Training

Pipe-in-Duct Notes
Overview – CHT Test Case
 Conjugate Heat Transfer (CHT) is a simulation of the variations in temperature between a
solid and fluid.
Air – Hot Inlet
 Outcomes:
1. Determine the Air Outlet Temperature.
2. Determine the Water Outlet Temperature.

Water – Cold Inlet

Overview – Parts, Mesh & Physics
 Three separate parts in the assembly: Air duct
1. Air duct. Metal
2. Solid metal pipe.
3. Liquid water inside pipe.
 One mesh to ensure conformity between Regions.
Water
 Three separate Physics:
1. Gas = Air.
2. Solid = Metal.
3. Liquid = Water.
Overview – Steps
1. Build the geometry within STAR-CCM+ using the 3D-CAD modeler.
2. Assign the 3D-CAD model to the Parts environment.
3. Split the part surfaces into their desired boundaries, Inlet, Outlet ect.
4. Assign all the parts simultaneously to the Regions to transfer the Contact to Interfaces.
5. Setup the one Parts Based Mesh.
6. Setup the 3 Physics Continua.
7. Generate reports to monitor the Outlet temperatures.
8. Make a Scene to visualize the flow.
9. Run the simulation.
10. Check convergence.
11. Make additional Scenes/Plots and extract the data.
Start – Make a New Simulation
 Make a new Simulation:
– Keep it as Serial to solve on 1 core.
– Parallel on Local Host to solve on multiple cores.
 Side note:
– License section > Power-on-Demand (POD).
– This is the cloud license that you can use anywhere.
– Primarily to solve on a remote Cluster (HPC) on 1000’s of cores.
3D-CAD vs Importing
 Use the 3D-CAD to generate the geometry.
 Please note that the geometry can be draw within a dedicated CAD software like NX or
SolidWorks and imported as a Parasolid (*.x_t).
 The built-in 3D-CAD is used in order to show how a geometry should be built so that it is
directly meshable (compatible with CFD).
 There is a tutorial on how to use the 3D-CAD:
– User Guide > Modeling Geometry > Using 3D-CAD
– Tutorial Guide > Geometry > 3D-CAD: Cyclone Separator
3D-CAD – Make a new Model
 Make a new 3D-CAD model:
– Expand Geometry folder.
– Right click 3D-CAD Models > New.
3D-CAD – Duct
Note:
 Generate the duct: Extruding a square gives the
– Sketch (XY) with a square 0.1 x 0.1m with the center at the origin. Inside (air) of the duct.
o Top-Left coordinate [-0.05, 0.05] m.
o Bottom-Right coordinate [0.05, -0.05] m.
– Extrude sketch by 1.0m.

