Professional Documents
Culture Documents
with Applications
Mark Troscinski
Multiphysics Product Manager
Presented By:
David Ellis
Idac Ltd
1
Agenda/Objectives
• Answer some questions:
–What is Multiphysics?
–What is FSI?
• Describe benefits of new ANSYS
FSI capability
• Illustrate some interesting FSI
applications
What is Multiphysics?
2
Multiphysics Coupling
Heat
Electricity
Transfer
Solid
Mechanics
Fluid
Magnetism
Mechanics
Multiphysics Coupling
Heat Solid
Transfer Mechanics
• Thermal-Structural Coupling
– Engines, Gas Turbines, Heat Exchangers
– Electronic Components, Solder Joints
– Cryogenic components and systems
• Needed for any product subjected to
extreme changes in temperature.
3
Multiphysics Coupling
Heat
Electricity
Transfer
• Thermal-Electric Coupling
– Current-carrying conductors, bus bars
– Electric motors, generators, transformers
– Electronic components and systems
• Needed for electric power handling
components and systems.
Multiphysics Coupling
Electricity Magnetism
• Low-Frequency Electromagnetics
– Motors, generators, induction coils
• High-Frequency Electromagnetics
– Waveguides, patch antennas, radar systems,
microwave systems
4
Multiphysics Coupling
Heat Electro-
Transfer magnetics
• Thermal-Electromagnetic Coupling
– Induction heating systems
– Microwave heating systems
• Used in many manufacturing processes:
– Heat treating
– Pre-heating for metal forming operations
Multiphysics Coupling
Fluid Electro-
Mechanics magnetics
• Fluid-Electromagnetic Coupling
– Induction furnaces for stirring molten metals
• Used by induction furnace manufacturers
– Environment too harsh to easily observe stirring
patterns
5
Multiphysics Coupling
Solid
Electricity
Mechanics
• Electrostatic-Structural Coupling
– Comb drives, torsional resonators
– Other MEMS devices
• Piezoelectrics
– Transducers, microphones, micropumps
– Inkjet printer actuation systems
Multiphysics Coupling
Electro- Solid
magnetics Mechanics
• Magneto-Structural Coupling
– Solenoid devices, stepper motors
– Alternators, generators
• Used by engineers to determine:
– Magnetic force (linear systems)
– Magnetic torque (rotary systems)
– Efficiency
6
Multiphysics Coupling
Fluid Solid
Mechanics Mechanics
What is CFD?
• Numerical analysis of fluid flow, heat transfer, and
related phenomena
• Within each finite element, the Navier-Stokes
equations are rewritten as algebraic equations
that relate nodal:
– Velocity
– Pressure
– Temperature
– Species concentrations
… to the values in the neighboring elements.
• Equations are assembled in matrices and solved
to yield complete picture of flow down to
resolution of mesh
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CFD Equations
• Conservation of Mass
– Continuity
• Conservation of Momentum
– Newton’s 2nd Law
• Conservation of Energy
– 1st Law of Thermodynamics
• Conservation of Species Concentration
CFD Elements
• 2D: Fluid141
– Quadrilaterals
– Triangles
• 3D: Fluid142
– Hexahedrals or bricks
– Tetrahedrals or tets
– Pyramids
– Prisms
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CFD Flow Descriptions
• Eulerian
– Focus on fixed volume of space, where fluid
enters and leaves
• Lagrangian
– Focus on particular fluid region which moves
relative to a fixed point of reference
• Arbitrary-Lagrangian-Eulerian (ALE)
– Boundary of fluid region moves at arbitrary
velocity (something other than fluid velocity)
– FSI’s dynamic mesh motion scheme
What is FSI?
In reality, it’s Fluid-Solid Interaction!
Fluid
Mechanics
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How is FSI done?
Numerical coupling is
established between the
different “physics” modules
Multiphysics Math
The finite element formulation which treats
a single phenomenon uses matrix
algebra represented by:
[K]{X} = {F}
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Matrix Coupling
[ [K11] [K12]
[K21] [K22] ]{ } { }
[X1]
[X2]
=
[F1]
[F2]
Matrix-Coupled FSI
• Positives:
– Solution of a coupled equation system
achieved in a single step
• Negatives:
– Requires complete re-writing of the fluid and
solid solvers (must develop new FSI elements)
– Matrix system tends to be very ill-conditioned
due to difference in “stiffness” of fluid and the
solid regions
– Large problems become computationally
expensive
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Load Vector Coupling
[ [K11] [ 0 ]
[ 0 ] [K22] ]{ } { }
[X1]
[X2]
=
[F1]
[F2]
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ANSYS FSI Initiative
• Tightly integrate FLOTRAN CFD &
ANSYS solid solvers into a load
vector-coupled FSI algorithm that
is:
–Fully-automated
–Time-accurate
–Easy to use
• Leverage ANSYS/Mechanical core
capabilities
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FSI Algorithm Benefits
• Full support for all structural
nonlinearities:
– Geometric, material, and contact
• Dissimilar mesh interface:
– Automatically transfers loads between
differently meshed fluid and solid regions
• Support for beam, shell, and solid
elements:
– With or without mid-side nodes
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FSI Algorithm Benefits
• FLOTRAN Element Birth and Death:
– Suitable for FSI problems involving
contact between immersed, moving
structures
– Fluid elements may be automatically
deactivated as surfaces come into
contact (e.g., valve closes), or reactivated
as they separate (e.g., valve opens)
Solid Solution
Load Transfer ANSYS SOLID
• Structural/Thermal/Coupled-Field
Convergence Check • Geometric Non-Linearity
• Material Non-Linearity
End Stagger Loop • Contact Non-Linearity
• All Iterative and Direct Solvers
Increment Time • All Transient Solver Options
15
Load Transfer
From FLUID side From SOLID side
Non-Conservative Interpolation
Nodal force fluxes: FX”, FY”, FZ”
Nodal heat fluxes: Q”
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Applications
• Truly applicable across all market
segments:
– Automotive fuel injectors, control valves, engine
dampers, fans & pumps
– Aerospace airframe and propulsion system
components
– Flexible flow control devices, biomedical
vessels and valves for blood flow
– Flow-induced vibration of piping systems and
heat exchangers
– Diaper manufacturing processes, paper copy
machines
– More, more, and still more!
