You are on page 1of 4

EE World Online Engineering White Papers DataSheet PRO MCAD Central

SEARCHHERE

August 30, 2016


HOME

VIDEOS

ARTICLES

SUPPLIERS

3D CAD MODELS

WEBINARS

LEADERSHIP

ENGINEERING RESOURCES

EVENTS

Home > Design World Articles > 5 Myths of CFD

5 Myths of CFD
October 12, 2010 Design World Staff : 0 Comments

By Dr. Ivo Weinhold, Product Marketing Manager, Mentor Graphics, Mechanical Analysis Division, Wilsonville,
OR

Enews Sign Up

Reprint Info>>
Computational fluid dynamics (CFD) simulation has long had the reputation of being too difficult, slow, and expensive
to be performed as part of the mainstream design process. That may have been true 10 years ago, but CFD has
changed over the past decade and today has become much easier, faster, and less expensive to use. Yet, myths are
standing in the way of greater use in the early phases of mechanical design. These myths help explain why only about
30,000 out of over 1 million mechanical design engineers worldwide use CFD to simulate fluid flow inside and around
their products.

1. The skills required to operate the CFD software are simple knowledge of the CAD system
and the physics of the product, both of which the vast majority of design engineers already
possess. FlowEFD Pro is fully embedded in Pro/E Wildfire.

possess. FlowEFD Pro is fully embedded in Pro/E Wildfire.

Myth #1: CFD is too difficult to be used in the design process


In a recent survey of mechanical design engineers, 58% said that most engineers dont have the necessary expertise
and knowledge to use a CFD tool. This is most likely because all CFD codes of a decade ago and many of today require
the user to have a deep understanding of the computational aspects of fluid dynamics in order to be certain of
obtaining accurate results. For example, users need to know how to translate their computer-aided design model into
the CFD environment, then reverse the model so that empty flow space rather than the solid product is modelled,
create a mesh with the right properties, determine boundary conditions, select the right physical models, tweak solver
settings to ensure convergence, and other tasks.
Previous generations of CFD software also required a substantial amount of tuning and tweaking such as manually
modifying cells to improve the mesh quality and adjusting solver controls such as the relaxation factors in an effect to
get it to convergence to a solution. These tasks provided another reason why CFD required the skills of a specialist
and could not be performed as part of the design process.
But in the last few years a new generation of CFD software has been introduced that addresses all the major reasons
for the relative lack of use of CFD software. Its use of native 3D CAD data, automatic gridding of the flow space, and
managing the flow parameters as object-based features eliminates the need for engineers to understand the
computational part of CFD and instead enables then to focus on the fluid dynamics of the product which is already
their responsibility to understand and master.
The newest generation of CFD software contains sophisticated automatic control functions that ensure convergence
in almost every application without the need for manual tuning. Perhaps the most important function controls the
quality of the mesh to avoid one of the biggest reasons for run divergence. Virtually the only situation where the
software will not converge is in a problem with a naturally unsteady flow. This type of problem can usually be solved
simply by switching to transient analysis.

Design World Digital Edition


Browse the most
current issue of Design
World and back issues in
an easy to use high
quality format. Clip,
share and download
with the leading design
engineering magazine today.
View Back Issues

Subscribe

The skills required to operate the CFD software are simply knowledge of the CAD system and the physics of the
product, both of which the vast majority of design engineers already possess. The engineer is able to focus on his/her
time and attention on optimizing the performance of the product as opposed to operating the software.
Myth #2: CFD takes too long to use during the design process
CFD has long been used as a validation step after the design process has been essentially completed. The major
reason is that in the past CFD took so long that if a design iteration were to be analyzed during the design process, it
would have been superseded by other iterations before the analysis results were available. The greatest amount of
time is spent during the meshing process. This used to require a time-consuming manual step of translating the
geometry from the CAD software to the CFD package. From this point, another tedious step was required to extract
the cavities from the CAD model and then mesh them. While automatic meshers have long been available, a
considerable amount of manual intervention was still needed in order to maintain the quality of the mesh by
eliminating gaps and overlaps, and maintaining the required skewness, aspect ratio, warpage, and volume of
individual cells. This manual process had to be repeated for every design change.

