- Accurately predict the performance, fuel efficiency and emissions of a gas turbine engine.
- Help design wireless antenna towers that resist wind loading while keeping costs to a minimum.
- Help engineers optimize the air flow and aggregate movement through an asphalt dryer.
- Optimize the conflicting objectives of pressure drop and uniform velocity in designing a heat exchanger.
- Enable engineers to optimize any product or process that involves fluid dynamics.
Computational fluid dynamics (CDF) may sound intimidating, especially if you don’t have any simulation experience, but it will definitely put your organization ahead. Modern CFD software solutions deliver never before seen abilities to accurately simulate complex physical models and interactions. Many even have the modeling versatility and computational precision needed to resolve the toughest design challenges.
CFD simulation can be used in more cases than you think
Despite its name, computational fluid dynamics software is not only for fluids – it can also be applied to airflow, thermal, and structural analyses.
Here are just a few of the examples of the problems CFD software has the ability to solve:
CFD applications go far beyond simulating water moving through a pipe. (although it can absolutely do that too)
Now the rub… powerful software typically comes with complexity – complexity is often the result of the challenge to achieve accurate results in less time.
Challenge of Achieving Accurate Simulation Results in Less Time
Today, with global competition intensifying and product complexity increasing at a rapid rate,
your engineers need to accomplish tasks in less time and with less training than ever before.
Their time should be devoted to improving the performance of your products or processes instead of understanding how to operate CFD software.
They shouldn’t be wasting time crawling through a plethora of options that are irrelevant to their task at hand.
In fact, your CFD software should presenting the right choices to reduce the amount of experience and user input required to ensure a successful simulation.
A CFD Simulation Game Changer: ANSYS Fluent
ANSYS has undertaken a large initiative to overhaul the Fluent user experience with these goals in mind:
- Provide a single-window CAD-to-Post solution in Fluent
- Accelerate the workflow for generating a mesh from imported CAD
- Remove barriers that frustrate users and waste their time
The new Fluent Experience builds on the advantages Fluent has always had over competitors – higher solver accuracy, broad range of physical models, moving and deforming meshes, superior parallel scalability, ability to resolve reacting flows, and integration with other CAD and simulation tools through the ANSYS platform.
ANSYS 19.2 pushed these differentiators to the limit by releasing a task-based workflow with Mosaic-enabled Meshing that speeds up CFD simulations and helps engineers get accurate results with less training.
Accurate Computational Fluid Dynamics in less time
ANSYS’s new computational fluid dynamics task-based workflows deliver more accurate results in less time – here’s how.
ANSYS redesigned its Fluent user interface to provide a task-based workflow for meshing that enables your engineers to do more and solve more complex problems than ever before, in less time.
Introducing a New Fluent Experience for CFD simulations.
The new Fluent task-based workflow streamlines the user experience by providing a single window that offers only relevant choices and options, and prompts your engineers with best practices that deliver better simulation results.
This workflow builds on Fluent’s existing advantages and it includes:
- higher solver accuracy
- broad range of physical models
- moving and deforming meshes
- superior parallel scalability
- ability to resolve reacting flows
- and integration with other CAD and simulation tools through the ANSYS platform.
The context-sensitive command structure in the new task-based workflow reduces the time required to find the right option and reduces the chance of making a mistake.
Best practices are embedded into the Fluent, task-based workflow in the form of defaults and messages to the user that:
- Guide the user by focusing on meaningful tasks
- Indicate status and warnings with graphics
- Create custom workflows by modifying the task-list
- Process upstream changes robustly
- Present tasks as simple inputs and choices
- Minimize user intervention with intelligence and behind the scenes automation
- Record and replay the workflow
This reduces the amount of training required to start using the software and makes it easier for occasional users to return to the software.
The new workflow provides navigation cues that guide the user through the meshing process.
As each task is completed, it turns green and folds up so only the elements needed for the current task are exposed.
The streamlined task-based workflow provides the right solution for most problems, but ANSYS
also recognized that one workflow cannot fit every potential application.
This is exactly why the new workflow has been created in the form of custom templates.
It allows users to modify, save and distribute built-in templates to optimize their workflow for industry-specific, company-specific or application-specific requirements.
Any workflow can also be recorded and replayed to accommodate users who run a series of simulations, such as to evaluate a series of candidate designs or make incremental improvements to a simulation to more accurately reflect the real world.
Saving time with simulation
The new advancements within ANSYS Fluent have customers everywhere raving.
R&D Thermal Research Engineer at INDAR, Itsaso Auzmendi-Murua stated , “Fluent reduced generator thermal simulation preprocessing from six to eight days to four hours.”
Solving the most critical concerns in CFD simulation
If you know anything about CFD (and even if you don’t) accuracy and solution time are two of the most critical concerns in computational fluid dynamics (CFD) simulation, and both are highly dependent on the characteristics of the mesh.
Why? Different types of meshing elements are needed to deliver optimal performance in resolving different geometries and flow regimes- but transitioning between varying types of elements has long been a challenge.
The transition zone has typically relied on non-conformal interfaces or on pyramids/tetrahedra, but these come with issues regarding mesh quality and excessive cell count.
