What You Will Learn ?

Introduction To CFD : What, how, why, for whom.. etc.?

Computational Fluid Dynamics Preprocessing

Solvers

Post-Processing

Centre for Computational Technologies Pvt. Ltd., Industrial Applications

Block No 6, Bharati Apt, 26/1,
Wakadewadi, Shivaji Nagar, Pune, India 411005
Market and Career Opportunity in India
Phone: +91-20-2552 1873
Way to be CFD analysis Engineer
Email: info.cctech@gmail.com
URL: http://www.cctech.co.in

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Solving Fluid Dynamics Problems Solving Fluid Dynamics Problems

Analytical Fluid Dynamics (AFD) Experimental Fluid Dynamics (EFD)

Analytical Fluid Dynamics

(AFD) Mathematical analysis
of governing equations,
including exact and
approximate solutions.
∇•U = 0
Experimental Fluid dynamics
DU
= −∇p +
1 2
∇ U + ∇ • ui u j (EFD) Observation and data
Dt Re
acquisition

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Solving Fluid Dynamics Problems Foundation Stone

Computation Fluid Dynamics (CFD) Faces of Fluid Mechanics

Archimedes Newton Leibniz Bernoulli Euler

(C. 287-212 BC) (1642-1727) (1646-1716) (1667-1748) (1707-1783)

Computational Fluid Dynamics

(CFD) Numerical solution of the
Animation by Vasily V. Titov, Tsunami governing equations Navier Stokes Reynolds Prandtl Taylor
Inundation Mapping Efforts, NOAA/PMEL (1785-1836) (1819-1903) (1842-1912) (1875-1953) (1886-1975)

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Fluid is Everywhere : Weather & Climate Fluid is Everywhere : Vehicles
Tornadoes Thunderstorm Aircraft Submarines

Global Climate Hurricanes

Surface ships High-speed rail

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Fluid is Everywhere : Sports & Recreation And it is Beautiful

Water sports Cycling Offshore racing

Auto racing Surfing

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CFD : Equations CFD : Equations

– Which equation CFD Solves ? The conservation equation for Φ in Integral form:

– Continuity, Navier-Stokes, and energy equations (∂/∂t) ∫∫∫(ρΦ)dv + ∫∫(ρΦ) V•S ds = ∫∫ Γgrad(Φ)•n ds + ∫∫∫ qΦdv

– Coupled, non-linear, partial differential equations Rate of change Convective Diffusive flux
Source or
of Φ in a control flux across across the
– For example, incompressible form volume the surface surface
sink term

∂u ∂ v ∂w
+ + =0 Rate of change Net flow rate Net flow rate Mass produced
∂x ∂y ∂z of density due to velocity due to concentration to reactions

∂u ∂u ∂u ∂u 1 ∂p µ ⎛ ∂ u ∂ u ∂ u ⎞
2 2 2
+u +v +w =− + ⎜ + + ⎟ Here : Φ = 1 Mass conservation equation
∂t ∂x ∂y ∂z ρ ∂x ρ ⎜⎝ ∂x 2 ∂y 2 ∂z 2 ⎟⎠ = u, v, w Momentum conservation equation
= Energy equation
∂v ∂v ∂ρ v ∂ρ v 1 ∂p µ ⎛ ∂ v ∂ v ∂ v ⎞
2 2 2
+u +v +w =− + ⎜ + + ⎟
∂t ∂x ∂y ∂z ρ ∂y ρ ⎜⎝ ∂x 2 ∂y 2 ∂z 2 ⎟⎠ Example: Conservation of Mass (Continuity Equation)

