MS

Proprietary and restricted rights notice; Trademarks

Proprietary and restricted rights notice

This software and related documentation are proprietary to Siemens Product Lifecycle Management Software lnc.

© 2018 Siemens Product Lifecycle Management Software lnc.

Trademarks

Siemens and the Siemens logo are registered trademarks of Sjemens AG. Teamcenter is a trademark or registered
trademark of Siemens Product Lifecycle Management Software lnc. or its subsidiaries in the United States and in other
countries. All other trademarks, registered trademarks, or service marks belong to their respective holders.

Page2 CTO9101 CM121

STAR-Com+ essential concepts §TAFtlccM+ Physics imulationpractiee
Demo: mixer.sim 6 ` WOFiKSHOP: Cctdplate g#ysies 239 Discussio ffective simulations 477
Workflow in STAR-CCM+ Discussiom^Physics
WOFtKSHOP: STAR.CCM+ ulation workf]ow 507
WORKSHC)P: STAR-COM+ workflow 2 49 STAR€CM+ data ana

Page3 CTO9101 CM121

STARCCM8 C |d S M S

Description

Essential Concepts Gul, Simulation Tree, Geometry Parts, CFD 5-20

Regions, Boundaries, Continua, Data Presentation

Workflow Geometry Processing, Meshing, Physics Definition, 21-66,

Post Processing 389-414,
469-500

Geometry CAD Creation, CAD Import, Surface Diagnostics and 67-130

Repair, Geometry Operations

Meshing Surface Mesh, Volume Mesh, Conformal/Non- 131-198,

Conformal, Prism Layers, Mesh Quality 447-458

Physics Fluid/Solid Solvers, SteadyITransient Solvers, 239-276,

Physics model setup, Boundary and Initial 4 1 9-446 ,
Conditions 459-465

Data Analysis Presentation of Simulation Results, Reports, Plots, 277-342

Visualization Scenes
(Post Processing)
Design Space Exploration Automation and analysis of many simulation runs 365-380

Page4 CTO9101 CM121

Din u S M S

! Launch STAR-CCM+.
i. In the menu, select File > Load and browse to the folder lnputFiles >

01 Essentialconcepts.
qy` Select mixer.sin and click Open.
I Right-click the Scenes node and select Open All Scenes.

EE--_
xpeb®/ev:froimfti:d><v*xpndg&e>qu#>b«rffl.)zr®+rAadeiAiFouZ3r"IqucArfe:ov`

Page6 CTO9101 CM121

Can you identify the menu bar, toolbar, panes, and windows of the STAR-
CCM+ Gul?

Where in the simulation tree are geometries and meshes prepared?

Where in the simulation tree are physics simulations conducted?

Where are the boundary conditions applied?

Which nods ih the tree makes the connection between mesh and physics?

Page7 CTO9101 CM121

One Program, Two Processes

Client-Gul

Server -Computations

--_.-` client-Server
Reconnected

No client is
client and server connected to the Server
running server

Software license is checked out by the server process

Page 8 CTO9101_CM12_1
Page9 CTO9101 CM121

smlt I MNS

gr a Geomem/
S ii Continua
giv ® A,r
` H Partshle5hes

er ® stag,
fr ii Regions
Contains all of the simulation F # F,Bid
giv a Boundaries
objects in the .sim file. giv Gi Feature curves
giv ii Phvs[cs conditions
ah a Physics Values

Folders are added/removed as JET N solld

er ii lntgrface5
objects/nodes are created in the gr ii Derived Parts
gr ii So[v€rs
simulation. a- ii Stopping Criteria
E Solutior\ Histories
tr ii Solution vie:us
gr ii Reports
er Ea Monitors
tr ji Plots
tr a Scenes
-Gi Summaries

tr ii] P`epresentations
th E] Tools

Page 10 CTO9101 CM121

 9 a Pregiur.5
g I f ,u,a
i; ii Bourrdar)es
giv I ae(at`,I
a. I DtJaul{ iFluic!/Selid 2)

cL I De/eL.ti !FluLc!/solid!

c> rm Outl¢,

9 I Punrler|
Properties can be modified ~ jE Ph/si£=Co/}drt[or)5

i iB Ph'is/I;`Jalug3

directly in the Properties B¥Fg-:1,=fr.Bg-

# Total Temp!ratorc
Window. # Turbul€n€e lritcngity
'# Tijrb(tlerrt 'iisco5rt'/ Pa`io

lf available, property customizer

(icon) can .Pe opened for more
Options.

Pagell CTO9101 CM121

``` Action .(, '`

se

Probe
|R + Reset iF:ii?i-;I-.j[8__; =F_6_T_::i_l=_`|-:.lil-:1:i:i ffigH

T Top Vlew - `|;LiiE]Fj[rL=:g.`=E--jir!g~,r}[6--;fl=-i+'=-i:r=i¥j:E€Lj

===H=REREillREF~]iTTTF.EEIT.I=E=rE
s Side Vlewi =EERE=;ffiREE]RETF_|EEr]r==
F \ Frond view
H Fit in view

Page 12 CTO9101 CM121

T lb S M

Commonly used actions have shortcuts in the Toolbars at the top of the Gul.

Page 13 CTO9101 CM121

Tin lgy G mtrypt M

A Part is an object's geometric definition in

physical space:

© Created from parametric CAD models or

tessellated surface data.

® Consist of Part Surfaces and Part Curves.

© Part Surfaces connected by Contacts.

© Pipelined Operations: scale, rotate, translate,

unite, subtract, intersect, etc.

© Used to create meshes and,regions.

Page 14 CTO9101 CM121

A region is a discretized volume in 3D
space (surface in 2D):
® lt js not necessarily contiguous.

© The core region is discretized by a

conformal mesh consisting of connected
faces, cells, and vertices.

a The solution of the discretized equations

is solved` in the region(s).

Page 15 CTO9101_CM12_1

Tin lgy a d M S

Boundaries are the exterior surfaces of regions:

a Physical obstructions (e:g. walls, baffles), open boundaries (Inlets, Outlets,
Freestream), or symmetry planes.
® Connections between regions that pass information are called Interfaces.
i; i wa,, I

•dll I(I

il
So I
-`(a.&:f?- ,.;.=.-,-.-

[i A TrT+.-- T+i-i
rl ! i

I • -d I I a
) Ill

ill
.IJli i i Solid-Solidlnterface I

.1\1\`,,+,
/,;,(/ `
-` ``\`
,`.
I•("t`;,'i,+ -\'1''

`%.!1 ' - \W,( 11 Ii \

+i/
1!
',„`\\,?
I`,-+--i

i.\\., ` %
i
_ Wall, Fluld-Solid Interface
II( .`\
-
i II

T_TT_ I
-+---.i-

i;
)
i

ir . ) ---
++`;.-i ri T-- ! i ( ,n,et I

Page 16 CTO9101_CM12_1
a a continua
- H Parts Meshes
A physics continuum is a collection of models
=- , Physics 1 that represent a single medium (fluid or solid).
3 a Models © Model properties, methods, equations and their
'i) Constant Density
3 a Gas coefficients can be edited in continua
3 a Air © Each physics continuum contains Reference
=r a Material Properties
`3 * Density Values and Initial Conditions.
• Constant
r3 * Dynamic VISCosity
• Constant
- jJ Gradients I

~6j Laminar •tte.``y \ i I `,sob A .i\

`.8i?&` i 1

i} Segregated Flow •^..i.„1\

-_.I -ii-i--+,---.-) i;J7il,rr-rt
aJ Steady .
-6:J Three Dimensional
-i., I . -., L,i,i:#: .,, ,-: f,(._.
1`

z i Reference Values
t,{,|,;# ;rm,.I __ ( i---i-.-.`.-`.-
3--i Initial Conditlon5
*` --:. fr; -
3*, . Physics Steel i
ex

Ei , Solid

)
i
-

Page 17 CTO9101 CM121

a Reports: retrieve or calculate solution data and return a scalar.

© Monitors: save or compute information (such as report quantities) from solver
iterations and/or time steps.
© Plots: display data points defined by two coordinate values.
a Scenes: display quantities in 3D space.

? a Reperlg
a Eff({!enc`/_percent
3 lnletTdea)Pressure
a iriputpowor
a outjetMa5SPlowR@t9
a outletTotdlpre$3ure
a out!?V\/olumeFlowpate
a Outler`,'olumeF)owRateln
a OutputpQyver
a Pres3urefiati`]
-a Torque
a Tott]l Pressure Bige
? ii Monttorg
- B condnufty
* a EfficieHey
a lteration
giv a. Mass Flow
a Phy3ical Time
ri~ a, pressure rat,a
ae B X-momentum

Page 18 CTO9101 CM121

What are the four main windows of the STAR-CCM+ Gul?

What is the difference between a geometry part and a region?

Page 19 CTO9101 CM121

Page20 CTO9101 CM121

This workshop covers the basic steps of the STAR-CCM+ simulation workflow,
starting from importing a geometry through meshing, physics setup, data
analysis, and running.

Page22 CTO9101 CM121

W kflw d I SM S

What are the major steps required to simulate the aerodynamic behavior and
compute drag on the car shown in the picture?

Page23 CTO9101 CM121

•ijL:RE),:{`;,i!, ).il:, ,!l

9

I... `]

Page24 CTO9101 CM121

Strt WSTARCCM m|t S M S

Start a new STAR-CCM+ simulation.

Launch STAR-CCM+.
' Select File > New.

ff} Rg!oacJ simulatior}-,.

Keep the default settings. MieTogoft HF€ Server

-=} Subrrii Usa`g Murosoft Job Scheduier

Click OK.
lrfuso
:=j ue I Power scs5rm I;' Poweron.Denrend

Page25 CTO9101 CM121

mprtg mty M S

Import the car and wind tunnel geometry a New~

-I gS 9 ~ A jf E! ai fas grj
a Lcod.. BIT=

files. fJ RCJIG,act sirrii,y`z±f'fr,n,

tg-,
\ Select File > Import > Import Surface ii Connectto server.`,
front FJles

@ sdv?

Mesh. E SaveAs,.
a SaveAll
a Autosave"
`.I Browse to the folder 02_Workflowcar,
select both parasolid files and click Open.

ln the Import Surface Options dialog, ensure that

Open Geometry Scene After Import is selected and
click OK. The remaining options are left at their
default values.

Page26 CTO9101 CM121

 9 Gi Geometry
Imported CAD: Car body, 4 wheels, and a wind tunnel. ii 3D-CAD Models

t jii Parts
+® car
ch a wheel
a All parts appear under the Geometry > Parts folder after tr 6 wheel 2
a- ® wheel 3
i_mport. a- ® wheel 4

© Geometry Scene 1 opens to show the imported parts. a eB wind_tunnel

fr Gil Surfaces
a Floor
© Expanding the Surfaces folder for each part shows the named a Inlet
a Outlet
surfaces. q> Sldewall
a Symmetry
®Top
tr EB Curves
Notice that the wind tunnel part surfaces were
pre-named in the imported surface mesh
(Inlet, Outl;t, Symmetry, etc.).

We need to create the simulation

domain by subtracting the car body
and wheels from the wind tunnel.

Page27 CTO9101 CM121

op t sbt I M

Generate the Air volume part by

subtracting the car from' the tunnel.

` , Select all of the parts (use either Ctrl or

Shift + Click to multi-select).

t`. Right-click any selected part and select
•, iL Dcse
i-Cone
Repairsurfece,..
Ec|itin3D-CAD
REffiife' un`rte lntemsect
r..`\sde.o¥jd`
.aco:uT:: i:P%:A£;bn 'mprjnt
iD tife!@#` ¥ _ndceTic=nj2en*c ~+c` a
Create Mesh Operation > Boolean >
Subtract.
Click the Select button for the Target Part
and choose wind tunnel.
I ln the dialog box, check the boxes for
Perform CAD Boolean and Execute
Operation Upon Creation.
.- Click OK.

Page28 CTO9101 CM121

op I sbt t M S

Rename the created Subtract Part and inspect it.

Right-click the Subtract part in the Parts folder and 8B Mesh
Jf scalar
select Rename.
. Name the part Air.

The Air part is now just the wind tunnel air around the
car, and it has inherited the part and surface names
from the original parts.
;?`' ffi Pan
•£ ® gr .
:?; ffi tr .
•£- iE ines
¥;. iE b-Parts

Page29 CTO9101 CM121

p tprt d M

Open a new Empty Scene using the Create/Open Scenes icon in the toolbar.
Drag and drop the Air part into the new scene.
I Click the Make Scene Transparent icon in the toolbar.

An Empty scene contains no displayer on creation.

The drag and drop action automatically created a geometry displayer.
Slmulatlon
a Scene 1
=::'sEL
_= i Attributes
E] Medel Wlndow
~f: a Background Color

a VIOw
:i- J* Update
H Anlmatlon'
EL Axes
i., il Lights
i, aB cllp planes
3) a Annotations

Page30 CTO9101 CM121

 a Geomtry
Transfer the Air part to regions for analysis. ii. 3D-CAD Models
:-:, i Parts
i a car
fu ® in ___I_ A __ __ _
Right-click the Air part and select Assign Parts •.f`© v! Highli(-jilt

LE e> v Edit„.

to Regions. {`+.® V SetNewTag.,.

' Select: •tiy

Lgiv Pie`Executf
i;-a De€ Upcl`,le
Create a Region for Each Part. i] Col
_= :£p:
Detach
Ereat.eye:h operat:on
J Create a Boundary for Each Part Surface.
Repair Surface..,

., Leave all other options as is.

Click Apply, then Close.

Page31 CTO9101 CM121

Df b dytyp M

The boundary type affects the prism layer mesher and

a Boundarles
creates prism cells only on the default type Wall. - car,Body
- wheel 2.Faces
I wheel.Faces
` Expand the Regions > Air > Boundaries node. B wind tunnel,Flcor

` Select each boundary in the table individually and in

the Properties window, set each Type as specified.

wl nd+unnol.Symmetry . Proportlos
Note the icons changed to indicate the boundary type. I-'Properttes

Outlet Pressure outlet

Page32 CTO9101 CM121

M hind| M S

a Geomtry
ln the Geometry > Parts node, right-click I 3D-GAD Modets
J I Parts
1 ® car

the Air node and select Create Mesh I,,in

e ll,qr,,I/i,,,
I e Edit,

Operation > Mesh > Automated Mesh. I 0 Set New Tag.

•:;.
Select the meshers -Co Detoch
.®OEas
` Surface Remesher, Boctlean

:`'fiiiii'...``9\-¥`t;rxptmutmesE(aaeBbvLf`.,-
aady for 2D Mashing
Trimmed Cell Mesher, Autorwhed Mech (20)
V®luma E;I tludct
Dltec[ed Mesh
\'\ Prism Layer Mesher.
Click OK.

A new entry appears under Operations.

The yellow exclamation mark ifeindicates that this
i of 7 gelected
operation has hot yet been executed. Select Meshce
Optlomal SuJtaco Mesl.®r9
`i-j Autonagc Srfece Repa]r

E Cancel Help

Page33 CTO9101 CM121

Df lt t I M

il operations
Set the default mesh settings for the automated 1 © subtract
-, qb Automated Mesh
meshers. tr iii Meshers
't Expand the Operations > Automated Mesh > Ei Default Controls
• I;EEENFH
• CAD Projectlon
Default Controls node. • Target Surface Slze
• Mlnlmum Surface Size
+ Select the Base Size and in the Properties • Surface Curvature
• Surface Proxlmlty
window set Value to 0.25 in. • Surface Growth Rate
• Number of Prism Layers
L~ Set the Prism Layer Total Thickness value to • Prism Layer Stretching
• Prism Layer Total Thickness
10 (% of the Base Size). • Maxlmum Core/Prlsm Transition Ratio
• Volume Gro\^th Rate
• Maxlmum Cell Slze

Ba8® Slz® . Properties

Value 0.25 in

Page34 CTO9101 CM121

The surface and volume mesh is created together in il -try
- jDeeb4RE
-`:\ a i.t!
One step. +^` a EN-the
ji, Cmue
Right-click the Automated Mesh node and select a il Ofxmelae
``-f=--` .*`
Execute QB press the Generate Volume Mesh
§ i. o SctNevTng_
toolbar icon.
I ctnELHE' a seRERERERERE
-Regxig Elca^e Surface meitiou
-€-

E Geometry
- ii-3D-CADModeis
The exclamation mark disappears and
a new Continua > Parts Meshes node appears.

Select File > Save As.

Name the file Workflow Car.sin.
Select Save.

Page 35 CTO9101_CM12_1

Create a new Mesh scene. 8 gg free£

i-B;,E!,th=ill r
`", Either use the Create/Open Scenes icon in the Vis toolbar,
' or right-click the Scenes node and select New Scene > Mesh. A sca,ar
£v"tor
The mesh is shown on all boundaries of the Region. To view the Empty

mesh on the Symmetry Plane, click the Save-Restore-Select LqD Qpen All scenes|

Views icon in the toolbar and select Views > -X > Up +Y.

' _-

I
Proj€`t!ori Mode

+z
-Z
`:

,? up-y

Lz

Page 36 CTO9101_CM12_1
phy mdl sM

Select the physics models for a steady, turbulent flow analysis.

In the Simulation tree, right-click the top node and select Collapse Tree.
Expand the Continua node.
Right-click the Physics 1 node and choose Select models.
In the Physics Model Selection dialog, select:
a. Steady, fiphysic,ti^M4in\;^infro;

Optiomal Models Enabled Models

b. Gas, I Co-Simulation a Two-Layer All y+ Wall Treatment
I Clroumferentlal Heat Flux Averaging Ezi Exact Wall Dlstanee

c. Segregated Flow, I Elecfromagnetlsm Real !zable K-Epellon Two.LjByer

I Passive Scalar K-Epsilon Turbulence

d. Ideal Gas, I Turbulence Suppress].on Reynolds-Averaged Nav{er-Stcke5

I Fluid F'lm Tufeuient

e. Segre.gated Fluid Temperature, I Mesh Defomatlon E Segregated Fluld Tenperature

I Dlspersed Multlphase EZ Ideal Gas

f. Turbulent, E] Muttlphase Interaction E Gradlents

C] Vlrfual Dlsk Segregated Flow
<optlonal> Gas
9. K-Epsilon Turbulence. CJGravlty

I Turbuleut Vlscasfty User Scaling EZ Steady

5. Click Close. I Cell Quallty Remedlatlon E Three Dlmenslonal

I I R.His+lnr`

Page37 CTO9101 CM121

a dy dt M

= iB Regions
The speed of air in the tunnel is set at the inlet '=. H Air

boundary. All other settings can be left at their = ii Boundaries

€; . car.Body
default values. ±. - wheel 2,Faces
£' I wheel,Faces
z I wind turinel,Floor
Expand the Regions > Air > Boundaries > =r * wind tunnel.Inlet
f ii Physics Conditions
wind tunnel.Inlet node.
=j Gi Physics Values
In the-Physics Values node, select Velocity giv Static Temperature

Magnitude and in the properties window set S. Turbulence lntenrty

giv Turbulent Vjscosity Ratio
Value to 50 mph (or 80 kph, if you prefer).
I,I 11111 wind tunnel.Outlet
Hit Enter after typing the value.

Velocity Magnitude - Properties x

'=Properties

M ethod Consta nt
Value 50.0 mph
Dimensions

Page38 CTO9101 CM121

Decrease the maximum steps because this model converges quickly.
Select the Stopping Criteria > Maximum Steps node.
` In the Properties window, set Maximum Steps to 300.

a ii Regions
a Derived Parts
E3 a solvers
¥ a Stoppin Criteria

h Stop File

Maximum Steps - Properties x

Bproperties
Enabled EE
Maximumsteps 300
Logical Rule Or
Criterion Satisfied
Tags

Page39 CTO9101 CM121

DtA ly Rpt SM S

i` gB Geometry
Create a report to compute drag on the car. +. iii Continua

I Right-click the Reports 'node and select i; a Regioris

i. Derived Parts
£3 a solver5
New Report > Force. +; i Stopping Criteria
th:'\ Rename the report to Drag by right- a Solution Hlstories
F. a solution views
• a E5E
clicking it and selecting Rename or
`.`L;;lf .`-` . `.`
selecting it and hitting F2.
`^ ln the properties window, set Direction to Force Coefficient
Frontal Area
Heat Exchanger (C}ual Stream)
Heat Exchanger (Single Stream)
[0, 0, -1]. Heat Transfer
lsentropic Eff'icieney
Click on the Parts field in the properties I ino lnfonral

window, and select the boundaries for

the car and wheels in the dialog box.
`fy¥- Click OK.

Page40 CTO9101 CM121

Create a monitor and plot of the drag report to track convergence.
Right-click the Drag report and select Create Monitor and Plot from Report.

A plot opens to view the value of the drag during the simulation, plotted versus
iteration.

=a.gReff=¥____.__.`_~_

±E Mo. RunReport
I -Drag Mormon I
:.IE plo. Highlight
f a sce Edit„.
ia sur SetNewTag.„
.+3 il Ref

jl ii TO(
Create Monitor from Report
Create An.nc)tation from Repc)rt

Copy
Paste
Delete
Rename...

Dependeiicles
ErrorLocj

Page41 CTO9101 CM121

DtA ,y S M

Create a scalar scene to visually monitor the pressure field.

I Right-click the Scenes node and select New Scene > Scalar.
':'` Right-click the colorbar in the scene and select the scalar field Pressure.
I Multi-select the boundaries car.Body, wheel 2.Faces, wheel.faces, and
wind_tunnel.Symmetry and drag and drop them in the graphics window.
\, In the pop-up dialog, choose Add to Scalar 1.

=T tip Reglons
:-, . Alr
•3; i Boiindaries

iE . wind tunnel,Floor
i * wind-tilnnel,Inlet
i. 11111 wind funnel.Outlet
t I wlnd-tunnel.Sldewall
I .diThffl -.
£i . wind_tunnel.Top
fij i Feature Curves
(a a Physics Condltion$
33 a Physlcs Values
ei Derived Parts

Page42 CTO9101 CM121

Create a vector scene to view the velocity field during the run.
Create a new vector scene. Default vector field is already Velocity.
Add the wind_tunnel.Symmetry boundary to the Vector 1 displayer.

L± 5i Regions
E I Air
E} ii Boundaries
5j . car,Bedy
`fl I wheel 2.Faces
3 I wheel.Faces
z! I wind tunnel,Floor
zj * wind tunnel,Inlet
¥i 11111 wind tunnel.outlet
z * wind tunnel.Sidewall

a . wind_tunnel,Top
3 ii Feature Curves
a a Physics Condltions
T±-: a Physics Values veloctry{m/5}

Ei Derived Parts

Page43 CTO9101 CM121

Run the simulation to convergence.

Save the simulation using the File menu or the toolbar icon. ; a
+: ln the solution toolbar, click Run: A *

When the run has stopped, Save th6;imTHation

Page44 CTO9101 CM121

A Iy lt M S

The goal of our simulation was to compute the drag on the car. Check the final
predicted value.
i Check the Drag Monitor Plot if the value has

converged to a stable result.

Right-click the Drag report, then select Run Report. The value is printed to
the outD.ut window.

Page45 CTO9101 CM121

What more could we do with this simulation to gain additional insight?

I___

Page46 CTO9101 CM121

 lF)in,"REfil Imported a CAD model and generated the simulation domain.
Generated the mesh using automated tools.
Assigned relevant physics and boundary conditions to solve
the problem.
Created post-processing objects to extract engineering insight.
Ran the simulation and analyzed the solution'.

Page47 CTO9101 CM121

Page48 CTO9101 CM121

lt a I M

A new design to cool an lGBT chip (insulated-gate bipolar transistor) needs to be

properly cooled. You, the engineer at BetterDesignsFaster have been asked to
assess whether a new cooling loop design will result in a pipe surface
temperature below 45 C. [n order to provide quick results within a day, only the
fluid is modeled.

Outer wall boundary

Heat flux = 30,00o W/m2

iiiiiiiiiiii

Simulation Objective: Determine if this design is able to maintain a wall surface

temperature below 45 C.

Page50 CTO9101 CM121

l#`il),: ' :,i.;:, )pri':,; I, )I,!l
Sct mesh base srdze\
Adidl part\s to mesh operation

Page51 CTO9101 CM121

I io!d § fife
open the starting file. ESTAR-CCM+
Type. Simu-fatlon

Edit Mesh Solution Tools Window Helg_ process ogivaTls

New,.. Ctrl+ N

Reload 5imulation...

Launch STAR-CCM+.
-\ From the File menu, select Load.
\ Choose to run Parallel on Local Host with the
default 2 Compute Processes.
- Browse to the folder 02 WorkflowTube and load
CoolingTube_Start.sim. ~
' Accept default settings and click OK.

Save the file as CoolingTube.sim.

F|[e ipts\CoollngTuP_e_Start.s|m v EEE

Page52 CTO9101 CM121

c ,gtbg mtypt d g M

a ti] Regions
Create a new Geometry scene and review the ¥ . CoollngTube
€] a Boundaries
tube geometry- i InletEnd
' Expand Regions > CoolingTube > Boundaries. - OutletEnd
I Wall
A: Select lnletEnd and change type to Velocity & ii Feature Curves
a Derived Parts

Inlet.
Change OutletEnd to Pressure Outlet. OutlotErid - Properties x
=Properfies
Index
lmerfaces
Wall is kept as boundary type Wall. Pa rt siirfaces [Coo ll n gTube. Outl etEnd]

Page53 CTO9101 CM121

Atmtdm hp I SM S

" `rm"fi _Cckrfeur`mr_~ . A`^ `un`yrm

\ ln the Geometry > Operations node, select
Automated Mesh and in Properties add •EBE-
=, il Cgivabe

BB-8
CoolingTube to Input Parts. % il Derutconbds
i Custom Gonbds
.._: Expand the Default Controls node. a Contfro
t,\ Select Base Size and in Properties set Value to a Redoma
\=i I cgivThrfe
(3 iD Boundaries
0-001 in. d ZrbetErd
` Generate Mesh by right-clicking Automated Mesh lw OudetEnd
1wal
¥ iB FeatLrecurus
and selecting Execute or clicking the Generate ii oenved pats
a §tx~ cntEria
Volume Mesh icon in the toolbar.

•=.Jptopun
per.Pert lt®shhg

(coongmde]

Page54 CTO9101 CM121

 When meshing operation is
complete, right-click in the graphics Refresh
```?=,4EL+aitianrfurp$3``t````
Hide All Parts

window background and select Ri.stcyre litdJ`le)` Put ts. .

ReFTc re A0 Hiclc(e!` F'5lt<

Apply Representation > Volume Hardcopyr.

Export 3D Vlsualization File„.
Create Scene lmage Annotation

Mesh. Report
uriked vlow

AJ1'mat/i,r)

~ click the Show All Meshes icon in Copy

i,=jste
Delete
Rename.. _ `~_ -
the Toolbar and rotate to see the
inlet and outlet.

E! RE Ea i:":i rig + + S a H ' te RE [J EL

Show All Meshes

Page55 CTO9101 CM121

phy md, 'vl

Select the physics models for a steady, turbulent flow analysis.

In the Simulation tree, right-click the top node and select Collapse Tree.
~r, [n the Continua node, right-click the Physics 1 node and choose Select
models.
In the Physics Model Selection dialog, select:
a. Steady' |E]Ptrysies!ModelSeledion
X

cbse4us Enarm Hbas

b. Liquid, Ecoirfutm E2j segreontea Fbe T-etr. <hlot reqLliut try other mddr>L
BC}amtoh!t€etFlixAVIr.orty EaTro+®ygrAly+WdlTrcabnent

c. Segregated Flow, LIEkgivorqufro

Bpedesdr
EZErdwtlastrx-
&e&aifer\-T.iac,+a)w
HTu&frog|~ ^<± Ttjrb{£er*e
d. Constant Density, Bthoefro" R¢/,Tuts-A\(,ffngedha,re¥£Tc*e±5

7afordert
BOGpedoutdur
e. Turbulent, ffruthaftyrm ECchstan.Oenatv
HwidCied EZG.afro

f. K-Epsilon Turbulence, Bftyaeun teeapedfk

aG'rty `,+,

HTgbu"ycos]tyl.s®scefro E5stw
9. Segregated Fluid Temperature. dctlQuaftyRen"un EaThaDinmut
dR-tin
4. Click Close.

Page56 CTO9101 CM121

a_Ei

I-i-
a dy dt M S

Expand the Regions > CoolingTube > .3 - Geometry

Boundaries > lnletEnd node. il i Cont)nua
L=J ii Regions

In the Physics Values node, select Velocity 3 I CoolingTube

a a Boundaries
!r; I InletEnd
Magnitude and in the properties window set a Iffl OutletEnd
=,, , Wall
Value to 0.15 in/s. Tap Enter after typing the E; il Physlc5 Conditions
giv Reference FraiTie Speciflcatjon
value. # Shear Stress Specification
fy Tangential Velocity Specification
Select Static Temperature and set the Value to
lcient 5peclfication
15 C. Tap Enter. -Jgiv Wall Surface Speclficatjon

a ii Physics Values
Expand the Physics Conditions node for a3 lil Feature Curves

boundary Wall, select Thermal Specification

and in th`e Properties window set Condition to |P.equ.al~5.a.e±9`Eg_t!o.rl_-.Erg.Pe.rq...a.rl_____~`._._,_h,
-L=\properties

Heat Flux.
In the Physics Values node select Heat Flux
and enter the value 30,000 W/m^2.

Page57 CTO9101 CM121

stppg I sM S

Select the Stopping Criteria > Maximum Steps node.

In the Properties window, set Maximum Steps to 250.
iE; i Regions
ii Derived Parts
f i Salvers
5 ii stopping criteria

Maximum Steps - Properties x

Ei`properties

Enabled E
Maximum Ste s250
Logical Rule Or
Criterion Satisfied
Tags

Page58 CTO9101 CM121

Create a report and plot of the maximum riL Ei stopping crlterla
- Solution Hlstories

temperature. e il Solutlon views

i ei. Reports
' Right-click the Reports node and select za Mardmum I

New Report > Maximum.

