(Intro To CAE) Fundamentals of CFD

Fundamentals of Computational Fluid
Dynamics
SimScale
Title
3 Column (full page)
What is Computational Fluid Dynamics (CFD)?

2 Column
1 Column
Half page
SimScale SimScale 2016

Computational Fluid Dynamics
Computational Fluid Dynamics (CFD) is a field in fluid dynamics that incorporates

numerical analysis to simulate and solve problems involving fluid flows.

Applications of CFD
External Aerodynamics of ground vehicles, aircraft.
Internal flow for automotive applications
Liquid and gas flow in industrial equipments
Ventilation, Heating, and Cooling (HVAC) for buildings
Industrial blowers, fans, air units.
Cooling for electronics applications.
Flow and heat transfer in power generation systems
Hydrodynamics of marine vehicles
Wind Engineering

CFD in the product development design cycle

Why Computational Fluid Dynamics (CFD) ?
Lower development costs
Shortened design cycle
Reduce the number of prototypes needed for physical testing
A more robust and reliable finished product
A product that is optimized for performance

Role of CFD in the development process
Virtual Prototyping and Testing
Easy, fast, cost-efficient design cycles
Design
Simulation Redesign Build
(CAD)
Iterations for optimal design

Title
2 Column
Steps in the CFD Process
1 Column
Half page

Step 1: Create geometric model
Model with CAD software

Step 2: Discretize flow domain
Create a mesh of the fluid domain

Step 3: Define the physics model
Flow Inlet
Velocity (flow rate) = known
Pressure = ? or may be known
Flow Outlet
Friction Walls Velocity = ?
Velocity = 0 Pressure = Known static pressure
Pressure = ?
Apply Boundary Conditions

Step 4: Results evaluation
Visualize Pressure, Velocity etc.

Step 5: Re-design as necessary
Analyse the design using simulation
Compute design parameters

- Pressure drop across the valve
- Outlet flow field
- Forces on the value plug
Evaluate the designs based on the parameters
Re-design to meet requirements

Title
2 Column
How CFD works:
The Finite Volume Method
1 Column
Half page

Physical Problem to Simulation Model
Types of Flows Quantity of interest
Incompressible / Compressible Density,
Steady-state / Transient Time, t
Laminar / Turbulent Reynolds number, Re or Velocity, v
Inviscid / Viscous Viscosity
Sub- / Transonic Mach number, M
Single- / Multi-Phase Macroscopic fluid properties

Navier-Stokes equations: Mass conservation
Change of mass Flow of mass Mass does not

in time through the disappear or
boundaries appear from
nowhere

Navier-Stokes equations: Momentum conservation
Time change Convection term Pressure Viscous force Extra forces

forces (gravity,
etc.)
Similar to mass transport. Forces that act on the fluid.

This time we move momentum They generate / dissipate momentum.

Most equations are derived by considering a very small fluid volume called
Control Volume (CV) and applying the conservation laws
Since each CV has finite size, this method is called Finite Volume Method ( FVM)
The entire continuous flow domain is discretized into these simple shaped
Control Volumes (CVs)

The Control Volume:
Face centroid
CV CV boundary
centroid

The Control Volume:
All fields are stored in the centroid.

Data between them is interpolated.
Velocity (U) vector field
Pressure (p) scalar field
Temperature (T) scalar field

How CFD works
Step 0: Physical problem to Mathematical model
Step 1: Meshing generation (discretize the continuum), Pre-processing
Step 2: Select Type of analysis (simplified model version of problem)
Step 3: Specify the Fluid properties or model
Step 4: Specify Boundary conditions
Step 5: Select Solvers and Interpolation Schemes for solution of equation system
Step 6: Post-processing results e.g Pressure loss/gain, Vorticity, Forces

How CFD works - Process





Solvers Tolerances Pre-Conditioners

GAMG Relative Conditions a given problem into a
form that is more suitable for
PCG Absolute numerical solving
Smooth Solvers

Example: 2D flow in pipe
Length = 5 m
Velocity (V) = Fixed value
Pressure (P) = ?
Velocity (V) = ?
Pressure (P) =
reference static value
Real Friction Wall condition Pressure at wall = ?

