Tutorial 11: Adjoint-morphing coupling for duct optimisation

RBF Morph for FLUENT

Current Release: V1.5
Last updated March 2014
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TABLE OF CONTENTS
1. Introduction .......................................................................................................................................3
2. Prerequisites .....................................................................................................................................3
3. Problem description ...........................................................................................................................3
4. Overview of CFD and adjoint solution set-up and results...................................................................4
4.1 CFD solution set-up and results ..................................................................................................4
4.2 Adjoint solution set-up and results ..............................................................................................6
5. Outline of the shape optimisation strategy .......................................................................................10
6. First conjunction shape optimisation ................................................................................................10
6.1 Preparation ...............................................................................................................................10
6.2 Source points definition and preview.........................................................................................10
6.3 Generating and previewing the solution ....................................................................................17
6.4 Morph testing ............................................................................................................................18
6.5 Saving the solution ...................................................................................................................18
7. Second conjunction shape optimization ...........................................................................................19
7.1 Control-Volume Morphing update .............................................................................................19
7.2 Preparation ...............................................................................................................................21
7.3 Source points definition and preview .........................................................................................21
7.4 Generating and previewing the solution ....................................................................................24
7.5 Morph testing ............................................................................................................................25
7.6 Saving the solution ...................................................................................................................25
8. CAD export ......................................................................................................................................25
9. Summary .........................................................................................................................................28
10. References ...............................................................................................................................28

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1. Introduction
This tutorial is called "Adjoint-morphing coupling for duct optimisation" and aims at showing how the
adjoint feature of ANSYS FLUENT (hereinafter FLUENT) can be combined with RBF Morph to guide the
mesh morphing in order to improve the fluid flow within a manifold, so as to increase the efficiency of the
whole mechanical system.
This tutorial demonstrates how to do the following:
 sculpt the shape of two runners creating 2 shape modifiers of RBF Morph;
 export the morphed CAD model.

2. Prerequisites
Requirements for working this tutorial:
1. you have the knowledge of FLUENT adjoint solver key ideas and workflow;
2. you are working in the directory where the tutorial problem resides;
3. you have already started the FLUENT-GUI application.

3. Problem description
This tutorial describes the procedure to couple the adjoint solution of FLUENT with RBF Morph in view of
driving the design of morphed configurations by exploiting the capability of the adjoint solution in
estimating the effect of a change prior to actually making it.
In particular, it is supposed that the adjoint converged solution is already available for the user. The
sensitivity-to-shape data obtained through adjoint computing are then employed as guidance on the
optimal adjustments to be applied through RBF Morph to reduce pressure losses.
The geometry of the manifold is shown in Figure 1. This model is courtesy of Chris Hills by ANSYS and
consists of a duct having one inlet, a cubic-shaped vacuum volume, and one box-shaped volume
connected to two exits.

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Figure 1: Surfaces names of the computational model of the duct

In the following paragraphs a brief description (set-up and outputs of interest) of the CFD and adjoint
solution are respectively reported.

4. Overview of CFD and adjoint solution set-up and results

4.1 CFD solution set-up and results
After starting FLUENT from the directory containing the tutorial files, read the case file
adjoint_3d_internal_s1.cas.gz and browse the CFD solution set-up. The principal settings that were
chosen or created are listed below:
 solutions type: steady state;
 energy: off;
 turbulence: k-epsilon with Standard Wall Functions;
 fluid: air with constant density and viscosity;
 boundary conditions: the types used are velocity-inlet for inlet surface, pressure-outlet for both
outlet.1 and outlet.2 surfaces, and standard wall for wall surface;
 Surface Monitors: mass flow rate to monitor the mass unbalance and Total Pressure (Area-
Weighted Average) at inlet, outlet.1, and outlet.2 surfaces.
Then read the results file adjoint_3d_internal_s1.dat.gz and plot residuals to gain what is depicted in
Figure 2, namely the profiles of scaled residuals of the CFD solution ranging from 0 to 400 iterations.

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Figure 2: CFD solution residuals profiles

To visualize the distribution of the physical parameter of interest for the analysis, plot the contours of the
Total Pressure on the surfaces of the model (Figure 3).

Figure 3: Surface Total Pressure distribution on the model surfaces

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4.2 Adjoint solution set-up and results

Now browse the Adjoint scroll-down menu items panels to acquire the knowledge of the adjoint solution
set-up. Figure 4 shows, for instance, the Adjoint Observable and Adjoint Solution Controls panels
and their set-ups respectively.

Figure 4: Adjoint Observable and Adjoint Solution Controls panels

The pressure drop between the inlet and outlets were imposed as observable, namely as the foundation
for specifying the quantity that is of interest for the computation.
Figure 2 illustrates the profiles of scaled residuals of the adjoint solution.

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Figure 5: Adjoint solution residuals profiles

To apprehend the distribution of the sensitivity of the pressure drop (observable of interest) to walls
movement, plot the vectors of the sensitivity-to-shape coloured by Total Pressure. Figure 6 illustrates the
just cited computational result.