In the properties window set:
Select the Temperature field function.
© CooringTube
Change units to C. e lnlctEnd
e outletEnd

Click on the Parts field in the properties a Wall

window, and select the CoolingTube *lnletEnd

fllll outctEnd
Re ione`,Cooft Tifoe

„ Wall
region.`
* Rename the report to Maximum

Temperature.
t Right-click the Maximum Temperature

report and select Create Monitor and Plot

from Report.

Page59 CTO9101 CM121

Simulation Sccoe/Pf
Adjust plot font size and line width. € Maxlmilm Temperfure Monitor Plct
I Switch to the Scene/Plot tab and in the = Ei Data Series
i_L±ratL,r,ezM`,:n,tor
Properties window, click in the text field Title • Symbol style I.r,
3 ii Axes
Font and replace Plain 14 with Bold 28. a. ii. Bottom Axis

`_ Expand Data Series > Maximum Temperature 3)

Jf update
Monitor and for Line Style change Width to 3. • Iteration Frequency
• Hardcopy
Click Legend and increase font to 24.
Maximum T®mporatrro Monitor Plot - Prop®rd®.xi -

X-AIis Bottom Axls

X-A{is Monltor lteratlon
X-Axis Monitor Unit
Tags q
i,Expert
Anti`aliasing EZ
tHover lnteractlons E

Footer Font Luclda sang plaiii 10

Data series order`(Maxlmum Temperature Moni(or] :

Page60 CTO9101 CM121

DtA Iy S SM

Create a scene to view temperature on a Wall Temperature

I Scdla/ Field . function
.-, gil D`sp!ayers

wall. I Ca outline 1 = 3i,ShowAll . temper

3 a Scala, I ITh .-T~~ ------- + -------
`FleldFunctions | Finer tiy palh r-`````-````
Create a new Scalar scene. J.', Extermal Amblem Temperature
'\'5 Local Heat Transfer Reference Ten`perafure

Rename the scene to Wall /rt Relative Total Temperature

t a Reports
/', Specified y+ Heat Tianster Reference Tempera [uJe
Temperature. • /Tf Tomp®rati.r®
¥ /I. Temperature Coefflclert
' Switch to the Scene/Plot tab and t`T, Temperature on External Slde
i /`` Total Temperature

expand the Disp[ayers > Scalar 1

H ~canc.er
node. -+ a inla; 1
`- Select Scalar Field and in the a parts,
• Scalar Field
Point size
properties window select function Ei Color Bar
ffi Anlmat.ons
Temperitu.re.
:- Change units to C.
`` Select the Parts node and in the
Min -27315
Max -273.15 -a lnletEncl
Tags n
properties window select boundary a outletEnd
a Wall
Wall. H lnletEnd
"1 outleiEnd
+ +++ wan

Page61 CTO9101 CM121

R th mlt M

` Switch back to the Simulation tab, drag Maximum Temperature plot from the

simulation tree and drop it into the Wall Temperature scene.

`:+ Arrange the objects in the scene.
Click Run in the toolbar. H £ EEB ,

`'``d{

Page62 CTO9101 CM121

Was the design objective achieved?

Maximum Temperature Monitor Plot

-Maxi in u in Temperature

Temperalure (C)
-¥.1# 33.7S4 41.8QD

Page63 CTO9101 CM121

R wq I 1 SM S

After the simulation reaches its Stopping Criteria, study the Maximum
Temperature plot and Wall Temperature scene. Describe below what you think
has happened physically in this model.

At the beginning of the simulation, what is the wall temperature associated with a
heat flux of 30,000 W/m^2? Where in the simulation can this information be
found?

Page64 CTO9101 CM121

R wq I 2 SM

What are some ways in which accuracy for this simulation could be assessed?

How could this simulation be made more realistic?

Page65 CTO9101 CM121

Page66 CTO9101 CM121

This workshop is the first in a series of focused exercises for each step of the
simulation workflow. Together the workshops will .cover the entire simulation
process for a single model.

I..---....---.-

Page 68 CTO9101_CM12_1
lt d I M S

An lGBT chip (insulated-gate bipolar transistor) is mounted on a water-cooled

heat sink. Heat is transferred between the chip, heat sink, water, and the
dg

i::--i-:i_-:-_I--_--:ir-ffi ¥T--
` `,-;:-.i-+= ,------- :--` '= .i----

Simulation Objective: Predict equilibrium (steady-state) temperatures.

Requirements: Chip temperature < 45 C.

Page69 CTO9101 CM121

Sklltb1 d dp I d M S

ry^ r' I >'

Page70 CTO9101 CM121

Open the starting file and import the geometry files.
Launch STAR-CCM+.
From the File menu, select Load.
A Browse to the folder 03_Geometry and load Geometry.Start.sin.

From the File menu,

select Import > Import Surface Mesh. a New.., rJ BS 9 1 A Jf I
G? Lcad-.

Select the files r} Relctatl simij}dTicjii..

a Connect to server..
: lGBT.x_b, Receiit Files

' and Heatsink.x b. 9 5av€

GB SaveAs...
q9 SaveAll
EE Auto save...

Mac,o

Recgiv Surface files

E§ lmportvolume Mesh..
Recem Volume Mesh FHes
EE Import CAE Model.„
Recent CAE Files

Page71 CTO9101 CM121

mptg mty M

Import the geometry files (continued).

A Leave the import options as default values.

Select OK.
\ Save the simulation file as Geometry.sim.

Page72 CTO9101 CM121

lmptdg mty sM

Familiarize yourself with the geometry.

Restore the saved view View 1 from the Save-Restore- + @ a ill g8 a ts RE I-' EL S \

Select Views icon in the Vis toolbar.

Selectthe parts individually to see them highlighted in ; project].onMode
the scene.
a The chip sits flush on the top of the heat sink.
a There is a channel that runs through the inside of
the heat sink.

Page 73 CTO9101_CM 12_1

ch kt Ill SIvl

Check the quality of the surface in the Surface Repair tool.

t Launch Surface Repair from the toolbar or part right-click menu,

:::::i-p.'.`On! Ea;:".
iii Contacts
GiE Operations

;'^ Ensure both Geometry Parts are included and select OK.
~\ Run the diagnostics by selecting
-399-
____ _______

the Execute button. --.- A ~

•-.-+

EN. q # EN

EZI Reset Vxav

Ea Reset DBpbyed

ifenage-.

Page74 CTO9101 CM121

ch kt Ill M

Discussion Point
\/Vhat is causing the pierced faces?

Page75 CTO9101 CM121

R wdg I it SM S

A Surface error found during diagnostic check.

a Pierced faces occur when the parts touch. We need to resolve

these errors by imprinting the parts to make the surfaces line
up and create a contact.
a The face quality and face proximity errors are addressed by
the surface remesher and are not a concern at this point.

Parts need to be imprinted before meshing.

Page76 CTO9101 CM121

 I Close the surface repair tool by selecting Close in the Edit tab.

Create an Imprint operation.

\ Right-click the Geometry > Operations node and select New > Boolean >

lmprintl
a i Coritact5

a Derived Part§! REorder Mesh |Hmers€ct

trii iiiiiiiiiiiiiiiE §ubtraEt )

Gi Solutlon Hist{ Refresh

th ii Solutiomvie
:-;in?r.nt. `
REE -ng EL--I
In the Imprint Operation dialog select:
i Input parts: Heatsink and lGBT, LiL¥:
2 of 2 selected

Activate Perform CAD Imprint,

• Click OK-
:.-_¥iJ I±:F._JH
Page77 CTO9101 CM121

All imprint operation values are left at default

t ? fropectieg
settings. irip ijt pairts {H€at5ir}*, lGRTj T
T®lErari£€ 1 i3E-4 in
) + Execute the Imprint operation from its right- M€rg€/lmprml F*ethod CAD Imprint
` R€su!tmg "e=h T'/pe Confrorm ar L1

click menu. Txp9

9 Exp€n

g a Operations
er a ,.Ftjri`*`S
iii Continua
E Regions j Edit..
ai Derived Parts ;, Set N€wTag< ,
giv a stopping CmerE=.-~~~ €1,I-i-\=
Ga Solution Histor;
gr i SalutlDn
6k a Monitors
t* a Plots E=.i_I

Page78 CTO9101 CM121

 Only the solid parts were imported.

The fluid part can be extracted from the solid geometry using
operations.
a Fill the holes.
® Extract the internal volume.

Fill Holes operation requires two inputs:

® Input Part(s) -parts on which the operation fills the holes.
a End Surfac.es or Curves -part surfaces or part curves that connect to the
hole that should be filled.

Extract Volume operation requires input part(s) that bound the volume to be
extracted .

Page79 CTO9101 CM121

Split the curves to be used in the Fill Holes operation.

Expand the Heatsink > Curves node to expose the Edges curve.
`r Right-click Edges and select Split Non-Contiguous-
. Locate the edges defining the inner loops of the pipe ends (see picture).
- Rename those edges to lnletEnd and OutletEnd.

Page80 CTO9101 CM121

op I FIIHI SM

Create Fill Holes op`eration.

Select Fill Holes from Operations > New > Surface Preparation.

ln the Fill Holes Operation dialog set:

T Input parts: Heatsink,
|H8atslnkj

End curves: lnletEnd, OutletEnd-Endsurtacfs (I

Activate Execute operation Efid curves LHfa{sinr inlc{End, Heat5inL.outietEndf

Upon Creation.
`,I Click OK.
[=i-i-i FIir_i
Page81 CTO9101 CM121

optM

Check the Filled Holes part in the scene by selecting the part in the tree. The
new surfaces are highlighted.

Scene/Plo( (

qE| Geom€tr/_start
S a Cfometry
6ii 3D-CAD M®dels

f a Parts
a- e3 ch\\If 'pof ee'<
a- a H€atsink
ar a ,CBT
giv GE De5Griptic]n§

ct. E] Cantacts
Ch I Operations
i Cominua
Ei P-egion5
Gil Derived parts
tr ia Stopping Criteria
a §oliltion Histories
tr a solutionvieus
a. a Monitors
i> i Plots
fr a `ScenE3,.
ii Summaries
qu a Representatioris
fr ii Tools

Page82 CTO9101 CM121

Create an Extract Volume operation.
Select Extract Volume from Operations > New > Surface Preparation.
a5- ii C¢ntactg

ln the Extract Volume Operation dialog set:

Input parts: Fill Holes, Heatsink.
Activate Execute Operation Upon Creation.
` ClickoK`
Ey Ey.?€¥te 9p€rapion Upon Cr¢at`iori

H.r,:cii+(=Eir

Page83 CTO9101 CM121

op I M S

Check the Extract Volume part in the scene.

` Right-click the Extract Volume part and Rename to Fluid.
_`r Highlight the Fluid part in the scene.

giv®fflLRE
OL a F,ii Holes
dr a Heat5ink
E==
a. ii Descripticns
gr a Comacts
giv ii operalions
a =ontinuai
i Regions
i Deriyed parts
oj` a S`opping Critgria

a Solutiori His`ories
tr i Salu`iorivlev\c
th ii I,'onitors
a- i Plots
- a Scenes
G] Summaries
a a Pepre3en{attoris
gr GB Tools

Page84 CTO9101 CM121

c I t S M S

Check the contacts in the Contacts folder. a ca Geometry

; Ga 3D-cADMod€i5

Expand the nede for the contacts folder. > ii parts

G- a Descnptions

' i coma[t5
a Gil Fill Holes/Fluid
Discussion Point \ tr i Heatslnk/Fluid

Are any other contacts required? I+ ii

ii Heatsink/Fill Holes
Heatsink/lc;BT
dr E C)peration5

Page85 CTO9101 CM121

ch kt Ill M

Check the quality of the sJurface in the Surface Repair tool.

: Launch Surface Repair from the toolbar or part right-click menu.

i¥ Change the description to Latest.
`'\ Select all of the parts that will be meshed.

Click OK.

Page86 CTO9101 CM121

Check the quality of the surface in the Surface Repair tool (continued).

Run the diagnostics by selecting the Execute button.

Review diagnostics results.
Close the surface repair tool.

Page87 CTO9101 CM121

All parts required for meshing

Contacts between parts that need to be connected

No tesse[Iation errors that prevent surface meshing

Parts can be assigned to regions.

Page88 CTO9101 CM121

Assign the Parts that need to be meshed to Regions.

Multi-select the Fluid, Heatsink, and lGBT parts.

Right-click and select Assign Parts to Regions.
S E Geometry
a 3D-C.&DModel§

9 ii Parts

Page89 CTO9101 CM121

Assign the Parts that need to be meshed to Regions (continued).

I Select
`,I Create a Region for Each Part,
`.1 Create a Boundary for Each Part Surface.
~ Leave all other options as default.
Click Apply, then Close.
rF=:I
>-=R

: i i,:!!u;rj',ensk

3 Of 4 sethed

Create a Regk]n for

Create a Boundary for Each Part Surface

Create One Feature Curve for AI Part Curves

Bouridary-node fnteife6;Froriconfaa;A ~ ~ -y
_irpivm E .inHS -

Page90 CTO9101 CM121

Change the inlet and outlet boundary types. p 5i' Rag,Dns
t # F,uid
Select the inlet boundary in region Fluid:
? E Boijndaries
Boundaries > FillHoles.Heatsink.InletEnd.
FillHoles,Heatstnk.C7iJtletEncl

In the properties window, change type to Hearsjnk.Faces

HeatsirikFaceg|Fluid/H€atsirik]
Mass Flow Inlet. tr ii Feature Curtye5

t Select the outlet boundary gr f| Heatsink

tr # 'GBT

FillHoles.Heatsink.OutletEnd and change

type to Pressure Outlet.
g Properties
I rl cl e '

I Save the file. ir'tE1.-1C€=

Part Surfaces [Fluid.Fill Holes Heatsinr.Inl, L

Page91 CTO9101 CM121

What operation was used to fix pierced faces?

What steps were compl'eted before the fluid volume could be extracted?

Why are contacts important?

Page92 CTO9101 CM121

p h k M S

We can now pr®ceedl to choosing our mesh

m®de[\'s\ and setting in,eshing praTamcter\s.

Page93 CTO9101 CM121

Page94 CTO9101 CM121

How are your geometries Created or obtained?

What kind of errors might exist in geometry?

What kind of geometry modifications might be required before simulation?

Page96 CTO9101 CM121

Smlt din S M S

Fluid and Solid

Flow, Energy, Stress,

Energy, Stress Flow, Energy
Energy Transfer

Page97 CTO9101 CM121

mp tf, typ M

Page98 CTO9101 CM121

Imported tessellated geometry Remeshed Resolution is only as
good as the imported
surface mesh.

Imported CAD geometry Remeshed Surface mesh vertices

can be projected back to
the analytical CAD
surface to ensure the
discrete representation is
as accurate as possible.

Page99 CTO9101 CM121

Can be imported into the 3D-CAD modeler or Geometry Parts.

When to import . , . (,

3D.CAD parts
• Removedetail. • CAD modifiication is not
• Add missing surfaces or build iequired.
missing parts. • Using a surface tessellation
• Automate design changes. data format.~

3D-CAD is a feature-based parametric modeler within STAR-CCM+.

You can prepare or modify imported geometry and create new geometry.
Not for drafting or creation/management of large assemblies.

Pagel00 CTO9101 CM121

Ch kgf CAD p M S

Find and fix CAD errors in 3D-CAD Bodies or Parts.

© Option during import.
a Can be executed interactively.
© Auto-repair addresses
Parasolid kernel
invalidities only.

If auto.repair cannot
I.emedy the issue, use:
• 3D-CAD
• SurfaceRepair
rfugS j& rfu A
• Source CAD
package
F8ceg 0 ?

@.\¥/a ffiF S /
EH RE,

Pagelol CTO9101 CM121

Ch kgf Sf p M

Find and fix errors in tessellated surfaces of Parts.

a Embedded tool executed interactively.
a Use on any tessellated surface (i.e. description).
a Cannot modify volume mesh.

=ZET='X kg§gffia£!4;:Ifa±'X rE=Z=:X * Dia

^ x^ x' .

Pagel02 CTO9101 CM121

 gsBHH±gqHHBggEEBggBBBBHBBEE©:asQi

Face's edges pierce a different face. Measure of a face. Perfect face = The ratio of the distance to the
equilateral = 1.0. nearest neighbor face to the size of
the face. j\ ^{\
Quality = A,/Al

Close proximity
faces
/' Self-intersecting
faces

Pagel03 CTO9101 CM121

Multi-mode toolkit to diagnose, modify, and repair tessellated surfaces.

Repair

Query
God rco8
Organize
and #.J!® ca @)®
F- Bgiv

&-i,_±:JL:,€_¥_
9, ,€'€tt¢d A\'.` ,
D,,i,,,'.a _®_-i

Pagel04 CTO9101 CM121

Face/Edgelvertex level functions for hands-on repair.

EE De,ete faces EE F[,, ho,es E2| Zip edges

J`"J

Pagel05 CTO9101 CM121

Part/Surface level functions for model preparation and repair.

|H Merge/Imprint ElntersecvBooleanFaces E offsetFaces/Edges

Page l06 CTO9101_CM12_1

 :-_`:`:
Distance Between Two Vertices Find Leak Path

Vertex Distance Report

Distance I 0.339408687794 (m`)
Laboratory (in):
Vertex 3 : [-0.0563497297057 -0.03 0J
Vertex 8 : [0,06 0.0779860997883 0.3]
Components rdx dy dz): (0.116349729706 0.107986099788 0.3)
Cartesian 1 (in):
Vertex 3 : [0. 224019789825 0.00728642763607 0.157484804765]
Vertex 8 : [cO.0611299627533 0.025cO98352269 -0.0256875967943]
Components (dx dy dz): (-0.285149752578 0.0183234075908 -0.183172401549)

E Length o.f Edge(s)

Edge Length Report {rii}
Total Etlge Length = 0.1,roco5
Hiri. Edge Lerigth = g.72937E-005
Max. Edge Length a 0.0278163
A.de. Edge Length = 0.014445

Pagel07 CTO9101 CM121

Organize: Group, move, or rename objects.

Sot Control

Set Control:
Defines collections of faces, edges, or vertices.
E.=Ee_±:I:==±-=[:EE±
Action Store \

Stores, recalls and browses sets.

=Recan i:rDBpdyed Ldi

Part Edit
Assigns faces, edges, and vertices to
'f£' Part surface r=i pait curve
part surfaces, contacts, curves, or points. C`:` Pert surf@ce contact t...r:I part point

Edx OptoJ)s

© Maintain Existing p3rf fJ Specify part

New partsurface T

Pagel08 CTO9101 CM121

pit/prt§rf 09 I sM s

Parts and part surfaces may need to be organized for:

Pagelo9 CTO9101 CM121

pt,pt f g I M

Organization and clear labeling needed for efficiency and control of the Mesh,
Physics and Post-processing.

-=--- 'E.------i--Ei--i:--i ..-.: ----: -... i -.--.- ] ---.---...-

Pagell0 CTO9101 CM121

Define the connection between coincident part surfaces.

Pagelll CTO9101 CM121

c t I M S

Contacts may be created in a number of ways.

a Importing geometry,
© Creating a geometry part from 3D-CAD model,
a Imprinting parts/part surfaces,
® Executing certain operations (Imprint, Extract Volume, Surface Wrapper, etc.),
© Manually creating contact from part surfaces.

Pagell2 CTO9101 CM121

op t sM

Operations are defined actions for part and part surface manipulations.

Transform Unite Automated Mesh

Replace Part Intersect Badge for 2D Meshing
Fill Holes Subtract Automated Mesh (2D)
Extract Volume Imprint Volume Extruder
Surface Extruder Directed Mesh
Surface Wrapper

a Create a sequence of steps called a pipeline,

a Repeatable and executed on demand,
a Original geometry is preserved and can be =:'`-:?=to-I----I-I

updated or replaced,
© Geometry processing and meshing steps available.

Pagell3 CTO9101 CM121

OP t T fin SM S

A single transform operation can have multiple transformations which will all

Pagell4 CTO9101 CM121

 Coordinate

-tit .y--Lan,cecoou,mo
System

Pagell5 CTO9101 CM121

Page 116 CTO9101_CM12_1

OP I Sbt tsrf Etd M

Surface
Extruder

Requires specification of a target part

from which the others will be subtracted.

Page 117 CTO9101_CM12_1

OP I FIIHI Et tvim SM S

Original Fill Holes (pink) Extract Volume (light blue)

•.,fSis:i.;S:. ,,;.Sis-.. ::.::.,:i:-,.; .,+f yrf.:.: --.:,:{`j

Creates planar surfaces Finds enclosed volumes

to close arbitrarily and generates a part.
shaped hole. Creates contacts between
the input and extracted
part.

Page 118 CTO9101_CM12_1

Creates part contacts between surfaces (within a tolerance).

Pagell9 CTO9101 CM121

op I ,mp I M

Imprints require designation of source and destination parts.

® The source part is modified to match the destination part.
® Conforma[ imprints move the source to the destination.

Pagel20 CTO9101 CM121

op I Rpi prt SM s

Existing part in Pipeline Operations is replaced with new geometry part.

a Matching part and surface names are automatically mapped to existing entities.
a Designate surfaces/curves for any unmatched entities.

Pagel21 CTO9101 CM121

R , g SM S

If you see. . .

± Surface
Fcafure
Pierced faces Non-manifold edges Free edges Active Model -
._ []-

J I-£alL|..u
±ai,' :i.TJ
¥ iiiiiEiiE
-? EiiiEiiiiii
rrd « ,Hill

-I Reset Vlew
8 Try imprinting
Try extracting the Try filling the i- Resct Displayed

volume holes ELfel

Pagel22 CTO9101 CM121

a Efficiently provides a closed, manifold, non-intersecting surface from poor CAD
data with holes, gaps, mismatches, etc.
® Can defeature surfaces to remove internal/external features/unwanted detail.
a Wrapped volume is put into a new part.

Pagel23 CTO9101 CM121

OP I Sf Wpp SM S

Limitations:
® Loses CAD connectivity.
© Defeatures geometry smaller than specified size.

The quality of the wrapped geometry depends on the user-specified controls

(sizes, contact prevention, gap filling, etc.).

Pagel24 CTO9101 CM121

The simulation domain framework includes both parts and regions.

Assign parts to regions

• Prepare simulation domain • Solve simulation domain

• Contains surface tessellations • Containsvolume mesh

Select parts for existing regions

Pagel25 CTO9101 CM121

A gprtt g M

=; L*
-Fhr;:-A-r|iT
.rfu _,
r+EE±isiri;

E¥egi®n forAll parts i ' i ;EL

[C==u=d===Eachpart ~TT .,.1
Ee one Feature curve forTzil part curvb;~sT=jFeature curve t
igF=teBoundary-l€fcsmC

T±EELITi_I
Defines how to create region level objects from part level objects.
ee One-to-One.
® Many parts level objects in a single region level object.
@ Assign part level object to existing region level object.

( .y,~ i , (-y

Pagel26 CTO9101 CM121

Prism layers are usually not desired on inflow / outflow / " : ::::;::
9 E Regions
symmetry boundaries. p I R€gionl
9 Gi BOLindane5
I D,efauit)
Er ra Feature €uLves
When prism layers are not desired: Gi Derivecl Parl6

a Use a custom mesh control to deactivate prism layer

mesher on part surfaces,
OR
a set boundary type prior to generating volume mesh.

Page 127 CTO9101_CM12_1

When should geometry be imported into 3D-CAD?

What types of tessellation issues can be addressed in Surface Repair?

What are the advantages of a pipeline of Operations for geometry processing

compared to other methods?

Page 128 CTO9101_CM12_1

R wq t M S

Given a car body, rear wing, and wind tunnel,

what steps are required to prepare the simulation domain?

`i, `''rc;`!3*Jct LiEec}I.cia REamagemeiit Scjfr`arare inc~

Pagel29 CTO9101 CM121

R wq I SM S

What are some options for repairing these parts?

LrlE¥#H¥
Ej±E__:-i
LJJifeRE
Ej ffEEffiEiffRE

•r-
r±| F-

View of parts colored by part Surface repair error view

Pagel30 CTO9101 CM121

This workshop covers generating an initial surface and volume mesh for the fluid,
heat sink, and chip.

The starting point is the sim file saved at the end of the geometry workshop.
If it is not open, load simulation Geometry.sin from the 04 Meshing folder and
open Geometry Scene 1.

Pagel32 CTO9101 CM121

Sklltb1 d dp I d SM S

C reate Automaterdl Mesh

Op@nati®n ainid2 choose\
meshers\.

C®\nsidler ain appropriiate

base siize.
Defiine` prism layer
propertiesh

Generate s\urface` and

volume mes\\he\s andl
i,nspeet.

Pagel33 CTO9101 CM121

C I tmtdm hp I M

: Create an Automated Mesh operation. a Gecmetry

i. 3DcO Models
i Select as Parts: f n Parts
i, il Descr.iptions
;=1 Fluid, i a Contocts

\\, Heatsink, i-coTREfiREREfroffiREREREaesurfacepreparation>

•,i IGBT. : :ng ::eocrudteer:" REREifeinife±

®': Select Meshers: a stol Pat!€ Ctil+V Automated Mesh (2D)
a Soll Refresh Volume Extruder
a. Solut-ioh -view5 Directed Mesh

:~t Surface Remesher, -

``j Polyhedral Mesher,

Prism Layer Mesher.

Click OK.
3 Of 4 selected

Select Mesher9

:`p#:::]a::Tuc#®#::poafr::,#ea:eM=9::rsh.;
Optional Volume Mo8her8 :

Page 134 CTO9101_CM12_1

 Execute the Surface Remesher.
click either the Generate surface Mesh in the y^' ng E E#
toolbar,
I:J ii] Operations
or right-click the operation. I-± ® Imprint
9 Fill Holes
View result in the Geometry scene. cg ® Extract Volume

a Geometry Scene 1 is updated. gfaELzimaHmEEil

ii] Continu! Select Meshers...
® lf it is not, right-click in the white space of the t ii Regionsl
7; - Interfaci
a Derived '
graphics window and select Latest for the scene £ a stoppin! Edit...

representation.
Turn on t`he mesh for all parts displayed in
the scene: ill RE + B + se S fa

Pagel35 CTO9101 CM121

A The surface mesh is inadequate for volume meshing.

a What does the surface mesh look like?

a Why did this happen?

Mesh settings need to be improved before volume meshing.

Pagel36 CTO9101 CM121

I P I rf in h M s

Take a measurement to understand the scale of the geometry.

H Efl ill
§::::: tch'eeaMre:::::aE::taMnecsehteoso,i:atrh]:::?'bar. i ng H

Click on two points on a surface and STAR-CCM+ calculates the distance

between them.

Discussion point
\/Vhat is an `appropriate base size?
© Consider the smallest geometry features,
© Compare to the overall size of the geometry.

Pagel37 CTO9101 CM121

Df lt I I M

Change the base size to 10 mm.

Expand the Default Controls node of the Automated Mesh operation.
'^.\ Set Base Size to 10 mm.
Operations
¥J, ca Imprint
a Fill Holes
`€ ® Extract Volume
J=+ ire Automated Mesh
3 iB Meshers
I;i a Default Controls
• ,=zELma
• CAD Projection
• Target Surface Size
• Minimum Surface Size
• qiirfAra riirvAIIire

Base Size - Properties x

±iproperties
Value 10.O mm

Pagel38 CTO9101 CM121

Regenerate the surface mesh and investigate.
+ Execute the surface mesh again.

+ Inspect the surface mesh. `

Discussion Points
a The base size is 10 mm. Are the surface sizes (face edge lengths) 10 mm
everywhere?
® \/Vhere are the surface sizes larger or smaller than the base size?

Pagel39 CTO9101 CM121

Determine an appropriate prism layer total thickness.

The thickness should be based on the thickness of the flow/thermal boundary

layer. For now, we estimate it to be around 150/o of the pipe diameter.

Use the measuring tool and estimate a thickness from the pipe diameter.
D = 7 mm
0.15*D = 1 mm

Pagel40 CTO9101 CM121

Df lt t I M S

Set the prism layer thickness.

Change Size Type of the Prism Layer Total Thickness to Absolute.
.'\ Set a value of 1.0 mm.
fa Automated Mesh
Generate Volume Mesh. `= a Meshers
--, i Default Controls
• Basesize
) % H Eg RJ • CAD Projection
• Target Surface Size
I . Minimum Surface Size
• Surface Curvature
• Surface Proximity
• Surface Growth Rate
• Number of Prism Layers
• Prism Layer Stretching
• i±rm I-rd niliifiREERE
• Mech Density
c\ r`L.ch.in r`^-£r^l-

Discussion point
Why define the prism layer total thickness as an absolute value?

Pagel41 CTO9101 CM121

p I ,mm h M S

Open the mesh scene and add two section planes to show the mesh interior.
I Open Mesh Scene 1.
~ry , Create a Section > Plane from the Derived Parts node menu.
a ia Geometry
a continua
td iE Regions
`£' ii Interfaces

Cell Surface...
as Iso5iirface...
Paste Ctrl + V
S-BS
Edit...
iiR
Refresh
faM Cylinder`..
-@BP
New Group Constrained Streamline... Sphere...
EE- D S Group By Vortex Core... Constrained Pla`ne...
Gii9 Separation/Attachment Line„. Arbitrary...

Pagel42 CTO9101 CM121

 ln the Create Plane Section tool, ensure all three regions are selected for
input parts.
Set the Origin in Plane Properties to [0, 0, 0] in.
Change Display to Existing Displayer.
Set existing displayer to Mesh 1.
click Create.

Don't close the tool.