Velocity at wall = 0 m/s

The Finite Volume Method: Governing Matrix
Global System of Equation
Source:
https://web.stanford.edu/class/me469b/handouts/incompressible.pdf

The Finite Volume Method: Boundary conditions
The Dirichlet condition:
Is a fixed value condition for a flow variable at the boundary e.g

velocity set to zero at the wall.
The value always remains constant .
u| = 0 on

The Neumann condition:
Is a fixed derivative condition for a flow variable on the boundary e.g velocity,
pressure
It is used when the actual value is an unknown and a variable but the rate of
change is known.
For example in fully developed condition at an outlet, the gradient of flow

variables is set to zero (gradients are taken normal to the boundary)
u/ | = 0 on
The Mixed/Robin condition:
Is a combination of fixed value and fixed derivative condition for a flow

variable and are suited for complex behaviour.
Here either the value of the variable or the derivative can remain constant
at a particular part of the boundary.
For example, in Heat Transfer, a Mix/Robin condition is used to model

cooling, where convective heat flux (derivative) and source temperature
(value) are both specified.

The Finite Volume Method: Numerical Schemes
Lets take a look at Navier-Stokes-Equation.
Derivative Gradient Laplacian
The necessary derivatives can only be evaluated numerically
1st order schemes Higher order schemes

Upwind Linear
LinearUpwind Van leer
Quick CubicCorrected

Cell 1 Need to be Cell 2
calculated!
Cell center 1 Cell center 2
Properties of Numerical Schemes:

Conservativeness: global conservation of the fluid properties must be ensured
Boundedness: values predicted by the scheme should be within realistic bounds
Transportive: diffusion works in all directions but convection only in the flow direction

First order upwind Central differencing scheme
Value of the face is the same as the Linear interpolation between the cell centered
centered value in upstream cell values
High robustness, low precession Can cause divergence if local Peclet > 2
Well suited to start calculation Hybrid approach possible

Second-order upwind
Linear interpolation from the cell values in the
two cells upstream of the face
Combination of accuracy and robustness

The Interpolation schemes:
Used for convective flux terms and pressure calculation on the cell faces
Gradient
Divergence
Laplacian
Scheme Order of interpolation Description

Depends on the flow direction
Upwind 1st
Very stable but dissipative, less accurate
Independent of the flow direction

Linear 2nd
Not dissipative but less stable
May depend on the flow direction

QUICK-Cubic 3rd
Not bounded
Depends on the flow direction

Linear Upwind 2nd
Less dissipative, can be made limited

The Finite Volume Method: Solution methods
Solvers for the Linear System of Equations:
Gauss Seidel (G.S)

Slow convergence
Very stable
Conjugate Gradient (C.G)
Faster convergence
Stability highly dependant on
mesh quality
Multi-Grid method (MG)
Very fast convergence (uses
multi-level approach)
Source:
Stable * A conjugate gradient method for solving the non-LTE line radiation transfer problem
+ http://people.bath.ac.uk/em459/research_ellipticsolvers.html

Are my results correct?
Experience and engineering judgement are the most important factors for
performing an accurate analysis.
Correct implementation of the physics and modeling steps is critical for
accuracy
Simulation results should be compared quantitatively with analytical data or
calculations
It is always recommended to compare simulation results to some experimental
data for setting a baseline case


The following criteria can also help to judge if a simulation is converged
Residuals Forces Probes

Errors in CFD
Modeling and Setup Error: 1st biggest source of errors
A simplified mathematical model, replicating physical setup & conditions
Discretization Error: 2nd biggest source of errors

Errors that arise from a bad or inadequate mesh
Domain approximations
Numerical Error
Introduced by the computer when it rounds or truncates numbers as it
assembles matrices and solved equations

Errors in CFD
Modeling Errors: Outlet Sections

Errors in CFD
Modeling Errors: Inlet Sections
Inlet
Outlet
Flow area of
interest

Errors in CFD
Modeling Errors: Inlet Sections
Inlet too close to

area of interest
Inlet at proper distance

to area of interest

Errors in CFD
Modeling Errors: Taking physics into account
Fluid entering
container
Outlet for Air in

the container

Responsibility of the user
Smooth and colorful contours can be produced by any model, good or bad
A responsible user must understand the nature of the problem and the inherent
assumptions before setting up the problem and analyzing the results
The results should always be first compared qualitatively and then with Analytical
calculations or Hand approximations to check for obvious inconsistencies

Books & resources
An Introduction to Fluid Dynamics by G. K. Batchelor
Physical Fluid Dynamics by D. J. Tritton
Fundamentals of Aerodynamics Book by John D. Anderson
Modern Compressible Flow: With Historical Perspective 2nd Edition Book by John D. Anderson
Modern Compressible Flow: With Historical Perspective by J. D. Anderson