∂w ∂w ∂w ∂w 1 ∂p µ ⎛ ∂ 2w ∂2w ∂2w ⎞
+u +v +w =− + ⎜⎜ 2 + 2 + 2 ⎟⎟
∂t ∂x ∂y ∂z ρ ∂z ρ ⎝ ∂x ∂y ∂z ⎠
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CFD: Discretization CFD: Discretization
– How the equations are solved? – Discretization Methods :
– All the continuous nonlinear equations are discritized – Finite volume methods (FVM)
– To solve NSE, the governing PDEs are converted to algebraic – Use CV (Control Volume) form of NSE equations on each
equations grid cell !
– Discretization Methods : – Most popular approach, especially for commercial codes
– Finite difference methods (FDM)
– Each term in NSE is approximated using Taylor series, e.g.,
– Finite element methods (FEM)
∂U U i +1 − U i
= + O ( ∆x ) – Solve PDE’s by replacing continuous functions by
∂x ∆x piecewise approximations defined on polygons, which are
referred to as elements. Similar to FDM.
∂ U U i +1 − 2U i + U i −1
2
= + O ( ∆x )
2

∂x 2 ( ∆x )
2

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What is CFD ? What is CFD ?

– CFD is use of computational methods for solving fluid Computational Fluid
engineering systems, including modeling (mathematical & Dynamics
Physics) and numerical methods (solvers, finite
differences, and grid generations, etc.). Means: Goal:
– Rapid growth in CFD technology since advent of computer Use of computers Study Fluid Flow
For Calculations, data storage

Forget analytical expressions

Convert Large amount of data
partial differential equations But only discrete data
(pdes) Look for data such as:
to x, y, z, ρ, p, T, h, e
algebraic operations x, y, z, ρ, p, T, h, e
(fdes) …….
…….
…….
Large no of …….
ENIAC 1, 1946 IBM WorkStation
algebraic and logical …….
operations …….

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What is CFD ? Understanding Physics

– The discritized PDEs can not be solved on continuous – Different flow physics is governed by different
geometry terms in equations
– The geometry need to be discritized. This is called grid
generation – Simplification of governing equations
– Overall CFD is solving discritized equation on discritized – Determines time required for solutions
geometry – Should be valid for give problem
– Needs physical understanding of each and every
term
– Real life problems are very difficult to simulate
– Can you make the problem simple ? This is the
regular question that you need to answer !!!

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Various Flow Models CFD Process
Flow Model Selection

Is µ = 0?
Create Geometry : CAD
Viscous Flow In-viscid Flow
No Yes
Is M <= 0.3? Is M <= 0.3?
Pre-Process
Compressible Flow Incompressible Flow Compressible Flow Incompressible Flow Create Mesh : Grid Generation

Irrotational Rotational Irrotational Rotational Irrotational Rotational Irrotational Rotational

Apply Boundary Conditions

Does not Does Rarely
exist not exist studied

Compressible Incompressible
Navier Stokes Navier Stokes Solve
NS Equations NS Equation Gas dynamics Ideal Flow
Realistic simulation Realistic simulation
of gases of liquids
Understanding physics is important !!
Realistic Mathematical Models for Flow Post-Process
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CFD Process Creating Geometry : CAD

Pre-Processing – Surface or Solid models can be created by
Computer Aided Design (CAD) softwares
Grid
CAD BC
– Need good understanding of geometry
creation
2

1. Build geometry 2. Mesh 3. Define boundary conditions – Very minor details are not required for CFD
Post-Process
simulation
Solution
– Fillets, rivets etc…

Good CAD model is half job done in pre-processing

4. Compute 5. Visualize

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Creating Geometry : CAD Grid Generation : Need

– Commercial CAD softwares can be used – Discritization of Geometry
– SolidWorks, ProE, IDEAS
– Data loss across the softwares need to be CAD Geometry
addressed
– All CFD pre-processing softwares has good
geometry creation capability
– Data loss issue will be resolved automatically
– Limited CAD capability for creating complex
model