Pagel43 CTO9101 CM121

I P t lmm h SM S

Change the origin to [0, 0, 0.01] in. 5{"ilatiorT Scenemc]t Edit

Change the direction to [0, 0,1] in.

[Fluld, Heat5!nk, lGRTJ Select...
Keep the existing displayer Mesh 1.
Click Create, then Close.

Save the file as Meshl.sim.

Coordinate System

Display

a No Dlsp!ayer

a New Geometry Djsplayer

a New Scalar Displayer

a New Vector Dlsplayer

© ENstlng Dlsplayer

Pagel44 CTO9101 CM121

R wq I M

•r-.rd..#*...-.;-,...,,^,-,I.-:-..--.-.A-``:+-//,.lf##:!

® How do the surface mesh sizes influence the volume mesh sizes?

® ls the mesh.between regions conformal?

a Which boundaries in the model do not have prism layer cells? Why?

Pagel45 CTO9101 CM121

p h k M S

Next we add som\e mesh refinements based

on our review of the initial mesh`

Pagel46 CTO9101 CM121

ln what way does a mesh' affect a CFD solution?

What should a good mesh resolve?

Pagel48 CTO9101 CM121

Mesh - mathematical description of space where
calculation is done. `t-Vertex

~ fosition Vector
Vertices -position vector in space.
Faces -ordered collection of vertices that define a
surface.
Cells -ordered collection of faces that defies a
closed volume in space. 'ceFace
Meshing divides a single surface or volume into
smaller di;crete surfaces (faces) or volumes
(cells) on which discretized equations can be solved.

Pagel49 CTO9101 CM121

CADIN h M S

Actual Geometry Starting CAD

Pagel50 CTO9101 CM121

Mesh resolution is face/cell size relative to geometry and physics.

Directly affects the solution accuracy with regards to:

Geometry -physical geometry representation.

Physics -flow feature resolution.

Pagel51 CTO9101 CM121

Geometry is discretized into faces and cells.

Faces are planar - curved surfaces are represented by connected planar
surfaces.

Pagel52 CTO9101 CM121

R , gphy M S

Mesh cells contain a single value for each solved parameter.

Gradients are not resolved within a single cell.
Physical flow structures smaller than cells are not correctly represented.

Pros s ure (bar)

-a.SO -0.2 5 0.00
:_+±`

Pagel53 CTO9101 CM121

Discrete representation of the system leads to

discretization error:
Difference between a PDE's (Partial
differential equation) exact solution and its
discretized approximation.

Estimate error by performing systematic

mesh refinement.

Pagel54 CTO9101 CM121

A discrete representation of a continuous surface.

A perfect quality surface face is an equilateral triangle:

Face Quality = A / AequH

Adjacent faces should be similar in size; growth

should be gradual.

Pagel55 CTO9101 CM121

Original surface (CAD tessellation) Remeshed surface

The Surface Remesher in STAR-CCM+ re-triangulates the initial CAD

tessellation and improves_ the,overall quality of surface faces.

Pagel56 CTO9101 CM121

Srf in h I I M s

??- ii G-try
Base Size ii soee arfuife
reference size for other parameters. &t iE Parts
`.&i H Gesgifro
Target Surface Size ii entaRE
edge length desired given no other constraints. ri{ iH giv8be
.=u.i # futrmrdun
Minimum Surface Size ¥4 il Wtebe
smallest edge length allowed. • surhaR±
:y£`# iB H€anentrds
Surface Curvature - . aaeeife
number of `points around a circle. * Cenprq-
a Target Surfime 5iae
Surface PFox'jmity * aArfro surfro sise
number of faces across gaps. • 5rfecgivadre
• sufrfe*®ffi
Surface Growth Rate / . SurifeGrmthifete
aB -Emtrds
growth rate of triangles on surface. ¥ 5H Cchfro

Pagel57 CTO9101 CM121

Srf in h I S Ivl s

Attempt to create triangles with edge length of target size.

Other parameters may force edge length to be smaller, down to minimum size.

Influencing parameters:
© Surface proximity,
a Curvature refinement,
® Custom controls.

Pagel58 CTO9101 CM121

A volume mesh is a discrete representation of a continuous volume.

A high quality volume mesh quality is essential for an accurate, stable, and
converged solution.

Unstructured volume meshing models in STAR-CCM+ :

Pagel59 CTO9101 CM121

Main volume is filled with a

template mesh of Cartesian-based
hexahedral cells.
a Resolution of template mesh
based on surface and
volumetric sizes.
Any part of a cell that extends
outside of the simulation domain is
trimmed off.

Pagel60 CTO9101 CM121

 =

Template trimmed mesh

at surfaces for internal CFD
Cartesian-based
template

Pagel61 CTO9101 CM121

The surface mesh is used to

generate cells with four triangular
faces adjacent to boundaries.
>m' Mesher continues to build cells away
from the boundaries into the volume.

Cell sizes increase as the mesh grows

away from boundaries according to
growth controls.

Pagel62 CTO9101 CM121

Generates irregular polygonal cells
with any number of faces.

First a tetrahedral mesh is built.

A dualization scheme is used to
combine the tetrahedrals into
polyhedrals.

Cell sizes increase as the mesh grows

away from. boundaries according to
growth controls.

Pagel63 CTO9101 CM121

Pagel64 CTO9101 CM121

 volume mesh volume mesh
surface mesh
tetrahedrals polyhedrals

Page 165 CTO9101_CM12_1

Vlmm h I I M S

Trimmed Cell =; iB Gconrty i il Gcogiv

Volume Growth Rate
ii munpRE i a}cO-
-,£¥ in Parts
& il Parts
:¥j iB DesBtrbe •'£i iii OesHtife
Rate of growth away from
il hare 9 Contads
surfaces. ¥£'* iEi Operaife it5 ffi opGofro
¥ tr fufroted" `S ffi ALFrmgivrm
Maximum Cell Size =~( qE Miede
-;; aB Ptrfe

Maximum volume cell • SurbeRemeha -Rairfe

I "whedcdrmer Poftya!-
allowed.
I 8aaesife I 8es€SqH9
* sepnogiv ® enprqgiv
PolvhedralITetrahedral * Trty-se • TagivgLrfesize
• lfumm sLrfeee stz£ • Pininsurfbe §ae
Mesh Density • strfegivafro • Strifecunatre
• 9rfebeatty I SLrfroprorty
Controls growth rate and • sLrfeGwhRIte • S`rfeeeGrowthRate

densfty of cells away from I lfelime Gcaaeth RatE "EHgiv

® fi-Ctlsife
surfaces. c¥ iB Centbe
:a iil Cont"

Page 166 CTO9101_CM12_1

No single best mesh for all applications.
Unstructured mesh types in STAR-CCM+:

Trimmed Cell Mesh

Preferred for flows with a primary flow direction.
Computationally more efficient than polyhedral mesh.
Cannot create conformal multi-domain meshes.

Polvhedral Mesh
Preferred for flows with high swirl or rotation.
Numerically superior to equivalent tetrahedral mesh.
Preferred wh.en conforma[ mesh desired (multi-
domain).

Tetrahedral Mesh
Solid mechanics or comparisons with legacy
tetrahedra[ models.
i i n ul ;( , i v,,

Pagel67 CTO9101 CM121

interface with no interpolation interface to overlapping faces and

Pagel68 CTO9101 CM121

C f mlJN I m|m h S M S

Conformal meshes require all of the following:

© One Automated Mesh operation for all parts.
© Polyhedral or Tetrahedral volume meshers.
a Per-part meshing is off.
a Strong contact between the parts at the interface.

Non-conformal multi-region meshes can be preferred when:

a Trimmed Cell Mesher is used.
a Required mesh resolution is different across interfaces.
© Geometric complexity prevents imprinting and creation of contacts.
a Only a portion of the domain is being meshed.

Page 169 CTO9101_CM12_1

p mLy M

Creates orthogonal, prismatic cells close to wall boundaries.

Pagel70 CTO9101 CM121

Prism layer cells resolve the
large wall normal gradient in
the boundary layer without
affecting resolution in flow
direction.

Provides accurate solution

without prohibitively large
mesh count.

Pagel71 CTO9101 CM121

Tbl tb dryly M
 a Gtaetry
Number of ca soeeb4edefa
prjsmLayers EEE5H;a;; \ffi a Par ts
`€i a Desongtxma
a Cenife
gal a apt#atus
a ife Ardmatirdun
Prism Layer •vg,`; iE -
Stretching al fifeerfuer

• Baeesde
• hLde ofprcoley-s
• Prtm laytr soetdrg
Prism Layer • PrmLarer TotH!Th.dmees
i i i i i i a ifeBer"
Total Thickness !!i
iB Cb5fro entrds
/,,,,,
!ii!!E

ib Conde

Pagel73 CTO9101 CM121

Advancing Layer

Generalized Cylinder Thin

Page 174 CTO9101_CM12_1

What is discretization error and how can it be measured?

What two things must a mesh resolve in a CFD simulation?

Name the three basic unstructured volume mesh types in STAR-CCM+ and
describe an application suited to each.

How do I ensure conformal mesh across interfaces in STAR-CCM+?

Pagel75 CTO9101 CM121

Which mesh better represents the intended geometry?

Which mesh produces more accurate results?

Pagel76 CTO9101 CM121

 R wq I SM

Consider the effects of mesh resolution on the solution:

-8.0000 -2.Z000 3.¥oe!°ocjtY[j](rag/.2'ooo

Pagel77 CTO9101 CM121

ls the mesh conformal or non-conformal?

wh

J II

•;( \\

:j' ,\.i..:!!

I,{` 1- `-`<_-

I,ii;y; =

Pagel78 CTO9101 CM121

What mesher(s) should be used to predict the solid temperature distribution
for the exhaust manifold? Why?

Pagel79 CTO9101 CM121

Pagel80 CTO9101 CM121

a
SIEMENS
luSz*.-;{y {..t^k

SIEMENS
lntroduction

This workshop covers analyzing the volume mesh and making adjustments to
models and input values as necessary.
The starting point is the sim file saved at the end of the Meshing I Workshop.
If it is not open, load simulation Meshl.sim from the O4_Meshing folder and
Open All Scenes.

lv

Pase182 CToelol-CM12_1 rffig *.Y*+ffi* eflqv{ *}4* !S;,:.}{

ffi . Tffi $:-.-r*"e#&S-s :***,=y.t*-...*, "
 SIEMENS
Skills to be learned and practiced
ry
Review the mesh and
inspect mesh quality.

Apply the Thin mesher.

Add custom controls and
refinements to improve
mesh.

Examine mesh before

and after refinement to
understand effect of
changes.

q,ailagefi*ni s(}ttwn/s in
Page 183 CT09101_CM12_1

SIEMENS
lnspect volume mesh

Examine the mesh again.

What refinements do you recommend to improve this mesh?

Page 184 CTO91O'l_CM'12_, .tlHi*jc b*l'q-\;rg. t ik:var.: -

ffi :;l*'.:;-,:.--^(,r:?. -!+r. s -.d.
 SIEMENS
lnspect volume mesh

Problem 1: Cells are too large for chip geometry.

. The cells at the outer surfaces of the IGBT are too large to adequately resolve
gradients at geometric features.
. Growth rate between large and small cells in heatsink is large.

Solution: Reduce cell size of largest cells.

Page 185 CTo91ol-Clvl12-1 ffiffiif$#ry{%H

ffi'i&dwr ffi

Fixing problem 1: Default controls

Reduce the target surface size and observe the effects of 4't.,
t.
'

t! " ',,
the change. .L . ,,.,<

ln the Automated Mesh operation, change Target &

a
j: \t
1
'tt
:'
t:'-_,
Surface Size to 20 (%1. a Trrq.r 5ud!r. Sir!
; 'rr _,r .,1, ''
Generate Surface Mesh.
i!r!er:rrfIr i,.. i-,rr,1.t x

:r \1" .l
' ''t"

i\-

Pase186 CT0e1o1_CM12_1
ffi ffi
 SIEMENS
lnspect volume mesh

Problem 2: Prism layers in solid parts.

' There won't be a large thermal gradient at the solid boqndaries, so prism
layer cells aren't needed in the solid parts.
' Additionally, the prism layers in the solids lead to a large change in volume
from the prism layer cells to the core mesh cell, which is undesired.

Solution: Remove prism layers in solid parts.

Page187 CT09101_CM12_1

Fixing problem 2: Create custom control

Disable the Prism Layer Mesher for the i;, ,.,,,,

., . la)t..
solids in the automated mesh ' 8|,
. ,it
t'i:. '--
.:.,, .,r,.::r,. ,,
operation. .'
-
* tr.rijt
d :r-ir.r',.1r't
st
From the right-click menu of the + f Contiilu
n a Prnirni
Custom Controls node select New
> Surface Gontrol. i* t,,rr.:

ln the Surface Control properties set I S u,'""i'ir*n

a :- i Show All
* n H*h.r,
Part Surfaces to the parts: + aI trfaui {on!reti
? f aunofi Cndrdl$
g 4j :ur*rcoam
HeatSink, . q Heatslnk
+ 5 {offtolt
. { lGBl r a T&rdrcrf*irian
IGBT. 2 of l0 *lecH
. a Yhtil{ntt*.itr,
. a tart*x a':*Asc
ln the Controls node, select Prism : : I SUS*liBe€y
' : a €rqckri,mfy
Layers and choose disable in the Lurter {.mh lr.
i I :uraa ao**:nn
properties window. .ffi
I X&Ril*emlft

Page188 CT09101_CM12-1
lnspect volume mesh l;=ffi]

Problem 3: Skewed core cells in pipes extending from heat sink.

. Core cells get compressed between prism layers on each boundary.
. Thickness of pipe is small compared to mesh sizes.

Solution: Use Thin Mesher.

Which part(s) should NOT use the Thin Mesher?

Page189 CT09101_CM12_1

Fixing problem 3: Choose mesh models i SIEMENS

Add the Thin Mesher to the Automated t. I oper*lons

Mesh operation. f" Q rmprim
i tl Fitt t-totes
Right-click the Meshers node and Select {.f extracrVorune
I l, l,rtonueu l,testr
Mesher. *n
Add the Thin Mesher to the selected 4- n Drfaull
r S -11;161 '""
P'efrsth
models list. 6* a8r*.)il.i4

gelect Mesh.B

Opuonal Surface irashersa Enablsd Mesherg:

. Automatic Surface Repair r,tsurface Remesher
Foitaedra, t"!esner
:. I Prism Lays Mcsher
raThin Meshct

i oi*l on..r Hdp

Page190 CT09101_CM'12_1
 SI EM ENS
Fixing problem 3 cont'd: Create custom control

The Thin Mesher is active for all regions by

default, but is only needed for the Heat Sink part. : iror*"i;";"
l ,i' Q r,prnr
r, i.$llrrores
Disable the Thin Mesher for the Fluid and IGBT. p I Erracrrrotume
i S l*ot*ea u"sn
l, *5 Merhtri
"l Create a new custom Part Gontrol. ll iabelaqhcnh\.dtt

? ln the Part Control properties set Parts to

a Fluid,
;: IGBT.
-' ln the Controls node, select Thin mesher and
choose disable.

.*:,.)"
'li "''

* hi^ frrthtt
4 .\,.,'.-:, ..

iilr {,":r.r *nt!i. !! X

Page 191 CT09101_CrV112_1 stry:5*idffitrej#. ;

t'i.1FY*igx -'Yl ffi

I
SI EM ENS
lnspect volume mesh

Generate the volume mesh again with the new settings and examine.
Save the simulation as Mesh2.sim.

Page 192 CTO91O1_CVI12_1 ffiWL ffid.,.friB"s:Ig, "t'q,s. k ; **$

"+*r*
ffi&x**':se*,ffi' il"'.1!-1t*-+,",e1-.. ..***v r .r-.,-., -,.1
Refi nement suggestions

This mesh is adequate for the purposes of this training. However, here are some
additional notes that would be relevant for production runs.

Curvature of the pipe not well resolved.

. Getting surface sizes close to 10o/o of base - minimum surface size.
. Curvature is driving refinement, minimum surface size acting as cutoff.

Prism layer cells are thick compared to core mesh cells.

. As noted earlier, total thickness and near wall thickness should be chosen to
properly model boundary layer in a production case.
. Core cells smaller than minimum size due to prism layer thickness.

Page193 CT09101_CM12_1

Review questions

How are mesh sizes adjusted for specific areas only?

Why did we implement the custom Part Control for the Thin Mesher?

Page194 CT09101_CM12_1
Process check

Evaluated the original mesh and

determined refinements where needed. vl
lmplemented mesh refi nements.
V,
Generated the final volume mesh and
examined. gil

Page195 CT09101_CM12_1

Page196 CT09101_CM12_1
 SIEMENS
laVer,.r{y {.. {^{"-

>!/

'!

SIEMENS
Thoughts to consider

Describe a scenario where speciffing local mesh settings to override the

global mesh settings might be required.

What are some benefits to inspecting the surface mesh before proceeding to
creating the volume mesh?

\-

Page198 CT09101_CM12_1
 SI EM ENS
Meshing workflow

No

Page199 CT09101_CM12_1

''.'.
What is mesh refinement?

What if generated mesh is not adequate for my simulation?

' Does not resolve needed geometry.
. Does not resolve relevant physics.
- Mesh count is not practical.

-..1
l

,&jj*lrri4d;li:," l.j-:.,..-,; . . .

:, :.t
ll
]
---l

Page200 CT09101_CM12_1
a

SIEMENS
Mesh refinement options

Original Mesh: 48k cells

Global: change Default Controls or Mesher
properties
- 360k cells with reduced base size

Local: create Custom Controls

(Curve, Surface, Part, or Volumetric)
-240k cells with local refinement
Page201 CT09101_CM12_1

SIEMENS
Local refinement - Custom controls

Custom controls allow local modification of mesh settings.

' Capture geometric features, improve cell quality, etc.
\J . Setting available depend on the control type and mesher

Curve Part

Surface

\*

Page202 CT09101_CM12_1
 SIEMENS
Local refinement - Curve controls

Curve controls allow modification of:

. Surface sizes,
' Wake refinement.

Page203 CT09101_CM12_1

SIEMENS
Local refinement - Surface controls

Surface controls allow modification of:

" Surface sizes,
. Surface growth rates,
. Surface proximity,
. Surface curvature,
' Prism Iayer parameters,
" Wake refinement.

Page204 CT09101_CM12_1
 SIEMENS
Local refinement - Part controls

Part controls allow modification of:

' Volume growth rates (polyitet mesher
. Thin mesher parameters.

Part Controls control the behavior of the Thin Mesher (often

required for CHT analyses with solid and fluid parts) and
adjust the volume growth rates in selected parts.

Page205 CT091o'l_CM12_1

SIEMENS
Local refinement - Volumetric controls
Volumetric controls allow modification of:
- Surface mesh size within the volume,
. Volume mesh size (within the volume),
. Volume mesh growth rates,
' Prism layer parameters.

\-

Can be Geometry Parts

Volumetric Controls enforce a maximum
or simple shapes. size on volume/surface mesh cells in a zone
Not necessarily part of the and modify prism layer mesh settings on all
simulation domain. objects in a zone with one control.

Page206 CT09101_CM12_1
 r
SIEMENS
Local refinement - Wake refinement I
E
Wake refinement projects from a curve/surface into the volume mesh.

Refinement zone specified via a direction, distance, and spreading angle.

Volume mesh sizes and growth rates controlled in the refinement zone.

Anisotropic refinement (differing sizes in various dimensions) possible for

the Trimmed Cell Mesher (useful for thin wakes, shear layers, etc.)

Page207 CT09101_CM12_1

SIEMENS
Local refinement - Controls hierarchy

Where multiple controls overlap, smallest specified size is applied.

No limit for custom controls, but recommended to use as few controls as
possible.
. Simpler setup that is more easily modified.
. Reduces chance of specifying incompatible settings on nearby areas.
3 {;gtact$
&.3 ;${es;.od&
ff'*ke
* 3 k@ra
S'3 enffi
* n *ff*ers
Q *tounate* t'le*r
t & &e*rers
i & *efait eoa'rrsls

' fBEilMB
, & {fl
Hsn,$
n Seqqrs

,. .l l:, ::.::|!r:n i::r;l;,.11 ,.,,:o,,

Page208 CT09101_CM12_1
 SIEMENS
Local refinement - Solution based refinement
Mesh can also be refined or
adapted based on the solution.

!citware
Page209 CT09101_CM12_1

SIEMENS
Surface mesh refinement L__
xx
Recall what makes a good surface mesh from the previous discussion.
, Resolves all relevant geometric features,
, Smooth growth rate of face area,
. Cells have adequate face quality.

How do we achieve this goal?

g - c*;r'
I $crotbd.b
;atlt
taE@E
1066
a r.a
e a orttEr
ei} rear+*
+l ler
a t tax*
6 - t6racdlb
a AE&! I

-.-.-ljaE&&-
t qrtu*o'*'- I
l g f rt-ogrt *. I
I arrra.or*o I
| . irtttery I
I a *rachcr*ra I
t Orercd**
a cofrE
) ;t!: ira:.lirii .rr.)*!:i a;irafare ,1;1r,t;;t,, I tl !*!iw,
Page2'10 CT09101_CM12_1
 SIEMENS
Surface Remesher- Target and minimum size

Page211 CT09101_CM12_1

SIEMENS
Surface Remesher - Growth rate and proximity

Page212 CT09101_CM12_1
 SIEMENS
\- Volume mesh refinement
I
Recall that the volume mesh is highly dependent on the surface mesh.

Many volume mesh problems can be resolved by adjusting surface mesh

settings for nearby surfaces.

\-

\*

Page213 CT09101_CM12_1

vorume mesh refinement fiil'* r'::''r l:

t
Each volume mesher also has parameters to control.

Core mesh size far from any surface/volumetric refinements.

Growth rate from finer cells to coarser

areas. n
,r
Behavior near prism tayer ceils. +:ll+, ,,{,?i
' t tf;-. r,''\).1 d

Alignment of template mesh (Trimmed Cell Mesher only).

Page214 CT09101_CM12_1
 SIEMENS
Trimmed Cell mesher - Volume growth rate

Volume GroMh Rate specifies the Trimmed Cell growth rate.

Surface Growth Rate controls growth near surfaces. -M
' : r*{ew
Default Growth Rate controls growth in entire mesh. Snsra
& I fisd*t
l 3 Cqltnlt
* a &6!M
aI* tuMrd*ch
S a r&$!#
,..4 ?ed!*Il*(
ii; al O&{taon}&
, i.. a &e&d
I . a t{C{3.48&

.t
l.

.:aetd* ,-.ffi
I
-l A#{qtdi
I Cei{*t

tolu6! 6rMh tu1. utr*t16. /

a.'r!, a.'.:- .n
a,',.,. rlr'r.^:, 1:}*

Decreasing the grovuth

rate forces the mesher to
add more layers of cells
of each size during mesh
transitions
? iJlanagsnleilt Scfid
Page215 CT09101_Cl\i112_'1

SIEMENS
Trimmed Cell mesher - Volume

Default Values

il

Surface Growth Rate = Very Slow

rl
:t I

i,frE
I
M-l:=ririi.' .

r li!:nao+;r*r:t EDfl'sarc irr.

Page216 CT09101_CM12_1
 I
Trimmed Gell mesher - Mesh alignment
The trimmed cell mesh should be aligned with the primary flow direction using
Mesh Alignment.

--4-'-i ;
--1 'd

ffi
Define both the alignment and the origin of the
template to avoid thin cells at outer boundaries.

Page217 CT09101_CM12_1

SIEMENS
Trimmed Cell mesher - Recommendations
Size parameters should be specified in factors of two of the base size.

@@@ @

Maximum Cell Size specified to avoid overly large

cells in core mesh
Maximum size generally should be set to the
farfield size (external flows) or
largest surface size (internal flows).

.!:,;'ri:i' :ii3ti:*ns -.}tirtl ,ilactaiS i|

Page218 CT09101_CM12_1
t-
SIEMENS
Polyhedral mesher - Mesh density
Mesh Density specifies the growth of the core polyhedral mesher away from
refinements and surfaces.
. Density controls mesh size in areas far from any surfaces.
, Growth Rate controls growth rate from fine to coarse cells.

Page219 CT09101_CM12_1

SIEMENS
Polyhedra! mesher - Recommendations
Use similar surface sizes for adjacent surfaces.
Avoid sharp cell volume transitions when using volumetric controls.

M ismatched surface/volume groMh

Match surface growth rate on numerical

boundaries (symmetry, period ic,
interface) to desired volume growth rate.

Page220 CT09101_CM12_1
 SIEMENS
Prism Layer mesher

Prism layers should properly resolve the physics of the boundary layer for the
simulated flow regime and chosen models.
. Consider physics models, surface sizes, acceptable mesh size for hardware,
simulation goals, etc.
S-
. Detailed discussion included in Effective Simulations section.

ln addition to the default parameters, can change the Distribution Mode to

either
" Prism Layer Near Wall Thickness,
" or Prism Layer Thickness Ratio.

Page 22'l CT09101_CM12_1

SIEMENS
Prism Layer mesher - Gaps and corners
\-
Thickness of the prism layer is automatically reduced or layers retracted to
maintain cell quality.
Behavior in gaps and corners is controlled by three parameters:
" Gap Fill Percentage,
. Minimum Thickness Percentage,
. Layer Reduction Percentage.

Page222 CT09101_CM12_1
t-
SIEMENS
Prism Layer mesher - Gaps and corners

Page 223 CT09101_Cl\il12_1

sl glvl Hsd$
sher - Recommendations
Ensure reasonable groMh rate between outer prism layer and first core cetl.

BAN! G'O&I}{

Avoid: i

r High stretching ratios and excessive cell aspect ratios near wall.
. Prism layer retraction where it is not expected / desired.

Page224 CT09101_CM12_1
a-

Review questions I sterurus

ii
l,

Which custom control might be used to refine a portion of a single part surface?

Which surface remesher parameter should be modified on the far-field-

boundary (far from the body 0f interest)?

What tools are available to refine the mesh in wakes?

What prism layer parameter should be modified if prism lpyers have been
retracted in an area that was not intended?

Page225 CT09101_ClVl12_1

Page226 CT0910l_CM12_1
 SIEMENS
laXzr^^rly {.. t^k

5I EM ENS
Activity

Which Surface Remesher Control(s) can be modified to refine the mesh below?

:. l',.;,, ,i,lf+c!ciF 1

Page228 CT09101_CM12_1
 SIEMENS
Activity

Which Surface Remesher Control(s) was modified to change the mesh below?

Page229 CT09101_CM12_1

SIEMENS
Activity

Name three custom controls that were used to produce this mesh.
See next slide for detailed view.

i.ri,.

Page230 CT0910l_CM12_1
 E
SIEMENS
Activity

Name three custom controls that were used to produce this mesh.

Page231 CT09101_CM12_1

SI EM ENS
Activity I

The next model is for internal flow through a muffler with flow baffles.

Page232 CT09101_CM12_1
 SIEMENS
Activity

Suggest some modifications to improve the adequacy of this mesh.

Velacity: Magnitude (m / s)

@
053

' oc
Temperature (C)
180

Page233 CT09101_ClV]12_1

SIEMENS
Activity

Suggest some modifications to improve the adequacy of this mesh.

Ve locity: Mag n itud e ( m / s)

ritlyre {c)

}U

Page234 CT09101_CM12_1
 SIEMENS
Activity

Suggest some modifications to improve the adequacy of this mesh.

Velocity: Mag nitude (m / s)

a1 t]

rature (C)
j.]0

Page235 CT09101_ClVl12_1

SIEMENS
Activity

Suggest some modifications to improve the adequacy of this mesh.

Velocity: Mag nitude (m /s)

Page236 CT09101_CM12_1
 SIEMENS
Activity

What things need to be considered when choosing settings for this model?

Page237 CT09101_CM12_1

Page238 CT09101_CM12-1
 SIEMENS
la6cr^-.{y{..t {z

SIEMENS
lntroduction

This workshop covers the selection of the physics models and setting initial and
boundary conditions.

The starting point is the sim file saved at the end of the Meshing Il Workshop.
lf it is not open, load simulation Mesh2.sim from the 05_Physics folder and
Open All Scenes.

Page240 CT09101_CM12_,,i,,-
 Skills to be learned and practiced
SIEMENS
I
i ] tu/eic.L

Q.$!tstr.n,tq
l. A esu*to.'rn..
; l) c"a,.n"
: t_d) r-F;rarrr*urm;r
t O r'q,'r
44 42,

*a r*rd$
. +f A!
&r*6
, *I a*.I r.rrd6&ea!*ed
r *.nltk&rg{co*e*
. s t *6**"re
. * lffirkftrd*ffi,
*-I!@M
*'a rhe*ldk
*jL ftne&ia
,* I rar4**
. $Iffir

Page241 CT09'101_CM12_1

SIEMENS
Process planning

Three different materials need to be represented:

. Water: Fluid
. Aluminum: Heatsink
. Silicon: IGBT (chip)

Define Physics continua for each material.

Model Chip heat generation with a volumetric heat source.

\*
Model energy transfer to the surroundings with a environmental boundary
thermal specification.
j

\- Define water temperature at the inlet.

Page 242 CT09101_CM12_,

\.-
a

SIEMENS
Physics models - Fluid
When a volume mesh is generated an empty physics continuum is created.
Rename the existing continuum to Water.
Select physics models for the fluid physics continuum.
Steady,
Liquid,
irr.l:Ii, rt n'{ |tr]r,','lalll,
Segregated Flow,
Constant Density,
Turbulent,
K-Epsilon Turbulence,
Segregated Fluid Temperature.

. Lrqrr:i,/:.11,'rr fr ij!

'..n\:1 ) 1.rt ) 1,r... \1.:n.1

Page 243 CTO91O1_ClV]12_,

SIEMENS
Physics models - Fluid
The model properties of the selected models can be viewed and edited within
the Physics continua, which we have just renamed as Water.