[-0.05, 0.05] m

[0.05, -0.05] m
Save Simulation
 Save the Simulation File > Pipe-in-Duct.
 There is no Undo button:
– Regularly save you simulation.
– When a mistake is made, simply close the simulation without saving.
– Load/open the previously saved simulation file.
 Incrementally save the simulation at various key points:
– After the Geometry has been finalized.
– After the Mesh has been generated.
– After the Physics has been chosen.
– After the desired Report / Plots / Scenes has been made.
– Just before clicking the Run (solve) button.
3D-CAD – Pipe
 Generate the pipe:
– Sketch (ZX) with two circles:
o Centre at 0.75m in x-direction.
o Radius Outer = 0.02m.
o Radius Inner = 0.0175m.
– Extrude sketch:
o Two-way Symmetrical.
o Distance = 0.25m.
o Body Interaction = None.
3D-CAD – Subtract
 Subtract the Pipe from the Duct.
– Bodies folder > select Body 1 & Body 2 simultaneously.
– Right click > Boolean > Subtract.
– Keep Tool Bodies.
 Delete redundant Body 1.
3D-CAD – Liquid
 Generate the Liquid inside the Pipe.
– Make sketch from pipe face edges.
– Mark Outside Circle as Construction.
 Extrude sketch:
– Direction Type: Reverse
– Distance = 0.5m.
– Body Interaction = None.
3D-CAD – Rename and Imprint
 Rename the bodies:
– Body 2 = Pipe.
– Body 3 = Duct.
– Body 4 = Water.
 Imprint bodies:
– Select Pipe & Duct simultaneously.
– Right click > Boolean > Imprint.
– Imprint Type = Tolerant Faces.
– Tolerance = 1.0E-4 m.
– Repeat for Pipe & Water.
 See also CAD Repair > Merge/Imprint Option.
Parts – Generate Parts
 Generate/Assign 3D-CAD model to the Parts:
– Close 3D-CAD.
– Expand 3D-CAD folder in main tree structure.
– Right click 3D-CAD Model 1 > New Geometry Part.
Scene – Geometry
 Make a new Geometry Scene to view your model.
Parts –Split Surfaces
 Split by Patch the surfaces accordingly.
– Imprint/Touching/Contact Surfaces
o IF (Interface).
– Inlet Air & Outlet Air.
– Inlet Water & Outlet Water.
Parts – Assign to Regions
 Assign/Transfer the Parts to the Regions:
– Select all 3 parts simultaneously.
– Right lick > Assign Parts to Regions.
– Create a Region for Each Part.
– Create a Boundary for Each Part Surface.
– Click Apply only Once, then Close.
 The 3D-CAD model is now coupled to the Parts
that is assigned to the Regions forming a chain.
Regions – Boundary Types
 Change the Inlet & Outlet boundary types to:
– Inlet = Velocity Inlet.
– Outlet = Pressure Outlet.
 Note that change in:
– Icons of the boundary.
– Color of the geometry.
Mesh – Models
 Parts-Based Meshing (operation) vs Region-Based Meshing
(continua).
– User Guide > Meshing.
 Either mods is applicable and will produce the same mesh.
 Although continua-based meshing operands are being
phased out.
 Parts Based Mesh will be used.
 Select Automated Mesh.
 Select the desired models:
– Surface remesher (always).
– Polyhedral mesher (Trimmer, Poly or Tet).
– Prism Layer mesher (always).
– Embedded Thin mesher (optional)  To mesh thin pipe
thickness.
Mesh – Models
 Develop an Automated Mesh for all Parts
 Under “Parts” select all part constituents.
 Select the desired models:
– Surface remesher (always).
– Polyhedral mesher (Trimmer, Poly or Tet).
– Thin mesher (optional)  To mesh thin pipe
thickness.
– Prism Layer Mesher(always)
 After enabling meshing parameters, a new link will
emerge under Operations: Automated Mesh
Mesh – Settings
 Choose an appreciate Base Size that describes the dimensions of your model. Base Size = 10mm.
o This is a trail and check basis to get to the desired size that produces a satisfactory mesh resolution.
 Default minimum surface size will produce a high-quality fine mesh, but it is to fine for training purposes.
Increase it to produce a coarser mesh on the pipe.
– Surface Size > Relative Minimum = 40%.
 Generate the interim Surface mesh to check the mesh settings.
 Make a new Mesh Scene to visualize the mesh.
– Toolbar at the top > Scene icons > Mesh.
Mesh – Settings
 Enable custom setting for thin bodies found in this part.
– Automated Mesh> Default Controls > Thin Mesher.
– Tick (enable) > Customize Thickness Threshold.
– Reference Values > Thin Solid Thickness folder > Change to Absolute.
– Absolute Size = 5.0mm.
Mesh – Settings
 The only part that only requires thin mesher is the pipe
mesh.
 Therefor we need to disable prism mesher on the Pipe
Part surfaces:
– Automated Mesh > Custom Controls
– Right Click Custom Controls and select Surface Control Select
the Pipe Part
– Controls > Prism Layers
 Additionally, use a Part Control to disable Thin Mesher in
the Air and Water Parts
Mesh – Settings
 Set the Prism Layer to more accurately capture the Boundary Layer Thickness on all mesher operations.
– Prism Layer Thickness = 3.0mm (Absolute).
Mesh – Refinement
 Mesh needs refinement in the air downstream of the pipe.
 Generate a dummy shape to use as refinement zone.
– Parts > New Shape Part > Block
 Assign it to a Volumetric Control.
– Automated Mesh > Volumetric Controls.
– Customize Surface Remesher.
– Custom relative size = 40%.
 The Polyhedral Remesher can also be set.
Mesh – Generate & Visualize
 Generate the Volume Mesh.
– Note: the Volume mesh button does everything before it, meaning the Surface mesh.
 Use a Threshold to isolate the cells in the x-direction.
– Derived Parts > Threshold.
– Scalar = Centroid > Laboratory > X.
– All Below = 0m.
– Existing Displayer > Mesh 1.
– Create Once, then Close.
Mesh – Visualize
 Switch to the Scene/Plot tab:
– Double-click the Parts folder.
– Remove (untick) everything inside Regions.
 To see each Region as a separate color:
– Mesh 1 displayer > Properties.
– Color Mode > Distinguish Regions.
 Save the simulation.

