The presentation gives glances of the importance of CFD analysis in engineering design with an illustration/ case study. For more details, follow the webinar "Role of CFD in Engineering Design" on https://www.learncax.com/knowledge-base/blog/by-author/ganesh-visavale

1. Introduction to CFD
Role of CFD in Engineering Design
Dr. Ganesh Visavale
Cofounder & General Manager
LearnCAx (Centre for Computational Technologies Pvt. Ltd)
Pune: 411007. India
March 16, 2014
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2. Introduction to CFD
Fluid dynamics is beautiful !
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3. Introduction to CFD
FD study approach
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4. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
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5. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
www.learncax.com Role of CFD in Engineering Design 4 / 31

6. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
www.learncax.com Role of CFD in Engineering Design 4 / 31

7. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
www.learncax.com Role of CFD in Engineering Design 4 / 31

8. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
www.learncax.com Role of CFD in Engineering Design 4 / 31

9. Introduction to CFD
Computational Fluid Dynamics
Dene CFD !
Computational Fluid Dynamics (CFD) is the science of predicting uid
ow, heat transfer, mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations which govern these
processes using numerical methods (i.e., on a computer)
CFD Capabilities
Computational Fluid Dynamics (CFD) provides a qualitative and
quantitative prediction of uid ows by means of:
mathematical modeling (partial dierential equations)
numerical methods (discretization and solution techniques)
software tools (solvers, pre- and postprocessing utilities).
www.learncax.com Role of CFD in Engineering Design 4 / 31