Expand the Water physics continuum node and consider these questions:

What is the default material for liquid? Does it fit our requirements?
Does the initialstatic temperature make sense?

Page244 CT091o1_Clvl12_,
 SIEMENS
Physics models - Solid

Create a new physics continuum. ,b'ltttt:;i

;63 Continua, ,.
-. .. -- ,

Select physics models for the solid physics #1 P''-" Ns )j [,1e;h,ionrrnuun

,rr.,., E'j,' ; ir,yiiii i""rir*initl,
'. *
continuum. g:ii Flt trr r,:
i;* lr,rt,jir. q.fre-r_l
;r Three Dimensional,
i; Steady,
'; Solid,
rl Segregated Solid Energy, :Segregated Solid Ensqy
i.l Electrochemistry
* Constant Density. i-l l'46h Deformation
il Radiation
Rename Physics 1 to Aluminum. r-: Casting
'l
r Solid Strs

The solid solver needs to match the fluid

' -- Finite Volume Solid Strs
solver. lf Segregated Solver is selected in 1, Multiphase Interadion

the fluid all other continua must use the ' Ele€tromagnetism
Il Co-Simulation
segregated (energy) model. 'r Auto-slect rs6mmended modeis

Pase245 croe101_cM12_,t
mffim

$tf;ft'*s'rui';
Physics models - Solid
Expand the Aluminum node and consider these questions:

What is the default material for solid? Does it fit our requirements?
Does the initial static temperature need to be changed?

Page246 CT091O1_CM12_,1
 SIEMENS
Physics models - Solid

Create a second solid physics continuum from b! qEFldG trlat.,,il

the first and change the material.

Copy the Aluminum continuum and paste it
on the Gontinua node.
Rename the copied continuum to Silicon.
Expand the Silicon > Models > Solid node,
right-click Al and select Replace with.
Expand the material database tree and select
Si (Silicon).
Click OK.
Save the file as Physics.sim.

The material properties are updated

automatically.

] 2017 Src,iens Produc: -itecvc d tldnaqement 50

Page247 CT09101_CM12_1

Apply continua to regions i

!
SIEMENS

Apply the solid continua to the solid regions.

i. Select the HeatSink region.
?. Change the Physics continuum to Aluminum in the properties window.
3 Select the Silicon continuum for the IGBT region.
dt ittlt''r,:
.., * F ,i,J
:- * Heatsink
+} tcrT

hl, --\ ,:., lr r,,l.rfr

F:11:
Ti l.

q Expen

Page248 CT09101_CM12_1
Check interface mapping tr EMENS

t.L t?prlr!fllirnt
Check the interface mapping. a ftory
$ a c.oB{ry
Expand the Representations > Volume i. I YoJumr u*rh
i a F,nt.!orq,!R.r,6',
+ t Frurd
Mesh node until you can select the i
i * H.45inr
I a rbl.volum.rolndur.s
HeatSink > Faces boundary. ;sffi
I F&.r(Frurd/ts.irtirk,
I F...s lfi.nsink/lc81J
Note the number of faces in the
boundary.
Right-click the Interfaces folder and Faces 't7445 Faces 7360

select lnitialize.
.Note that the faces in the contacting area
have been moved to the interfaces.
-
t'a Rrtio", --.---
?I Ftuad

I f xcnsinx
* I Somcrrirr Boundarv I
-!I-- ----r
'. r.FII Fadrr lFtutdlHcctirlkl
Fncr(H.rr5rnk/lcGTlG lnte.faces I
. o. I Fcr*urc Cuilct

nent S{)ftdarg
Page 249 CT09101_CM12_1
-,

SIEMENS
Apply physics to boundaries
x
Boundary conditions must accurately represent the problem statement.
' The wall boundaries of the solid regions transmit energy to the surrounding
environment,
' The chip region produces heat.
. The flow boundaries of the fluid region introduce and remove cooling water.
Conditions at interfaces will be solved.
Silibon
Power = 300W
Water HTC=5W/mzK
rit : 0,005 kg / s = 300 K
Tambient
T6so1 = 15 C

Aluminum
HTC=5W/m2K
= 300 K
Tambient

Page250 CT09101_CM12_1
 SIEMENS
Boundary conditions

Boundary thermal specification methods define energy transfer at wall

boundaries.
Set the thermal specification for the external solid wall boundaries.

ln the regions node, multi-select the boundaries i' n E,iii"i

s t Ftuid
HeatSink > Faces and IGBT > Faces. r t * HeatSink
t Il Eoufrdarier
Select Edit from the right-click menu.
. *l 'Dffi
races[FIuid/Heatsirkj
Set the condition Thermal Specification to , ir l FafftlieatSinkflf;lTl
Environment. + - Frature C,Jfrei t
, I +3 PhyricsCsrtdilisns
i : lB ph.r'ricstatuBs
* * tcEI
t n B*qndaries

t'oll
5 Fearurr
t 5 PhYritt !ei lleruTag
6- 3 Pnyslrs

Page251 CT09101_CM12_1

SIEMENS
Boundary conditions

Set the thermal specification for the

external solid wall boundaries (continued)
in the Physics Values.
hd tudares
fype

i Then set Heat Transfer Coefficient Taqt

All&kr-Strtee Yalqat
value to 5 Wm^2-K. I f Wt*t Crndftions

i Ambient Temperature is 300 K.

I &fkfrat tgaclfrruio.
Canlhlon
, & Utet wail fred Flua Caetri.irnl
3 Close the Edit dialog. ? arytt .vzluet
1 $*ntianrcnp*aure

I *oo* |
I {fHclTrmfrrcodciam

lffilr.rwri;?nl::r.:

.. --.ll:: l a'r

Page252 CT09101_CM12_1 '.&'i*aitlt6:.&in4t.

li.i.i;.Irir;'l,l,*'
 SIEMENS
Boundary conditions

Activate the heat source for the chip.

Expand the Physics Conditions node for the IGBT region.

Select Energy Source Option and change the property to Total Heat Source.
Then select Heat Source in the Values node and change the value to 300 W.

. tE :!!rr.l : rja P:rr,rr,-'

E r,1
.-.* rr,,,-,

* i'ri' ,il r'

. * ,:?t . * '.\:i .,
- d, | ,:, 1:1rL_ cr I

. & ..|ttf. ,,lt, . . tA&,,:1:trr aj.:.:

. b r" ..iitr r!.
, ira prr r: i,rii,r..,_
, aai i'fr :r: r , il ,i :
Energy ssurce opron u
:;- ';' ',
t;' .t n:jr- l!':trl i. :.,i.r, ir r, r. rir.t:,tl:: i.r ,,ir,r
''', ';,- Htu Sourcc
t;t
+trrt,:ut
ya.*
Enrrgy Sourca OptiEn - Prnp.n e: x
e: x -i
-j

Enarqy Sourtr Option {Bn4

ai 5.

Page253 CT09101_CM12_'l

SIEMENS
Boundary conditions

Set the known boundary conditions for the incoming water.

Expand the Physics Values node of the lnletEnd boundary in the fluid region.
2 Set Mass Flow Rate value to 0.005 kg/s.
$
"J
Set Total Temperature value to 15 C.
4 Outlet boundary values can be left at defaults.

* A F.eqisnt
?t Fruid

f .l goundarie,
tX-t- 1 Ff i; -r:i,1 ffi I r ".r,- r1.1,:..i ),t t":r1
. fi ri,r :-. -. ,.,.1t',i- ' {* tfr; i: :iil,..rr:
I ra rFr,-i rii,r & ;t\ . :: \i1j 11-
,,,
:,- Mnsr FlowRate u.-, lt, , r_,,
;-''r r'rr':.r,'r .' rorir leffpar!lurr
Turbulence lnlenrily 'r. a 1.ar) rt :a \.r. . I
Turbulent Vircorky Ratio

ila:a FlowRare - F.oprnirr X !'j

1 PropaniiJ
!i,lEthnd
.Vane
ill'!.".11":,rl

: i! ! i' ;ir*ryt: i[r]i.,ii -i:lri

Page254 CT09'101_CM12_1

v
 SI EM ENS
Process planning - Status check

Physics continua created and assigned. V

Verified initial conditions and interfaces.
V
All known and necessary boundary conditions applied.
V
N
-_.,1 \
-'Y Set solver and/or run parameters.
@fuip

Page255 CT09101_CM12_1
I

t'=*=*r
Stopping criteria I I

Set the stopping criteria.

Expand the Stopping Criteria node.
Change the Maximum Steps to 350.
Save the file.
 SIEMENS
Process check t

can now proceed to setting,up the Data Analysis

objects to query and visualize'our simulation. i,

Page 257 CT09101_ClVl12_1

t
SIEMENS
Review questions I
I
t
I
I

When are separate physics continua required?

How can material properties be modified?

What determines the conditions required at a boundary?

Page 258 CT09101_Cl\il12_,

]
a

SIEMENS
la6*r.^,{7 {..t^k

SIEMENS
Thought questions

For a simple pipe flow, what fluid behaviors are important to consider?

When mixing two flows of differing speeds together, what happens to each?

How does a hot object transfer heat to a surrounding fluid?

ISJ 7 5is**|i: Pfoil:rct i-if+flysle M*nd

Page260 CT09101_CM12_,
 SIEMENS
Physics in STAR-CCM+

CFD simulation is the solution of a set of Conservation of ...

governing equations in a discretized ,,, mass o
..- momentum :)
J
domain. ... energy lr
* aontinua
Chosen by the user to represent the - a rlater
* rqcoels
,a ,, Constant Dcnsrs
t
simulated medium. > ,, Grrdists
. Grouped into physics continua. ;. Laninar
, ,, Lrquid
.j E Continua
.'I Wrtcr
n Segregated Flow
. Assigned to regions. ir s Mgdels
r.i Coni@nt Dcnsity
q thre Dimangicnal .:E@EIE@I
' a Refgencevalues Gradtents
' d Initial Conditions ")
aGffi!fi@ElGl
a Ste.l i.g
t s R.gions t)
,I InternalFluid .-
.a Pipe
' Segregated Flow
' s€r€gated Fluid TmpeEture
Unknown terms are modeled with an r
I
Steady
Thre Dimensional

equation of state, constitutive relations,

'*
;ffir$,Mffir,
and additional transport equations. Reference Values
e Iiitial CcnCitions
, a Steel
& Regicns
'i IntarnaFiurd

Page261 CT09101_CM12_1

SIEMENS
Physics models - Time

Does a global time-average represent the full system?

No
-'
1- -
Unsteady Solver Steady Solver
. lncludes time dependent derivatives. " Time dependent derivatives = 0.
" Solves at discrete time-steps. . Averages effects due to motion.

Appreciable fluctuations in space or

I
high/fluctuating residuals with iteration?
\- No
\, \5
Change to unsteady solver and then Done
time average.

Page262 CTo9101_CM12_1
,

SIEMENS
Physics models - Time: Unsteady solver

ln the governing equations, time needs to be discretized.

lmplicit Explicit
Stable with large time-steps with Less stable, small time-steps
the consequence of smoothing tiny required which preserve tiny
oscillations oscillations
Appropriate for aeroacoustics
More CPU time/iteration, Less CPU time/iteration
More memory Less memory

lmplicit unsteady solver generally preferred because most problems don't require
high temporal resolution.

RAM available is usually sufficient.

Pase 263 CT091 0 1_Cl\il 1 2_1 ;-q3ila:*tti$8!aep"*L

SIEMENS
Physics models - Materials
Material models manage thermodynamic and transport properties.

Single component
A single solid, liquid or gas.

Multi-component:
Single-phase, fully miscible mixture of single components.
Properties weighed by composition in a given cell.

Multiphase
Two or more immiscible phases.

Page264 CTo9101_CM12_1
 SIEMENS
Physics models - Equation of state

Affected only by changes in pressure.

Affected by changes in density and temperature.

Pase265 croelol-clvl12-t
ffiffi

SIEMENS
Physics models - Solver

The system begins at some initial state.

Momentum, pressure, and density are solved, plus

any additional enabled equations.
.The Coupled Solver updates all of these simultaneously.
'The Segregated Solver updates equations sequentially.

The solution is updated, and this becomes the

current solution. This loop continues.

Page 266 CT09101_CMlr_1

,.
 T
SIEMENS
Physics models - Solver

Solver choice for the system of equations is driven by density and

compressibility.

Segregated Coupled

Governing Simultaneously with

Separately, with predictor-
equations are pseudo time-marching
corrector approach
solved... approach

, Compressible flows
- lncompressible flows . Natural convection
Best for... , Mildly compressible (large body forces
flows ' Flows with large energy
sources.

Page267 CT09101_CM12_1

I
I

Physics models
i SIEMENS
- Viscous effects j
i
i_-,....,..,. .

' Shearing behueen fluid layers results in a frictional resistance known as

viscosity.
. Most flows have a non-trivial level of viscosity (they are viscous).
. Molecular scale collisions transfer energy between particles.
. Flows with a trivial level of viscosity can be modeled approximately as an
inviscid fluid with zero viscosity.

Page268 CT09'101_CM12_1
 SIEMENS
Physics models - Viscous flow categories
Laminar: Flow features are directly resolved (using a continuum assumption).
Turbulent: Small, high frequency features are typically modeled instead of
resolved.
Dramatically reduces mesh size and computational expenses.
\--

Inertial
Laminar
--:=---- = Rg
Viscous Smooth flow

lnertial Turbulent
\- Yiscous Chaotic flow --*!;-_,
-=Re
:. ?l1 l Sf,;:'er: P.ildu{t l-ai*i
Page269 CT09101_CM12_1

Physics models

Gharacteristics
- Turbulence @l
. Significant, irregular fluctuations in (3D)
space and time.
. Rapid mixing, and energy dissipation.

Modeling
Many models available, resolving
turbulence in more or less details.
. RANS: time-average of mean and
\- fluctuating components.
. LES / DES: model small-scale
motions.

Page2TO CT0910l_CM'12_1
 SIEMENS

Energy models enabled:

Allow to simulate conduction and convection.
Convection
Radiation can be enabled as an optional model.
. Surface to Surface (S2S): Surfaces participate.
' Discrete Ordinates Method (DOM): Surfaces
Conduction
and volumes participate.
v^\"r''\-/'\-.,
\-/'\-/'\*/_\,,
\,/\//\.,4-,
...//\-r'\"/-\,
Radiation

Page 271 CT09101_CM12-1

Physics Models: Reference values & initial

conditions ] SIEMENS
I

- ta Continua Context is needed to solve the chosen physics models.

i# Faris Meshes
,; I Physics 1
t r Mod€is Reference Values
-* Const;nt
..4
Density . Gravity direction, reference altitude, environmental
Gradients
a) Lanninar pressure, etc.
r';i Uquid ' Constrain and improve the accuracy of the numerical
ci Segregated Flow
ri, etaerir,
. Jllvv,
schemes.
*; Three Bimensional
l I f*erencl-Vatues- - - i
fr
lnitial Conditions
l, :. n*e,en*Pro.u*i
. . Populates the solution fields with values.
t,-"'--.'lrn*'J[ni*;*-
i* i
rtl ,.pressure I
. Can affect stability and simulation time to
convergence.
, Represents the state of the flow at t=0 for (non-
periodic) transient simulations.

Page272 CT09'101_CM12_1
a-

SIEMENS
Boundary conditions

Physics models determine transport equations - *a Regions

iteratively solved in each region. . * Region
ra Boundaries
{ Inlet
' B Physics Conditions
Cell's values are dependent upon neighbors.
- Physics Values ffil
. Boundaries require special treatment *E@@
, { Ouflet
because no neighbor exists beyond a , rs ytall
boundary.
. lnterfaces are connections between regions
to allow transfer of simulation information.
Method Constant
Value 1.0 m/s
Values and/or gradients are imposed with Velocity
D!mensions
Boundary Conditions.

Page273 CT09101_CM12_1

SIEMENS
Boundary types

Open boundaries allow flow and energy transfer. lnlets and Outlets.
>>{ Velocity Inlet ilU Pressure Outlet
X Mass Flow Inlet $" Flow-Split Outlet
B Stagnation Inlet
(8 Free Stream

' Define flow direction, temperature, turbulence, , Pressure Outlet allows backflow.
and phase conditions. . Flow-Split Outlet: ratio of mass flows for a set
' No backflow. of outlets.
' Stagnation lnlet and Free Stream have
additional options.

Closed boundaries allow only energy transfer. walls and Symmetry planes.
wall x Symmetry
',
. Prescribe zeto ot non-zero near-wall velocity. " Velocity across boundary is zero (slip).
' Several energy conditions available. heat flux, , Temperature and pressure are zero gradient.
temperature, heat transfer coefficient, ambient . All physical quantities have zero-derivatives in
temperature. boundary-normal direction.
" Allows for phase-specific outflow

Page274 CTO91O1_CM12_1 m
ftffi*
 SIEMENS ]

Boundaries - conditions and values

Physics Conditions: Set boundary behavior.

Choices reveal corresponding Physics Values nodes.

Physics Values: Set boundary values.

Scalars, vectors, tables of values, or field functions.

E - Regions : n Regions
a r Region i * Region
t B Boundaries ; iB Boundari6
* tt Wall r, Wail
n - ElilE&E&@G r n Physics Cbnditiong
r 'F Referenee Frame SpecificaUon ,,* EEIEIIEIEEI
:- Shear Stress Specification {rBlended Wall Function
r" Tangential Velocity SF
. EllH7*rlIitk
.' ur-#di--[h;,*Jir*_*u , ,n
e@E
Feature Curves
i' User Wall Heat Flux Coefficient Speaification
i' Wall Surface Specification
,e Physics Values
'I Featura Curves

Page275 CT09101_ClV112_1

tt SIEMENS
lnterfaces i
it I

Topology
ln-Place Periodic Repeating

in-place
rnlertace

Coincident Physically separated by a Mixed: ln-place when touching,

rotation and/or translation periodic when separated

Type
. lnternal: Mass, momentum, and energy transfer.
" Contact. Only energy transfer (solid-solid or fluid-solid).
. Baffle: lnfinitesimally thin solid barrier (porous or impermeable).
Additional types exist for specific applications
Page?76 CT09101_CM12_1
 SIEMENS
la6u,-rly{..l^k

T
SIEMENS
lntroduction

This workshop covers the creation of reports, plots, and scenes, running the
simulation, and analyzing the solution results.

The starting point is the sim file saved at the end of the Physics workshop.
lf it is not open, load simulation Physics.sim from the 06_Data Analysis folder.

Pase278 CT09101_C|V12_1 ;:rf ':.' ', "ilr. t,:\.1 * 'u\\ ..'h . '., -.%*a!l!-!SH(!FL
tru-gy
 SIEMENS
Skills to be learned and practiced
*
Create reports, monitors, and
plots to jud.ge convergence and
extract .desired engineering
values.

FffiI Create scenes to visualize and

wrw;,q analyze simulation results.
Create a threshold to do that"

Data
AnalYsis
Br
X
1l
.- .-
re
.r".)

Page279 CT09101_CM'12_1

SIEMENS
Process planning

which quantities are good indicators of convergence for this model?

How can convergence of those quantities be judged?

What visualizations will provide insight into the solution?

a T

SIEM ENS
Greate reports

B !m tit r: rrnl
Create a report of the water outlet }E NewRcporl
E

se
temperature. tE
FJrrl
l;rit a:,trtf,:irr11
Select new Mass Flow Averaged report E
*E E'JiI Heir Er aiirrjqer il-rrrl, ir:"ari )
from the Reports right-click menu. sE F.rlrr: n Hiat E.rclatrger ii n!lr ilfeifll
l).\n t:roup Heal fr aBriar
Rename the report to Outlet irenrfJf:it ef ir|?r|:9
Lri! 1r,r!qrll
Temperature.
Set the Field Function to Temperature.
Change the Units to C. t aiirr,rln i,1rilo./ Report
Select Parts: Regions > Fluid > Fill
, .&
Holes. HeatSink.OutletEnd. ?..a':tt1.

Save simulation as BaselineRun.sim.

,l,jtir1 T.mFeraiuri - FrsFe11 ie: x

. T afi rttrlr, iri

! lFluid: Fill Hcles.Healsink.OutletErdl

a Expen

Page281 CT0910l_Clvl12_1

Create reports

Create a report of the chip temperature. &a ett,:rt

Create a new Maximum report. J uaximum ChipTrmp.rarum

,,,.t.. I inrirt.il,it
!
Rename the report to Maximum
ChipTemperature.
Choose to report Temperature in degree
Celsius on the chip region.

t Exprn

Page 282 CT09101_Cl\il12_1

t-
SIEMENS
Create reports

Create a report of the maximum heat sink

temperature.
Copy the Maximum Chip Temperature
report and paste it onto the Reports node.
Change parts to the HeatSink region.
Rename the report accordingly.

Page283 CT09101_CM12_1

SIEMENS
Create monitors and plot

Create one plot containing all report values.

I Multi-select all of the reports.
? Select create Monitor and Plot from Report from the right-click menu.

t+E Mont
r t' E Ptott
+B

e E tool5
t:r.11n lJi'nittr f, ail P.p.n

Choose Single Plot.

i4,riirplt rep.fr: r:(le!:1r11 l-lre !itrglr plor, L1r (rea1. m!lilple plqta:

Page284 CT09101_CM12_1
 r
SIEMENS
Plot options

I Modify the plot options for better visibility.

In the menu, select Tools > Options. ;lle E'rlli f/ie:h Soilitirn Tools !Vinri.rr./ Hel|)
t1e-:-- - )C2 tdrl-ons
Select Plotting.
F Rt:iel Options

Firqirs

Servics Prr

Seryiccs Anli
E En,Jiroameni Lin€
? P:niJci s/ry

i..!censing

uaj

Page285 CT0910l_CM12_1

SIEMENS
Plot options

Set the properties as shown.

Line Width: 3.
Symbol Size: 10.
trtz9
b.ii 1u
Title Font: Bold 20. agnl Sasserif Bold 20
ForS tanss€rll Plaln 16
Legend Font: 18. Tltles Fon: Sansserif Bold 20
Labe{ icnl rrn:j.il f ai.iir 1:
Axes Title Font: Bold 20.
aj,J. -:. {1. i ;,j\i\
\,1

Axes Label Font: 18. l,hjtr :ri.J !?tie

Tick Count: 2.
Close the Options dialog.
ln the Plot node, right-click Reports
Plot and select Apply PIot Options.

Page286 CT09101_CM12_1
 SIEMENS
Scenes - Temperature Sections

Create a scene of the temperature inside the domain.

Create a new Scalar scene.
Rename to Temperature Sections.
Drag and drop both plane sections to the scene.
Add them to the Scalar 1 displayer.
" &r Interfaces
* Derived Pads
. j, Plane Section
- ,:. Plane Section 2
, Add to Outline 1
,a Solvers
. r3 Clannina l'ril-ari>

?C1 I Sremef,s pr oduci Lriecvcle Manaqe

Page 287 CT09'10'1_C|VI12_1

SIEMENS
Scenes - Temperature Sections
[,
-r;-FllrtrE
Create a scene of temperature inside the domain aa '-.::n.lr Jr: :a,:"..i'.-
.) &&.:l.,tf.i,:
(continued). t" -' ...,,:,r,. :
I . ,:1i,1rl
i, *ii* -"r:.:
"1 !n the scalar displayer, select the Scalar Field a ,{ali.r !i.ld

and in the properties window set Function to

Temperature.
? Then change the Units to C.

: .': r:f.i.ra \t:.al 1!1, ,t.:a:

". | : a !.|t !,:rti 4,,:rr,ir,ia. ;t;i:
-r
fryMin'Abeesaz
-7t3.1t
*1r3.:5
-1.) I l

Page288 CT09101_CM12_1
a
\-

SIEMENS
Scenes - Temperature Sections
T
Create a scene of temperature inside the domain 1g irrng,1r1" ).a "a',il.ri
l gk :: .:! '1t.'
(continued). + ._- .-,,;rtltit 1
i .ri,1r.i
''" &* 11' -

1 Change the Color Bar to show a different color L.linr ij.l,l

I ?''.1' '.))"
map: Select cool-warm. aii {olarEar

4:.itr l:. i"

Restore View 2. q + ,9., ir_ Et ft i-,

Page289 CT09101_CM12_1

SIEMENS
Scenes - Temperature Sections

\- Create a scene of temperature inside the domain (continued).

The default Outline 1 displayer shows the region outlines. We want to see the
outlines of the different components on our plane sections.

\-

ets v.rslJil Litef,vgls sana

Page 290 cT09101_CM12_1
 t
(

Scenes - Temperature Sections i STEMENS

lr
Simulrhon
ln the Outline 1 displayer, right-click Parts * Sciar Sccne 1
9,il,
* Displayers
and select Edit. :. outline t

In the selection box, right-click in the

. d Regicns
whitespace and choose Deselect All, then * Se.ived Pafts

select both Plane Section parts.

Finish with OK.
9 of 33 elected

OK Cancel Help

fi eurtt

Show All : ': ! Show All

Faces Plrn6 Section

'. .

+ Faces Plane Section 2

+ Faces
+ Heatsink.In 2 of 33 *lcctd
.a UaalCinlr Tn

Page291 CTO91O1-CM12-1

Scenes - Temperature Sections fT-Y.,

Annotations display additional visual information in scenes.
Annotations can show:
' lteration, solution time, or time step.
' Logos, images, background, grid, or custom text.
" Report data or plot / scene images.

We add the temperature plot to the scene.

1 Drag and drop Reports Plot onto the Temperature sections scene.
? Right-click the plot annotation in the scene and select Edit.
3 Set the Width and Height to accommodate the scene layout.
ci Arrange the scene objects as desired (see example on next page).

Page292 CT091o1_C|VI12_1
 rI srerueus i

Run I

I
Save the file. The simulation takes a couple
Run the simulation fu minutes to reach the stopping
criteria of 350 iterations.

L
ha{ion

Page293 CT09101_CM12_1

SIEMENS
Analyze results - Temperature Sections

Discussion points
, What were the simulation objectives? Were they achieved?
" Recall the design requirements. Were they met?

Page 294 cT091 01_CM1 2_1

 Scenes - Temperature IGBT

Create a scene of the temperature outside of the chip.

Copy and paste the Temperature Sections scene.
Rename to Temperature IGBT.
Right-click the Outline 1 displayer and select Toggle Visibility.
Change the parts for the Scalar 1 displayer to the IGBT region.
Remove the plot annotation from the scene under Attributes > Annotations.

* E Anribrres
..ffi1 Modett#indow
l. 3 'Eirkgreurd calor v
i&Yiro
?- J$ uptare
. ffiX Ar'inali6n
v'
.-j- Axe=
* E Light, \/
q- I CliF Planeg
* f Annstatisflt
.T
Eril
\,
Edil qnn.idlion.
\/
Page295 CT09101_CM12_1 \/
\_

Iv
I Analyze results

Discussion points
- IGBT

" Where is the temperature too high?

i
I

SIEMENS

, Why is the highest temperature located where it is?

:'-'-*
vhv\

r. rt .:

4*. //5

3S 099
a-

Scenes - Temperature Threshold F""",'l

Create a scene showing the volume with Simulation Sene/Plot
! Temperatur€ Threshold
temperatures above 45 C. * Displayers
I Outline 1

Create a new scalar scene. '

6
Mesh Color
parts
$
Rename to Temperature Threshold. Animations

Modify the Outline 1 displayer.

a Set Opacity to 0.2.
i:. Show the surface.
rOutlina V
Modiff the Scalar 1 displayer to show Featurc Linee D

Temperature in degree Celsius with a thermal lElemer* qhdnk 1.0

color map. Color iJcde

Tags
Type (Default)
i]
Restore View 1.

-
3il$ Produ(a Lifecysle llla*aqement Softwa
Page297 CT09101_CN412_1

SIEMENS
Scenes - Temperature Threshold
Create a scene showing the volume with temperatures
above 45 C (continued). ; i 1.:'

'i Create a new derived part Threshold with these

settings:
a Parts: IGBT.
b Scalar: Temperature.
'.),/a'
e Extraction Mode: All Above.
* Threshold Value: 45 C.
e Display: Existing Displayer > Scalar 1. DrrplU
^
:".:
2 Click Create, then Close. .: a ..
r,t. :4.:_ -:_ _ -,.,.!'

a-a|r. :.,,a tatr,

Page 298
 SIEMENS
Analyze results

The portion of the chip above the temperature limit is quite large.

Discussion points
' Assuming the boundary conditions cannot be changed, how can the design
be modified to reduce the maximum chip temperature?
" What determines the amount of heat transfer to the water?

Page299 CT09101_CM12_1

i SIEMENS l
Scenes - Heat Flux t

Create a scene of the heat flux at the cooling channel interface.

1 Copy the Temperature IGBT scene.
2. Rename to HeatSink Heat FIux.
3. Change the parts for the Scalar 1 displayer to the HeatSink > Faces
[Fluid/HeatSink] boundary.
{. Change the scalar field to Boundary Heat Flux.

!r

Page300 CT09101_CM12_1
 SIEMENS
Scenes - Thoughts
* Regions
' * Fluid
' x Solid
lnterface boundary contains , *a BOUndarieS
solution data at the interface. . tt Default

lnterface object contains interface

model setup and prroperties. ',: {} n PhYsics Conditions

\ , i* n Physics Velues

rE@l*= Interfaces

'
ir,io t,i ,r,"*" sotid tide inteiete

ffi rs1I
Interfaces are two-sided, so it is possible for
the solution to vary depending on which
side of the intErface boundary is selected.
tlail Yt
Wbfi Y+
t&, T

Page3O1 CTO91O1_CM12_,1

SIEMENS
Analyze results
IEIT'

Discussion points
. Where is the heat flux the highest?
. How can the design be modified to have more areas of high heat flux?

,*
!* *l1

etralsa. iaai
i -r::'-. -:'j,.1i
*;*:,.. ii.