Grid

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What is a Grid? Classification of Grids
– Fill a given domain with simple Cartesian Quad tree/Oct tree
shapes such as triangles,
quadrilaterals, etc. so that the
given domain is fully covered. Patched Grid
Mono-Block
– Domain here is space between
Structured (BFC)
two circles.
Overlapping Grid
– The simple shape chosen to fill Multi-Block
the space is triangle.
– Note that
– Triangles collectively cover the Unstructured Triangulation / Tetrahedron
complete space triangles do not
intersect each other Cartesian triangulations
Quadrilateral / Hexahedrons
– Emphasis is on cells (triangles in
the present case); there are grid Cartesian Structured
points but no continuous lines or
what can be called as grid lines. Hybrid
Structured triangulations

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Understanding Grid Structured Grid

y η
– Various grid generation algorithms
– Each has there own advantages and disadvantages
– Few are successful on some geometries and few fails
x ξ
– Which method to use for problem in hand ?
– Quality of grid determines quality of results
– Local clustering for capturing geometry and flow physics

Creating good quality grid with minimum time possible

needs understanding of grid generation algorithms !!

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Structured Grid : Surface Mesh Unstructured Grid

Branches in Human Lung

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Hybrid grid Data Flow Analysis of Complex System
• More than one types of grids CAD Interface Geometric
Geometric
IGES Modeler Visualization
Visualization
• Un-structured grid superposed DXF
Modeler

on structured grid STL

• Unstructured grid embedded
on cells produced from
structured grids or collection CAD
Filters
of tetrahedrons and Solver
Solver
Geometry &
hexahedrons CAD Grid Kernel
Patches

Volume
VolumeGrid
Grid
Stitching Generator
Generator
SurfaceGrid
Surface Grid
Generator surface grid
Generator patches
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Commercial Preprocessing Packages Boundary Conditions

– Typical conditions
– ANSYS-Fluent – Wall
– GAMBIT – NUMECA – No-slip (u = v = w = 0)
– Tgrid – HEXPRESS – Slip (tangential stress = 0, normal velocity = 0)
– ICEM-CFD – IGG – With specified suction or blowing
– Turbo-grid – AutoGrid
– With specified temperature or heat flux
– Inflow
– Outflow
– Interface Condition, e.g., Air-water free surface
– Symmetry and Periodicity
– Zeus Numerix – Usually set through the use of a graphical user
– GridZ
interface (GUI) – click & set

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Solve Post-Processing
– Run CFD code on computer – Most important step in project execution
– 2D and small 3D
simulations can be run on – Gives insights of system you are studying
desktop computers – Needs good understanding of physics for
– Unsteady 3D simulations
still require large parallel interpreting the results
computers – Different post-processing tools can be used
– Monitor Residuals – Color plots
– Defined two ways
– Change in flow variables – Contour plots
between iterations – Vector plots
– Error in discrete algebraic
equation – Path lines
– Animations etc…..
Different Type of Solvers are available. Which solver to use ? Which
Boundary Condition to use ?
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Commercial Solvers &
Postprocessing Tools Industrial CFD : Aerospace

– Fluent – FINE/Turbo
– CFX – FINE/Design3D
– FINE/Hexa
– CFView

– Combustor
– External aerodynamics
– FlowZ – Fire suppression
– ViewZ – Inlets and nozzles
instrumentation
– Missile systems
– Propulsion
– Pumps
– Rotor-airframe interaction

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Industrial CFD : Automobile Industrial CFD : Chemical

– Drying Technology
– Air handling systems
– Emission control
– Engine cooling
– Filtration
– Intake and exhaust manifolds
– Heat and mass transfer
– External aerodynamics
– Materials processing
– Motor sports
– Mixing Simulation
– Power train
– Valve & Pump design
– Oil filters
– Chemical reactors
– Combustion chamber
– Crystallizing equipments
– Passenger Comfort

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Industrial CFD :
Industrial CFD : Biomedical Power Generation Systems

– Blood handling equipment

– Extrusion performance – Boilers
– Glucose monitor – Burners
– Physiological flows – Combustors
– Surgical analysis – Hydropower
– Nuclear reactors
– Toxicology research
– Heat exchangers
– Valves & Tubing
– Thermal stratification
– Sterilization equipment
– Fuel cells
– Blood separators
– Drug delivery systems