Elements of Gasdynamics by H. A. Liepmann and A. Roshko. Liepmann and Roshko
Boundary Layer Theory by H. Schlichting
Turbulent Flows by Stephen B. Pope
Thermodynamics, Schaums Outline Series by M. M. Abbott and H. A. van Ness

Title
2 Column
CFD in SimScale:
Meshing
1 Column
Half page

CAD formats on SimScale
*STEP*, IGES, BREP, STL

Describes precise geometry
Make sure CAD is clean
SimScale uses SI units i.e Meters
STEP/STP format is most compatible
and recommended

CAD formats on SimScale
Always check the CAD import Info and Log
.....
Units are
Meters

CAD Operations on SimScale
Scaling the model

Perform unit scaling for uploaded or imported
CAD models. Important if CAD model was not
in meters.
Scales all the solid parts in an assembly
Splitting of faces for STLs

Perform face splitting operation based on a feature
angle for STL files that have only 1 face/shell
Splitting is important for boundary condition
specification

Meshing - Why Is It Important?
The original problem is discretized via the meshing process
Simulation computes the results of the discretized domain
Mesh resolution and quality has major effects on the results

Rate of convergence
Solution accuracy
CPU time required
A Bad mesh (based on resolution and quality) is the 2nd biggest

cause of simulation errors or crashes

The discrete representation

Elements of control volume
Volume Face centers
Centroid Boundary
faces
Mesh nodes Volume edges

Element Types: 3D Tetrahedrals
SimScale supports tetrahedral volume elements

for CFD
Very robust
Medium-quality meshes
Optional boundary layer refinement
Underlying algorithm: Netgen
4-node
Tet Element

How Netgen creates the Tet mesh
Meshing steps: Parameters to control:

Split 1-D edges Minimum edge length
Mesh surfaces Maximum edge length
Grow mesh in 3-D Overall mesh fineness
So called Bottom-up Element order
approach

1-D Tet meshing
Node
Element

2-D Surface Tet meshing
2D Cell/Element

3-D Tet meshing

Element Types: 3D Hexahedral mesh
SimScale supports Hexahedral volume

elements for CFD
Robust
High-quality meshes
Optional boundary layer refinement
Underlying algorithm: snappyHexMesh

Hex-mesh*: Defining bounding box
Top-bottom approach.
*Uses the Snappy Hex Mesh algorithm from OpenFOAM

Hex-mesh: Base Mesh for Domain

Hex-mesh: Base Mesh and refinement level
Base Mesh
Cell Size
for X
Refinement level n
n = 1, 2, 3..10, 11.

Hex-mesh: Surface refinement

Hex-mesh: Region refinement

Hex-mesh: Mesh removal

Hex-mesh: Surface snapping

Hex-mesh: Layer addition

Which Mesh Type To Select

Which Mesh Type To Select
Automatic mesher
For simpler models with less or no relatively small faces and edges
Tet-mesh: Auto Global and local surface refinements with layers, works for single part or assembly.
Hex-mesh: Global surface refinement with layers, works only for single part that must be the fluid domain.
Parametric/Manual
For complex models with complicated small features, faces and edges
Tet-mesh: User specified Global and local surface refinements with layers, works for single part or assembly.
Hex-mesh: All types of refinement with layers, works for single part or assembly.

Checking mesh quality
Always check the meshing log for illegal cells

(The number should be low, relative to total size )
Then, inspect the mesh body visually at critical areas

(e.g. by hiding mesh surfaces)
High Aspect-Ratio cells
Non-Orthogonal cells
High Skewness
Concavity

Checking mesh quality
The accuracy of the simulation depends highly on the quality of the mesh
---------------------
Layer mesh : cells:8250379 faces:26747115 points:10388056
Cells per refinement level:
0 102169
1 4096
2 14944
3 282757
4 111811
5 539081
6 2103732
7 2559871
8 2531918
Writing mesh to time constant
Wrote mesh in = 27.97 s.
Layers added in = 249.49 s.
Checking final mesh ...
Checking faces in error :
non-orthogonality > 75 degrees : 21
faces with face pyramid volume < 1e-13 : 5
faces with concavity > 80 degrees : 2
faces with skewness > 4 (internal) or 20 (boundary) : 0
faces with interpolation weights (0..1) < 0.01 : 0
faces with volume ratio of neighbour cells < 0.01 : 3
faces with face twist < 0.005 : 17
faces on cells with determinant < 0.005 : 25
Finished meshing with 73 illegal faces (concave, zero area or negative cell pyramid volume)
Finished meshing in = 820.84 s.
Should be smaller than 75 Degree!
End