Figure 6: Sensitivity-to-shape vectors coloured by Total Pressure

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Considering this output, and in particular the area in which the highest values are present, the adoint
solution advises to act on the junctions between the cylindrical ducts of the exits and the box-shaped
portion of the duct.
According to the adjoint approach, to reduce pressure losses a control-volume enclosing the first
conjunction was generated. To show its set-up open the Control-Volume Morphing Controls panel
(see Figure 7) and click the Update button.

Figure 7: Control-Volume Morphing Controls set-up for the first conjunction

To know the value of the expected change, press the corresponding button (Expected Change) to gain
the value of -721.57007 Pa. Then display again the surfaces of the model and the position of the control-
volume should appear (see Figure 8).

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Figure 8: Control-Volume Morphing Controls location for the first conjunction

To see the effect of the morphing action driven by the adjoint solution, set the value of the field Scale
Factor equal to 5 and press the Modify Mesh button. What is shown in Figure 9 should appear in the
View Port. To retrieve the baseline configuration press the Revert button. Then set 0.5 as the Scale
Factor value and press Apply.

Figure 9: Adjoint solution driven morphing to the first conjunction

Once the morphing action induced by the adjoint solution is available in memory, the RBF Morph tool is
able to acquire and utilise the adjoint-morphed data to assign this motion to the nodes of the surface
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mesh nearby the area of interest by means of a surface set. To this specific end, a domain encap
enclosing the Control-Volume is defined to limit the morphing action.
Currently an automatic data exchange between the adjoint control-volume box and RBF Morph domain
encap is not allowed and, as such, this domain encap has to be defined manually.

5. Outline of the shape optimisation strategy

The strategy adopted to optimise each of the afore-indicated junctions by means of RBF Morph foresees
the generation of a shape modifier built using a domain encap with no points, and 3 surface sets coupled
with a selection encap each. The First two of them (surf-set1 and surf-set2) are defined to constrain
portions of the surface mesh (i.e. preservation of flat walls), whereas the third one (surf-set3) uses
adjoint solution data on cylindrical wall to apply the nodes motion. Plenum wall and the runner hole are
left free to deform.
This strategy is applied for both conjunctions to generate the corresponding solutions that are termed
adj-1 and adj-2.
Notice that to edit, update, and create different set-ups, the adjoint morph box (Control-Volume) has to
be relocated manually in order to update sensitivity so that shape information are properly located.

6. First conjunction shape optimisation

The basic operations for the generation of the morphing solution for the first conjunction are described in
the following paragraphs.

6.1 Preparation
Execute the following actions:
 open the RBF Morph GUI via the menu Define -> RBF-Morph;
 load the library by clicking on Enable RBF Model.

6.2 Source points definition and preview

Define three surface sets in the Surfs panel. For the surface set 1, assign the settings reported in Figure
10 and Figure 11.

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Figure 10: Set-up of the surface set 1 for the first solution

Figure 11: Set-up of the selection encap of surface set 1 for the first solution
Show the position of selection encap of the surface set 1 as depicted in Figure 12.

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Figure 12: Location of the box-shaped selection encap of surface set 1 for the first solution
For the surface set 2, accomplish the set-up according to what is shown in Figure 13 and Figure 14.

Figure 13: Set-up of the surface set 2 for the first solution

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Figure 14: Set-up of the selection encap of surface set 2 for the first solution
The localization of the box-shaped selection encap of surface set 2 is illustrated in Figure 15.

Figure 15: Location of the box-shaped selection encap of surface set 2 for the first solution
For the surface set 3, assign the settings reported in Figure 16 and Figure 17.

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Figure 16: Set-up of the surface set 3 for the first solution

Figure 17: Set-up of the selection encap of surface set 3 for the first solution
Figure 18 shows the location of the cylinder-shaped selection encap box of surface set 3.

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Figure 18: Location of the cylinder-shaped selection encap box of surface set 3 for the first solution
The set-up of the domain encap is illustrated in Figure 19. The coordinates of the opposite points
defining the box differ of 0.1 m with respect to those of the Control-Volume (as earlier stated the encap
domain is required to completely enclose the Control-Volume).

Figure 19: Set-up of domain encap for the first solution

The location of the box-shaped domain encap for the first solution is depicted in Figure 20.

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Figure 20: Location of the box-shaped domain encap for the first solution
Once all settings have been completed and accepted, select the Surfs panel and click the Finalize
button. Then display the source points by clicking on the DispPts button (Figure 21).

Figure 21: Source points for the first solution

In view of previewing the final position of source points after morphing, click on the PrevPts button.
Figure 22 illustrates what should be reported on the screen.

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Figure 22: Preview of the location of source points after morphing for the first solution

6.3 Generating and previewing the solution

Switch to the solution panel by selecting Solve in the Main Sidebar (see Figure 23) and press in
sequence the Source Points and the Solution button.