Page302 CT09101_Cl\112_1
 SIEMENS
Design change

Let's analyze a modified heatsink design intended to improve performance.

First save the simulation of the current design (BaselineRun).

Then save as DesignGhange.sim.

Page303 CT09101_CM12_1

r-
] SIEMENS
Design change: Replace geometry part
I
Replace the baseline HeatSink in the Geometry node with & .:: .:..:,'.. jax :

the modified design part. '*B

. 't: '^ ,,
Ii
t..'t,
1 Select Replace Part from the HeatSink part right-click ,'lr, fieal5ink
'€, '
:Aar::nin
menu. ; i* : - i,:!rii:rr

i Navigate to HeatSink_5bend.x_b. *
- & 'r.'at.1.,4.:h.:2.ft\rn
:r'
-
!_fn.,.tlt:
,

3 Select Open. - & +....:a

ilr
t:!iiri
r :.t-,:!,
:ri.l

,1. To examine the geometry: t

,...at ha. i{: Ft}: r..:

* Activate Geometry Scene 1. a

_ * r n.,i'
. "".i-r'J_,4,'rrr_
)r7.1.1.,.1\r.. )

: Change the Representation to Geometry.

* ... '" ':i..:? r'1:;4.t
. d 1' . '
'.,: rri,ir,-,

; Make the scene transparent.

a . : ilii :,.:j j,1:

l.a.:t:),t t I

!iplr.,,. :!,jri. i.!,:,i!n,

,pii1 ii!i-,:i. ti!r :. i:

L,ri. ar ":rr):41 'r.:, t

 SIEMENS
Design change: Examine geometry
E
The geometry of the HeatSink part has been replaced with the new design.
The operations and output parts that were affected are labeled as out of date.

& c*qr€t'Y
& O-.AD!"tadeh
& pa!
" r:i. F* a.i6
,qs.lM
' Q| eae<*
' *; res'
' *8t t"sD;6e
' & crta<ts
. i& Cpaabos
' &! r"o''
:'-i.F*#d
. @ arraaro*
; $, Agtrut*rtae*
& csrg

Page305 CT09101_Cl\r12_1

SIEMENS
Design change: Part organization L___
The new HeatSink part surfaces have replaced the existing ones.
The new part only has a single named curve, just like the first HeatSink part did.
The empty curyes can be removed.
Delete all curves except Edges.
Confirm deletion.
if a ems
,' b.l Ftu'd
F €f rrrnore,
fO Hedslnt
': * - iufieat
..t ,'tcuoas
-.. :1 tt:

+$ lcor jrt t?:lrre ra.rrlrt I

e I Dercripliont ar!\:tt.:
iL E Cotradt ::lLtii,:i'rrrri:
ir 3 Opentiens
B (odinua
Delatc
5 Prgiont t

Pase 306 Cr0e101_CM12_1 Trd#)':*.;ni$k'"*S;, ' o""tt\gs'!lt?!t!Ell!Fl

Sg "'t' il +54aS*:."..,*'*"r,ryt7
 SIEMENS
Design change: Part organization

Split the curves to be used in the Fill Holes operation.

Split Edges using the Non-Contiguous option.
Locate the edges defining the inner loops of the pipe ends (see picture).
Rename those edges to lnletEnd and OutletEnd.

lnletEnd

SIEMENS
Design change: Update operations

A dynamic query can be used to populate the

End Curves for the Fill Holes operation in case
there is another design change.

Update the inputs for the Fill Holes operation.

Select the Query Editor for End Curves under
the Fill Holes operation. Y-
Y-
Y.

Page308 CT09101_CM12_1
a-

SIEMENS
Design change: Update operations

Construct the dynamic query predicate: Select the predicate inputs: Name,
contains, end.
. Results: lnletEnd, OutletEnd.
Select OK.

Name (onbins end { x Rasuits

InletEnd
OutletEnd

L 9{... Cancel Hclp

Page309 CT09101_ClVl1'_1

I
SIEMENS
Design change: Execute pipeline

Execute the pipeline of operations to update the geometry and mesh.

Select Execute All from the operations folder right-click menu.

Page310 CT0910'l_CM12_1
I Design change: Analyze results

Discussion points
" Has the modified design simulation reached an equilibrium state?
t--
SIEMENS

' Has the design requirement been met?

Repon5 Plot

? '':: i j::: -:

Page311 CT09101_CM12_1

SIEM ENS
Design change: Analyze results

ffi'"'
':. ':

_
.' i:i

Page312 CT091o1_Clvl12_1
 SIEMENS
Review questions

What objects had to be created, and in what order, to monitor temperature

convergence?

s- How was it confirmed that the design criterion was not met with the original
design?

When the geometry is changed, what needs to be updated in the operations

before running the pipeline? ls there a way to avoid this step?

!ens Produ{t Lifeevaie Mana{

pase 313 croelo1_cMi2_,
ffi sx_Btw,;lj,::,W Fw ;M

SIEMENS
Process check

\-

We have finished our steady-state analysis!

:le M611r{re{}q
Page314 CT09101_CM12_1
Review questions - entire coldplate workshop

What are some assumptions that were made in this analysis that might affect
prediction accuracy?

lf you wanted to explore the design, what things could be investigated with a
design sweep or optimization study?

,} 201? Sieffiens trroduct Lif*cy{:ie

Page315 CT09101_CM1r_1

Page 316 CT09101_Cl\i112_1

 SIEMENS
lay*.-rl7{..{^k

SIEMENS
Thought questions

What role does data analysis (or post-processing) play in simulation?

What is an example of a quantitative result that may be obtained from

simulation? Example for qualitative result?

What makes a visualization of simulation results effective?

Page318 CT09101_CM12_1
 SIEMENS
Overview I

Solution data: values of each conserved variable on each volume mesh cell and
boundary face.

,i ., ---'
I.'.r ro!

Data analysis: evaluate solution data to gain insight, draw conclusions, and
support engineering decisions.

Page319 CT09101_CM12_1

SIEMENS
Data analysis workflow

Page320 CT09101_CM12_1
 SIEMENS
Data analysis objects

Most data analysis objects require two inputs:

lnput Part(s)
Volume, surface or derived
part

Scalar or vector field function

Geometric information: Area,
Position, Mesh data, etc.
Solution data: Pressure,
Velocity, etc.
User-defi ned field fu nction

Page321 CT09101_CM12_1

'v
lnput parts F"=-l
Various simulation objects are available as input Parts for analysis objects.
Parts / Part Surfaces Regions / Boundaries Derived Parts
'::-:;bt* -, '".-- .= ,ii tua - n .'

! .! r*nk
I i i*'r*s*
*tm:
, I .!9*.i

S r (1 aar:e r Il r,
a1 aa8@ I
. A ii-,!i 7rr.
-', tua *(ton

I " $} sarre: i r; ;l;ffii.M .' ,.n. !s*. :

I " :!1, aa'* "' i . ' "ll**r'ry: '" 4"2'z'*

, q)a4(Er 1r i -lrwtiM :
| ! ,' ,. -;b$*,*2 '!'.J!x'

'@i*s*'tc*t t.l-: . tffiffi

- r:l r* xe: 1 *sftr&rs:
ir: ta*rw
' iai 8ilrn ' i . i {lamrxtxz
' q) '*'re' : I .: :, *la'ewu
, 6,1 idtat i,$n*! i : 'DlBee*
, *1 :dr..r:r&crr : ,
i , I f l*?*,i'*r:!$
i ,, ] .fffirh*2$t
' ra negonr ! :I .f *ro*,r*r:p1
, ,it C..a.i &, Ii l*ffizzfrl
I@M
{ of 7:. *ishd ! -: ,*:o.rde
L"-.--:.-* *-*.---
*.lArddi

.: :li1a $::ili)*i li.)trci a;!'**vi;i* ryl aeeillaii $rtritsar* ifi(

Page322 CT09101_CM12_1
 SIEMENS
Data analysis object representation

Representation defines which version of the input part to use.

Different information exists on d ifferent representations,

Geometric data exist on all representations.
Solution data exist only on the volume mesh representation.

Geometry Automated Mesh.Remesh Volume Mesh

Page323 CT09101_CM12_1

Derived parts F EMENS

EIII-

Derived parts are geometry objects created only for .< Derived Pafts
analysis. ' r, Arbitrary Section
. Not part of model geometry or mesh. * Cell Sur{ace
. Do not influence the solution. ' "' Constrained Streamline
' ,:',, Cylinder Section
" Must exist within the discretized domain. ' ,:j' Isosurface
. lnput part(s) define what part of the volume mesh ,'.' Line Probe
, .:, Plane Section
to intersect. '., Point
. Data are interpolated from mesh if derived part "',' Presentation Grid
not coincident with solution data. ':, Resampled Volume
,': Scaiar Warp
, 'i, Streamline
Many different types of derived parts are available. '. Threshold
For example...

Page 324 CT09'101_CM12_1

 SI EM ENS
Derived parts: Examples

Point Probe: a location defined Plane Section: a plane that cuts

by coordinates within the model. through one or more volumes or
surfaces.

Page325 CT091o'l_CM'12_1

SIEMENS
Derived parts: Examples

lsosurface: surface defined by points Streamline. represents particle paths,

of constant value of a scalar function. computed from a vector field.

Threshold: a group of cells isolated based on

their relationship to specified scalar values.
Examples:
. Temperature above 500 K.
. Cell centroid z-coordinate greater than 2 m
or less than -1 m.

Page326 CT09'101_CM12_1
Reports retrieve or calculate solution data and return a 's Reports

single value. ",@@E

9 Mass Flow
:J Torque
The report type determines the mathematical operation 3Volume Flow (CFM)
is Monitors
used to compute this single value.
's Plots
Report types include:
' Specific: force, mass flow, rigid body angle, etc. Average density on surface - Properti,
. Statistical: maximum, surface integral, sum, etc. Properties

. System: memory, total solver CPU time, etc. Units kg/m^3

Field Function Density
Pads fRegion 1; Inlet]

Representation Volume l,lesh

Page327 CTo9101_CM12_1

Monitors

Monitors sample and save information during solver iteration.

[;;;l I

Residual Monitors: tracks RMS values of Report Monitors:

the residuals for each equation. retain report values.
lte:.ile tetieity Alffi !t
611 : - ?ttAS3.-$2 t.l1tt€{&llt 1. $14r 9rl-$6
61' t. ?a3rlt-&z r- 161*{'3-s, ?,3{ritL-d{
513 ?-erTt r*-4, t.strt.dt ,"lSir5!.-S
5!a 2.'t2*2r1*$t. 8, ?S65rX&93 a. tt6lt{r.-{}6
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i,?31559.-tj 8.5?36.3l}S3 i" $E5510|*So
91? 1.r31?3t *$, ,.rfr7rb$3 5.rlX*3tr1.-{t
51t 2 ,'l<l{}1lr- *! s -al9r&tr-s3 6,n1tgrd.-06
3rt , -81ft?5r-i3 6-l'16e-fr

statistically sample data (Mean, Maximum, Variance, etc.) for a selected part.

Monitor data can be visualized in Plots and/or used by Stopping Criteria.

Page328 CT09101_CM12_1
t-
Plots

Plots graphically display data in 2D.

Monitor Plot: display XY PIot display any Histogram PIot: bar

history of monitored scalar field as a function chart displaying data
values' of any other one. distribution.
Residuars
Cell Quality DistriLtution

'ti;
r?i " i 6\tl
eR(,!ahlr r. .' .i\Le: r.ct!

Cell Q.ality

Plots are a critical toolfor judging

solution convergence.

frsnaqpmerll Software lr
Page329 CT091o'l_CM12_1

SIEMENS
Discussion

Reports, monitors, and plots can be used separately but are usually used
together. Which one action best describes the function of each analysis object?

Monitor

Build Transform Combine

Locate
Track Display

Animate Sort

Calculate

Page330 CT09101_CM12_1
 SIEMENS
Discussion

Reports, monitors, and plots can be used separately but are usually used
together. Which one action best describes the function of each analysis object?

Build Transform Combine

Locate
Track

Animate Sort

Page 331 CT09'101_Cl\i112_1

STEMENS j
Scenes

Scenes provide visualization of the model entities and solution in space.

Parts and information shown using Displayers.

Certain displayers are added to newty created scenes.

Outline and and Mesh (= Outline Outline and None

Geometry Geometry) Scalar Vector
Useful for

@ffi*ffi' ;"i:rY

Page332 CT09101_CN]12_1
 SIEMENS
Displayers

Displayers visualize objects and data in a scene.

Displayer type defines what data are available.

. Geometry: Outlines, feature lines, mesh, surfaces.
. Scalar: Scalar field function.
. Vector: Glyphs or line integral convolution (LlC) of vector field function.
" Specialized Displayers: Streamline, DFBI, etc.

Displayer properties define how data are displayed.

eA Sshr t
g n ParS
Y:i aPressure tPa)
:..:l& evt )'i'
i.-- r Smlar field ', {:, ,?
;i::::
.;/)!)

i
, 'i r F$nt Se*
.
.t' -
-

\- *#l Cclar &r

Ir,,
1_8 Stfm_a-fionq

.t .i,,'" r' :l:eir\9rs 3;',:ii;r'i:r ;ii.i;r'i:li: 1!1,.ii

Page333 CT09101_CM12_1

i
I

SIEMENS
Displayers - Layering information t
i
I
L- ,.- __--_,--. __ -, - -

Effective visualizations often combine multiple displayers to convey a specific

message or insight.

Each displayer presents a unique set of data in a specific way

(temperature on a surface, velocity vectors on a plane, etc.).

Pressure (Pa) k Combined, these layer together into a

complete image.
rcc0
sco a
What information does this
a ooco
540.0 scene convey?
10c0

1500

Vetocity: Magnitude (m s)
400 054 1.o 1.5 / 20
re iJ
Page334 CT09101_CM12_1
 T SIEMENS
Displayers - Layering information I
I
i

Each displayer in a scene contains a layer of information.

Displayer
Geometry lnput Part Solid Valve

@ Representation
Properties
Geometry
reduced opacity

&
Vel..ty: M)sniude aht, il
Streamline

Scalar
lnput Part
Representation
Properties

lnput Part
Representation
Streamline derived part
Volume Mesh
Veldcity Magnitude

Pipe wall boundaries

Volume Mesh
Scalar Pressure
Properties reduced opacity

Page335 CT091o1_Cl\il'12_1

SIEMENS
Exporti ng visualizations

lmages and visualizations can be exported for viewing outside of STAR-CCM+

Hardcopy: saves images of scenes and plots.

Export 3D visualization file: saves entire scene to view with STAR-View+.

. STAR-View+ is a license-free standalone scene viewer for STAR-CCM+.

Page336 CT09101-CM12_'l
I Exporting data
SIEMENS

Auto Save saves the full sim file at specified intervals or checkpoints.

Export Data tables and plot data can be extracted and exported to .csv file.

Simulation History file (.simh) saves solution data from many simulation states
for later comparison.

Page337 CT09101_CM12_1

SIEMENS
Running and data analysis

Recommended to complete data analysis setup before running a simulation

because the simulation file contains data for current iteration / time step only.

Additional benefits:
. View solution progress interactively during run.
. Export hardcopies of plots/scenes.
.

ffi
ExtracUexport data.
Rendering scenes during a run can

E-
slow down the solver depending on
hardware, simulation setup, and
complexity of visualization.

Page338
W
CT09101_CM12_1
 il
I

Triggers
! SIEMENS .

ii
I

Triggers define when data are sampled.

' Monitors store data at the interval specified in the Trigger.
" Plots and scenes update at the interval specified in the Update property.
Maximum Chip Temperature (C) Maximum Chip Temperature (C)
timj (s) Time (s)
tol-- 10 20 1g {0 50 60 70 80 90
_-0 100 _^0 l0 20 30

I
,-
u'l1 -, 45 ^oov-
-^oooc
o F
U
vo
3 mi --F dO
:40 c

El .4
33S F
'I
,E lteration . i
FJ
30
a o Time Step
i.
i
)ct-. "-*E*-6''--:t-=5'-=;"--66"--r6'--6-*&"-f
"4 Ar
IteEalnn

Every n iterations Every n time steps

Page339 CT09101 C|VI12 1

Triggers [il;-j
Maximum Chip Temperature (C) Maximum Chip Temperature (C)
Time (s) Time (s)
soo l-q 20 o 40 to 6_q 7g 80 90 lg0 --o l0 lo 40 50 60 70 80 90 100
j
j

4tj
i
'r-rr .15
a
I U
9oi 40
!l
si
5a'.
= a 35
Fi F
30i
1
I
. Delta Time = 10 s
10
AIUpdate Event = Every 2 G
!

20 30 40 50 60 70 EO 90 250 5 lo
100 is 4
lErifoE Iteration

Whenever simulation time User-specified logic

advances amount specified based on monitor data

Page340 CT09101_CM12_1
I
SIEMENS
Review questions

. How many displayers are used in this scene?

' What does each displayer show?
' What displayer types are used?

.t-

Page341 CT09101_CM12_1

Review questions
SIEMENS
I
What objects can be used as input parts for analysis objects?

What objects are needed to produce a time-history plot?

What is the advantage of using multiple displayers in scenes?

flanaag;re;lt Soitwar*
Page342 CT09101_CM12_1
t-
SIEMENS
la6zr.-;{7 {.. {^k

t-
I:
-
l-
SIEMENS
lntroduction

This workshop is an extension of the previous cold plate heat transfer analysis.

The steady state model provided equilibrium results of the system. We will now
address the transient behavior of the system as it starts from initial conditions
and it moves towards equilibrium.

15

re::
oOO at 193 la ]-:
, ,,j4it
,a t66

Page344 CT09101_CM12_1
 i-
--_--*** :
Skills to be learned and practiced srEMENs
L j

6' ady-Statersetufi'.to'iun' r.

,a.{mnSient iana&ig, r,,

;.,,,,,,:,,.,,..

.Set,times@pal1d
r$loppi$,eiiteria'r''

:G,reate motiitofs :to judge I,,

e0nYg,IgenC€.L1:,1;,'1:,

Modify post processing

'to.track convergence,,,
and system behavior
over time.

Page345 CT09101_CM12_1

Process planning

Simulations that investigate transient behavior need to be run unsteady.

The model setup needs to be modified to:

. solve system startup transients (Time model).

' correctly capture desired details (Solver parameters).

' achieve convergence for each time-step and stop entire simulation (Stopping
criteria).

" update with different triggers and save solution states (Post-processing).

Page346 CT091ol_CM12_1
 T
SIEMENS
lntroduction I

Silicon
Water Power = 300W
tit = 0.005 kg / s HTC=5W/m2K
Ts67a1 = 1,5 C Tambient = 23 C

Aluminum
HTC=5W/m2K
= 23 C
Tambient

Simulation Objective: Solve component temperatures over time starting from

room temperature (23 C).
Design Requirements: Maintain chip temperature below 50 C during startup.

Page347 CT09101_CM12_1

f-
SIEMENS
lntroduction I

The starting point is a modified version of the sim file saved at the end of the
Data Analysis workshop.

Load the file Transisnr Start.sim from the 07_Transient folder.

Open the scene Temperature Sections.
Save the file as Transient.sim.

Page348 CT09101_CM12_1
 SIEMENS
Physics models

ln all physics continua the time model Enabled Modeis

:i Segragated FluiC Temperatur!
<seleci one>
has been changed from steady to PISO Unstady
. Steady
,t Two-uy.r All y+ wail rre.tmert
'l Exact'y'/all Drstance
implicit unsteady. Opticnal Models
:- Circumferential Heat Flux Averaging
r"a 1)...;.\:-a

a: Electromagn.tism
i Pa*ive SGlar -...-:. a :
The initial temperature has been set to '- Turb!lenca SupprGion
-'Constant
Densiv
i:: f'1csh Oeformation r:Gradients
23 C (room temperature) for all physics : Di;perscd Muitlphase aa.j at:.'a:: : '..,

a lvlultlpha* Interacton
continua. -Virtual Disk ' Thre! Dimansionai

t, ., ...
Also the ambient temperature in the -- E4anc. ac.lad rr+ 3 €xFodl@rb.d !t u€
i.:--.rr Slr(cr Liate.
solids has been updated to 23 C. a;luminw,Siic6,V/at

fag5

' . Referne !bl!6

.lnrtial Co.di!trs

. Shhc T.mFr&r.
ar.rari -4..::.or -arisb.!

Page349 CT09101_CM12_1

SIEMENS
lnitial conditions

ln steady state simulations the initial conditions:

. Provide starting values for solver iteration,
' Can influence time to convergence; doesn't influence the converged solution.

ln transient simulation the initial conditions:

. Define the state of all variables at time t = 0,
. Affect the solution at subsequent time steps.
 i SIEMENS
Apply model settings i
i

Specify the solver settings. 30r

i
1 Expand the Solvers node. :

? Select lmplicit Unsteady. za-sl

3. Set the Time-Step property to 0.{ s.

fl 27.st

; 271

Transient simulations incrementally advance 26"51

i

the solution in time. 2E

25.5:
The Time-Step in STAR-CCM+ specifies this
Phvsi.al TinrE'sl
time increment.

Page351 CT09101_CN412_1

SIEMENS
Apply model settings
l
The simulation starts at time t = 0 seconds.
l-]: l,larrmum tnnrr llerarroni

Specify the stopping criteria.

Expand the Stopping Criteria node. I'lai1fi11fll inr,ar lleraiiarr: - i'rtpentn: x

Set Maximum Inner Iterations to 20.

Set Maximum Physical Time to 0.3 s.

[5 Mazimum lftn$ lteralions

l\^

b1a:inrrn Phr,:iari Tinrt - Pr!pEnii; x

; Propeniet
Several iterations are made within a time-step
(Maximum lnner lterations).
Simulation stops after a specified time
(Maximum Physical Time).

Page352 CT09101_Cl\il12_1
Stopping criteria

Unsteady simulations do not run to a single converged state.

I
Instead, the solution needs to converge for each time step, before advancing to
the next.

lnner lterations
Once the stopping criteria for the inner iterations have been satisfied, the solution
is stepped fonryard in time.
Default criterion: Maximum lnner lterations.

Outer Iterations
The model stops running when the outer iterations stopping criteria are satisfied.
Default criterion: Maximum Physical Time.

Page353 CT09101_CM12_1

Data Analysis - Plots

ln transient simulations there are two significant tracking events that report
values can be plotted against: Iteration or Physical Time.

Iteration
. Displays iteration history of the parameter.
. Used to judge time-step convergence.

Time
. The curve includes only the converged time step value of the parameter.
. Used for time history.

The trigger event is chosen for each monitor.

The value displayed on the x-axis is chosen in the plot properties.

Page354 CT09101_CM12_1
 SIEMENS
Create monitors and plots

Create a plot to monitor chip maximum temperature over time in addition to the
existing plot over iteration.

i Create another monitor and plot from the Maximum Ghip Temperature
report.
? Verifu the monitor Trigger is Time Step.

? Expand/Conhd Trce

Vaxrmum Carp Temeecture Montor Maxrmur Chrp T.mp.rBtLr. lloniior 2

Comparison of the two monitors: Rep{ lttraxinum CiiD Tempe€turel - Itlarif;um Chip Temperailre]
EBbl.d ?a ..

Maximum Chip Temparature Monjtor,Maximum Chip Temperature Monitor2 I

Clo* Help

,:is Manaaement Sofiwer

Page355 CT09101_CM12_1

SIEMENS
Setup scene and run

Add solution time annotation to the Temperature

- " SGlar
Sections scene: Click the Annotations node and in the e Attributes
1

r l,lcdel Window
properties window select Solution Time. , & Background cclor
6 View

"f update
. Delta Time Frequmcy
il Clear the existing solution. r Hardcopy
i+ Animation
- " Axes

3 Save the file. ' ;

*
Clio Plancs
Annotations

I Piot Image 2
d Run the simulation.

I neralicn
. T Logo
I Plcl lmage 'l

.f Plot lmage 2

Annolalicns.ontained in ihis scene

Page356 CT09101_CM12_1
 ;
!

Analyze results
! sreurus
!
!

Review the Temperature Sections scene and residuals plot.

. Cold water is entering the pipe from the inlet boundary.
, All three temperature reports are converging for each time-step.
, The residuals drop and temperature stops changing.

r,Fpe.al|./P,:i
:3 tl5 :r:r,
Solution Time O.3 (s)

Page357 CT09101_CM12_1

SIEMENS
Process planning

\- The time-step size and number of inner iterations can now be modified to reduce
total run time.

The goal is to use a greater time-step size with less inner iterations while
maintaining solution stability and time-step convergence.

Change one parameter at a time and monitor the results.

We start with the time step size.

1 Set the Time-Step property to 1.0 s.

? Set Maximum Physical Time to 5.0 s.
3 Run the simulation.

Page 358 cTo9101_CM12_1

 SIEMENS
Analyze results

Review the Temperature Sections scene and residuals plot.

All three temperature reports are still converging for each time-step.

Next we attempt to reduce the number of inner iterations.

Solution Time 5.3 (s)

Page359 Crootot_Cn/ItZ_t W

SIEMENS
Additional stopping criteria

Monitor Based Stopping Criterion.

Additional stopping criteria can be created using monitors.
, System monitors.
. User-created monitors.

When the monitor satisfies the given criterion the solver moves to the next time-
step, or can be set to stop the simulation (outer iterations).

The criterion are based on statistical operations (Maximum, Minimum,

Asymptotic limit, etc.).

lnclude logical rules or / And for managing multiple stopping criteria.

Pase360 croelol_cM12_1 S?ryY$ry$qffiiffi

t-
Define stopping criteria for inner iterations F="=-l
Right-click the Stopping Griteria node and select Create New Criterion >
From Monitor.
Z Select the Maximum Chip Temperature Monitor.
? Repeat for the Maximum HeatSink Temperature Monitor.
a Multi-select both new stopping criteria and set:
Criterion Option to Asymptotic.
Logical Rule to And (both criteria must be met).
Multi-select the Asymptotic Limit node of both criteria.
[Max-min]: 0.001 C.
Multiple Objeck - Properties "
Number of Samples: 3. Properties
Enabled Z
f,4onrlor <Different Values>
Criierion
Loqrcal Rule And

Stop Outer ltera'lions I

Criterion Satisfied
Taqs 0

101:r $ielneris Prodfi;t iifecv*le ${ar

Page361 CT09101_ClVl12_1

r SIEMENS
Analyze results

lncrease the maximum physical time to 180 s.

Save the model and run.

The simulation runs for approximately 15 minutes.

Were design criteria met?

femperalurc tC)

Solution Time 180.3 (s)

Page362 CT09101_Cl\iI12_1
 SIEMENS
Review questions
I
Which solver setting added by a transient time model should ALWAYS be
considered prior to running the model?

How are the stopping criteria different for steady models and transient models?

What data sampling control needs to be chosen correctly for monitors and
plots to appear as expected?

Page363 CT091o1_C|VI12_1

Workflow steps

Physicr

Data
AnalYsis We have finished the entire cold plate
workshop. Now we try to optimize

Page364 CT09101_CM12_1
 SIEMENS
lay*,-r{y {.. t;{e-

SIEMENS
Introduction

We are going to do a sweep of the chip power vs chip maximqm temperature.

Before we can do this, we need to make a few adjustments to our simutation file.

The starting point is the sim file saved at the end of the Data Analysis workshop.
Load simulation BaselineRun.sim file from the folder 07_DesignManager
folder.

Page366 CT09101 CM12 1

t-
SIEMENS
Skills to be learned and practiced
T

Preparation of a simulation for design exploration.

How to setup a design study.

Visualization of results of a design study.

Page 367 cT09101_ctvt 12_1

g.--'-*--l
Parameterize the chip power IsrErvrENs j

, i6 Annctatons Load the file BaselineRun.sim.

. iai Cohrrmaps Create a new Scalar simulation Parameter in the
' & Coordinale Systems
6 Cuslom Trees Tools node and call it ChipPower.
€ Data FoCUS
6 Data Mdppers Set the Dimensions property's Power exponent to 1.
iA Data Set Functbns Set the Value property to 300 W.
. jA Environntent tlaps
' 6 feu Functkrns
A F*ters
' s* Ldyouts
" & l"latenal Databases
, &A Mobons
rB Parameters
\ ffiqFEl
' L:L:i&'s'A
, 6 Refetence Fralles * fi rn pr.u,e,, orn,en: on,

urg lal lntom;loF t)

0
o

Type
Value 300 0 \tJ
Oimensions Power
Tags il

Page 368 cT09'101_CM12_1

a

Parameterize the chip power i SIEMENS

Next, locate the Heat Source node for the E E Regiors

,e**-rid
IGBT Region, , g * Heatsink
* * 168T
and change the Value from 300 W to I 6 3 Bocndaries
${GhipPower}. , fr t fuaturecurvs
', * 3 PhFi:sconditbns
. *.n Phy*:s Va&res
, : $'lxis

Heat Source - Propenies i

, Properties
l,lelhod Constant
Value S{ChipFower}
Dimensions

Page369 CT09101_CM12_1

SIEMENS
Sim u lation adjustments

Fix the temperature range in the displayer of . Mesh Scene 1

=
- Temperature IGBT
Temperature IGBT scene to 20 C to 50 C. {i D6players
, Orltbne 1
Clear the solution and save the simulation as 5caBr 1

Basel i neRu n-Paramete rSwee p.sim. r *il pats

e ffiEH
e Point Stze
rJ; n-'
-6t6r

Scalar Freld - Propenres .

Properties
Function TEmperaluae
Aulo lvlin

Auto tu'lax

Auto Range Off

Auto Range Mode D'splayer Parts
Cl'p Bebw Min, Ahrve Plax
Units C
h,rin 200
ldax 500
Tags i1

!13 ratefllent !i$ifi!are l$s

Page370 CT09101-CM12_1
t-
Create the design project

:{ere/Pbt
frrq
From the root node of the simulation tree, Create Srnulation

SmYi{%ffis
*6i
Design Manager Project. e L ?i1i...

