FloEFD Overview - Boundary Systems

Richard Ozaki

Americas Channel AE

FloEFD Overview

www.mentor.com© 2016 Mentor Graphics Corp. Company Confidential

About Mentor Graphics Corporation

� Founded in 1981

� Annual revenues > $1.2B (FY16)

� Electronics Design Automation and simulation software products :— Electronics for EDA:

– IC– PCB

— Mechanical Analysis– General Purpose 3D CFD– 1D System CFD– Electronics cooling CFD– HVAC CFD

� 5,000 employees worldwide— Over 70 offices

Wilsonville, Oregon U.S.A. Headquarters

� Fastest growing EDA company with 25% of the market


CFD Technology

� Computational Fluid Dynamics

� Mathematical prediction of fluid flow and heat transfer


Principal Lines of Business

� Thermal Design of Electronics— FloTHERM - Market leading software

for optimizing airflow, temperaturedistribution and contamination controlin and around electronics equipment

— FloTHERM.XT – Next generationelectronics cooling simulation tool.

� Engineering Fluid Dynamics— FloEFD - a different breed of CFD

software that is fully embedded in themechanical design environment, forall general engineering applications

� 1D System Level Analysis— Flowmaster – a system level analysis

tool for pipe networks. 1D flow andthermal network characterisation withextensive transient capabilities fordetermining network performance

� Thermal Transient Tester— T3Ster – a hardware measurement

product for the thermal characterisation of semiconductor devices.

FloTHERM

FloEFD

FlowMaster

T3Ster

4


What is FloEFD?

� Engineering Fluid Dynamics

(FloEFD) is:

— Integrated with CAD� Uses native solid model� Detects fluid region automatically� Supports iterative design analysis

— Written for the Engineer— Fits into your development process— Easy to use — Cost effective

� Computational Fluid Dynamics

(CFD) is:

— Stand alone� Translates solid model � Model fluid region� Redo for every iteration

— Written for the Specialist— Forces you to shift away from your

development process— Difficult to use— Expensive


Comparison of Flow Simulation Design Processes

CAD CAD CAD CAD

Manufa

cture

Conventional CFD

Concept Detailing Prototyping Testing

CAD CAD CAD CAD

Upfront CFD


Manufa

cture

Concurrent CFD


Manufa

cture

CADCFD CFD CFD

TraditionalCFD

TraditionalCFD

TraditionalCFD

UpfrontCFD

UpfrontCFD

UpfrontCFD


CAD CAD CAD CAD

Manufa

ctureConcept Detailing Prototyping Testing

CAD CAD CAD CADConcept Detailing Prototyping Testing

Manufa

cture

Concept Detailing Prototyping TestingM

anufa

cture

CFDCFDCFD

TraditionalCFD

TraditionalCFD

TraditionalCFD

UpfrontCFD

UpfrontCFD

UpfrontCFD

CAD

Comparison of Flow Simulation Design Processes

Create Cavity

CleanGeometry

MeshingTransfer

Geometry

Transfer Geometry

CleanGeometry

Create Cavity

MeshingBoundaryConditions

Solve

(Batch)

PostProcessing

ReportGeneration

Transfer Geometry

CleanGeometry

Create Cavity

MeshingBoundary

ConditionsSolve(Batch)

PostProcessing

ReportGeneration

Conventional CFD

Upfront CFD

Concurrent CFD

MeshBoundaryConditions

Solve(Batch)

PostProcessing

ReportGeneration

Meshing


FloEFD Enabling Technology – Full CAD Embedding and Integration with PLM packages

� FloEFD, Seamlessly integrated within major MCAD systems :

� Direct use of MCAD geometry � Automatic detection of the fluid region� No coming in and out of the CAD

package for the CFD simulation

� Benefits� No translation step necessary with loss

of geometrical fidelity� No complex definition of regions� Design and CFD models stay in sync.� Reduces re-synchronization effort and

errors

1/7


FloEFD Enabling Technology –Fast Automated Meshing

� Immersed Boundary Meshing:

� Automatic meshing for fluid and solid regions

� Deals quickly with “dirty” CAD geometries

� Automatic mesh refinement/unrefinement

� Benefits� No manual meshing time� No CFD algorithm expertise

required� Reduces execution time yet

delivers accurate results

2/7


FloEFD Enabling Technology –Intuitive Easy-to-use Interfaces for Engineers

� Engineering User Interfaces:

� Easy-to-use wizards provide guided model setup

� Comprehensive result analysis & visualization capabilities

� Optional MS Office-based results

� Benefits� Eliminates the need for CFD

expertise in the setup� Reduces setup times� Automates the product

documentation

3/7


FloEFD Enabling Technology –

a unique Transitional Turbulence k-ε model

4/7

� Laminar – Transitional – Turbulent k-E Model:

� Automatic laminar to turbulent CFD modeling with universal, grid independent modified 2 equation Wall Functions

� Laminar, transitional, and turbulent flow regimes automatically determined -- no need to specify flow characteristics

� Benefits� Direct ability to model flow regimes

eliminates CFD specialist requirement� Shorter setup times and increased model

accuracy compared to traditional approaches


FloEFD Enabling Technology – a unique modified Wall Function for Boundary Layers

5/7

� Automatic Modified Wall Function:

� Grid-independent near-wall modeling using “Partial Cells” technology

� Physically correct simulation of boundary layer phenomena for fluid flow and heat transfer

� Multiple scenarios automatically calculated

� Benefits� Accurate simulations including near-wall

boundary condition effects� No specialized/expertise setup

necessary� Reduces trial and error near-wall setup

of traditional CFD approach


FloEFD Enabling Technology –Automated Solution Convergence Built-in

� Automatic Convergence Control :

� Very robust convergence behavior

� First run converges without additional numerical diffusion

� Benefits� Reduces multiple re-runs due

to lack of convergence� Short run times enables

multiple variant scenarios� Eliminates CFD specialist

tweaks for convergence, i.e. model modifications

6/7


FloEFD Enabling Technology –Multi-variant “What if?” Analysis

� Design Variant Analysis:

� “What-if” analysis without further definition of model data

� “Cloning” feature� Full support of product MCAD

“configurations” and “instances”

� Modify design, run auto-mesh, execute!

� Benefits� Multiple “what-if” simulations

result in optimum design� Saves CFD specialist’s

resources for only most critical analyses

7/7


FloEFD Meshing Technology

� Well defined and robust algorithm

� FloEFD supports: — Flow Only (Fluid Cells)— Conduction Only (Solid Cells)— Fluid Flow and Heat Transfer (Fluid, Solid, Partial Cells)

� Refining Fluid and Solid cells allows for higher resolution

� The real FloEFD technology is within Partial Cells


Partial Cells

� Partial cells are always present at the fluid-solid interface

� Modified wall function captures boundary layer without need for high cell count at wall

� Proprietary technology based on physical test and empirical results

� Developed originally at Moscow state university during 1980s


Solution Adaptive Meshing

� Solution adaptive mesh will refine mesh in localised volumes based on flow gradients

� Automatic meshing requires little user input

� Solver does not start again, interpolates, continues

� Benefits:— Non-expert users can generate very

high quality grid— Only refined in critical areas— Higher accuracy with minimal

increase in solve time


Mentor Graphics CFD applications in the Aerospace & Defense Industry

Pumps & Valves

External Aerodynamics

Heat Exchangers

Fuel Injector Cavitation

Cabin Climate Control

Injectors,Pipework& Ducting

Aerodynamicsof Aerofoils

Air Intakes& Exhaust Flows

Lighting

ElectronicsCooling

Nacelles& pods

Fans Avionics

Fuel Tanks


Mentor Graphics CFD applications in the Automotive Industry

Valve Design

ExternalAerodynamics

Dashboard Electronics Cooling

Catalytic Converter

EngineManifold

Cabin ComfortModeling

Turbocharger

Cylinder Head Cooling

Exhaust DuctAfter-treatment

PowerBrakeBooster

Clutch Fluids

ClimateControlFans

WindshieldWipers

HeadlightThermal Effects

WindshieldDeicing Ducts

In-Cylinder Flows


Lighting & Displays

Fans & Cooling

Equipment

Heatsinks

Cold Plates & Chillerblocks

Pumps

Vents

Liquid Cooling

Disk Drive

LEDs

Networking / Telecommunications

Power Electronics

Heatpipes

Consumer Electronics

Computers & Peripherals

Graphics Cards

Audio / Hi-Fi

Connectors & Switches

Packaged ICs & Semiconductor

Rack Mounted Equipment

Automation

Multimedia

PCB Design

Mentor Graphics CFD applications in the Electronics Industry


Mentor Graphics CFD applications in the HVAC & Built Environment Industry

Hospital Wards

External Building Flows

Atriums & Auditoriums

Data Centers

Car Parks

Laboratories & Clean Rooms

Classrooms

Offices

Fans & Air Conditioning

Solar Panels

DomesticBoilers

Pipework& Ducts

Filters & Valves


FloEFD Functionality

22

Feature

Basic

FloEFD

Electronics

Module

HVAC

Module

Advanced

Module

LED

Module

Drafting

Module

External (<M5) & internal flows / Steady-state and transient analysis ✓

Compressible gas, liquid & incompressible fluid ✓

Free, forced, and mixed convection ✓

Boundary layers, including wall roughness effects / Laminar & turbulent flows ✓

Heat transfer in fluid, solid & porous media ✓

Isotropic, unidirectional, biaxial/axisymmetrical and orthotropic thermal conductivities ✓

Non-Newtonian liquids / Real gases / Two-phase flow (fluid & particles) / Relative humidity ✓

Moving/rotating surfaces and/or parts ✓

Cavitation in incompressible water flows / Steam Modelling with Condensation ✓

2 Resistor Components / Heat Pipes / Electrical Conditions / PCB Smartpart ✓ ✓*

Extended Engineering Database ✓ ✓

Thermal Radiation Model (Absorption in semi transparent solids) DT DT/DO DT/DO/MC

HVAC Comfort Parameters ✓

Pre-mixed / non-premixed steady state gaseous combustion ✓

High Mach Number Flow (M5-M30) ✓

Advanced LED modelling (2R and T3ster derived compact model) ✓

Engineering drawing creation (FloEFD standalone only) ✓

FloEFD Overview - Boundary Systems

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