve quality, split the single surface into two

surfaces

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Geometry repair/cleanup

Sew faces
Align faces
Delete overlapping faces
Connect/disconnect edges

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Geometry repair/cleanup

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Geometry generation using open source tools
Many times, it is not necessary to model all the details of the geometry. In these
cases you should consider simplifying the geometry (geometry defeaturing).
Geometry defeaturing can save you a lot of time when generating the mesh.
So be smart, and use it whenever is possible.

Original Geometry

Defeatured Geometry

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Geometry generation using open source tools
On-shape: it is a full-cloud 3D CAD system. It runs in a web browser and on any
device with a working web browser. It has the same capabilities of commercial CAD
systems. You can create a free account and start to use it with immediately.
http://www.openvsp.org/

OpenVSP: is a parametric aircraft geometry tool. It allows users to create a 3D model

of an aircraft defined by common engineering parameters.
http://www.openvsp.org/

Sketch-Up: is a direct 3D modeling tool. There are many plugins available that extend
Sketch-Up capabilities.
http://www.sketchup.com/

Free-CAD: is a history based CAD tool (parametric design). Light CAD software, good
for not very complicated mechanical designs.
http://sourceforge.net/apps/mediawiki/free-cad/

Friendliness/Easiness to use: Good Fairly

Module Good
2 - Lecture 2 Mild Bad Very Bad 15
Geometry generation using open source tools
Blender: is a direct 3D modeling tool. Extremely powerful for surface modeling and
manipulation.
http://www.blender.org/

Salome: is a history based CAD tool (parametric design). It has quite extensive
capabilities for creation and manipulation of solid geometries.
http://www.salome-platform.org/

pythonOCC: is a 3D CAD/CAE/PLM development framework for the Python

programming language. It provides features such as advanced topological and
geometrical operations, data exchange (STEP, IGES, STL import/export), 2D and 3D
meshing, rigid body simulation, parametric modeling.
http://www.pythonocc.org/

Openscad: is a 3D programming modeling tool. It reads in a script file that describes

the object and renders the 3D model from this script file.
http://www.openscad.org/

Friendliness/Easiness to use: Good Fairly

Module Good
2 - Lecture 2 Mild Bad Very Bad 16
Module 2
Lecture 3

Module 2 - Lecture 3 1
 Todays lecture

1. Geometry generation using open source

tools - Salome

Module 2 - Lecture 3 2
Geometry generation using open source tools

Introduction to SALOME

Open Source project carried on by CEA, EDF and OpenCascade.

SALOME has quite extensive capabilities for creation and
manipulation of solid geometries
capable of producing tetrahedral, hexahedral and prism meshes with
several algorithms
supports ACIS, BREP (native), IGES, and STEP
exports solid geometries in ACIS, BREP, IGES, STEP and STL (both
ASCII and binary)
meshes can be exported in DAT, MED, I-deas UNV, and STL format
(ASCII or binary).
There is a utility for data conversion from UNV format to
OpenFOAM mesh form
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 2D geometry model

Lets try to model a simple 2D geometry

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 2D geometry model
Using SALOME to draw a 2D cylinder case

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Geometry generation using open source tools

To run this case, go to the directory:

$PTOFC/meshes_and_geometries/salome_cylinder2d

From this point on, please follow me.

We are all going to work at the same pace.
Remember, $PTOFC is pointing to the path where you
unpack the tutorials.

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Geometry generation using open source tools
Before we start
If you are using our virtual machine or using the lab workstations, you will need to source OpenFOAM (load
OpenFOAM environment).

To source OpenFOAM, type in the terminal:

$> of3x

Remember, every time you open a new terminal window you need to source OpenFOAM.

By default, when installing OpenFOAM you do not need to do this. This is our choice as we have many
things installed and we want to avoid conflicts between applications.

To use Salome you will need to invoke it. Type in the terminal:

$> salome

Module 2 - Lecture 3 7
 2D geometry model

Salome is composed by several modules for CAD modelling, mesh

generation, data visualization and more.