Figure 23: Solve panel

Select the Preview item in the Main Sidebar and use the settings reported in Figure 24 to generate the
animation frames.
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Figure 24: Preview panel set-up for the first solution

Save the animation frames according to what reported in Figure 25.

Figure 25: Save picture panel set-up

6.4 Morph testing

Run a morph testing by enabling the Morph item in the Main Sidebar so as to verify if within the interval
of the amplification value the mesh has an acceptable level of quality.

6.5 Saving the solution

After the solution has been checked, save it by specifying the file name adj-1 as shown in Figure 26.

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Figure 26: Solve panel set-up for the first solution

7. Second conjunction shape optimization

7.1 Control-Volume Morphing update
To obtain the adjoint solution mophing action for the second conjunction, change the settings of the
Control-Volume Morphing Controls panel as reported in Figure 27 and press the Apply button.

Figure 27: Control-Volume Morphing Controls set-up for the second conjunction morphing
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Press the Update button (in the case that it is not active, press in sequence Lager Box and Smaller box
buttons). The value of the expected change is -535.33093 Pa and the bounding box is positioned as
shown in Figure 28.

Figure 28: Control-Volume location for the second conjunction study

To see the effect of the morphing action driven by the adjoint solution, press the Modify Mesh button.
What is shown in Figure 29 should appear in the View Port using a Scale Factor value of 5. Then use
the Revert button to go back and set the value 0.5. Then press Apply.

Figure 29: Adjoint solution driven morphing for the second conjunction
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7.2 Preparation
Continue the RBF Morph study session.

7.3 Source points definition and preview

Maintain unchanged the settings for the first two surface sets and change the surface set 3 according to
what reported in Figure 30.

Figure 30: Set-up of the selection encap of surface set 3 of the second solution
Figure 31 shows the location of the cylinder-shaped selection encap box of surface set 3 for the second
solution.

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Figure 31: Location of the cylinder-shaped selection encap box of surface set 3 for the second solution
Change the settings of the domain encap as reported in Figure 32.

Figure 32: Set-up of domain encap for the second solution

The location of the box-shaped domain encap is depicted in Figure 33.

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Figure 33: Location of the box-shaped domain encap

Once all settings have been completed and accepted, click the Finalize button in the Surfs panel. Then
display the source points by clicking on the DispPts button (Figure 34).

Figure 34: Preview of the distribution of source points for the second morphing solution
In view of previewing the final position of source points after morphing, click on the PrevPts button.
Figure 36 illustrates what should be reported on the View Port.

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Figure 35: Preview of the location of source points after morphing

7.4 Generating and previewing the solution

Switch to the solution panel by selecting Solve in the Main Sidebar and press in sequence the Source
Points and the Solution button.
Select the Preview item in the Main Sidebar and use the settings reported in Figure 36 to generate the
animation frames.

Figure 36: Preview panel for the second solution

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7.5 Morph testing

Run a morphing test using the features provided by the Morph panel.

7.6 Saving the solution

After the solution has been checked, save by specifying the file name adj2.

8. CAD export
Assuming that the CAD model of the manifold system is available and that, for optimisation purpose, the
interest is exporting the CAD file (in step format) of the first runner when an amplification value of -10 is
applied, the manner to export this morphed geometry is reported hereafter.
The baseline geometry (STEP file format) of the first runner is shown in Figure 37 visualized through
ANSYS DesignModeler.

Figure 37: Geometrical representation of the first runner

Update the adjoint solution employing the Control-Volume settings used for the first conjunction and load
the adj-1 (adj-1.sol) morphing solution.
Switch to the CAD panel, select the file runner1.stp after pressing Select in the Input STEP File area,
set 1 in the corresponding Scale Factor field (Figure 38) and then press Display.

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Figure 38: CAD import set-up

Figure 39 depicts the visualization of the data of the imported step file of runner1.

Figure 39: Runner1 step file data visualization

Then write runner1_morphed.stp in the Output STEP File field, set 1 in the corresponding Scale Factor
field (Figure 40), set-10 for Amplification and then press Display to see what is shown in Figure 41.

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Figure 40: CAD output set-up

Figure 41: Data of the morphed configuration of the CAD file of the first runner
To export the CAD file of the morphed configuration, press the Morph & Write button.
Figure 42 show the superimposition of the CAD models referring to the baseline and the morphed
configuration of the runner1.

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Figure 42: Comparison between the baseline and morphed configuration of the runner 1 (visualized through
ANSYS DesignModeler)

9. Summary
This tutorial demonstrated the guidelines for coupling the adjoint solution of FLUENT with RBF Morph to
drive the mesh morphing in order to improve the efficiency of a manifold.
Moreover, the manner to export the CAD file of the morphed configuration of a portion of the entire
mechanical system was described.

10. References
R 1. ANSYS Inc., 2013, ANSYS FLUENT Adjoint Solver, Release 14.5, October 2012.

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