' A new design manager project is created. ' * h

' * u
ller,ir
1ur,-erylepcd
&$
Save the design manager project as , e 5i Adi.ri

ParameterSweep.dmprj in the same location as the . d Sk acllip3. T"?€

.slt
Basel ineRu n-ParameterSweep.sim fi le. @ )'
cas;teD*,qnM;nacerProid

, *, (?rriqitdirri

:ilE adJi i!!ciEr Tcal., t'l\.dqa Ne-\p

t I S;Snulatiss
il D6ignstudix
f s#pdrots
'L Plots
ri L Teb

Page371 CT09'101_ClV]12_1

SIEMENS
Setup the design study

Right-click the Design Studies node and select , :.j:r:\_1i1r-|.)t,.j

6k
New. A new design study is created and set to ,n
B inip-rt.i,t::
the default study type of parameter Sweep. B ii.rtl
, Edit the lnput Parameters node. +-rl
Click Add/Remove Parameters, select ffi pii"**t*.ii**r
ChipPower and click OK. *t' iB Sintulatiar:s
t--
? I Ue$tgn stuores
4 Set the range to 75 to 300 W, and the increment * iii s*$isn study
to 75 W, then click CIose. &
3 -i4r.,rrt l ei:ii4
&

E0*igf,Slsdy-lnputPdrimtu X i

I'lrfllP Type Reiereni:e ViluE RaIge lntrentert Resiuinn tr

,i Ccnlruous ' :,.1,.: .., [75.0, ]t_ill 0l w 75.11 \rj

. cb= , Help

Page372 CT09101_Cl\i112_1
a-

SIEMENS
Setup the design study

Select the Responses node and in the properties window select Maximum
Chip Temperature.
Select the Scenes node and select the Temperature IGBT scene.

a aa ll\aalat'-, tia.p I at att-atat :Jea:1,

. ,€a ,rii,rliti.i: ' *tA iil', tlal'iit:
, ,& i.)a""\,Jrt ait"t,li"', : ,Sia ,)a :):)t1
r, r-.,!: "t-\-iltaa
F l
,. A* rt:i,ri e 1-Tiilar..

E--
'* Scan€6

saen.s-Proparties X E;

Responses 6 Scen€s g
Stud:,, rE:F,rn:? nlandg*r 5-oleat refiren(e r{€nes

Page373 CT09101_CM12_1

tisrEMENs
Setup the design study Iti i

Expand the Seftings node and select Run f 71 ara.?f,' l-;> .

Settings. & :-.a-,ja),i a

':):.:.

Set the Simultaneous Jobs property to the t iii *esisn study

9L l. lntut Par.msterts
number of processors in your system (probably 4). : a Design Tab,t
t- E Responies
Collapse the Design Study node. + 3 scana*
-'3 Flots
i' e s"ttinlu
o Rrn Settingc

,:,:fftr'.jla P, \caaaa a

Simultaneous Jobs g
l.)\mb.r ){ f,irir!n: ti .!eiute :iflr!lta.}e$(.1,'

Page374 CT09101_CM12_1
 SIEMENS
Create a scene snapshot

Partfiretat i eeiF
On the Snapshots node, create a new ,- sA tirrlatiii,:
Scene Snapshot. : .8 Oz';iar'',,t..tiiz'.
_.r
.ri lLi-,r il
Select the Temperature IGBT scene. ; B :r,,:i:;!r;,t:-.
r ;S s."n" Snapshat
t{ ltrrnrri rr'
r*.lnriitilir[:
M ""
' u ,\) -

D: :iitn 'itL;C..
ij.:i,lrr:it lii{l
Scenc lTamperature IGBTI
Tin:, tl
? Expert
L:t --'t D < :t grt
arn;ign

S(ene
:

I
,.ere iit i:t 4t:cla'f7

Page375 CT09101_CM12_1

T*-*-* --*l
Create a plot of design study results I srerurrus
it i

Collapse the Snapshots node and $& p"iim*ersweep

* n Simubtbns
create a New Plot. S n Desiln Serdies
r E Snapshots
Add Data to the Data Series sub node ,-n P,bts
: * H xvget
in the plot. :N&
Then select the Design Study. E! ,fa.i outu Pro!iCeE tc Piot

DesQn Studies
iiiDesign stuc,y

1 of 1 sehcted

I OK Cancei Help

Page376 CT091o1_Clvl12_1
 SIEMENS
Design study series

The type of the bottom axis shall be changed. xv pkt

Li
Beware that there are two Axes folders. One for the plot
and one in the Data Series node. B Sottom AxE Datd
Left AxE Data
: i r.EestDedgnHietory
: : '' BestDe*ln
For the Design Study data series that was just added, , : :. sase&teDesgn

change the Type property of the Bottom Axis Data , . :'. Line5ryb
. . 'tsymbol5byk
: GnAx€s
node to Parameter. E BottomAx6
. : &e n
ln the new Parameter sub node, change the , a LfrAxis
' e Legend
Parameter property to ChipPower. ;6'ile"-- - --
'nwwP*i'.
For the Left Axis Data node, change the Response tam*
*:_ Deqrnstrdy
to Maximum Chip Temperature. * a BotbmArbDBta
..@
3- L* A)(b Dae
Change the Line Style to a solid line. ,
.
.
B€* D€qO
hs€lre tteEn
' r l"|1e style
' . Symbsqy'e

Prr:mrtar. Propenres ,

Propert€s
Pr.rnari.,, ittrrFFrrcl

Page377 CT09101_CM12_1

SIEMENS
Save and run

i Save the Design Manager Project.

!: To run the study, right-click the ffi Fararnaters*€ep
g- fE Simulatirn*
Design Study node and select Run
1I Design Studies
Study. ,.1* r. t
Study ,
t
a- B Snap* h Run
!- B Fists
Wait approximately 7 minutes for the *' El Tsol::
4 designs to run. (l*ar 5tlrdy
Edit .

5et Ue',* Tag..

ireate Plot )
Op;n All Fl*t:

t ,: p-.

lJ l l8tr
EdIIdIIIE

Iependenrie:

f,3iaa*!11e
Page378 CT0910l_Ctul12_1

L
 SIEMENS
Review results

Rearrange the Plot, Scene Snapshot, and Output Table so that you can
interact with them all.
Review the results, selecting each design in the design table and reviewing the
Scalar Scene.

Page379 CT09101_CM12_1

The simulation file was prepared for a design study.

A Design Manager Project was created.

A Design Study was created and configured.

Data analysis obiects were prepared.

f,he Design Study was run and analyzed.

Page380 CT09101_CM12_1
 SIEMENS
lan*r^-r{y{..t (e-

lntroduction

This activity includes:

. Establishing analysis goals.
, Planning appropriate geometry, mesh, physics, and data analysis steps.
. lmplementing the workflow plan.
. Validating the plan's outcome.

The planning phase will be done in small groups for discussion, then you will
individually implement your workflow plan.

At the end of the activity, we will discuss the problem as a group and walk
through the simulation.
,

Problem overview t!'Y1Yl

You are a CFD analyst at BetterDesignsFaster Valves Division (BDF VD). You
have been tasked with simulating the flow through our newest valve design,
shown below.

The simulation objectives are to predict:

" Pressure drop and
. Mass flow split between the two outlets.

Pressure Drop
(lnlet - Outlet)

Outlet 1

Outlet 2

Page383 CT09101_Cl\41r_1

SIEMENS
Process planning

Load the sim file BallValve_Start.sim in folder 08_Assessment.

Open the scene named Geometry.
Take 2 minutes to familiarize yourself with the geometry and the parts under
the Parts folder.
Working with your teammate(s), discuss the questions on the Partner Activity
slide. Take 10 minutes to discuss.

Page384 CT09101_CM12_1
 SIEMENS
Partner activity
T
1. Do you need to generate any additional geometry in STAR-CCM+ to analyze
the fluid flow? lf so, what operations/workflow steps are needed?

? What will you choose for the base size for this model? How did you determine
that value?

3 What custom mesh controls may be needed?

4. What physics models will you choose for this analysis? ,

5 What boundary conditions will you specify on the inleUoutlets?

6. How will you determine convergence? What data analysis objects are needed?

7 What scenes would be useful to visualize the problem?

ent S{]&ware
Page385 CT09101_CM12_1

SIEMENS
lndividual activity
I
lndividually carry out the analysis plan your group worked out.
. Complete as much as you can in the time allotted.
' Yon will not be "graded" on your progress - there should be no pressure!

lf you get a converged solution, write down the values

of the quantities of interest (mass flow rate and pressure
drop to each outlet).

After the allotted time, we will discuss the answers to the worksheet questions
and go through the workflow as a group.

Page386 CT09101_CM12_1
 SIEMENS
la6c*,-r{y{..t {z

lntroduction SIEMENS
l.:;M

We are engineers at a fan company tasked to evaluate the performance of a new

design for an exhaust vent fan.

The simulation objectives are to predict the following performance

characteristics:
. Flow rate,
. Pressure drop,
. Torque.

The design requirement is to provide a volumetric

Y
flow rate of at least 200 CFM (ft3/min).
V

Page388 CT09101_Cl\i112_1
lri,
,M
 SIEMENS
Workflow steps

lmpqrt and organize CAD geometry.

Generate the somDutational donlain, s
-
I
Define meshing models and settings
Generate mesh, inspect, and refine

Page389 CT09101_CM12_1

SIEMENS
Simulation overview

(atmospheric P)

Duct Walls (Stationary)

Ambient Air (27 "C)
,il :li: I *:r...i|,.i r:1ia{lii:,".:f*t:}.j
Page390 CT09101_CM12_'l
 SIEMENS
Process planning

Which physics modeling strategy should be followed to model the fan rotation?

Which areas of the model might need a higher level of mesh refinement than
others?

Which engineering values should be monitored in this simulation?

Which scenes should be created to visualize the solution? ,

irerier:s PI3itilJt L:{ec, C'e Manuqen

Page391 CT09'10l_CM12_1

il

Startup Irl sleruerus l

We begin working from a sim file with geometry already imported.

Load the simulation DuctedFan_Start.sim in the 09_WorkflowFan folder.

Use Save As to save a copy of the original as DuctedFan.sim.
Open the Geometry scene and familiarize yourself with the geometry.

Page392 CT09101_CM12_1
 SIEMENS
Organizing parts
I
Two parts exist in the Parts folder. Duct and
Fan. Duct represents the air volume inside

s of the duct. Fan represents the solid body of

the fan and is organized into several
surfaces.

Questions
Are any additional surfaces needed to account for
boundary conditions or mesh refinements?

Which parts, if any, still need to be created?

lf parts must be created, which operation(s)

should be used?

Page393 CT09101_CM12_1

SIEMENS

We need to split the duct surfaces in order to apply :;. :,:

e j!'r.-

boundary conditions. +fl

' & -.'t.
1. Split the Duct > Wall surface into three surfaces: r $ k:er.
LJ[-
jd rir. rr9

Wall, lnlet, and Outlet. & *.?!. spfblPdrri-

. Use either Split by Patch to interactively rename * :r.s*

i*'vt
*lr !'r\
,rid tiDr.a:rtr9,i!.

* t@.a:t, ktn a- :'t'r'':r

CAD patches, & *av,e.??, ;rtdh:^li.

. or choose Split by Angle to automatically split

into multiple surfaces and rename.

i Create a Boolean Subtract Operation with the two

parts. Set the Duct as target part and Perform CAD
Boolean option. lr. l''':"::''
3, Execute and rename the new part (the result of the
boolean subtraction) to Air. !:.
Create regions and set boundary types r SIEMENS :

Assign Parts to Regions of the extracted part Air would create the region and
boundaries shown in the picture.
ry'5 *s#,:B
Are all of the boundaries necessary? ie-ile
i *,L&t&
Could we merge some of them? : : *-gf ***xrr
i , i"lffi rxrce*:e
i ,,: .*|; &#,{r*
| i,; rrxr***r&
: : r"-t; err,&&*
t' : i'-* tuLlrs
; ry-f Mrc€txrux
i ry- * *rds*afrsslx
i e'* ryG*H

Page 395 CroStOt_CwtlZ_t ffi

SIEMENS
Create regions and set boundary types

*-
Assign parts to regions manually. More efficient if a ; {Cesion;*"-
large number of surfaces are used for meshing
ux@
;* n Boundaries
purposes but only a few are needed physically. , .t;Fan
I Inlet
. I Outlet
: lI Wall
Create an empty region with four boundaries by i-n Feafure Curves
right-clicking. Use the same names as for the
surfaces if possible: lnlet, Outlet, Wall, Fan. Region 1 - Propertieg
Propertres
Link the Air part to the region (properties window). Indei
. Surfaces with matching names are assigned Mesh Contrnuum None

automatically. The rest are assigned randomly Y

to one of the boundaries. Tags 0

Page396 CT09101_ClVl12_1
 SIEMENS
Create regions and set boundary types

Link all fan surfaces to the Fan boundary. a 3 Regions

a * Region I
Change types to Stagnation lnlet and Pressure 9 3 Boundaries
t-:rEffil]
:El
Outlet. : Inlet
| , Itrrl Outlet
: .f \(all

Fan -

We set the boundary types for the inlet and lndex

outlet before meshing. Do you recallwhy? lnlerfaces

Type !e lnlet
Taos + Cutlet

Page397 CT09.101_CM12_1

SIEMENS
Mesh setup

A polyhedral mesh with a prismatic boundary layer is suitable for this simulation.

1 Generate a new Automated Mesh Operation with the parts that are assigned
to the region.
2 Select these meshing models:
a" Surface Remesher (for improving triangulation quality).
*. Polyhedral Mesher (to resolve the swirling flow).
,,;, Prism Layer Mesher (to resolve the boundary layer).

3 Set Default Controls:

* Base Size: 0.015 m.
: Prism Layer TotalThickness: Absolute Size, 0.003 m.

Page398 CT09101_Cl\i112_1
 W

Generate / inspect surface mesh

Generate the surface mesh.

SIEMENS
T
Create a new mesh scene and review the surface mesh.

Question
Is the surface mesh acceptable?
Check the mesh size on critical
parts, growth rates, etc.

3se j/(#$.i:! YFii:\*f k'.e-: i+ {;ri...

Pase Croelol_Cl\i112_r $ffi{S$$:f$!}$;" u. y,rll.\,rI",',
**r!X$*s**ilrs1.rL'i3:tri' "t".., rl: l.-

SIEMENS
Refine mesh: Surface control
ffi

The surface mesh size on the fan should be reduced.

Create a new Surface Control with the fan surfaces as lnput Parts.
change the Minimum and rarget sizes to 5% and 25o/o, respectively.
Re-execute the surface mesher.

Page400 cT09101_Cl\i112_1 ix+-i'i";'45{ts!}s

"'T;n-*."r"r-.i j|i-
 r 'iri i"':.:r::."i )r"ii
mesh
I

Generate / inspect volume i

Generate the volume mesh.

Create two Plane Sections:
One through the blades normal to the z-direction.
One through the middle of the duct, normal to the y-direction.
Create a new Mesh Scene and review the volume mesh.
Add the two plane sections to the Mesh 1 displayer.
Hide the Duct > Walls surface.

Page4Ol CTO9101_CM12_1 ui*#&r45{ d**'{. S' *qt.,rst r.^t..'

s@ I "is- : I
ffi l"4sll .,:*{:1!"-t. ;r '-,,. , L ... -

SIEMENS
Mesh assessment

Discussion points
' How many cells are in the volume mesh?
. Are any refinements needed to improve
the mesh quality? Pay special attention to
the mesh in the area around the blades.

- {& kF16
& ;f@rJ
' & i*€l;trrt
1 I ?@€t;
, bm
IIr.rjJI
, @ :3i3

Voiume ile3i - Prcp€nles r

402
Pase cr0e101_cM12_'
lt$Tilffift,
Refine mesh - Create cylinder F,'"*"l I
We will use a single Volumetric Control to reduce the
prism layer size and improve growth rates in the entire ; ;;* )r- :::-, . '-.1, .

zone near the fan. fai,i1t. t,t,61t_,r I

Ein

Sli ai

First, create a new simple Cylinder part to use for

refinement.
l. Right-click the Parts folder and choose New Shape
Part > Cylinder.
Set the cylinder extents:
Start Coordinate. [0, 0, 0.16] m
Gylinder Radius: 0.15 m
End Coordinate: [0, 0, 0.28] m
Click Create, then Close.

Page403 CT09'101_CM12_1

Continue with the creation of a volumetric control.

Create a new Volumetric Control under the Automated Mesh operation and
set the Gylinder as the input part.
I Enable customization for Surface Remesher and Prism Layer Total
Thickness in the Controls folder.
Custom Size: 50o/o of Base Size.
Prism Layer Total Thickness: 1 mm.
Re-execute the operation.

Page404 CT09101_CM12_1
 SI EM ENS
Mesh assessment t_
L
Discussion points
. ls the new mesh appropriate for the simulation?
' How many cells were added when the refinement zone was included?

Page 405 CTOS'I01_CM 12_1 ffin 1r$*; ,e;; ,

::,:-:'.i- \4?: !: n L!i'

SIEMENS
t__
Select models for the Physics 1 continuum:
-
,: Steady,
,... Gas,
Segregated Flow
,; ldeal Gas,
* Segregated Fluid Temperature,
r Turbulent,
,.l. K-Epsilon Turbulence.

,: Set the initial Velocity to [0, 0, -1] m/s.

Discussion point
Are the physics models chosen here reasonable for simulating the bulk air flow
in this fan duct?

Page406 CTo91o1_CiI12_1
a

SIEMENS
Background information MRF approach

The MRF (Moving Reference Frame) approach mimics the effect of a

constant motion without moving the mesh.
' Constant grid flux term applied to the governing equations of fluid motion.
. Motion applied to all boundaries when an MRF assigned to a region.
Alternatively tangential velocities can be applied to boundaries as needed.

Example: Pump total pressure

E approach

Page407 CT09101_Cr\/112_1

_l
Reference frame setup
SI EM IN5

6 Rqqian5
Create a new Rotating reference frame under Tools > * 1aq!r)n i
s StrNainriE!
Reference Frames. * Featiir? a*aei
. * Phyi,.s r:ondili.rnt
Set the properties of the Rotating reference frame. * ,hysra5 Values
n:?qffi
Axis Direction: [0.0, 0.0, -1.0].
Rotation Rate: 2000 rpm. Motioh Spacillcldon - Proprrti6. .

Set the Motion Specification of the region to use the [4?1,on 5tair.iont]
F.aaeta-Lefiaie Ralntrr!)
Rotating reference frame.
Set the duct wall boundary to stationary (non-rotating):
Under Wall > Physics Conditions, change
Reference Frame Specification to Lab Frame.

* rhrr;,-ilE\
.

R.t.r.nc. Fr.m. Sp..ifc.ton'Prop.d.t .

Page408 CT09101_ClVl12_,1
 SI EM ENS
Reports, monitors, and plots

We create a number of reports, monitors, and plots for relevant simulation

quantities.

1.Create Reports for:

a lnlet mass flow.
b. Pressure rise due to the fan (use Pressure Drop Report).
c. Torque (Moment) on the fan surfaces.
2 Create monitors and plots for all of them.

\* Questions
. Wh,"h engineering quantities might be of interest in this simulation?
. Can you"ther
create a report to measure Power required? (Power = Torque "
Rotation Rate)
. Which monitors would be appropriate for judging convergence of the
simulation?

Page409 CT09101_CM12_1

Scenes

\- Create scenes to view these fields:

Relative Velocity magnitude on section planes.
Pressure on blade surfaces with the Torque Plot as an annotation.
Pr.ssure lPa)

re.,. ,....$

Torque converger.€

Questions
' Why might Relative Velocity be recommended instead of Velocity?
. Could another Derived Part better display velocity than the current planes?
" What other Scenes might be of interest in this simulation?

Page4'10 CT09101-CM12_1
 T

Stopping criteria and run

Change the Maximum Steps Stopping Criterion to 500.

Save the file.
I
SIEMENS
I
Run the simulation.

Question
' How will we judge if the model is converged at the end of the run? ls there a
way that could be incorporated into the Stopping Criteria?
. Does this design meet our design requirements for flow rate?

ti Silib,Yart
Page 41 1 CT09101_CM12_,1

SIEMENS
Scenes

Create a new Geometry Scene in which to display streamlines and set the
Opacity for the geometry displayer to 0.2.

2 Create a new Streamlines Derived Part:

a Vector field: Velocity
b Seed parts: Duct.lnlet
c Resolution: 8,8
* Display: New Streamline Displayer
* Choose Velocity Magnitude as
the Scalar Field for the Streamline displayer.

Question
. Why do many of the streamlines
appear to end at the fan?

Page 412 CT09'101_CM12_1

 '.;.1, .i]! ri ...) ,1:,ri ;.i
ri .'lli
..aJ i,,.. : t.J :,.. -i ,.::.

Design evaluation
I
Can you improve the current design to reduce the torque required while still
meeting the design requirement of a200 CFM (0.11 kg/s) flow rate?

The design has been parameterized to allow you to modify the design. To modify
the design:
, Design Parameters are found in 3D-CAD Models > 3D-CAD Model 1 >
Design Parameters.
. The number of blades and hub radius of the fan can be modified subject to the
following constraints:
. NumberOfBlades:2-8
. HubRadius: 0.01 - 0.09 m

Mesh and stopping criteria need to be updated before running the simulation.

Page413 CT09101_Cl\il12_1

L-

Summary and review

SIEMENS
I
Completed the entire STAR-CCM+ simulation workflow.

W Practiced mesh assessment and refinement.

Selected physics models to solve a rotating system using
the moving reference frame (MRF) approach.
Defined post-processing to analyze and visualize the
simulation results.

ffi Explored possible design improvements using 3D-CAD

design parameters (optional).
t3

!-

Page414 CT09101_CM12_1
 SI EMENS
MRF Approach: Background lnformation

Using a moving reference frame is suitable for:

. Resolving system-lefel flow behavior (average flow rates, pressure jumps,
torque, etc.).
. Systems with little circumferential variation (axial devices, systems with
many blades, multi-row devices, etc.).

Example: Laptop docking station fan, showing temperature on laptop.

Page 415 cTo9101_CM12_1

t SIEMENS
MRF Approach : Background lnformation t
w

Not well suited for:

' Resolving transient flow structures (unsteady pressure loading, transient
wake effects, cavitation, etc.).
" Systems with significant circumferential variation (some radial machines,
devices with few blades, etc.).
" systems where surrounding velocity is normal to axis of rotation (e.g.,
blowers)
Example: Water pump with volute.

Velocty: ntagntude ttnls)

a oo 4.4 8 0 1..1 t5 ,)a
I il
PPV ;610 rin RPN; ]600 en
,awet. i J:'7j lktt) -- )rg. 1 3i941 Poftet: l.j089l i*ltl -- Aq.. 1.i0909
,?ad :.;A:5;'n, -- Jtg. :.it:::,n) HrdC J.8/9/8 tn) -- ,tryq.: ].88016 (il)

- -t.

Page416 CT09101_CM12_1
 SIEMENS
lNnz*,-rly {.. ti{z

When is a simulation done or complete?

How do you know there might be a problem in the model setup?

What aspects of a simulation have the largest effects on solution accuracy?

lntroduction SIEMENS t

Effective simulations
run efficiently to convergence and produce the desired fidelity and accuracy.
I
\
\

how the solution is reached what influences the solution

Page419 CT09101_CM12_1

SIEMENS
L
The STAR-CCM+ solver attempts to
balance the conservation equations i

from a set of boundary conditions,

initial conditions, and sources.

Cell values and gradients are

calculated.

This process of updating cell values

for velocity, pressure, and
temperature in response to local
gradients is CFD simulation.

Page420 CT09101_CM12_1
 -___==:I____-

_-` -` ,_ .--,
Recall: The discrete solution is obtained
in an iterative manner.
a An initial solution is established.
® The solver updates the solution each
iteration by attempting to satisfy the
discrete equations being solved.
IPL±iL=
i -'--i-i
Page421 CTO9101 CM121

When the solver begins iteratjng, the initial

solution is unbalanced.
® The ltri}rm(arrf 1©©[® runs to converge the

system of equations.
© Steady state simulations only involve
this step and end when converged.

Page422 CTO9101 CM121

Conservation laws (mass, momentum, energy, etc) dictate that the total flux of a
conserved quantity entering and exiting a given volume are equal.

ri v,in ri
ln a discrete simulation, however, there can be differences between the two
fluxes. The`se are referred to as Residuals:

r=Z/!uxesm,simu!afion-I/Zttxesout,Simu!ation

The residual in each cell indicates how well the discretized equation is satisfied.
Residual values are limited by machine round off.

Page423 CTO9101 CM121

Residuals are a measure of the overall solver progress and should decrease
as a simulation progresses.

Residuals

i 2 '3 4 5 6 8 9 10

lteration

Page424 CTO9101 CM121

A solution at a given state is considered converged (or sufficiently solved) when
BOTH of these fall below a desired tolerance:

© the residuals (imbalance of fluxes) in the domain

AND

a the change in desired engineering quantities.

This can happen from one iteration to the next.

Search for fluctuations

Page425 CTO9101_CM12_1

C g St dy mit SM

Convergence behavior is visualized with monitor plots.

Steady State simulations converge to an equilibrium solution.

Desired convergence behavior:
® Residual monitors drop a number of orders of magnitude over many iterations.
a Relevant engineering quantity monitors level out and remain constant.

Reports Plot

1e-06l

i i ; .i . ` ~\ (

Page426 CTO9101 CM121

Correctly determining convergence requires monitoring the correct quantities.
Temperature «}

Cylinder
temperature
appears to be
converged.

Page427 CTO9101 CM121

Page428 CTO9101 CM121

Stopping criteria are the limits imposed by the user to indicate that
convergence has been reached and to stop the simulation.

Stopping criteria based on monitors use the monitor data as well as logical
triggers to stop the simulation or advance the solver to the next time step (for
transient models).

Page429 CTO9101 CM121

ln Transient simulations, the solver now advances in time.

a Time-steps (outer loop Steps) introduce a sudden change
to the system being solved.

® The !ifl!fl©B£' I©@j[Q) is engaged again to

EEREERE
converge the new flow conditions.
HRE © Once converged, the Outer Loop
HEEEERE steps forward again, and the
qE T process repeats until the simulation
Lrm-ffiRE
3unn;
is complete.
¥

-g|ngrf-RESTRE;apRE
•^J.

Page430 CTO9101 CM121

ln a transient simulation each time-step is similar to a steady state simulation,
® The time-step begins with final values calculated in the previous timestep.
® Boundary conditions, gradients, and sources (allowed to vary with time) are
updated if necessary.
a The inner loop iterates on the current solution until converged.
® The converged cell values become the initial conditions for the next
timestep, Res ;clua/s

1rj 20 3CI 4i-j 50 6Ct 7\'j 8rj 90 1t~JO 1113 120

'teration

Page431 CTO9101 CM121

Proper inner loop stopping criteria are critical for effective transient simulations.
© Advancing too early (before convergence) compounds system error.
® Advancing too late wastes solver time after the time state js converged.

r-----.\E-

60 BCJ lt:ic) 12rj 140

lte,atlon

Page432 CTO9101 CM121

Advancing an unconverged state introduces error; advancing additional
unconverged states compounds that error.

10 15 2rj Z'5 3lJ 35 4Ci 45

ltel.atlon

Minimum I`nn.er [terations criterion: p ii stoppingcr,teri&

® forces the solver to perform
a set number of iterations.
a helps prevent advancing
from an unconverged solution.

I .) ,-,, A--

Page433 CTO9101 CM121

E mpl Ad g tnt it M

Tolerances set too conservatively can prevent a stable solution from

advancing.

Maximum Inner lterations criterion:

© advances solver after a set
number of iterations.
© preventsthesolverfrom , E± Maxlmum Steps
h Minimum liner lterations
E± 5topF,,E
iterating indefinitely. a Solution Hist®ries

Page434 CTO9101_CM12_1
The solver outer loop advancement interval is determined by Time-Step.
© Time-step should be chosen to resolve flow phenomena and maintain stability.
a Courant Number is a measure of how far the fluid travels in one time-step.
a For time accurate simulations (and all Explicit simulations), choose time-step to
maintain Courant number below 1.0 for all cells, passing no more than one cell
length per tjmestep.

ve,oc,ty)A£¥step
size

Courant number = ®

A%\ L ttA£
characteristic
cell length

LAx-
Page435 CTO9101 CM121

An incorrectly chosen time step can change a motion or flow structure.

Too large a time step can miss transient phenomena.

Top view: Timestep yielding goo rotation Top view: Timestep yielding 2° rotation

Solution Time 0.125 (s) Solution Time 0.00277778 (s}

Page436 CTO9101 CM121

c t1,g , pg SM

The solver's progression can be controlled to prevent instability.

Can be useful when:

a Don't know enough about the solution to formulate good initial conditions.
® Range of variation of parameter value in domain is large or will have abrupt
changes and large gradients (shocks, high temperature areas, etc.).
© Modeling motion or other transient behavior.

Page437 CTO9101 CM121

The segregated solver uses under-relaxation factors (URFs) to control the solver
progression at each iterati'on.

When a new solution is calculated, it can be blended with the previous solution to
yield a more conservative answer.
© URF = 1 uses the new solution only.
© URF = 0.5 uses 50% each of the previous and current solutions..

A correct choice of URF is essential for effective simulations.

© A URF that is too large may lead to oscillatory or divergent solutions.
® A URF that is too small causes slow convergence.
t a Solver5

Page438 CTO9101 CM121

The coupled solver uses a pseudo-time marching approach to drive the solution
to convergence.
© The Courant Number specified on the Coupled Implicit Solver is used to
determine a local pseudo-time-step per iteration in each cell.
© Higher Courant Number produces faster convergence, but too high a value can
lead to solver instability.