Select the geometry module from this

drop-down menu

Module 2 - Lecture 3 8
 2D geometry model

Salome is composed by several modules for CAD modelling, mesh

generation, data visualization and more.
1. Select the geometry module from this
drop-down menu

2. Click on New to initialize the module to a

blank project

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 2D geometry model

Lets explore the geometry module

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 2D geometry model
Familiarizing with the geometry graphic interface

3D Viewer

Menu Bar
Main Controls
Toolbars

Pipeline Browser

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 2D geometry model
Familiarizing with the geometry graphic interface

Basic entities

Primitve entities

Boolean operations

Transformations

General operations

Entities generation

Build entities

You will find a lot of additional operations and functions in the textual menu

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 2D geometry model
Familiarizing with the geometry graphic interface

Select view orientation in the Camera

Activate the mouse interaction style Controls

Mouse interaction in the

3D viewer

Rotate

Zoom

Pan

Zoom

Module 2 - Lecture3D
3 Viewer 13
 2D geometry model
Lets create a primitive entity:
New Entity Primitives - Rectangle

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 2D geometry model
Translate the rectangle
Operation Transformation - Translation

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2D geometry model
Create the cylinder circle
New Entity Primitives - Disk

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2D geometry model
Create the cylinder circle
Operations Boolean - Cut

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 2D geometry model

Your simple 2D cylinder case is now complete

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 2D geometry model

Dont forget to save the Salome project file (.hdf extension)!

Module 2 - Lecture 3 19
 Python scripting

We have saved the Salome project in a .hdf file, but we can also
produce a trace of every action we have performed so far.
This trace will be saved in Python script, a human readable file.
This file can be used, in the dull way, to bring us back to the point where
we were at the saving time.
However, this is what we do when we save the file in the .hdf format.
The great power of scripting is that you can also modify all the
parameters you have used during the geometry and mesh generation
process.

Now go to File Dump study and chose a python file name, e.g.
cylinder2d.py

Module 2 - Lecture 3 20
 Python scripting
Everything we did in Salome by mouse-clicking will be reproduced by
textual input in the python syntax.

The names of the commands are quite self-explicatory. Some examples

are

p0 = geompy.MakeVertex(0., 0., 0.)

circle1 = geompy.MakeCircle(pz, vxy, 30)
status = Mesh_1.AddHypothesis(Max_Element_Area_1)
isDone = Mesh_1.Compute()

On the web you can find a lot of documentation about them on

salome-platform.org
Module 2 - Lecture 3 21
 Python scripting
Textual user inputs are very useful once they are gathered in a unique
file (a script). This can helps you speeding up your production and be
more flexible.

For instance, in the GUI mode you cannot modify a geometry once you
have created it, and moreover this change does not reflect on other
geometries.

One possibility is to use the Notebook in the GUI interface, but it does
not allow you the same flexibility as scripting.

Moreover, once your geometry and mesh are created in an automatic

way by parametrization it is possible to insert this process in an
optimization loop or a parameter exploration..

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 Python scripting

To load a scripted mesh or geometry go to File Load Script

Try to open and view the geometry/mesh created by the
cylinder2d.py script

Now take a look at the file created by dumping the study

$> gedit cylinder2d.py

We can now parametrize a copy of this file in order and test the power of
this procedure.

Module 2 - Lecture 3 23
 Python scripting

This is a small change in the cylinder2D.py script that you may try.
Lets find the following lines:

Disk_1 = geompy.MakeDiskR(1, 1)
Cut_1 = geompy.MakeCutList(Face_1, [Disk_1], True)

and modify them into

Disk_1 = geompy.MakeDiskR(1, 1)
geomObj_1 = geompy.MakeCutList(Face_1, [Disk_1], True)
Scale_1 = geompy.MakeScaleAlongAxes(Disk_1, O, 1, 0.5, 1)
Cut_1 = geompy.MakeCutList(Face_1, [Scale_1], True)

to obtain the geometry of a different shape, in this case an ellipse-

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 Python scripting

If you load the new python script, something like this should appear

Module 2 - Lecture 3 25
 Python scripting
run Salome in the bash
When dealing with parametrization problems (but not only) its useful to
execute our python scripts in the bash:

$> salome t scriptName.py

The python script can include geomety or mesh export functions to

.STL or .UNV files as follows:

geompy.ExportSTL(Cut_1, "ellipse2d.stl", True, 0.001, True)

or

Mesh_1.ExportUNV( r'Mesh_1.unv' )

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 3D geometry model

Lets now try to model a 3D geometry

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Geometry generation using open source tools
Using SALOME to draw and to mesh a simplified mixing elbow

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Geometry generation using open source tools

Our goal

Module 2 - Lecture 3 29
Geometry generation using open source tools

Lets run this case. Go to the directory:

$PTOFC/meshes_and_geometries/salome_elbow3d

From this point on, please follow me.

We are all going to work at the same pace.
Remember, $PTOFC is pointing to the path where you
unpack the tutorials.

Module 2 - Lecture 3 30
3D geometry model
Lets create a primitive entity:
New Entity Primitives - Disk

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 3D geometry model
Creation of a plane passing through the origin and
perpendicular to Z
New Entity Basic Plane

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 3D geometry model
We define an extrusion path as follows
New Entity Basic 2D Sketch

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 3D geometry model
We define an extrusion path as follows
New Entity Basic 2D Sketch
Fist point
X: 0 Y:0
Click Apply
Add the new point coordinates and Apply
X: 3 Y: 0
Add the elbow arc and Apply
Element type: arc
Type: direction
Direction: tangent
Radius: 1,5 Ange: 90
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 3D geometry model
We define an extrusion path as follows
New Entity Basic 2D Sketch

Add the final point coordinates and Apply

X: 4,5 Y: 4,5
Press Close

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 3D geometry model
We define an extrusion path as follows
New Entity Basic 2D Sketch

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 3D geometry model
Extrusion of Disk_1 along the path line
New Entity Generation Extrusion Along Path

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 3D geometry model
Adding a point in the outlet center
New Entity Basic - Point

Coordinates
X: 4.5 Y: 4.5 Z:0
Press Apply and Close

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 3D geometry model
We create a second disk related to the secondary inlet
New Entity Primitives - Disk

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 3D geometry model
Extruding Disk_2 to model the secondary inlet
New Entity Generation - Extrusion

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 3D geometry model
Lets fuse Pipe_1 with Extrusion_1
Operations Boolean - Fuse

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 3D geometry model

Dont forget to save the Salome project file (.hdf extension)!

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 Exporting the geometry

Rename Fuse_2 with some more helpful name (in my

case mixingElbow)
Dont forget to save the project file! (.hdf files)
In the next modules we will see that the standard
OpenFOAM meshers needs triangulated surface
geometries in Stereolithography (STL) format to perform
the discretization of the computational domain.
At this end, triangulated surface geometry file must be
generated by Salome and then located in the directory
constant/triSurface.
Salome allows exporting of the selected faces in the
geometry module in the STL format.
Module 2 - Lecture 3 43
 Exporting the geometry

l An .stl (STereo Lithography interface format or Standard Triangulation Language) file

is a simple list of triangles (the facets) with an outward normal versor (needed to
recognize what is inside and what is outside):

facet normal -1 0 0
outer loop
vertex -1.5 1.5 -1.5
vertex -1.5 -1.5 -1.5
vertex -1.5 -1.5 1.5
endloop
endfacet

l The union of different facets forms a patch (called solid).