10. Introduction to CFD
CFD process ow
Pre-processing
Geometry creation cleanup
Mesh generation
Boundary conditions
Solver
Problem specication
Additional models (asked by physics)
Numerical Computations
Post-processing
Understanding ow with color, contour etc.. plots
Line and contour data
Average values (Drag, lift, heat transfer coecient)
Report generation
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11. Introduction to CFD
CFD process ow
Pre-processing
Geometry creation cleanup
Mesh generation
Boundary conditions
Solver
Problem specication
Additional models (asked by physics)
Numerical Computations
Post-processing
Understanding ow with color, contour etc.. plots
Line and contour data
Average values (Drag, lift, heat transfer coecient)
Report generation
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12. Introduction to CFD
CFD process ow
Pre-processing
Geometry creation cleanup
Mesh generation
Boundary conditions
Solver
Problem specication
Additional models (asked by physics)
Numerical Computations
Post-processing
Understanding ow with color, contour etc.. plots
Line and contour data
Average values (Drag, lift, heat transfer coecient)
Report generation
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13. Introduction to CFD
CFD process ow
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14. Introduction to CFD
CFD process ow
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15. Introduction to CFD
CFD process ow
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16. Introduction to CFD
CFD process ow
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17. Introduction to CFD
CFD process ow
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18. Introduction to CFD
Inside the CFD process
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19. Introduction to CFD
Inside the CFD process
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20. Introduction to CFD
Inside the CFD process
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21. Introduction to CFD
Inside the CFD process
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22. Introduction to CFD
Inside the CFD process
The CFD Process
Analysis begins with a mathematical model of a physical
problem.
Conservation of mass, momentum, and energy must be
satised throughout the region of interest.
Simplifying assumptions are made in order to make the
problem tractable (e.g., steady-state, incompressible,
inviscid, two-dimensional).
Provide appropriate boundary and initial conditions for
the problem
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23. Introduction to CFD
Inside the CFD process
Meshing your way into it
CFD applies numerical methods (called discretization) to
develop algebraic equations to approximate the governing
dierential equations of uid mechanics in the domain to
be studied.
Entire domain should be divided into small cells or volume
The collection of cells is called the grid or mesh.
The equations are solved for each such grid or mesh
volume
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24. Introduction to CFD
Inside the CFD process
Solver
The system of algebraic equations are solved numerically (on a
computer) for the ow eld variables at each node or cell
System of equations are solved (usually through iterations) to provide
solution
ρφv · dA = Γφ φ · dA +
V
SφdV (1)
Nfaces
f
ρf Vf φf · Af =
Nfaces
f
Γφ( φ)n · Af + SφV (2)
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25. Introduction to CFD
Inside the CFD process
Post-processing
The nal solution is
post-processed to extract
quantities of interest
Example: lift, drag, heat
transfer, separation
points, pressure loss, etc.)
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26. Introduction to CFD
CFD within Design Cycle
Problem denition
Dimensional reduction
Experimental design
Management of CFD simulations
Data analysis
Design phase
Performance testing
Issue resolution
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27. Introduction to CFD
CFD within Design Cycle
Advances in
computational technology
Continuous eort by CFD
providers to implement
comprehensive physical
models
Advances in numerical
methods
1
1
Image from: Future Trends for Computational Fluid Dynamics in Process Industry, Ahmad H.
Haidari Brent Matthews
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28. Introduction to CFD
Commercial Simulation packages
1 ANSYS
Provides wide range of established commercial packages from tools of
geometry cleanup, mesh generation, solver and postprocessing
FLUENT
CFX
ICEM CFD
2 The STAR-CCM+ solver provides one of the most eective
numerical methodologies available in an industrial CFD code with the
high level of accuracy needed for complex unstructured meshes
3 COMSOL Multiphysics is a modeling package for the simulation of
any physical process you can describe with partial dierential
equations (PDEs)
4 OpenFOAM, FLOW3D
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29. Introduction to CFD
Some Applications of CFD: Automobiles
Air handling systems
Engine cooling
Intake and exhaust manifolds
External aerodynamics
Motor sports
Power train
Oil lters
Combustion chamber
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30. Introduction to CFD
Some Applications of CFD: Automobiles
Air handling systems
Engine cooling
Intake and exhaust manifolds
External aerodynamics
Motor sports
Power train
Oil lters
Combustion chamber
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31. Introduction to CFD
Some Applications of CFD: Automobiles
Air handling systems
Engine cooling
Intake and exhaust manifolds
External aerodynamics
Motor sports
Power train
Oil lters
Combustion chamber
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32. Introduction to CFD
Some Applications of CFD: Automobiles
Air handling systems
Engine cooling
Intake and exhaust manifolds
External aerodynamics
Motor sports
Power train
Oil lters
Combustion chamber
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33. Introduction to CFD
Some Applications of CFD: Electronics
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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34. Introduction to CFD
Some Applications of CFD: Electronics
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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35. Introduction to CFD
Some Applications of CFD: Electronics
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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36. Introduction to CFD
Some Applications of CFD: Electronics
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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37. Introduction to CFD
Some Applications of CFD: HVAC
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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38. Introduction to CFD
Some Applications of CFD: HVAC
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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39. Introduction to CFD
Some Applications of CFD: HVAC
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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40. Introduction to CFD
Some Applications of CFD: HVAC
Component level ow and
cooling
Telecommunication
equipment
Engine and transmission
controllers
Magnetic storage devices
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41. Introduction to CFD
Some Applications of CFD: Aerospace
Combustor
External aerodynamics
Fire suppression
Inlets and nozzles instrumentation
Missile systems
Propulsion
Pumps
Rotor-airframe interaction
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42. Introduction to CFD
Some Applications of CFD: Aerospace
Combustor
External aerodynamics
Fire suppression
Inlets and nozzles instrumentation
Missile systems
Propulsion
Pumps
Rotor-airframe interaction
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43. Introduction to CFD
Some Applications of CFD: Aerospace
Combustor
External aerodynamics
Fire suppression
Inlets and nozzles instrumentation
Missile systems
Propulsion
Pumps
Rotor-airframe interaction
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44. Introduction to CFD
Some Applications of CFD: Aerospace
Combustor
External aerodynamics
Fire suppression
Inlets and nozzles instrumentation
Missile systems
Propulsion
Pumps
Rotor-airframe interaction
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45. Introduction to CFD
Case Study: Boiler outlet duct design
Flow through the ducts
Important to analyze ow physics as it
induces resistance to the ow.
Essential to design it in such way that the
duct oer less resistance to the ow.
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46. Introduction to CFD
Case Study: CFD Approach
1 What is the objective statement for CFD?
Minimize the pressure drop across the ducts
2 What is the physics ?
Incompressible, steady, single phase, turbulent
3 What is CFD domain and BCs?
No solid, only uid domain modeled. Mass ow rate at inlet
4 Geometry?
Domain I need, Simplications I can make, Parts necessary for physics,
symmetries
5 Mesh?
Type of mesh, Possible all hex mesh, Some parts too complex while
some are simple.
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47. Introduction to CFD
Boiler outlet duct system design
Objective
We need to optimize the design to ensure minimum
pressure drop for the given ow through duct to the
ow.
CFD Solver
Incompressible - steady ow - Pressure based solver
Realizable K-e turbulence modeled
Imbalances in the domain : Less than 1
Convergence 1 × 10−03
Second order upwind
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48. Introduction to CFD
Mesh generation
A hexahedral mesh is created using structured Multi-block technique in ANSYS
ICEMCFD
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49. Introduction to CFD
results
Typical Pressure contour
Typical Velocity contour
Flow pathlines
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50. Introduction to CFD
Design Iterations
Existing design
Design Iteration 1
Design Iteration 2
Design Iteration 3
Design Iteration 4
Iterative design process using
CFD simulation results the
overall pressure drop within
the ducting system by about
80%
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51. Introduction to CFD
results
Typical Pressure contour
Typical Velocity contour
Flow pathlines
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52. Introduction to CFD
CFD Learning Path
What a fresher Engineer should learn in order to get into CFD analysis ?
Fundamentals of Fluid dynamics and Thermal sciences
Fundamentals of CFD
How to use CFD software ?
How is CFD used in Design ?
What should a fresh engineer expect from CFD eld ?
How to make sense of CFD results ?
How to make design decisions based on CFD results ?
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53. Introduction to CFD
Thanks...!
LearnCAx
Inspire | Educate | Mentor
CCTech - Pune
1 Akshay Residency, 50 Anand Park, Aundh, Pune-411007. India.
ganesh@learncax.com, www.learncax.com
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