CFD in Mechanical Engineering
CFD in Mechanical Engineering
Yufeng Wei *
Beijing Institute of Technology, Beijing, China
1. Introduction
With the rapid development of computer and computational fluid dynamics (CFD), CFD numerical
simulation has become an important auxiliary method of engineering design [1, 2]. Computational fluid
dynamics has been widely used in high-tech products such as aerospace, large-scale power equipment
and nuclear reactors, and has promptly expanded to various types of general machinery products related
to heat and flow, such as fluids, chemical machinery and equipment.
CFD came into being after the Second World War. In the 1960s, CFD became an independent
discipline with the introduction of a CFD-related magazine “Journal of Computational Physics” and
American scholar Harlow and Welch's presentation of staggered grids. After this, CFD technology
developed rapidly: American scholars Thompson, Thames and Mastin proposed differential equations
to generate aptamer coordinates; Lenard published the famous QUAICK format, which is a third-order
precision convective discrete format; giant computer promotes the development of parallel algorithm,
direct numerical simulation (DNS), research of turbulence with large eddy simulation (LES) and so on.
[4]
In general, the experimental method is often limited by model size, flow field disturbances, personal
safety, and measurement accuracy, while CFD compensates for these deficiencies. It involves many
advantages, such as a shorter duration, easier operation, lower cost, and higher repeatability, which gives
an access to selecting different flow parameters to perform various numerical experiments and to
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carrying out multi-program comparison. And with a good flexibility and adaptability, it is also not
restricted by physical models and experimental models.
In all, CFD, as an analog and simulation tool, has been widely used to study various transmission
processes, including fluid flow, heat transfer and mass transfer and has been extensively recognized by
researchers and users. It consequently plays an essential role in hydraulics scientific research and
engineering design.
This paper is aimed at introduces the theoretical basis of CFD numerical simulation, the concrete
example that CFD uses in engineering practice, the research achievements of CFD in hot engineering
field in recent years, and the challenges as well as application prospects of CFD in mechanical
engineering.
div S m , (1)
t
2
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a x a y a z
div represents divergence, that is div a . Equation (1) is the general form of the
x x x
mass conservation equation and is suitable for compressible flow and incompressible flow. And is
the density, t is the time, v is the velocity vector, and Sm is the mass added to the continuous terms, such
as evaporation or heterogeneous reaction of the dropping.
u p yx zx
t
div uv xx
x x y
z
fx
v p xy yy zy
t
div vv
y x
y
z
fy , (2)
w p yz zz
t
div wv xz
z x y
z
fz
Where p is the pressure on the microfluidic body; xx , yx and zx are the components of the
viscosity that acts on the surface of the micro-body due to the viscosity of the molecule; f x , f y and f z
are the components of the volume force ( f ) in the three directions acting on the unit mass microbody.
E
EV F V V
t
, (3)
E e V 2
3
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primarily by the British CHAM [9]. CFX was developed by British AEA Technology. CFX software is
now widely used in aerospace, rotating machinery, energy, petrochemical, machinery manufacturing,
automotive, biotechnology, water treatment, fire safety, metallurgy, environmental protection and other
fields [10]. CFX is unique in that it uses a finite volume method based on finite element method, which
guarantees numerical accuracy. The STAR-CD is the first commercial software package for fluid
analysis using a completely unstructured grid generation technology and a finite volume method to study
the complex flow in the industrial sector [11]. FIDAP is based on the finite element method and can be
used to solve the problems of various flows and turbulence in polymer, film coating, biomedicine,
semiconductor crystal growth, metallurgy, glass processing and other fields. It provides an accurate and
effective solution to problems involving fluid flow, heat transfer, mass transfer, discrete phase flow, free
surface, liquid-solid phase transition, fluid-solid coupling, and so on. FLENT is currently the most
comprehensive, most widely used CFD software, its design based on "CFD computer software group
concept." For each physical problem of physical characteristics, FLENT will be used for its numerical
solution, so that the software's computing speed, stability and accuracy are to achieve the best. Different
areas of computing software are combined to become CFD software group, so as to efficiently solve the
complex flow of computing problems in various fields. Using a unified post-processing tool and being
able to calculate the flow field, heat transfer and chemical reactions, all different software can be
exchanged between the values directly, which established the foundation for generalization of FLUENT
[12].
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It has been successfully applied in the field of plug-in/buried airborne missile separation [34], sub-shells
[35] and civil aircraft ice [36].
6.2.1 Based on CFD, the numerical simulation of the external flow field of automobile is directly applied
to the exterior design of automobile. In the early stages of body design, CFD can be crossed with
computer-aided design to predict, analyze and optimize automotive aerodynamic characteristics, and
further provide the basis for vehicle selection and modeling [38]. In the early 1980s, the simulation
object of CFD was limited to the basic shape of the body. With the development of computer technology
and turbulence theory, CFD has been applied to the simulation and design of complex body such as
rearview mirror, spoiler, complex floor, mobile ground, engine compartment, wheel and so on.
Moreover, CFD can also carry out the wind stability and cross wind over the uniqueness of the two cars
meet the transient aerodynamic characteristics of the simulation [39-41].
6.2.2 The CFD-based noise control technology is applied to the engine noise, tire noise and wind noise
controlling fields. For the noise generated by the engine, the design of exhaust muffler is the main means
of noise control. CFD is used to analyze the flow field and temperature field of the engine under typical
operating conditions. It uses the surface temperature of sensitive parts such as discarded streamlines,
fuel tanks and side skirts to evaluate the optimal design of the muffler so as to achieve the effect of
controlling the engine noise [42-43]; the noise generated by the tire, during tire rolling outflow field
characteristics is the main cause of the noise. Based on the theory of fluid-solid coupling, the researchers
couple the fluid and solid of the outer wall surface when the tire is rolling, so that the finite element
method and the CFD method are combined to simulate the flow field of the tire rolling process. As a
result, the transient aerodynamic characteristics of the rolling tires were proposed, which laid the
foundation for the control of the noise produced by tires [44]; The noise caused by wind vibration is
mainly caused by the opening of the car side window or skylight. Simulation of CFD simulation of
vehicle side windows, skylights, and wind noise generated by the accurate prediction has been achieved.
Further, the influence of the factors such as the front window, the rear window, the speed, the
compartment volume, the yaw angle, the number of passengers and so on to the noise has also been
found, which has made the researchers propose a variety of ways to reduce the the noise [45-46]. All in
all, CFD has made a significant contribution to vehicle noise control. Unlimited potential in CFD will
be tapped out and it will change the area a lot in the future.
7. Conclusion
CFD technology is an advanced virtual design method, which simulates the influence of the structure
on its performance by simulating the flow field inside the mechanical equipment. It can simulate the
flow field inside the mechanical equipment, including the speed distribution, pressure distribution,
concentration and temperature distribution of the flow of various detailed and intuitive information. This
paper introduces the theoretical basis and calculation method of CFD, expatiates the application status
of CFD technology in mechanical engineering, summarizes a series of key technologies of CFD in
engineering application, and some difficulties and challenges. In the future, the development of CFD
technology in the field of mechanical engineering should focus on the development of multidisciplinary
coupling calculation, general engineering software and the extraction of massive flow field data, so as
to improve the calculation precision and efficiency of CFD and the ability to process data.
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