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Industrial CFD :
Electronics and Semiconductors Industrial CFD : Environment

– Electronics
– Component level flow and cooling
– Telecommunication equipment
– Engine and transmission controllers
– Magnetic storage devices – Aeration
– Semiconductor design – Archimedes screw
– Crystal growth – Atmospheric plume dispersion
– Equipment thermal control – Caned turbine pumps
– Etching – Clarifiers
– Controllers – Contact tank
– Plasma processing
– Ovens

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Industrial CFD :
HVAC and R Design Industrial CFD : Marine

– Off-shore
– Air flow around buildings – Propulsion
– Burner design – Sail design
– Fan noise – Ship hull design
– Environmental control systems
– Waterborne craft design
– Heating system design
– Ducts, hoods, valves, fittings
– Room flow distribution

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Industrial CFD : Steel CFD Market

– Worldwide market :
– CFD software : $933 Million
– Software + Consultancy : $ 1.9 billion
– Air purification
– Annual growth rate : 25 - 27 %
–
–
Combustion
Continuous casting
– Current developments :
– Dust catcher – ANSYS acquiring Fluent for $570 million
– Ladle furnace
– Burner design – Dassault System acquire ABAQUAS - $413 million
– Oxygen steel making – Dassault System declared new multi physics
– Vacuum degasser
simulation package to be developed – Simulia

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CFD Companies in India Way to be CFD Engineer
– Product:
– Fluent, StarCD, ANSYS, Matrix CFD Solutions, ESI Software, Flomerics, Zeus
How to execute Man power for
Numerix, Partial Derivative, Flowmaster ###### + 2 student
CFD software Industry
1 1

Engineering
Use of CFD CFD User : Analysis

Colleges
– Consultancy: Basic fluid Software ? of Engineering

UG
– Infosys, Infotech, Quantech Global Services, Pacific MindwareEngineering, Transoft mechanics
International, MachWell, Neilsoft, TCS, Satyam, Sungrace, Plexion, Mahindra Problem
Engineering Design and Development Co. Ltd., CADES, Onward Technologies,
Bechtel, CSM Software, QUEST, Apramaya
Rudimentary 2 2 Courses in

Engineering
Colleges
knowledge of Turbulence
– Engineering:

PG
Computer usage
– Tata Engineering, Ashok Leyland, Mahindra and Mahindra, Thermax, Bayer India, Combustion
BHEL, Kirloskar, MICO, NHMG India, Reliance, NTPC, Escort, Forbs Marshall, Maruti,

Laboratories
Magna Steer, Toyo, Atlas Copco, TVS , Concentric, BHER Numerical methods
Gas Dynamics

R&D
– Design Centers:
– John Deere, John F. Welch Technology Centre GE, Emerson, Cummins, General Computational geometry
Motor, Whirlpool, Snecma Aerospace, Honeywell, Ford, DaimlerChrysler, Intel, TACO,
Delphi Man power for R&D Grid generation
Data structures
CFD Code developer:
This is representative list developing a special Parallel computing
code for a problem ..

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Entry Barrier for Engineer Conclusion

– Awareness of advanced technology and its usage
– CFD course in curriculum:
– CFD solves flow equations through discretization
– Indian Institute of Technology (IITs) – CFD is three step process : Preprocessing, Solution
– Indian Institute of Science (IISc) and Postprocessing
– Regional Engineering Colleges (RECs)
– Training provided by product companies :
– It needs good understanding of physics
– Focused on particular package – Lot of commercial softwares are available to solve
– Missing in-depth theoretical training real life problems from different industry
– Carrier opportunities are bright if you cross the entry
barriers

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Thanks a lot

Simulation is The Future!

Centre for Computational Technologies Pvt. Ltd.,

Block No 6, Bharati Apt, 26/1,
Wakadewadi, Shivaji Nagar, Pune 411005
Phone: +91-20-2552 1873
Email: info.cctech@gmail.com
URL: http://www.cctech.co.in

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