Performing a mesh convergence study
Do a convergence study to obtain mesh-independent results
Create a mesh using the fewest (coarse), reasonable number of

elements/cells and analyze the velocity field on a cross section
Recreate the mesh with a smaller (finer) element/cell distribution,
re-analyze it, and compare the results to those of the previous mesh.
Keep increasing the mesh density and re-analyzing the model until the
results converge and are not changing anymore.
Accurate results with lowest computation times

Performing a mesh convergence study
Use point and line plots at critical sections to check value of velocity and pressure
Compare velocity contours at cross sections for changes in results
Static Pressure (mPa)

Mesh 3D cells

Title
2 Column
CFD in SimScale:
Analysis Types
1 Column
Half page

CFD in SimScale
1 CAD Import 2 Mesh & Simulate 3 Design Decision

CFD Analysis in SimScale
CFD Analysis Types in SimScale
Incompressible flow
Compressible flow
Passive Scalar Transport
Multiphase flow
Discrete Phase Model (coupled
particle-fluid interaction)
Advance Concepts
Rotating Zones, Porous Media, Solid Body
Motion and 6 Degree of Freedom (6DOF)

Incompressible vs. Compressible
Incompressible Compressible
Mass and Momentum conservation Mass and Momentum conservation
only Energy (heat) balance also solved
No Energy (Heat) balance
Density is a variable
Density is constant
Mostly all Liquids Mostly gases at high speed or
Usually low speed gas flow pressure

Single vs. Multi-Phase
Single Phase Multi Phase

Only a single fluid (liquid or gas) is Two fluids of different phases or 2
present different components of same phase.
Less complicated Example Air-Water (gas-liquid) or
Oil-Water (liquid-liquid)
less compute intensive
More complicated and compute
Domain is always filled with the specified intensive
fluid
Domain has both fluids present, so
No phase change can occur interface tracking is required
No phase change can occur

Title
2 Column
CFD in SimScale:
Incompressible Flow Analysis
1 Column
Half page

What is an Incompressible Flow Analysis?
An Incompressible Flow Analysis can be used to predict the fluid (liquid/gas)

flow in systems where the density change in time and space of the fluid can be
neglected. This assumption is valid at low fluid velocities and temperatures.
This assumption is valid at:
Low fluid velocities
Low temperatures

When is incompressibility NOT valid
Compressibility:
Flow is compressible if the pressure or temperature changes due to flow are large
enough to cause significant density changes.
Liquid flow is predominantly incompressible e.g water, oil
Gases are generally compressible ( = ), but can be regarded incompressible at
low speeds
Gases with high Pressure and Temperature variations are compressible
Compressible flow is more demanding numerically (additional equations) and should only
be selected if necessary

Gas Properties and Models
Mach Number
Mach Number=Velocity of flow / Velocity of sound
Gases become significantly compressible at M>=0.3
Ma = /
Rule of thumb:
If Ma > 0.3 then compressible flow should be applied for gases

Fluid Properties and Models
Incompressible Fluid Compressible Fluid
Density is constant Density changes are significant,

Depends on Pressure and Temperature
Viscosity is constant Equation of state
(no variation due to temperature change)
Viscosity may be constant or can change with
So only Kinematic Viscosity is required: temperature
Sutherlands law etc
= /
Several properties are required e.g Cp, , Pr

Steady-State or Transient
Steady or Transient Flow
If the system is expected to converge to a state where it doesn't change any more, use
steady-state.
Transient flow changes with time and has periodic phenomenon e.g vortex shedding
Sources: http://www.bakker.org, https://en.wikipedia.org/wiki/K%C3%A1rm%C3%A1n_vortex_street

http://www.rpi.edu/dept/chem-eng/WWW/faculty/plawsky/.../CylinderTransient/Ch13CylinderTime.html

Turbulence
Turbulence is characterized by [Ferziger et al, 1999] :