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 Exporting the geometry
solid solid1
facet normal -1 0 0
outer loop
vertex -1.5 1.5 -1.5
vertex -1.5 -1.5 -1.5
facet vertex -1.5 -1.5 1.5
endloop
endfacet solid1
facet normal -1 0 0
outer loop
facet ...
endloop
endfacet
endsolid solid1
solid solid2
facet normal 0 1 0
outer loop
...
facet endloop
endfacet
facet normal 0 1 0 solid2
outer loop
facet ...
endloop
endfacet
endsolid solid2
Module 2 - Lecture 3 45
 Exporting the geometry

l An .stl file can be stored in two different formats:

l ASCII (human readable),

l Binary format (machine format).

l Binary format is lighter (usually ~ 1/3 of hard drive space) but cannot be edited
via text editor.

l However, the facet splitting can be done by hand just with simple geometries.
With longer surfaces, the splitting can be done by using surfaceFeatureEdges

l Having all the .stl in binary format can however be advantageous if we have to
merge different parts of the surface together.

Module 2 - Lecture 3 46
 Roadmap

1. Geometry generation using open source

tools Salome
2. Geometry generation using open source
tools - Onshape

Module 2 - Lecture 3 47
 3D geometry model

Onshape is a web browser 3D CAD modeler freely available online with

an Educational account type.

https://cad.onshape.com/

The projects are saved in the Onshape cloud storage storage with public
and private sharing options and its possible to export the geometries in a
number of traditional formats such as STEP, STL, Parasolid, etc.

Module 2 - Lecture 3 48
 3D geometry model

To execute this tutorial you havet o sign in to Onshape, this operation

will take just one minute.
An educational account will allow the user to save up to 10 different
projects a 5 Gb of total storage.

Module 2 - Lecture 3 49
 3D geometry model

Lets explore the Onshape modeler

From this point on, please follow me.

We are all going to work at the same pace.
Remember, creating an Onshape account is necessary to
proceed with this tutarial
Module 2 - Lecture 3 50
 3D geometry model

The users main page is organized as follows:

User folders by
projects type Documents
list Project preview and details

Use the Create button to name and initialize a new document

Module 2 - Lecture 3 51
 3D geometry model
The users main page is organized as follows:

Tools bar

Drop down
geometry
elements View cube
menu

Interactive 3D
modeler viewer
Tabs menu

Use the Create button to name and initialize a new document

Module 2 - Lecture 3 52
 3D geometry model
There are no Save/Save as buttons, any change in the project is automatically
stored and you can easily jump back in a previous state of your sketch by means
of the Versions and History menu.

Versions
and history
menu

Returns to the status

associated with each
previous change

Module 2 - Lecture 3 53
 3D geometry model

In the bar menu of the Part Studio Tab you will find the Feature toolbar:
Sketch creation and basic
modifications

Sketch advanced modifications

Boolean and transformations

Planes and advanced functions

In the Sketch mode the bar menu is composed as follows:

Back/Forward and Extrustion

Basic entity generation

Entity operations and measure

Entitiy adjustements

Module 2 - Lecture 3 54
 3D geometry model

Interacting in the 3D viewer:

Mouse interaction in the

3D viewer

Selection

Rotate

Pan

Zoom

Module 2 - Lecture 3 55
 3D geometry model
And finally, some keyboard shortcuts that may turn out useful for your
work:
General 3D Viewer Sketch mode
purposes

Module 2 - Lecture 3 56
 3D geometry model
In a newly created document, left click on the Document menu and then
on Workspace units to choose a metric length unit.

Document menu

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 3D geometry model
Exit from the Workspace units window and left click on the Sketch
button and select the Front plane as the Sketch plane

Switch to a perpendicular view with respect to the front sketch plane by

right clicking on the Front planeModule
and then View normal to sketch plane
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 3D geometry model
Now left click on the line button in the toolbar (or l shortcut) and draw
a vertical line that starts from the origin with an arbitrary length.

Dont worry about sizing, the extent of the geometry elements can be
easily adjusted after having created the sketches
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 3D geometry model
After having selected the second point of the line, the line allows you
the definition of the next point in order to create a polyline. You can
escape the polyline creation by pressing the Esc key.
Now its time to draw the arc of our extrusion pattern. Select 3 point
arc (or the shortcut a) and specify in the order: the initial point, the final
point and the arc radius.