•h= F=_=====
- jB Soivers
Coupled froplleit , Properties X

/"±.\ tg REhiB she

k,End
g.; a Egivmifebm
f a Schr5ontha
€, 5B Gomnergivee Acoe)erode

Page439 CTO9101 CM121

Initial conditions should be your best guess at

the final solution. Uniform _ "=-~.:i,T= .-...- ==, I
a Reduces the amount of change required to lnitialization===-.=~_===`.~=
_=-. _--_ -.-.-
get to the final solution.
a Improving the initial solution will reduce
computational time.
=f==:==:¥
•-I_-I A-
© Some solvers have advanced initialization
options to provide a better initial guess:
® Segregated: Continuity lnitialization. r==i=-==JJ±='=

® Coupled: Grid Sequencing lnitialization. Gridsequencing-===_==T=-=j

lni+iali7a+inn
lnitialization ~7L--~-I,-i_~=-=
_~i-a i:=--==
© Turbulence: Boundary Layer lnitialization. -.___I.I-i.;===:t--==

Initialize the solution before running to

-_'-~ -
check and verify values.

Page440 CTO9101 CM121

Improper values may cause solver instabilities in the first few iterations.
a Solver may not be able to converge to the correct solution from a very poor
initial distribution (example: initially reversed flow in a compressor).
® Boundary values very different from the initial flow field create abrupt gradients
near the boundary (applied across one cell by definition).
a Modify initial conditions to be closer to final solution.
© Gradual application of boundary condition (ramping) can allow simulation to

:-,ngREdiit-
Page441 CTO9101 CM121

User Field Functions are user-defined algebraic expressions that exist

throughout the simulation domain. They can be used to:
® Apply non-constant profiles for initialization parameters.
a Useful for known areas of large change -shocks, free surfaces.
a Speed up development of flow features - boundary layer.
© Ramp boundary values over iterations/time.
© Initially set boundary value similar to the local flow field.
a Change the value slow enough to maintain solver stability.

Page442 CTO9101 CM121

Sometimes the change from jteration to iteration (or iterative error) in the
simulation does not decrease but grows larger and larger.

If this error continues to grow, the simulation can become unstable and diverge.
© Irregular, increasing residuals signal the solution is diverging.
© When this happens STAR-CCM+ will output an error message and stop.

Residuals

io 2cl 3o 4ci 50 6{t 7o 8ci 9rj loo iio

lteration

Page443 CTO9101 CM121

Divergence is typically caused by improper model

setup. E 8aL=e±m€Puri
qu iB Ceom€tr.t

© Poor spatial/temporal resolution. § a Continua

® Improper/mismatched physics settings. I Pan5Mesh€g

ch . froon
a Solver settings. g , war er
tr a frodrfe
giv a Rereren€evalue§

Setting appropriate values also improves initial rT===icondit{Sme

S iE Ffuld
iteration and speed of convergence. giv i 8§undanes
fty ii Feattlr€ Curves
de a Chr¢sj€s €ondition5
qu iii ftysitsvatues
giv I Heatsthk
giv . ffl
tr a intofac€5
)pr ii| Dgived fty5
¥ ii 9®iver=

ft Wall B`istance
a-+#^ S€gregmed Flow
dr `fr Segregated Energy
th ¢ rL-Epsilon Turt)ul€nc€

# *`-Epgilon Ttjrt}Lilent v'isfosrtv

th j@ 5t®ppifig crfuena

Page444 CTO9101 CM121

Monitor plots of solution quantities can help detect divergent behavior.
a lf solution quantities start to go far out of range the simulation should be
stopped and investigated.
® Example: lf freestream velocity in a simulation is 50 in/s, a maximum velocity in
the domain of 200 in/s may indicate a diverging solution.

Activate Retain Temporary Storage for the solvers to gain access to additional
terms computed during update.
a Residual field functions, Ap Coefficients, Corrections, Reconstruction
Gradients, Gradients.
a Can be used to locate sources of errors.

Page445 CTO9101 CM121

D g L tg SM S

Diagnosing the cause of divergence usually requires locating the source.

Use Threshold derived parts to visualize areas of interest.

® Create a threshold of the diverging quantity above/below a physical value
® View the threshold in a scene to visually locate where divergence is occurring.
® Scalar quantities can also be displayed on the threshold part for further
investigation.

Cc)nvective Courarlt Number

GOO.13 2027.8 3455.S 4883.2 6310.9 7738.6
.'=___________

11`

Page446 CTO9101_CM12_1
Mesh quality affects the accuracy of cell-to-cell fluxes and solver stability.

Page447 CTO9101 CM121

Mesh metrics are available as scalar functions for thresholds, reports, and
scenes.

gej{ •`1*.S;

Ratio of the volume of a cell to that of Correctness of the face normal

its [a[ge§± neighbor. A value of 1.0 relative to cell centroid. Good cells
indicates a volume equal to or higher have face normals that point outward.
than the adjacent cells. ,Good Bad Low values indicate concave or
negative volume cells.
t' \ _ , I1\--riI````+,~+:I1``I,,

` ``` ,,`-`-Good Bad

Recommended limit > 0.01 Recommended = 1

Page448 CTO9101 CM121

Mesh metrics are available as scalar functions for thresholds, reports, and
scenes.

Cell Qualify SkewnessAngle

Function of the distribution of the cell Angle between the face normal vector
centroids and orientation of the cell and the vector connecting the two cell
faces. Flat cells with highly non- centroids. An angle of 00 means
orthogonal faces have low Cell perfectly orthogonal.CentroidO
Quality. `.I \ ,u.GoodBad

Face
dg

Centroid 1

Recommended limit > 1e-5 Recommended limit < 85 degrees

Page449 CTO9101 CM121

Plotting mesh metrics helps identify where the mesh should be improved.

a-8 1.0

I_ ___

Page450 CTO9101 CM121

Available options for improving mesh quality for the
Surface remesher:
Minimum Face Qualify
© Requires surface remesher to spend more time p Properties
{Perform Curvature Refinement

Perform proximity Refinement I

optimizing the face quality of the surface mesh. Perform compatibilit`/ Refinement L|
© Increasing from default of 0.05 can improve volume S Expert

mesh as well.

Page451 CTO9101 CM121

? a rtl€shers
Available options for improving mesh quality for the • SurfaceRfmesher t

Polyhedral mesher: • gQur€drapHes~h€~r ±

Optimizer cycles/threshold
® Increase the optimization cycles and quality threshold f Expert
Field Furic{ion Refinfm€m Table None +
to improve the polyhedral mesh quality.
® This can greatly increase the time to generate the
Optimization cr/cl8s 3

volume mesh. Quality Threshold 0,4

Page452 CTO9101 CM121

 Effective simulations
run efficiently to convergence and produce the desired fidelity and accuracy.

)
how the solution is reached

Page453 CTO9101 CM121

Mesh resolution must be capable of resolving the flow gradients.

Flow solution gradients peak near surfaces, physical obstructions, sources, and
flow structures.
Resolving these gradients makes a solution accurate.

•<^. `i..

Page454 CTO9101 CM121

Reduce cell size in gradient areas + Adds accuracy by solving more points in
Space.

Make mesh size changes gradual + improves solver stability and convergence.

¥___i_
Page455 CTO9101_CM12_1
E

Distribute cells to areas of interest with custom controls.

® Improves solution detail'while minimizing effect on mesh count.
a Requires knowledge of the solution -can start with coarse mesh, then modify
based on solution.

Page456 CTO9101_CM12_1
 All viscous fluid flows have large gradients in velocity, temperature, etc. near
walls, called boundary layers.

Boundary layers can be laminar or turbulent depending on ratio of inertial to

viscous forces (i.e. Reynolds Number).
BOTH regimes require mesh near walls to resolve gradients.

I
I-i)
r,//,///////////////,////,/,,//„//`
/,,/////,,///////////,
Laminar boundary Turbulent boundary
layer layer

Page457 CTO9101 CM121

Turbulent boundary layers require additional considerations when meshing.

Turbulent boundary layers have a common non-dimensionalized mean

velocity (u+) vs. wall distance (y+) profile.
a ln the viscous sublayer
(nearest the wall) the velocity
is reasonably approximated
as linear with y+.
a ln log-law layer (fully turbulent),
velocity is proportional to the
logarithm of y+.
® In between (buffer layer)
approximating is more difficult.

=-
y+=5 y+=sO

5Lscous suftyeFr i : =birfer layerF! = IogJaw layer "

yt a Sun

=-;=
f

mrrer regron ; oLrfergiv

` Page458 CTO9101 CM121

The near-wall region should be fully resolved or left to wall functions.

lf Wall Y+ < 5, the near-wall region is lf Wall Y+ > 30, the single near-wall cell
resolved enough to model explicitly. has an assumed velocity profile
Low y+ Wall Treatment is appropriate - 8- determined by wall functions.
30+ prism layers typical. High y+ Wall Treatment is appropriate -2-
4 prism layers typical.

IImEE
Page459
Wall Y+ values between 5 and 30 are not recommended.

CTO9101 CM121

For general turbulent flow simulations mesh requires:

Appropriate near-wall Y+.

Total thickness that covers the entire boundary layer.

Stretching ratios below ~1.5.

Boundary layers will be properly solved.

Page460 CTO9101_CM12_1
Ensure boundary conditions and values accurately represent the problem
statement.
© Boundary values are imposed on the cell face.
© If incorrect values are applied the wrong problem is being solved.
® Example: Wrong boundary type or value is applied for inlets/outlets.

Page461 CTO9101 CM121

Inflow / outflow boundaries placed too close to areas of high flow gradients may
result in improper modeling of the physical problem.

Example: Outlet boundary location for flow past a backward-facing step.

< 3L, recirculation region, not purely an outlet.
3L - 10L, structures still washing out, possibility of recirculation.
> 10L, relatively uniform flow, good location for outlet.

Page462 CTO9101 CM121

Reference values should accurately represent problem conditions.
© All specified pressures in STAR-CCM+ are in gauge pressure relative to
Reference Pressure set in the Continuum.
® Gravity vector must be set in the correct direction if Gravity model is active.
© Reference Density is used for hydrostatic calculations at boundaries.
Example: Stagnation inlet, static pressure, different reference densities.

Reference Density -997 kg/m^3 (water) Reference Density -1.18 kg/m^3 (air at 25 C)
Total Pressure - 0 Pa Total Pressure - 0 Pa
Page463 CTO9101 CM121

Achieving convergence is a necessary outcome of an effective simulation.

However, for a simulation 'to be truly effective, it must be the ideal balance of:

Fldellfy Stablllfy Speed

This balance will change depending on the simulation goals.

Page464 CTO9101 CM121

What characteristic of the numerical method introduces the concept of
convergence?

How can convergence be determined?

What model details should be inspected before running to verify the model will
produce the desired solution and accuracy?

Page465 CTO9101 CM121

Page466 CTO9101 CM121

This workshop explores the concepts introduced in the Effective Simulation
discussion.

A simulation of a rocket nozzle will provide the platform for refining simulation
techniques and gradient management ideas. The simulation will be set up to
converge efficiently and in a stable manner.

Page468 CTO9101_CM12_1
 Problem Statement: A rocket nozzle is operating under subsonic test
conditions. A large inlet pressure drives the flow towards the low pressure
downstream outlet.
Ambient Pressure

Ambient Pressure
__-:____--_ - ____-___-:-i

Total Pressure: I
25'000 Pa

Simulation Objective: Simulate nozzle flow at given conditions.

Design Requirement: Flow must remain subsonic (Mach < 1) in the nozzle.

Page469 CTO9101 CM121

Load the base rocket simulation.

Launch STAR-CCM+.
Load the file RocketNozzle Start.sim in
folder 10 Effectivesimulation.
Open Geometry Scene 1.

The geometry is a thin slice of fluid inside

and downstream of the nozzle. This will be
converted to a 2D surface for use with
axisymmetric assumptions.

Page470 CTO9101_CM12_1
Prepare the Rocket Nozzle geometry part for 2D meshing.
Create and execute a Badge for 2D meshing operation (Operations > New >
Mesh) for the Rocket Nozzle part.
Requires a separate face coincident with the z=O plane (already present
here).
The axis of symmetry will be defined in the physics models.
Assign Parts to Regions using the Create One Region for All Parts and
Create A Boundary for Each Part Surface options.

Page471 CTO9101 CM121

Axis

The domain includes space for the jet to expand radially and axially.
? Ei Regions
a * RocketNozzle
Assign boundary types before meshing. S Gi Boundaries
id Centerline
; Stagnation lnletto the Inlet patch.
I Defau,t
H ,n,et
Axis boundary condition to centerline. 11,,I Out,et

Pressure Outlet condition to Outlet and Sidewalls. giv 5ia

||11| Sidevralls

Feature Curves

er a Ph.¢sics Conditions
gr GE Phvslcsvalues

a Denvedparts

Page472 CTO9101 CM121

Set mesh settings and generate 2D mesh.
t a Operations
i`ff 8adg€for2D Ne5hmg

Create an Automated Mesh (2D) operation. t qfl

?
AutomatedMesh{ID}
a Me5hers
Parts: Rocket Nozzle. • PolygonalMesher
• Prism Layer[vlesher

Meshers: Polygonal, Prism Layer. i E] Defaultcontrol5

• Basesize
Base size: 0.3 in. • CADprojection
I Number of Prism Layers: 16. gr ii Target Surface 5ize
er a Minimum Surface Size
gr E] Surface Curvature
\ Prism Layer Total Thickness: 4%.
• Surface pro#imity

Execute the volume mesh. • Surface c;rovuth Rate

• Numb€rofpnsm Layers
Create a mesh scene to examine the generated • Prism Layer stretching
cr a Prism LayerTc}talThick,ness
mesh. * Gil Custom Controls

Page473 CTO9101 CM121

Discussion Point
How should the mesh be refined?

Page474 CTO9101_CM12_1
 Geometry
Create parts for volumetric controls by right-clicking the P G]
F= E 3D-CADModels
Geometry > Parts node and selecting New Shape Part. # E Parts
gr ire Jet Refinement
Cylinder (Nozzle Refinement). th fi Middle RefinE!ment
Start Coordinate: [0,0,0]. tr a Nozzle P`efinement
tr ffi.Rocket ND=zle
Radius: 0.6 in.
End Coordinate: [3,0,0].
Cylinder (Middle Refinement).
Start Coordinate: [1.6,0,0].
^ End Radius: 1.0 in.
End Coordinate: [10,0,0].
Cone (J;t Refinement).
Start Coordinate: [3,0,0].
Start Radius: 0.5.
` End Coordinate: [10,0.8,0].
End Radius: 1.0 in.

Page475 CTO9101 CM121

Add Custom Controls to further refine the nozzle, middle, r=' Gi operations
@ Badge for 2D Meshing
L=j fa Automated Mesh (2D)
jet mesh regions. i3i ii Meshers

Create a volumetric control to customize the 2D a 6ii Default Controls

=J a Custom Controls
Surface Mesher, rename to Nozzle Refinement. 3 ffi; Jot Refinement
3 a controls
`] , Part: Nozzle Refinement. • 2D Surface Mesher
Relative size: 8%. • Prism Layer Mesher
-± EE values
Copy the volumetric control, rename to Middle • Custom Size
E fr! Middle Refinement
Refinement. 3 Gi controls
Part: Middle Refinement. • 2D Surface Mesher
a Prism Layer Mesher
Relative Size: 20o/a. 5 a values
• Custom Size
Copy the volumetric control, rename to Jet a fr! Nozzle Refinement
Refinement. Ej Ei controls
• 2D Surface Mesher
i Part: Jet Refinement. • Prism Layer Mesher
= a Values
Relative Size: 12%. • Custom Size

Page476 CTO9101 CM121

Generate and examine the new mesh.

Discussion Point
How can we quantify if the mesh is valid?

Page477 CTO9101 CM121

Check mesh metrics to confirm overall mesh quality.

Create a scalar scene.
Toggle on the show All Meshes Button. i;.._¥_._E¥__E.`:.}_¥__i_. 'i _P_~.±.__E:._F#_i
Select Face validity as the scalar Field. EEEE5ERE
I Check that all cells are equal to or above the recommended values.
Repeat for Volume Change and Skewness Angle (note that the function Cell
Quality is only used in 3D).

Metric Value

Face Validity =1

Volume > 0.01

Change

Skewness <850
Angle

Page478 CTO9101 CM121

 Space
Two Dimensional was automatically selected a Axisymmetric

due to the mesh models. C} Shell Three Dlmensional

a Three Dimensional
Axisymmetric is its own 2D model, deselect a Two Dlmemsional

Two Dimensional to be able to choose it.

Deselect the Two Dimensional model.

Select the models:
Axisymmetric,
Steady,
Gas, .`
Coupled .Flow,
. Ideal Gas (Coupled Energy added
automatically),
Turbulent,
Spalart-Allmaras Turbulence.

Page479 CTO9101 CM121

Assign the gauge pressure values to the boundaries: 8 GB Res,ons

Stagnation Inlet: Total Pressure = 25000 Pa. i- X
?I
Regjor,
EE Boundaries

Pressure Outlets: Pressure = 0 Pa, 9- I Bodv' 1,Default

th B }B`§giv l^,^!\q}\givi

Ch ||11| Body i,Outlet

1 Body 1 one side

Discussion Point a- ||11| Body 1.Sidemalls

qu a Feature Curves
ls there anything challenging about these conditions? a-ii Physlcs condltions
gh a Phys)csvalues

Primary outlet
P - 0 PcL

Page480 CTO9101 CM121

 SIEMENS

Finer control is required in two areas -we need to:

a Ramp the inlet pressure to the desired boundary value.
® [nitialize the doinain pressure to different values in different areas.

User Field functions are algebraic expressions that can change value during
the simulation.
a User-definable math with scalars, vectors, higher order tensors.
a Can be derived from other quantities (velocity, pressure, etc.) or stand alone.
a Used to perform internal calculations / implement equations.

Field functions can be used for intelligent initialization and boundary conditions.

Page481 CTO9101 CM121

Use a User Field Function to define the inlet pressure

ramp.
In the first 500 iterations we slowly increase the pressure
at the inlet and take advantage of the iteration number
for the calculation.

Right-click Tools > Field Functions,

select New > Scalar.
Rename to ramplnlet.

? Properties
Function Name UsErFieldFimctiQn_1
Open the Definition editor by clicking
Type Scalir
Dimensjons Dimensionless H for more advanced editing.
Deflnition 0

Tags []

S Expen
Inverse Distarice weight I
Assembly Code
ignore Boundary valLles I

Page482 CTO9101 CM121

Expressions can be defined manually here.

Double-clicking an
existing field function in
the list adds it to the
definition box
EL

givFSJu-rT}|-
Existing field functions are chosen from here

Page483 CTO9101 CM121

Scalars are called with a single S and {curly brackets}.

S{TEfflpEraturE3}

Vectors use double S, with [brackets] added to call a single component direction.

S S [VEl oEi ty i [1 ]

x = [0]
y = [1]
z = [2]

Page484 CTO9101_CM12_1
System Functions

Trigonometric Eni3{TffiTVTITo+cTtT#)I

Vector operations F¥_Tej:ofj¥='

;ros§(SS{FiT6irATFTe-} SS{Relativevelocity})

Exponentia`l

Symmetric Tensor Operations

Page485 CTO9101_CM12_1

The boundary pressure will be defined as a function of iteration.

Define ramplnlet: 5000+(S{lteration}*40).

iiHi_ii;-i`=ti.mr___`_ __y_ y_ -_.. _

_-eT=e_|=. _`_.______I

FEa=Fai:-_a=;=c:J=TgTafr,,-ai,-ie-atE,i;-i:::vee:,s::::iir==fe-
i
i
lntemalwall Heat Flux cci
Internal wall Heat Flux co
ln{ernalwallHea!Flux.. Potuer/Leng`nA2-Te
lntermlwallHeatFlux Powcer/Lerigth^\2-Te
EEEEEi
I,I,I. xl `,`1

___i,l±T_ This function increases as

S{lteration} increases.
H1=±=~E±:i

Page486 CTO9101_CM12_1
 SIEMENS

The ramp can be bounded with a conditional statement.

Enter the conditional statement:

If condition is true, Else, use

Condition
use this value this value

|S{Iteration} < 500? 5000+{S{Iterai:ion}W

Examine the function in the

Preview tab.
Enter [0,`2000] for Range.

The function is now constant

after reaching 25,000 Pa.

Page487 CTO9101_CM12_1

Assign the field function ramplnlet to the Inlet boundary.

Change the Inlet Physics Value Total Pressure Method to Field Function.
9 5i Peg,ons
a , Peg,on
9 ii Boundaj-i.S
> - Body I t)cfau[T

P H Bodyllri{et
a-ii my!Ics C.rtdrlior3!

g lil Ph,`sicsvalucs

fr Sup!r3Dntc 5latit Preg5ure

•#i:iia(&~.ng,!iei
# Total remperature
fr Turbulence intensny
S Turt)utem VIScosrl/ Patia

Select ramplnlet for the Scalar Function.

Page488 CTO9101_CM12_1
 SIEMENS

The initial pressure is defined as a function of space.

® SS{Centroid} returns the location of each cell center.
® Recall: [0] = x, [1] = y, [2] = z.
a For values of the centroid X-component below 1.58, Pressure will be 5000 Pa;
above 1.58, 0 Pa (relative to atmospheric).

Centroidpr] (in)
0.0000 1.9200 3.8400 5.7600 7.6800 9.6000

Page489 CTO9101 CM121

Create a new scalar field function.

Rename to initialpressllre.
' Definition: |SS{Centroid}[o] < 1 555@TIT1 p a Continua
E PartsMeshes

9 ® Phy5i[Sl
dr i Models
a-a Referencevalue5

p a Initial conditlons
• ifeedha;
Assign the field function to the continuum's initial • StaticTemperatur€
• Turbulence Intensity
conditions. • Turbulence specificatlDn
t Change the Initial Conditions for Pressure Method • Turbulent velocity scale
• Tiirbulent viscosity Ratio

to Field Function. Veloclty

Select initialpressure for the Scalar Function.

S F.ropertiE5
!Method Field Function T

5talar Function
: D i in i 11 S i a n ± Fi r ,= L= L" r t

Page490 CTO9101 CM121

 SIEMENS

lnitialize the solution and check the results.

Initialize the solution.E A # fiB
The field values for initialpressure and Pressure should match.

Initialpressure
0.0000 1000.0 2000.0 3000.0 4000.0 5000.0

Page491 CTO9101 CM121

We will use a Courant Number Ramp to ensure =- ii Sots

fa^ paretry
stability during startup and efficiency in convergence. fx wtli-
`=`,z fr EEnEE±
\S.'} ji CoLrmtNfwher RErrty

Set appropriate solver settings: f ife` AraL~sofrog

` Select the Coupled Implicit solver and set the • iijB

Expert beifeto
-Err
il Corvengerce Accelerators
Courant Number to 10. SpalartTAlmrmsTirddence
Sp3far{-Afroaras TLrfetdent \ifecoENr
Activate a Courant Number ramp by choosing Linear
Ramp under Coupled Implicit > Courant Number
Ramp'
•S' a Sotwers
ln the Linear Ramp, set the Start lteration to 250, ft partltry
the End lteration to 500, and the Initial Value to tx wd.eb-
:=1 fr C-"
5.0.
.H-
i;.' a CcorantNilthier Race

*j ife usLnear fro

iB Egrt fuifefty
ii Schjtrm orrur
a Gomurgerue Acicelerabe
a, ,A~ Spalart~Amarasnirtiirfence:
A SpalartAhara6 TrfeLfent veeraty

Page492 CTO9101 CM121

 SIEMENS

For monitoring convergence, we will look at the inlet mass flow rate in the nozzle
and overall mass imbalance on all inlets/outlets.

Create separate Mass Flow reports for these parts:

Inlet boundary.
Inlet, Sidewalls, and Outlet boundaries combined.
Rename the reports to Inlet Mass Flow and Mass Imbalance, respectively.
Create monitors and a plot for the two reports (single plot for both).
I Rename that plot Mass Flow.

For a conveTg.ed solution, we expect the mass imbalance to converge to nearly

zero, since it measures the overall flow in and out of the domain.

The inlet mass flow should converge to a stable, asymptotic value.

Page493 CTO9101 CM121

Confirm that velocity does not exceed the Speed of Sound on the centerline. To
do so, create an XY Plot Of the centerline Mach Number.

' Create a new XY Plot and choose the Centerline boundary for the Part.
. Change the X Type to Scalar and select Centroid[X] for the scalar value.
\ Choose Mach Number (in the Laboratory Frame) for the Scalar Function
under Y Type > Y Type 1.
Under Axes > Left Axis, set the Maximum to 1.0.

Optional:
Change the Plot Title to Centerline Mach Number and the Bottom Axis Title to
Axial Position, the Left Axis Title is already Mach Number. I

Page494 CTO9101 CM121

 SIEMENS

Prepare a scene, then run and observe the developing velocity.

Create a Scalar Scene with Velocity: Magnitude as the scalar field.

Check that the Maximum Steps stopping criterion is active and set to 1000.
Save simulation.
Click the Run button and let simulation run to 1000 iterations.
Save a copy of the simulation for later comparison of results.

Questions
® Has the simulation reached convergence?
a \/Vhat is the .maximum Mach number on the centerline?

Page495 CTO9101 CM121

Velocity: Magnitude {m/a)

LOB.89 L6¢ 84

i:REillRE_

Page496 CTO9101 CM121

 SIEMENS

Change the Maximum Steps stopping criteria to 2500.

Run the simulation.
Mach Number on Rocket Centerline

a Rocket Nozzle: Conterllne

Question
a Was the model converged at 1000 iterations? If not, what has changed?
® Did we achieve the design requirement of maintaining subsonic flow in the
nozzle (Mach < 1.0)?

Pule497 CTO9101 CM121

In this workshop, you have:

a Generated and inspected a 2D mesh.
® Created user field functions for non-constant initial and boundary conditions.
a Set appropriate solver settings.
a Created post-processing for verifying proper model setup, determining
convergence, and investigating simulation results.

Page498 CTO9101 CM121

 SIEMENS

What can be used to apply non-constant profiles?

What are the general characteristics of good quality cells?

What could be used in this case as an intelligent stopping criterion to ensure

convergence?

Page499 CTO9101 CM121

Page500 CTO9101 CM121

Determining what to model for an effective simulation.

Page502 CTO9101 CM121

 SIEMENS

What geometry and domain are necessary to simulate?

The domain \should include all areas that affect regions of interest
~tf3fjj/Ffrfff.»gyssgr_fu,-Zj4:::iarff$5K3if:aror§sef?;ffffi:§se;{:s/if!£esi±sffi::/f]f8::::fgi;::I_~_rsIfi:±!s#f:/!¢r!r:fi_srw_iJJSSK^:±aeii§:psRTr^fRE_J!3r:isf»ENffREr=_.___

Page504 CTO9101 CM121

Unneeded fidelity should be excluded.
® Reduce mesh -> reduce time, memory requirements.
© Refine mesh -> selectively use more cells in regions of high gradients.
© Reduce physics/solver requirements -> redirce time, compute power.

Page505 CTO9101 CM121

Flow boundaries should not intersect strong flow phenomena.

a Boundary Conditions impose values and gradients in the flow field.
a They must be accurate to the local solution.
a Example: Boundaries interfere with local flow structures in ship wake.

Page506 CTO9101 CM121

When the locations of flow structures or important influences are unknown,
© make an educated guess to size the domain.
a run the simulation to verify the locations of flow structures.
a modify boundary locations if they interfere with the solution.

Page507 CTO9101 CM121

Remove geometric details not required by the simulation objectives.

a Manufacturing CAD ha's all geometric details, clearances and tolerances.
a CFD geometry can be simplified by removing fillets/chamfers, holes, small '
details, etc.

Page508 CTO9101_CM12_1
 SIEMENS

Consider modeling complex details instead of meshing intricate geometry.

a Represent small surface details with surface roughness.
© Use porous media or porous baffles for flow restrictions.
® Use fan interfaces instead of full fan geometry.

Full Geometry Fan Interface

Page509 CTO9101 CM121

Omit physics models that aren't

expected to influence simulation
objectives.

Make simplifying assumptions

where possible. IIus*T i;REill
a Moving reference frame vs. rigid
body motion.
© Constant density vs. ideal gas.
a 2D vs. 3D.

Example: Complex chemical reactions

(DARS) vs. simplified reaction
mechanism (FGM).

Page510 CTO9101 CM121

 SIEMENS

Reduce the geometry or use a simple representative geometry.

Use a simple example to validate the settings, i.e. radiation in a box.

Test advanced physics models incrementally.

Passive Scalar

Page511 CTO9101 CM121

lncrementally build up the physics models.

® Run steady state before'changing to transient.
a Run single phase, then add in particle phase.
© Run stationary, then change to MRF or RBM.

Page512 CTO9101_CM12_1
STAR-CCM+ offers multiple methods for simplifying, repeating, and automating
processes.
® Leveraging existing .sim files.
® Custom Simulation Trees.
® Java macros.
© Simulation Assistant.
© Design Manager.

Page513 CTO9101 CM121

Parts based meshing allows users to build and manipulate complex, automated
workflows to prepare and hiesh any input model.
g ii Geometry
Ei
ch ii Parts
3D-CAD Models
a Add operations to create a pipeline.
oL ii Descrlpt!ons
a Operations can be reordered.
6ii Contacts

a Individual operations or entire pipeline

5i Continua
dr ii| Regions
Cii Denved Flarts
executed on demand.
I____.___._____

:t:i::i:n:g:::rEL

Objects and/or properties can be copied and pasted across sim files.

Files can be opened in versions newer than in which they are saved.

Page514 CTO9101 CM121

Create smaller simulation trees by: a a poraitEtErs
'L'f gas.Sjfe

a Drag and drop, T` Botfro cp

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Page515 CTO9101 CM121

STAR-CCM+ permits scripting through the use of Java macros.

