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ME 5337/7337 Notes-2005-002
Numerical Simulations
Includes all components in the product Identifies the issues in a specific component or a sub-component
Different tools for the level of analysis Coupled physics (fluid-structure interactions)
ME 5337/7337 Notes-2005-002
CFD Codes
Available commercial codes fluent, star-cd, Exa, cfd-ace, cfx etc. Other structures codes with fluids capability ansys, algor, cosmos etc. Supporting grid generation and post-processing codes NASA and other government lab codes Netlib, Linpack routines for new code development Mathematica or Maple for difference equation generation Use of spreadsheets (and vb-based macros) for simple solutions
ME 5337/7337 Notes-2005-002
Computational Fluid Dynamics (CFD) is the science of predicting fluid flow, heat transfer, mass transfer, chemical reactions, and related phenomena by solving the mathematical equations which govern these processes using a numerical process (that is, on a computer). The result of CFD analyses is relevant engineering data used in:
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ME 5337/7337 Notes-2005-002
Applications
flow and heat transfer in industrial processes (boilers, heat exchangers, combustion equipment, pumps, blowers, piping, etc.) aerodynamics of ground vehicles, aircraft, missiles film coating, thermoforming in material processing applications flow and heat transfer in propulsion and power generation systems ventilation, heating, and cooling flows in buildings chemical vapor deposition (CVD) for integrated circuit manufacturing heat transfer for electronics packaging applications and many, many more...
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ME 5337/7337 Notes-2005-002
Conservation of matter, momentum, and energy must be satisfied throughout the region of interest.
Simplifying assumptions are made in order to make the problem tractable (e.g., steadystate, incompressible, inviscid, twodimensional). Provide appropriate initial and/or boundary conditions for the problem.
Domain for bottle filling problem.
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ME 5337/7337 Notes-2005-002
CFD applies numerical methods (called discretization) to develop approximations of the governing equations of fluid mechanics and the fluid region to be studied.
Governing differential equations algebraic The collection of cells is called the grid or mesh.
The set of approximating equations are solved numerically (on a computer) for the flow field variables at each node or cell.
The solution is post-processed to extract quantities of interest (e.g. lift, drag, heat transfer, separation points, pressure loss, etc.).
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ME 5337/7337 Notes-2005-002
Goal
Assumptions
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ME 5337/7337 Notes-2005-002
Mesh Generation
Geometry created or imported into preprocessor for meshing. Mesh is generated for the fluid region (and/or solid region for conduction).
A fine structured mesh is placed around cylinders to help resolve boundary layer flow. Unstructured mesh is used for remaining fluid areas.
ME 5337/7337 Notes-2005-002
Import mesh. Select solver methodology. Define operating and boundary conditions.
Initialize field and iterate for solution. Adjust solver parameters and/or mesh for convergence problems.
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ME 5337/7337 Notes-2005-002
Post-processing
x-y plots contour plots vector plots surface/volume integration forces fluxes particle trajectories
Temperature contours within the fluid region.
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ME 5337/7337 Notes-2005-002
Advantages of CFD
Low Cost
Using physical experiments and tests to get essential engineering data for design can be expensive. Computational simulations are relatively inexpensive, and costs are likely to decrease as computers become more powerful.
Speed
CFD simulations can be executed in a short period of time. Quick turnaround means engineering data can be introduced early in the design process
Many flow and heat transfer processes can not be (easily) tested - e.g. hypersonic flow at Mach 20 CFD provides the ability to theoretically simulate any physical condition
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ME 5337/7337 Notes-2005-002
CFD allows great control over the physical process, and provides the ability to isolate specific phenomena for study. Example: a heat transfer process can be idealized with adiabatic, constant heat flux, or constant temperature boundaries.
Comprehensive Information
Experiments only permit data to be extracted at a limited number of locations in the system (e.g. pressure and temperature probes, heat flux gauges, LDV, etc.) CFD allows the analyst to examine a large number of locations in the region of interest, and yields a comprehensive set of flow parameters for examination. Courtesy: Fluent, Inc.
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ME 5337/7337 Notes-2005-002
Limitations of CFD
Physical Models
CFD solutions rely upon physical models of real world processes (e.g. turbulence, compressibility, chemistry, multiphase flow, etc.). The solutions that are obtained through CFD can only be as accurate as the physical models on which they are based.
Numerical Errors
Round-off error - errors due to finite word size available on the computer Truncation error - error due to approximations in the numerical models
Round-off errors will always exist (though they should be small in most cases) Truncation errors will go to zero as the grid is refined - so mesh refinement is one way to deal with truncation error.
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ME 5337/7337 Notes-2005-002
Boundary Conditions
As with physical models, the accuracy of the CFD solution is only as good as the initial/boundary conditions provided to the numerical model. Example: Flow in a duct with sudden expansion
If flow is supplied to domain by a pipe, you should use a fully-developed profile for velocity rather than assume uniform conditions.
Computational Domain Computational Domain
poor
Courtesy: Fluent, Inc
better
Ram Ramanan 4/2/2014 CFD 15
ME 5337/7337 Notes-2005-002
Summary
Computational Fluid Dynamics is a powerful way of modeling fluid flow, heat transfer, and related processes for a wide range of important scientific and engineering problems. The cost of doing CFD has decreased dramatically in recent years, and will continue to do so as computers become more and more powerful.
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ME 5337/7337 Notes-2005-002
As h-> 0, error -> 0 (hn, tn) Converging methodology Gets close to exact solution Physical quantities are conserved Higher order schemes can have overshoots and undershoots
Stability
Convergence
Conservation
Realizability (Be able to model the physics) Accuracy (Modeling, Discretization and Iterative solver errors)
ME 5337/7337 Notes-2005-002
CFD Methodologies
Simple grids (rectangular) Complex geometries -> Transform to simple geometry (coordinate transformation) Complex geometries (conserve across faces) Complex geometries (element level transformation) Higher order interpolations in elements Basic momentum principle-based
Ram Ramanan 4/2/2014 CFD 18
Lattice-gas methods