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 3D geometry model
The final horizontal line follows the arc final point .Lets draw it.

Snap
indicator

Snapping indicators will pop up when you are selecting the second
point of an element and are useful to obtain basic alignment or sizing.

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 3D geometry model

The adjustment buttons can facilitate the correction of our lines/curves,

lets explore their meaning by leaving the mouse arrow on their symbol
and waiting for the description to pop-up.

E.g. the tangent button (or the shortcut t) ensures that the selected
sketch entity is tangent to the second selected entity. Try to use the
tangent function between our arc and the horizontal line.

Snap indicators

Now you should see the horizontality and tangential snap indicators
appearing when the mouse arrows hover on the horizontal line.
Module 2 - Lecture 3 62
 3D geometry model
The dimension toolbar button (or the shortcut d) is an handy tool that
allows adjusting the size of the sketch elements. Leave the mouse
arrow on the dimension button to see the instructions and enable the
dimensions of the three elements.
If you prefer, you can switch off the Front plane view by right clicking on
Front from the drop-down element list and then left clicking on Hide

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 3D geometry model
For the moment, we have finished working on Sketch 1, close it by left
clicking on the green sign.

Lets change the view to a normal to the Top plane and create a new
sketch on this plane.
Select the Center point circle entity (shortcut c) and draw a circle
centered in the axis origin with a diameter equal to 1.

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 3D geometry model
In Onshape, the extrustion along a path is performed by the Sweep
operator. Close the Sketch 2 and leave the mouse over the Sweep tool
in the Feature toolbar to see the instructions.

Sweep
Module window
2 - Lecture 3 65
 3D geometry model
The Sweep window requires the definition of the sketch to sweep and
the sketch of the path. We are interested in doing a Solid sweep, the
results is a brand new Part.
In the Onshape language, Parts are 3D geometries that are separated
components of an Assembly and can be treated separately. The
Assembly Tab allow the manipulation of group of Parts and manages
their connection.

Final entities
Destination of the
new Part
Sketch to be swept
Sweep patch

Transparency

Module 2 - Lecture 3 66
 3D geometry model
Now we want to create our secondary mixing inlet. We can use the
extrustion function but first we need to create a plane parallel to the
existing Right plane. We will draw our next circle sketch in the new
plane.
Click on the Plane button from the Feature toolbar. We will define the
Right plane starting entity with an Offset distance equal to 1.

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 3D geometry model
For the next step Id recommend to hide the Right plane from the
geometry drop-down menu and use a view that is normal to Plane 1,
now you should know how to do it.
Create a new sketch and a Center point circle to realize a 0.5 diameter
circle that lays on Plane 1 at the level of the elbow. The center of the
circle must intersect the Z axis, if it doesnt dont worry, you can adjust it
later.
The Concentric tool will be used to make the new circle concentric with
respect to the outlet face.

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 3D geometry model
Close the Sketch 3 and perform an Extrustion (shortkey shift-e) having
selected the new circle face. We will perform a Blind type extrusion with
a depth equal to 3.

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 3D geometry model
Close the Sketch 3 and perform an Extrustion (shortkey shift-e) having
selected the new circle face. We will perform a Blind type extrusion with
a depth equal to 3.

Defines if the extrusion is added to an

existing Part or not
Face to be extruded
Extrusion type
Extrusion type option, in this case Depth

Choose to merge with all the existing Parts

Specify the destination Part

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 3D geometry model
After the latest operation our 3D mixing elbow model is complete.

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 Exporting the geometry
We can export our solid in the STL form by right clicking on our Part in
the Part Studio list and left click on Export.
Lets choose the Text STL format and Meter units.

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 Exporting the geometry
The exported STL geometries can be open in paraview to check the
final result.
$> paraview elbow3d.stl

You can also check the quality of the STL geometry by taking
advantage of the surfaceCheck OpenFOAM utility.

$> surfaceCheck elbow3d.stl

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