Irregular, chaotic and unsteady 3-dimensional phenomenon
Presence of eddies, vortices and vortex stretching
Increased mixing and interaction in the flow
Highly dissipative process
Energy cascade from large vortices to smaller vortices
Increased heat transfer
Usually at high flow speeds
Reynolds experiment showing the transition from

laminar to turbulent pipe flow. Van Dyke, 1982

Reynolds number
Flow remains laminar if Reynolds number is low
The flow becomes turbulent if Reynolds number

is higher than critical value e.g. for pipe flow Velocity scale Length scale
critical Re=2300
Reasons Re becomes high:

High velocities
Large domain size Kinematic
Low kinematic viscosity of fluid
viscosity

Turbulence Models
Turbulence models have been developed in order to simulate turbulence in a feasible

way.
k-epsilon models RANS family

Available on SimScale
k-omega models
Large Eddy Simulation models LES family
Available on SimScale

Applications and Comparison
k-epsilon models k-omega SST model
Popular due to good convergence rate Useful in several cases where the k-epsilon model is not
accurate, e.g. internal flows, separated flows and jet flow
More robust and widely used despite the known k-omega-SST model is a combination of the standard
limitations as it is computationally cheap k-epsilon in the free stream and the k-omega models near
the walls.
Valid for fully turbulent flows only
k-omega-SST is recommended for high accuracy boundary
Works well for external flow cases without flow layer simulations.
separation Works well for external flow cases with flow separation e.g
Airfoils
Poor predictions for swirling and rotating flows Works well for internal flow cases
Sometimes difficult to converge
It performs poorly (not accurate) for flow that
exhibit adverse pressure gradients, flow separation, Computationally more expensive than standard k-epsilon
strong curvature to the flow, or jet flow and k-omega
Requires a good resolution mesh

Title
Case Study: Laminar Steady pipe flow

2 Column
1 Column
Half page

Laminar Steady Pipe Flow
Fixed Flow Inlets
Wall
Flow Outlet

Laminar Steady Pipe Flow
Problem Overview:
Velocity: Low
Flow behaviour: Independent of time
Fluid: Water
Interested in time
Fluid: Water Velocity: Low independent flow
Incompressible
Laminar Flow Steady-State
Analysis

Thank you for your attendance!
For further information about SimScale and upcoming webinars
subscribe to our social media channels or go to
www.simscale.com

(Intro To CAE) Fundamentals of CFD

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

(Intro To CAE) Fundamentals of CFD

Uploaded by

Copyright:

Available Formats

Fundamentals of Computational Fluid

What is Computational Fluid Dynamics (CFD)?

SimScale SimScale 2016

Computational Fluid Dynamics (CFD) is a field in fluid dynamics that incorporates

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

Lower development costs

Shortened design cycle

Reduce the number of prototypes needed for physical testing

A more robust and reliable finished product

A product that is optimized for performance

SimScale SimScale 2016

Virtual Prototyping and Testing

Easy, fast, cost-efficient design cycles

Iterations for optimal design

SimScale SimScale 2016

SimScale SimScale 2016

Model with CAD software

SimScale SimScale 2016

Create a mesh of the fluid domain

Apply Boundary Conditions

Visualize Pressure, Velocity etc.

Analyse the design using simulation

Compute design parameters

Evaluate the designs based on the parameters

Re-design to meet requirements

SimScale SimScale 2016

SimScale SimScale 2016

Types of Flows Quantity of interest

Incompressible / Compressible Density,

Steady-state / Transient Time, t

Laminar / Turbulent Reynolds number, Re or Velocity, v

Inviscid / Viscous Viscosity

Sub- / Transonic Mach number, M

Single- / Multi-Phase Macroscopic fluid properties

SimScale SimScale 2016

Navier-Stokes equations: Mass conservation

Change of mass Flow of mass Mass does not

SimScale SimScale 2016

Navier-Stokes equations: Momentum conservation

Time change Convection term Pressure Viscous force Extra forces

Similar to mass transport. Forces that act on the fluid.

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

All fields are stored in the centroid.

Velocity (U) vector field

Pressure (p) scalar field

Temperature (T) scalar field

SimScale SimScale 2016

Step 0: Physical problem to Mathematical model

Step 1: Meshing generation (discretize the continuum), Pre-processing

Step 2: Select Type of analysis (simplified model version of problem)

Step 3: Specify the Fluid properties or model

Step 4: Specify Boundary conditions

Step 6: Post-processing results e.g Pressure loss/gain, Vorticity, Forces

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

SimScale SimScale 2016

STEP, IGES, BREP, STL