Macros can:
a Automate routine tasks to increase speed and reliability of workflows
© Run complex tasks and simulations in batch mode.
® Be recorded interactively using the build tools in theToolbar: + ®

The Java API Documentation lists available classes and methods and is
accessed from the Help menu:

Page516 CTO9101 CM121

Guides users through a STAR-CCM+ setup workflow
without using the simulation tree.
© Simple way of scripting simulation tasks without a high
level of Java knowledge.
® Tasks are executed by selecting the links in the panel.
© Explanations and instructions can be included as text.
® Writers choose what is included and the complexity.

The Simulation Assistant appears in a frame on the right

hand side of the STAR-CCM+ window.

A NetBeans plugin is available for coding assistance.

Page517 CTO9101 CM121

What must be determined in order to properly plan a simulation setup?

List some benefits of making simplifying assumptions to geometry or physics.

Give an example of how a model can be built up from simple to complex.

What are some tools available to automate simulation processes?

Page518 CTO9101 CM121

This workshop provides a place for you to
apply the concepts learned in the other
workshops.

We will switch roles as follows:

Attendees: You are technical support
engineers.

Instructor: I am a customer using STAR-

CCM+. I work at BetterDesignsFaster Aero
Systems, in the ECS (Environmental
Controls System) group. My job is to design
the bleed air distribution system for a large
commercial aircraft.

Page520 CTO9101 CM121

Page521 CTO9101_CM12_1

TO: SIEMENS PLM SUPPORT CENTER

FROM: BDF AERO SYSTEMS
DATE: JUNE 28 2017
SUBJECT: STATIC MIXER SIMULATION

Overview
I am customer using STAR-CCM+. I work at BetterDesignsFaster Aero Systems, in the ECS
(Environmental Controls System) group. My job is to design the bleed air distribution system for a large
commercial aircraft. A summary of the system is shown in the figure:

A; Cool Air Inlet

Simulation Objectives 0.5 kg/9
400K
Predict average temperature difference
8: Hot AIr Inlet
between the outlets. 0.3 kg/s
600K
Required: < 15 K.
C: Static Mixer
No rofaton
Predict maximum temperature variation D: To all condltlonlng system
Ambient Pressure
on each outlet.
Required: < 80 K across an outlet. , E: To lee protection system
0.3 kg/s

Page522 CTO9101_CM12_1
Model Issue Summary
I setup and ran the analysis of the static mixer in STAR-COM+. After some initial problems with model
divergence, I was able to obtain a converged solution. I followed your wall y+ recommendations,
avoiding the 5 < y+ < 30 area. I found that I needed to use the "Enable Enhanced Stability Treatment"
under the Segregated Flow Solver or the code was highly unstable.
The results of the simulation and the final product physical tests are in the table:

Metric STAR-CCM+ Physical Test

Difference in Avg Outlet Temperature 12K 20K

Max Outlet Temp Variation 60K 100K

The product was sent to production because the simulation results met the design specifications, The
system failed.in the final validation test, as outlined in the above table.
Can you help me -understand why the CFD predicted results were largely different than the physical
validation test?
My file StaticMixer_Finalsolution.sim is provided in the folder 12_StaticMixer.

Kind regards,

BDF AERO

Page523 CTO9101_CM12_1

What portions of the customer's description of the problem might indicate a

problem?

_. What will you check first when you open the sim file?

Design a test plan of items you will check in the simulation to diagnose errors.
How will you assess the quality and suitability of the mesh?

Are the chosen physics models and boundary conditions appropriate?

Are any additional post-processing objects needed to analyze the data? lf

so, what is missing?

Page524 CTO9101_CM12_1
You are a CFD analysts at BDF Motors (BetterDesignsFaster Motors). For the
new model engine, you need to determine the solid temperature distribution of
the exhaust manifold shown here to ensure the design meets our required
specifications.

Simulation Obiectives:
Predict the flow and thermal performance of the exhaust manifold at the
given design point.

Page526 CTO9101_CM12_1
 Runner 1
Mass Flow Rate = 0 05 kg/s
Tc)tat Temperature = 514 5 C
Turbulence Intensity = 10%
Turbulent Viscosity Ratio = 10

Outlet
Absolute Pressure = 1 atm
Static Temperature = 400 C

External Surfaces
Static Temperature = 75 C
Convective Heat Transfer Coefficient = 50 W/m2~K

Mass Flow Rate per Inlet = 0 001 kg/s

. Total Temperature = 500 C
` Turbulencelntensity= 1%
.Turbulent Viscosity Ratio = 10

Static temperature at all inlets is 500 C.

Our structural analysis team has set the following manifold requirements:
Material: UNSG 101000 (Carbon Steel) and Air.
Maximum Temperature in solid must remain below 420 °C.

Page527 CTO9101 CM121

What geometry is included in the CAD file (in folder 14_ExhaustManifold)?

Do you need to generate additional geometry in STAR-CCM+?

\ What would be a good base mesh size?

How many prism layers should be used, and where?

Given the operating conditions provided, is a steady or transient anal :JIf.

suitable?

I Which engineering values should be monjtore

How will you determine convergence?

Which scenes should be created to visu\alize t

re inc.
Page528 CTO9101 CM121
Run the simulation in STAR-CCM+.

Once the model has finished running, review the design requirements. Have we
achieved our objectives?

Which simplifying assumptions regarding the physics have been made? How do
these affect the accuracy of the predictions?

Page529 CTO9101 CM121

After you've run the baseline simulation, assess the design to determine if
the design requirements have been met. If they have not, here are some
ideas for modifications that might improve performance:

a Add a thermal coating resistance to the model by adding a Contact Resistance

at the gas-solid interface.
a Increase the convective cooling by increasing the Convective Heat Transfer
Coefficient at the exterior wall.
a Change the solid material to another.

Page530 CTO9101 CM121

Where do you look for information about a function or feature in a software
package?

How do you get help when you aren't able to solve a simulation issue on your
own?

Page532 CTO9101_CM12_1
The documentation can be accessed in three locations:

In the STAR-CCM+ GUI Help drop-down menu,

ln the STAR-CCM+ installation directory,

Online from the Steve Portal.

The Steve Portal SIEMENS

HEEDS ,

Page533 CTO9101_CM12_1

Context sensitive help is available using the Fl key.

Example: for help on Stopping Criteria,
a Select the Stopping Criteria node,
a Press the Fl key.

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Page534 CTO9101_CM12_1
 SIEMENS

Targeted tutorials for specific functions and applications.

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Start files and/or input files are located:

a in the installation directory, doc > startutorialsdata,
a on the Steve Portal, Products > Downloads > Related Files and
Documentation.

Page535 CTO9101_CM12_1

The online support console for STAR-CCM+ and HEEDS.

The Steve Portal

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Page536 CTO9101_CM12_1
DSE: Dedicated Support Engineer
Your contact for technical assistance with the software such as:
a modeling processes and procedures,
© software features and capabilities,
© simulation issues.

Account Executive
Your contact for business assistance such as:
a license upgrades, server migration & renewal,
a product a`nd training quotes,
a account plahning,
S help achieve simulation goals quickly and effectively,
a on-site support and services,
• burst capacity.

Page537 CTO9101 CM121

Search fry sLiqeEL ease nLJmter or desengiven a OPEN CASES I ClosED l=ASES

Lri ul

Currently open
support cases

hiul
E] rty Group'8 Cases

Page538 CTO9101 CM121

 SIEMENS

a Search ire Knot,ledge Bast. Dormmer`tatiDnL anal ldeastQmi

Search keywords for articles from all article types.

Search also returns documentation and ldeastorm entries.

Additional filters are available to narrow down the results list.

Page539 CTO9101 CM121

Article types include:

FAQ -a question with a detailed answer,
Example -simulation file and instructions that demonstrate a feature or function,
Best Practice -details of application best practices,
Video -video demonstration of performing a task in STAR-CCM+.

Video library can be searched separately.

Knededge Base

8Barch the Knowledge E!ase, Dc}eximentation, and ldeas{orm

video Library

Page540 CTO9101_CM12_1
General information about STAR-CCM+ and HEEDS.
Software downloads. products The

Power on Demand license management.

Page541 CTO9101 CM121

User forum for submitting, discussing and voting on software enhancements.

The steve portal ldeavs;f:;Qiwr;i ap S]EMENS

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Page542 CTO9101 CM121

 SIEMENS

Calendar of currently scheduled training sessions.

Register for and purchase classroom or web-based training.

Access the training calendar outside of STAR Academy

httDs://cd-adaDco.Iearninacart.com/custom/Cataloa.aspx

Page543 CTO9101_CM12_1

Apply for Certified STAR User status.

The Steve Portal SIEMENS

CERTIFIED STAR USER PROGRAM

B®como a Certified user ol STAR-CCM+I

Reacl below to learn how you can begin your path toward demonstrating competency as an advanced STAR-COM+ user who solves advanced multLphysk;s simulationsl

WllAT IS THE CERTIFIED STAR USER PROGRAM?

The Certifiecl SIAR User program is a system in whieh S1-AR-COM+® users can demonstrate knowledge and skill usmg the soft\^rare for conducting advanced mul{lphysics
slmu)atlons. The program is provided as a volunrary. no-cost serv(ce to current users of the Slemens PLM Software product STAR.CCM+. users who elect to pamc`ipate

ancl whose competency can be adequately demonstrated lhrough clooumentable evidence wlll recelve an assessment-based certificate that confirms (he users
demonstrated level of competency as judged by exanis and/or evaliiations developed by Slemens PLM Sotware's Sl-AR-COM+ Tralning Advisory Group. Competency
levels lncliide Blue (beginner), Bronze (lmermedlate I)` Silver (intermedlate 11), Gold (advanced), and Platlnum (expert),

Page544 CTO9101 CM121

Select New Case.
Fill out the form and select Next.
Review the suggested Knowledge Base articles and Documentation.
Scroll to the bottom and select No, thanks, submit a case.
riew Case for your DSE

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Page545 CTO9101 CM121

lf you need to contact your DSE, whether through the Steve Portal, phone or e-
mail, providing good information will expedite the process.

Before asking for help:

Search the User Guide and Knowledge Base for information.
Work through a tutorial case to learn setup processes.

Page546 CTO9101 CM121

What information should you provide to your DSE?
Background/description of the simulation.

What is the issue you are having -clearly state the question.

What are you trying to accomplish in the simulation.

Urgency of the issue.

Any information that will help the DSE diagnose the issue:
a things you h.ave tried and the outcomes,
® software version,
a operating system,
a log files,
a User Guide > Using STAR-CCM+ > Getting Support.

Page547 CTO9101_CM12_1

Where is the STAR-CCM+ user guide located?

What is available on the Steve Portal?

Page548 CTO9101_CM12_1
 SIEMENS
laXz*.-rl7 {'. L;{z
\-

t
I

SIEMENS
Coldplate workflow workshop - review questions
Was the desiqn objective achieved?
No, temperature is too high.

Studv the Maximum Temperature plot and Wall Temperature scene. Describe below what
you think has happened phvsically in this model.
. Maximum temperature converges as the solution reaches a steady state value.
' Wall temperature varies because the fluid is heating up as the water flows through the
pipe and because the heat transfer coefficient varies as the water travels through the
turns in the pipe.

At the beqinnino of the simulation. what is the wall temperature associated with a heat flux
of 30.000 Wmn2? Where in the simulation can this information be found?
The initial condition makes the wall temperature constant at the beginning of the simulation
and is independent of the boundary condition.

Page550 CT09101_Cl\i112_1
 SIEMENS

\Mat are some wavs in which accuracv for this simulation could be assesed?
' Do a grid dependency study.
. Check the length of the pipe and do a simple hand calculation to make sure that energy
balance is correct.
. Check residuals.
. Check convergence history of the maximum temperature.

How could this simulation be made more realistic?

. Conjugate heat transfer with the heat sink and the chip.
' lncrease mesh resolution.
. Model more of the pipe where the fluid comes from and goes to.

Page551 CT091o1_Clvl12_1

i
SIEMENS
Geometry workshop - discussion points

U/hat is causinq the pierced faces? The pierced faces occur where the two parts touch -
minor intersections.

Are any other contacts required? Yes, Contacts are required between all of the parts that
will be meshed.

Page552 CT09101_CM12_1
 SIEMENS
Geometry workshop - review questions
What operation was used to fix pierced faces?
Imprint. Pierced faces are commonly caused by separate parts touching or intersecting
each other. The lmprint operation aligns surfaces that are supposed to touch, eliminating
those pierced faces.

What steps were completed before the fluid volume could be extracted?
Before extracting the volume the holes needed to be filled, and curves needed to be split to
be used as inputs for the fill holes operation. Alternatively surfaces could have been split
for the flll holes operation.

Why are contacts important?

Contacts define connectivity between parts, are used to create interfaces when parts are
sent to regions, and are one of the things that determines mesh conformality.

Page 553 CT09101 Cl\412 1

SIEMENS

When should qeometry be imported into 3D-CAD?

Geometry should be imported to 3D-CAD only if CAD level manipulations (not achievable
with operations) are required.

What tvpes of tessellation issues can be addressed in Surface Repair?

Surface repair can be used to control vertjces, edges, and faces, through tools such as
delete, fill, zip, collapse, imprint, intersect, offset (etc.), to fix pierced faces, free edges,
non-manifold edges and vertices (etc.).

What are the advantaoes of a pipeline of Operations for: qeometry processing compared to
other methods?
The original parts are preserved and the input parts can be changed and the steps re-
executed.

Page554 CT09101_CM'12_1
 T
n
SIEMENS
Meshing workshop - discussion points I

What is an anpropriate base size?

Selecting a base size that allows for minimal adjustments to other default parameters and
prevents the need for custom controls is recommended.

U/hy define the prism laver total thickness as an absolute value?

Prism layer total thickness should depend on the thickness of the boundary layer that is
being resolved. lf the base size is being used to scale mesh resolution - as in a mesh
sensitivity study - the prism layer thickness should not be changed as the boundary layer
thickness doesn't depend on the mesh.

Page555 CT09'l0l_CMl2_1

Meshing workshop - review questions ti EMENS

How do the surface mesh sizes influence the volume mesh sizes?
The volume mesh sizes should mirror the surface mesh sizes. Since the volume mesh is
built from the surface mesh faces, the sizes should correlate near the boundaries.

ls the mesh between reqions conformal?

Yes the mesh is conformal. We met the conditions for conformality - single mesh operation,
strong contacts, polyhedral mesher, no per-part meshing.

Which boundaries in the modeldo not have prism layer cells? Wrv?
lnlet and outlet because of their type. PL are generated only on walls,

Page556 CT09101_CM12_1
 SIEMENS
Meshing discussion - review questions
What is discretization error and how can it be measured?
the difference between the exact solution of the differential equation (mathematical model)
and the exact solution of the algebraic system of equations obtained through discretization.
Discretization error can be estimated by performing systematic mesh refinement and
comparing the solutions.

What two things must a mesh resolve in a CFD simulation?

Mesh needs to resolve geometry/geometric features and physics/physicalflow structures.

\--

Page557 CT09'1o'l_CM12_1

Meshing discussion - review questions

Name the three basic unstructured volume mesh types in STAR-CCM+ and describe an
application suited to each.
Trimmed cell, suitable for flows with a primary flow direction - external aerodynamics,
acoustics, marine.
Polyhedral cell, suitable for flows with circulation or swirl and for multi-region conformal
meshes - vortex tubes, internal flows, heat transfer.
Tetrahedral cell, not recommended unless required for comparison to legacy data.

How do I ensure conformal mesh across interfaces in STAR-CCM+?

Conformal meshes require: a single meshing operation, contacts, polyhedral cell mesher,
no per-part meshing.

\-

Page558 CT09101_Cl\i112_1
 SIEMENS
Meshing ll workshop - review questions
How are mesh sizes adiusted for specific areas onlv?
Custom controls are used to modifly the mesher behavior locally; however, we saw that
changes to the Default Controls (like the reduction in the Target Surface Size) can also
result in local refinements. The difference is that Default Controls apply globally in the
domain, while Custom Controls are only applied to their input entities.

Whv did we implement the custom Part Control for the Thin Mesher?
The Custom Part Control for the Thin Mesher was used to explicitly turn off the Thin
Mesher in areas that we did not wish the mesher to be active. The thin mesher increases
meshing time and can have undesired effects (thin-thin interfaces have no prism, mesh
quality at transitions from thin/bulk can be affected, etc.), so it is a general best practice to
explicitly tell the mesher which regions should be active for the Thin Mesher.

Page559 CT09'101_ClV112_1

t--
I SIEMENS
Meshing ll discussion - review questions !

Which custom control miqht be used to refine a portion of a sinqle part surface?
Volumetric controls are the obvious ones here, though Curve Controls could also work in
some cases.

Which surface remesher parameter should be modified on the far-field boundary (far from
the bodv of interest)?
Target size

What tools are available to refine the mesh in wakes?

Either wake refinement directly (from a surface or curve control) or volumetric controls.
Might also mention anisotropic trim mesh refinement here.

What prism laver parameter should be modified if prism layers have been retracted in an
area that was not intended?
Minimum Thickness Percentage (and possible Gap Fill or Layer Reduction) would be a
global setting, but this can be done using the total thickness, distribution, and number of
layers as well.

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Page560 CT09'101_CM12_1
Activity - mesh

Which Surface Remesher Control(s) can be modified to refine the mesh?

Most likely the current tessellation is being limited by the minimum surface size. Reducing
the minimum surface size should allow the surface curvature setting to drive the surface
sizes to be smaller. lncreasing the surface curvature may be necessary, as long as the
minimum surface size is small enough to allow it.

Which Surface Remesher Control(s) was modified to chanqe the mesh below?
Surface proximity was increased from 2 points to 10 points"

Page561 CT09'101_CM12_1

SIEMENS
Physics workshop - physics models
What is the default material for liquid? Does it fit our requirements?
Water. Yes

Does the initial static temperature make sense?

lnitial static temperature is 300 K. Yes.

What is the default material for solid? Does it fit our requirements?
Aluminium. Yes.

Does the initial static temperature need to be changed?

lnitialstatic temperature is 300 K. No.

Page562 CT09101_CM12_1
 SIEMENS
Physics workshops - review questions I
\Nhen are separate phvsics continua required?
Separate physics continua are required when different physics models need to be applied
to different regions. A single continua can be applied to more than one region if the models
are correct for each region. Multi-part solids and multiphase fluids are advanced models
not discussed here.

How can material properties be modified?

lnitial conditions are only applied to the mesh before the first iteration. Once the solver
iterates the initial conditions are no longer enforced. Boundary conditions are applied at
boundary faces and enforced throughout the entire simulation run.
Material properties can be modified by replacing materials with those found in the materials
database. Properties can also be changed individually by manual input of new values.

What determines the conditions required at a boundary?

The boundary type determines what values need to be applied at the boundary. Different
boundary types require values for different parameters - ex. Pressure, velocity, mass flow
rate, static temperature, total temperature, Mach number, etc.

Page563 CT09101_CMlr_1

SIEMENS t-
I

Data analysis workshop - discussion points

I
t

What were the simulation obiectives? Were thev achieved?

Simulation goals were to solve the steady state equilibrium temperatures in the
components. These goals were met and the temperature plots show convergence.

Recallthe design requirements. Were they met?

The engineering design goals were to keep the chip temperature below 45C. This was not
met as the chip is seeing temperatures over 47C.

Where is the temperature too hiqh?

The temperature is too high at the highest point (z-direction, furthest from the cooling
channel) and'downstream' (y-direction).

Page564 CT09101_CM12_1
av
\--
SI EM ENS
v

\/
U/hy is the hiqhest temperature located where it is?
v The high temperature is there because it is the furthest from the cooling channel (z-
direction) and the cooling is uneven as the water temperature increases along the length of
the cooling channel (y-direction).

Assuminq the boundarv conditions cannot be chanoed. how can the desiqn be modified to
reduce the maximum chip temperature?
More turns.

\IUhat determines the amount of heat transfer to the water?

Page565 CT09101_CM12_1

Data analysis workshop - discussion points

'

Where is the heat flux the highest?

Heat flux is higher at turns where the near wallfluid velocity is higher.

How can the desiqn be modified to have more areas of hioh heat flux?
The fluid heats as it moves through the pipe so the heat flux progressively decreases for
each subsequent turn.

Has the modified desiqn simulation reached an equilibrium state?

Yes. Temperature plots show convergence.

Has the desiqn requirement been met?

Yes. Maximum temperature is below 45C.

Page 566 CT09101_CM12 1

 I

i
I
r--
I

SIEMENS t
I

Data analysis workshop - review questions

t
I

What obiects had to be created. and in what order, to monitor temoerature converqence?
To monitor temperature convergence, first create reports of the temperatures of interest,
then monitors and plots from the reports.

How was it confirmed that the desiqn criterion was not met with the oriqinal desiqn?
The maximum chip temperature report confirms the chip is too hot somewhere. A scene of
temperature on sections, a scene of temperature on the chip boundaries, and a scene of a
temperature threshold all confirmed that the chip temperature exceeded 45C and showed
where.

When the oeometrv is chanqed. what needs to be updated in the operations before runnino
the pipeline? ls there a waLto avoid this step?
The operation input parts need to be updated. This can be avoided if dynamic queries are
used to populate the operation inputs.

Page567 CT09101_CM12_1

SIEMENS
Entire coldplate workshop - review questions I

\Nhat are some assumptions that were made in this analvsis that mioht affect prediction
accuracy?
We didn't simulate external environment, did not include effect of adhesive contact
resistance, wally+, geometry was simplified - chip was assumed as pure silicon.

lf you wanted to explore the desion, what thinos could be investioated with a desiqn sweep
or optimization studv?
Sweep water inlet temperatures, optimize geometry of cooling tube, heatsink main body,
location of chip on heatsink.

Page568 CT09101_CM12_1
 SIEMENS

How manv displayers are used in this scene?

2 displayers.

What does each displaver show?

1 scalar displayer with field plotted on the body.

What displayer types are used?

1 streamline displayer, streamlines default color.
U

Page569 CT09'101_CM12_1

SIEMENS
Transient workshop - review questions
Were desiqn criteria met?
Yes. The maximum chip temperature did not exceed 50 C during the transient heat-up
period.

U/hich solver settinq added by a transient time model should ALWAYS be considered prior
to runninq the model?
Time-step always needs to be chosen intelligently in transient models and should not be
left at the default value.

How are the stopping criteria different for steady models and transient models?
For steady models stopping criteria are only needed to stop the simulation. ln transient
models, stopping criteria are required to stop the time-step as well as the simulation.

data samplinq control needs to be chosen correctlv for monitors and plots to appear
\y'Vhat
as expected?
Triggers control the data sampling.

Page570 CT09101_CM12_1
 SIEMENS
Ducted fan workshop - planning
Are any additional surfaces needed to account for boundarv conditions or mesh
refinements?
Yes, inlet and outlet.

Which parts. if any, still need to be created?

Fluid volume.

lf parts must be created. which operation(s) should be used?

Subtract.

Are all of them necessary? Could we meroe some of them?

No, fan could be collated into one boundary.

We set the boundary types for the inlet and outlet before meshino. Do you recallwhv?
Do not create prism layers on these boundaries.

. ,li"l'l i,."te11; ,ti+.tlri:: :.i1i.j!it!* lrjrji:t!iy,l::!i:: ilr',r:ti:i,r.

Page 571 CT09101_CM'12_1

SIEMENS
Ducted fan workshop - mesh
ls the surface mesh acceptable?
The surface mesh on the leading edge of the blade is choppy (not fine enough), requiring
finer cells to resolve that curvature.
Also, the surface size on all of the fan parts (blades and hub) should be capped to avoid
large cells - look especially at the hub and at the trailing edge of the blades.
Other features that could be noted are the proximity refinement causing smaller cells on
the duct walls near the blade tips, and the excessive growth from those cells to the rest of
the wall.

Page572 CT09101_CM12_'l
 Ducted fan workshop - discussion points

ls the new mesh aporopriate for the simulation?

Yes.

How manv cells were added when the refinement zone was included?
-100,000
.\-
U/hich other enqineerino quantities rnioht be of interest in this simulation?

'\- Can you create a report to measure Power required? (Power = Torque * Rotation Rate)
1 Surface average density report on inlet.

,l Max value Rotation Rate report.

,,r Design Power expression report. report 2
* report 5 (rotation rate *
torque)
.{. Design Volume Flow expression report with unit ft^3/min (= CFM):

(${M assFlowReport/${DensityReport})*(60.3 5.31 47)

Conversion from m^3/s ) ft^3/min (CFM)

Page573 CT09101_ClV112-1

\-.

\- SIEMENS
Ducted fan workshop - discussion points

Which monitors would be appropriate for iudqino converoence of the simulation?

Page 574 CT0910l_Ciil12_1

Ducted fan workshop - questions

Whv mioht Relative Velocitv be recommended instead of Velocitv?

The Relative Velocity is chosen instead of Velocity in order to look at how the flow
incidence to the blade and the blade wake. Velocity in the Lab Frame will show the swirl of
the flow after the blade, but fan designers are more concerned with the flow incidence
angle to the blade leading edge, separation of the flow around the blade, and the leakage
flow between the blade tips and the duct wall.

Could another Derived Part better display velocitv than the current planes?
ln the image shown, I'm using a LIC (line integral convolution) on a cylindrical plane in
order to really zoom in on the flow around the blades. A cylindricql plane section with a
radius of around 0.075 m is perfect for showing this.

U/hat other Scenes miqht be of interest in this simulation?

It can also be useful to view Relative Velocity on the plane normal to the Z axis that cuts
through the blades, since you can really see the leakage flow and tip vortex that way.

Page575 CT09101_CM12_1

srEMENs
Ducted fan workshop - questions I
How will we judqe if the model is converged at the end of the run? ls there a wav that could
be incorporated into the Stoppinq Criteria?
Stopping criterion from monitor.

Does this desion meet our design requirements for flow rate?
Yes, requirements (> 200 CFM) are met: Report returns 208.78 CFM

Whv do many of the streamlines appear to end at the fan?

Since we are running an MRF simulation, a lot of the streamlines will "end" at the blade
surfaces. ln this case, we are using the Velocity in the Lab Frame for integration for our
streamlines. The MRF model adds the effect of the rotation of the blades, but the blades
themselves are not actually rotating. Thus, a parcel of fluid moving in the Lab Frame may
impact the blade surface, where the mesh gnds and the streamline appears to "end".

Page576 CT09101_C|VI12_1
 Ducted fan workshop - questions
i sreruerus
I

t
I
I

Can you improve the current desion to reduce the torque required while still meetinq the
desiqn requirement of a 200 CFM (0.11 kq/s) flow rate?
A design with 5 blades and a hub radius of 0.04 m will achieve the design requirement of
200 CFM (202 CFM or 0.1125 kg/s) with a lower Torque than the baseline (0.008 N-m vs
0.009 N-m). Though there are numerous other designs that may also work.

Page577 CT09101_CM12_1

!, SIEMENS
Effective sim u lation discussion

\y'/hat characteristic of the numerical method introduces the concept of converqence?

The numerical method is iterative, which means the solution changes every time the solver
calculates it. Convergence is the concept that the solution is no longer changing
appreciably; continued solving will not change the solution in a meaningfulway.

How can converqence be determined?

Convergence can be determined by stabilized solution quantities and residuals. These
values are plotted to record the iteration history.

\I/hat model details should be inspected before running to verify the model will produce the
desired solution and accuracv?
Prior to running one should inspect the: boundary conditions, initial conditions, reference
values, mesh resolution near flow structures and walls (including boundary layers), mesh
quality.

Page578 CT09101_Cl\i112_1
 SIEMENS
Effective simulation workshop - discussion points

Has the simulation reached converqence?

No.

What is the maximum Mach number on the centerline?

Ma=0.8078.

Was the model converqed at 1000 iterations? lf not. what has chanqed?
No, now most don't drop any more although they start to oscillate.

Did we achieve the desiqn requirement of maintaininq subsonic flow in the

nozzle (Mach < 1.0)?
Yes. Ma=0.80305, it was always below 1. (axial (x-) position - 0.93 1.11).
-

Page579 CT09101_CM12-1

I
StElMEtUS Simcenter
l*Vzt*a;{y{--h.b STAR.GGM+

sl.# Training Course Days

1 Simcentet ST-\R-CC\I* [roundarion 3

2 Ileshrng Bcst Practices 2

-) Iltfcctir-e Hear Ttansfet 2

4 Ptocess lutomarion usinu ]ar.a 2

5 l".ng1ne (-ompartment Thermal \Iodcling 2

6 ( -omputatronal Combusttr-rn 2

7 Selective Catalr.dc Reductton 2

8 Iiulenan ]Iuluphase 2

9 Lagtanstan Niultrphase 2

10 Paruclc Ilodehng LIsing D[]NI ?

1l Ae roacoustics 2

t2 Fltud-Strucrut e In teractions 2

1j \-irrual Tou'Tank 2

1+ ST'-\R-( -D lroundarion 2

15 Rasic cs - ice J

16 Custom Training AI{Y

17 S]'.\R-CC\I+ Chemical Prrcess Industn- J

18 S1'.\R-CC\,[* Foundation-Oil & Gas f

sl.# Training Course Duy

1 Inroduction to CFD 1

2 Ilultiphase \Iodels - ,\n Oven-ierv 1.

-) Adr-anced Post Processing 1

4 Wizard Creation 1

5 Introduction to Parts Based N{eshins 1

6 STAR-ICE 1

Fot more information. Dlease contact:

Vikram Dadhich
Ttaining Manager
vikram. dadhich@siemens.com
+91-80-40341633 (D)

Siemrns Industry Softu'are Computational Dvnamics Indi;,r Private Limited

Bengaluru * Chenn:ri * Pune * Gurugrirrn
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