This is why it has often been necessary to compromise on a common element type in order to minimize transitions.
ANSYS Mosaic meshing technology changes the game by automatically combining disparate meshes with polyhedral elements for fast, accurate flow resolution.
This Mosaic mesh-connecting technology conformally connects any type of mesh to any other type of mesh, making it possible to build optimal meshes that use the best type of element in every section of the mesh.
ANSYS Fluent Mosaic Meshing for CFD Simulations
Mosaic technology allows native polyhedral meshes to connect with the following element types:
- Surface: triangle, quad, polygon.
- Volume: hexahedral, tetrahedral, pyramid, prism
Simulate faster than ever before
I’ll leave you with a quote from a little Italian car company you may have heard of before. Just like them, adding a tool like Fluent to your tool shed will help you simulate and solve complex problems faster than ever before. If you want to talk through specific use cases or pricing please contact our sales group and we’ll get back to you as soon as possible.
Now for the quote…
“With Mosaic technology and the Fluent end-to-end workflow, our team runs three times as many simulations in the same amount of time and develops cars faster than we ever could before.” –Ferdinando Cannizzo, Head of GT racing car development at Ferrari
The latest ANSYS 19.2 release enables users to solve product development challenges faster than ever with Pervasive Engineering Simulation solutions.
Shane Emswiler, Vice President and General Manager for ANSYS electronics, fluids, and mechanical business units says, “ANSYS 19.2 delivers product enhancements that enable more companies to remove design barriers and bring their innovative products to market faster than ever without sacrificing quality.”
Computational Fluid Dynamics (CFD) Improvements
The workflow for CFD Simulations is accelerated for watertight geometries supported by Mosaic meshing technology. ANSYS Fluent meshing delivers higher quality results at faster speeds using high-quality polyhedral meshes for accurate flow resolution. Users are now able to produce fewer and better quality cells to deliver solutions twice as fast as before.
System Coupling 2.0 for multiphysics design simulation has been added with the new release offering consistent performance and validation against the original version of the engine. High-performance computing (HPC) resources for multiphysics simulations are able to quickly map data. Text-driven workflows have been improved to make it easier to start and restart coupled fluid structure interaction analysis.
Functional Safety Analysis Improvements
ANSYS 19.2 makes it easier and faster to build, validate, and deploy digital twins and provides new functionalities for the development of autonomous and electric vehicles. ANSYS VRXPERIENCE allows users to use virtual reality simulation and predictive validation for autonomous vehicle simulation for additional intelligence such as smart headlamps, interior and exterior lighting, autonomous vehicle controls, and HMI validation. VRXPERIENCE uses realistic real-world simulation conditions including weather and road conditions, oncoming vehicles, pedestrian scenarios, and anticipation to critical situations.
Embedded Software Improvements Users can design easier and faster with embedded system architecture and develop and verify safety-critical embedded code. ANSYS SCADE Suite has been improved to the design verifier and the Simulink importer and now ANSYS SCADE LifeCycle offers Jama Software to support manageability tools and enable bidirectional generation of matrices.
Physics Simulation Improvements
ANSYS 19.2 expands the physics simulation capabilities into Optics and Optoelectronics to be able to design and simulate illumination, interior and exterior lighting, cameras, and optical performance faster than ever. The ability to simulate optical performance within a system allows designers and engineers to perfect the optical product performance while reducing development time and costs.
3D Design Exploration
ANSYS Discovery Live now allows users to use a parameter studies to test new ideas with minimal setup and run time. It allows designers to customize and learn more about simulation results to accomplish better design goals. ANSYS Discovery AIM includes improved physics-aware meshing for faster results.
Design Simulation Improvements
Inverse analysis, material designer, and topology optimization enhancements allow engineers to calculate the cold shape of a component to achieve the desired hot shape and performance. ANSYS Additive Print and ANSYS Workbench Additive now includes physics-driven lattice optimization; additional topology optimization loading options; manufacturing constraints for additive manufacturing; and lattice optimization capabilities. These improvements help dramatically light-weight parts which saves companies a lot of material costs.
Electromagnetic Design Improvements
New advancements include light-weight geometry modeling for rapid meshing and actor movement in road scene simulation – producing a simulation 20x faster than the previous release. ANSYS Icepak allows users to compute thermal impact from multiple electromagnetic loss connections and ANSYS SIwave allows users to easily define and explore printed circuit board (PCB) stackup layers to evaluate PCB design performance.
EAC’s been in the engineering and design technology world for a long time. Over the years we’ve carefully cultivated our product portfolio to meet the ever-changing needs of people and companies that design, manufacture, and service products. Our partnerships with PTC and ANSYS allow us to offer a few different design simulation and analysis solutions to our customers.
Design simulation, Computer Aided Engineering (CAE), Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and many other terms all fall into the “simulation and analysis” bucket. These tools help engineers and designers create virtual prototypes of their products. This helps groups rapidly prove, or disprove, design ideas in a digital space – reducing the time and money spent on physical prototypes, and increasing confidence in designs.