~80,000 cells
Physics – Models (Air)
 Three [3] Physics Continua will be created.
– Air for the Duct.
– Water for the fluid inside the Pipe.
– Solid for the Pipe thickness.
 Choose the appropriate models to the physics that needs to be captured.
 Right click the Continua Tab
 Continua > New > Physics Continuum
Physics – Models (Water)
 Water requires an optimal model, Segregated Fluid Temperature in order to specify the
temperature of the liquid.
 Note: do not choose IAPWS-IF97 (Water). This is the steam tables for phase change
(boiling) that will not occur here.
Physics – Models (Copper)
 The Solid requires Segregated Solid Energy to specify the temperature and account for
conduction.
Physics – Properties
 The starting temperature of each phase needs to be set.
– Initial conditions > Static Temperature = 20°C.
 Change the default solid from Aluminum (Al) to Copper (Cu).
Physics – Assign to Regions
 By default each Region is assigned to the first Physics continua.
 Set each Region to use the corresponding Physics continua.
Physics – Values
 Set the Inlet boundary values.
– Duct > Inlet Air > Physics Values
o Static Temperature = 600°C.
o Velocity Magnitude = 25m/s.
– Water > Inlet Water > Physics Values
o Static Temperature = 20°C.
o Velocity Magnitude = 1.5m/s.
 Set the Outlet boundary values.
– Duct > Outlet Air > Physics Values
o Static Temperature = 20°C.
– Water > Outlet Water > Physics Values
o Static Temperature = 20°C.
 The outlet temperature is required for reverse flow across the outlet face
for flow that comes back into the domain. Does not specify a mean that a
temperature difference is set.
Monitoring – Reports
 Generate reports for two reasons:
– Quantify the outcomes of the simulation.
– To use as a criteria to monitor convergence.
 Different reports can be used in different ways:
– Mass Flow Averaged = Temperature.
– Surface Average = Pressure.
– Max or Min to monitor a single value.
 Generate the following reports:
– Mass Flow Averaged Report
– Function = Temperature.
– Part = Regions > Duct > Air Outlet.
– Units = °C.
– Right click > Create Monitor and Plot.
– Repeat for the Water Outlet.
Monitoring – Scenes
 To visualize the fluid/solid thermodynamics and heat transfer behavior Scenes can be
used.
– Make a new Scalar Scene that will be used to display Temperature.
 Make a section that cuts through your geometry:
– Derived Part > New Part > Section > Plane.
– X-direction = Normal [1, 0, 0].
– Existing Displayer > Scalar 1.
Monitoring – Scenes
 To show different values, Right click the blue color bar > Temperature.
 Change the Unit from [K] to [C].
Solving – Run the simulation
 All the required setup has been completed in order to run the simulation:
– The Geometry has been finalized and boundaries split up.
– The volume Mesh has been created.
– The Physics models has been chosen and setup correctly.
– Some reports / plots / scenes has been made to monitor the Convergence of the simulation.

 Click the Run (solve) button.

Convergence – Plots/Scenes
 Convergence is reached when:
– The Report Plots has stabilized.
– The Scene images does not change (Steady State).
– The Residuals Plot has come down and leveled out.
Results – Interpretation
 There is a very small temperature difference on both the Air and Water side, the reason being:
– The air/water contact area is very small.
Results – Interpretation
 Check Wall y+ values, should be within 30 < y+ < 300 for the High y+ mesh that was built.
 Wall y+ values in the air side is a bit close to 30, suggest increasing prism layer thickness.
 Right click on a Plot > Export (*.csv). Can then be use in Excel to draw additional plots.
 Right click on any Scene to make a Hardcopy of the window.
Results – Interpretation
 Mesh is too coarse. ~80,000 cells
– Strong gradient/color changes, needs to be gradual.
– Can see individual cells.
 Cell sizes need to be so small that individual cells
should not be visible.
 It is like taking a high resolution image where the
pixels should not be visible.
Results – Interpretation
 Example of a finer mesh resulting in a much more ~1,600,000 cells
gradual gradient change.
 Individual cells are still visible, but they are much
smaller.
Summary
 There are several tutorials in the User Guide that can be done to better understand the workflow and
also to get more familiar with the software.
– Accessed by going Help > Help. Opens in the default web browser.
– If Chrome does not open it, update Chrome or use another web browser.
 The following tutorials will be useful to complete for most user:
– Introduction.
– Mesh > Mesh Operations: Imported Control Valve.
– Incompressible Flow > Steady Flow: Channel Flow with Multiple Meshes.
– Incompressible Flow > Steady Flow: Backward Facing Step.
– Heat Transfer and Radiation > Conjugate Heat Transfer: Heated Fin Introduction.
End.