Under
low ∆P
Under
high ∆P
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So What?
• Vernay Labs currently designs these
devices by “seat of pants” method:
– Guess at shape to get right flow control
characteristics
– Build and test, build and test, …
• They have no automated process in place
for designing these FSI-type devices.
• ANSYS/Multiphysics can significantly
reduce their overall time to market.
Problem Description
• Fluid:
– Incompressible, turbulent water flow
– Prescribed inlet-to-outlet ∆P = 45 PSI
• Solid:
– Hyperelastic, high strain (>100%) materials
– Treated with Mooney-Rivlin model
• Simulation objective:
– Determine steady-state shape of solid and
accompanying steady-state fluid flow rate
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Axisymmetric Model
CONTA172’s TARGE169’s
Rubber -
PLANE183’s
Water - FLUID141’s
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FSI BC – on Fluid
FSI BC – on Solid
20
FSI Results
Steels
E = 206.8 GPa
ν = 0.29
18.36 mm
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So What?
• Fuel injector leakage:
– Unavoidable parasitic loss
– Adversely affects system efficiency - Must be
minimized!
– Current predictions grossly underestimate
measured leakage volumes
• Caterpillar has NO automated method of
predicting leakage rates.
• Tiny gains in system efficiency would
provide tremendous advantage over their
competitors
0.0E+00
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Time (sec)
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Model Geometry
Plunger
Barrel
Cavity
Model Geometry
10º Chamfer
Leakage Inlet
23
Model Geometry
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Boundary Conditions
UY=0 P=0 UY=0
VX=0
VY=0
UX=0
FSI(1) FSI(2)
P(t)
UY=0
FSI Results
500X Displacements
25
Leakage Flow Rates
FSI CFD
6.00
5.00
Mass Flow Rate (gm/sec)
4.00
3.00
2.00
1.00
0.00
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Time (sec)
Pressure-Limiting Valve
Spring constant:
kspring = 8.0E+05 gm/sec^2
Spring preload:
Fpreload = 2.5E+06 gm*mm/sec^2
Ø 4.5 mm
Ball density:
ρball = 7.8E-03 gm/mm^3
Fluid density:
ρfluid = 7.5E-04 gm/mm^3
Fluid viscosity: Ø 4.0 mm 55º
µfluid = 4.0E-04 gm/(mm*sec) 0.25
mm
Relative inlet pressure:
Pinlet = 6.0E+05 Pa Ø 2.4 mm
Ø 10.0 mm
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So What?
• Pressure-limiting valves are used in anti-
lock brake systems
– Huge liability ramifications
• Per VDO, tiny geometric design changes
cause wide variations in valve response
and performance
• Currently guessing on new valve designs
• Automated FSI tool will significantly reduce
overall time to market and improve reliability
Axisymmetric Model
COMBIN14
SOLID42’s
FLUID141’s
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Finite Element Mesh
Mesh Detail
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Mesh Detail
FSI Results
29
Ball Displacement History
f ≈ 875 Hz
2 in 8 in
Plenum Outlet:
∆P: 3.0 in H 2O
30
FSI Results
31
Piezoelectric Micropump
PZT Layer
± 500 V Silicon
Membrane
Air
~ 3 mm
FSI Results
32
Pulsing Blood Flow
Fluid element: 142’s
Solid element: 45’s
Dissimilar mesh interface
Material Properties
Solid density: 1150 kg/m^3
Young’s modulus: 3.0*10^5 Pa
Poisson ratio: 0.3
FSI Results
33
Vortex Shedding – Re = 100
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VX = 20 mph; VY = ± 5 mph
Summary
• ANSYS FSI solution capability:
– Easy to use, fully automated, time-accurate
– Full support for all structural nonlinearities
– Dissimilar mesh interface for beam, shell and
solid elements, with or without mid-side nodes
• Future developments:
– Add automatic re-meshing capability
– Add nth physics to stagger loop
– Enhance FSI post-processing
– Add AMG parallel solver
35
Thank You!
Any Questions?
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