“If you’ve seen one, you’ve seen ‘em all” does not apply to simulation software. Different tools offer different benefits, accuracy, speed, and ease-of-use. Here’s a quick overview of some of the tools we offer. Contact our sales group to learn more about pricing, full capabilities, and packaging.
Option 1) PTC Creo Simulate
Simulate is a fantastic tool that’s fully integrated into PTC Creo Parametric CAD software. It offers fantastic meshing capabilities and accurate simulation results directly within a user’s familiar CAD software interface. All you need to do select the PTC Creo Simulate tab and you’re off and running. This is great for designers and engineers looking to test the stresses and loads under which a product will operate in ‘real world’ conditions. Based on your simulation and analysis results, you can either fix design flaws or forestall them. If you’re already using PTC Creo you should explore PTC Creo Simulate. Because, why would you ever manufacture a product without testing and analyzing it first? Creo Simulate comes in two flavors – Simulate and Advanced Simulate. They come with two different price points. One or the other might be the best option for your company. It really comes down to whether you need to simulate materials with linear or non-linear properties.
Option 2) ANSYS Discovery Live
ANSYS Discovery Live blows my mind. This tool was released in late 2017 and delivers functionality never seen before. Discovery Live uses ANSYS Discovery SpaceClaim to pull in IGES, STEP, and CAD models. Then the interface guides users through applying materials and some constraints – and Boom! It runs the simulation…in real-time…right in front of you. I’m talking about the ability to run wind-tunnel testing in real-time! Discovery Live is different from PTC Creo Simulate and most other simulation tools. It uses the Graphics Card (GPU) to run the simulation. This means it doesn’t occupy your core processor and RAM to while solving. You get better computer performance and instantaneous results for structural, thermal, fluid flow, wind tunnel, structural/fluid interaction, and more. Discovery Live is a great tool for engineers and designers that want to test a lot of design options quickly. The price is incredibly reasonable for a tool this powerful. You can see pricing and compare Discovery Live to AIM here.
Option 3) ANSYS Discovery AIM
Sometimes simulating real-world conditions requires more features and control than tools like PTC Creo Simulate, Solidworks Simulation, or Discovery Live might offer. ANSYS Discovery AIM is a great option when that’s the case. ANSYS Discovery AIM is a “multi-physics” simulation tool. What does that mean? Multi-Physics or Multiphysics refers to the ability to combine properties and solvers to simulate product usage. “Physics” in the simulation world refers to the kinds of simulation you are running – e.g. electromagnetic, thermal, structural, radio frequency, fluid flow, etc. AIM is a workflow driven multi-physics tool. It guides users through the steps necessary to complete a successful simulation. This is the perfect option when companies want a robust solution, but may not have experienced analysts on staff. Much like how PTC Creo Simulate maintains a familiar interface to make simulations easier; AIM uses guided workflows to make detailed upfront simulation accessible to engineers and designers.
Option 4) Dedicated ANSYS analysis software
When product simulation and analysis goes to the next level you need the ANSYS flagship products. These are sometimes known as the ANSYS Workbench products. Unlike PTC Creo Simulate or the Discovery software, each of these tools focus on one area of simulation…and deliver results you can take to the bank (or the regulatory agency). They are more complicated and come with a higher price point, but the results are unmatched. ANSYS’ comprehensive software suite spans the entire range of physics, providing access to virtually any field of engineering simulation that a design process requires. Organizations around the world trust ANSYS to deliver the best value for their engineering simulation software investment. If you need to test a specific physic – fluids, structures, electronics, semiconductors, or embedded software – this is the option for you. Contact us to learn more about a specific solution’s pricing and functionality. Also, if you’re a start-up make sure you ask us about special offers available through the start-up/entrepreneur program.
So there you have it. My layman’s take on a variety of simulation options. I hope you found this helpful. Please reach out to us if you have any questions or would like to see a demonstration of any of these tools.
If you are an OEM supplier to a major fortune 500 manufacturing company it probably took you a while to become their supplier. You had to prove to them that you could deliver a quality product on time, at a fair price.
Now that you have won their business it is probably equally as important to maintain that business as it was to win it in the first place. Your company probably has a nice cash flow and your employees are enjoying a nice secure job because of this win. However, the most important thing that will keep your customer coming back to you is quality.
Most major manufacturing companies realized years ago that the sooner that you can discover flaws or issues in the design phase, the easier and more cost-effective it is to fix the problem.
They found out that after completing the design process in CAD, they could move on to using simulation software, like ANSYS, to simulate prototypes. By simulating their prototypes they are able to run multiple simulations of their prototypes at one time and pick out the prototype that met their requirements to move forward and begin manufacturing.
Over the years these huge corporations have saved millions of dollars in time-savings and reduced the amount of times projects have to be constructed.
In the interest of time-savings and cost-savings, I suggest you consider looking into a simulation tool yourself. As your customer will appreciate knowing that their supplier realizes how important a quality product is. Who would you rather buy from? A company that has thoroughly tested their product or one that hadn’t?
If you’re interested in learning more about the benefits of simulating your products early and often, download our brochure here.