Forum for Electronics


Covering Microcontrollers, DSP, Networking,
Analog and Digital Design, RF, Power Electronics,
PCB Routing and much more
2. The major reason why CFD has taken so long is because when a design iteration was to be analyzed during the design process, it
would have been superseded by other iterations before the analysis results were available.

The new generation of CFD software greatly reduces the time required for analysis by automating all of these steps.
In the new approach, native 3D CAD data is used directly for fluid flow simulations without the need for translations
or copies. All ancillary data required for flow simulations, such as material properties and boundary conditions is
associatively linked to the CAD model and carried along with all design changes. The software analyzes the CAD model
and automatically identifies fluid and solid regions without user interaction. Then the automatic mesher creates the
mesh while maintaining the skewness, aspect ratio, warpage, and volume to high levels of quality, completely
eliminating the need for any manual intervention. The result is that new parts and design changes can be meshed in a
matter of minutes, dramatically reducing the time required for analysis.

Myth #3: CFD is too expensive to be used by mechanical engineers


Another factor limiting the use of CFD in the past has been the high cost of software. Traditional CFD codes cost in
the region of $25,000 to lease for one year. An even greater cost for most companies is the need to hire analytical
experts to run the codes. Analytical experts were required for all CFD codes and are still required for most codes
because the software requires the user to have a deep understanding of the mathematical aspects of computational
fluid dynamics. These analysts need to spend a considerable amount of time training in order to keep up with the
latest changes in the code. In the recent past, CFD codes also required specialized hardware such as supercomputers
in order to provide results within a reasonable period of time.

The Engineering Exchange is a global educational


networking community for engineers.
Connect, share, and learn today

Tweets by @DesignWorld

format right here - ow.ly/fd61303QNNG


04 Sep
Design World
@DesignWorld
3. Concurrent CFD software runs inside the same CAD software environment that design engineers are already familiar with.

The latest generation of CFD code intended for use during the mainstream design process substantially reduces the
cost of performing CFD. The cost of the software has fallen to something in the order of $25,000 for a perpetual
license, with the only ongoing cost being a maintenance fee of about 18%/yr. This software eliminates the need for
analytical specialists because it can be used by mechanical design engineers with minimal training. The software runs
inside the same CAD environment that design engineers are already familiar with, and there is no need for the user to
understand the mathematical aspects of CFD. Finally, the latest generation of CFD software runs on PCs and laptops
which have the power possessed by a supercomputer only a decade ago but cost just a few thousand dollars.

Register now for this webinar on working safely


with #3DPrinting and metal additive
#manufacturing machines - ow.ly/3kQA303J5Z4
Work Safely with 3D Printi
Register Today! Learn the to
designworldonline.com

Embed

Myth #4: You cant directly use your CAD model to do CFD analysis
In the past, it was necessary to copy or translate the CAD model to a different program and then modify it
substantially in order to create the CFD model. The main reason was that the tools available to translate the CAD
model to the CFD program required a considerable amount of manual intervention. Typically, the translation process
might work for 80% of the geometry but the rest had to be re-created or simplified by hand. Many users found it more
reliable to start from scratch by creating the geometry in the CFD program, although this also involved a considerable
expenditure of time.

View on Twitter

Design World Network


498,490 likes

Like Page

Be the first of your friends to like this

Design World Network


19 hrs

Check out the latest Design World


podcasts here!

Podc...
Network...

DESIGN...

4. FloEFD V5 is embedded in the CATIA V5. Concurrent CFD software uses the native 3D CAD data directly for
flow simulations without the need for translations.

The new generation of CFD software uses the native 3D CAD data directly for flow simulations without the need for
translations or copies. All design changes based on simulation results are carried out directly in the CAD system using
familiar solid modelling functions. There is no need to create phantom objects in the feature tree to represent the
fluid spaces. Flow conditions are defined directly on the CAD model and organized similarly to other design data in the
feature tree. As a result, the original CAD model can be used without modification for CFD analysis.
Myth #5: Most products dont need CFD analysis
In the past, the use of CFD has been concentrated in a relatively small number of industries such as automotive,

Comment

Share

Design World Network


20 hrs

Design World
Follow

+1

In the past, the use of CFD has been concentrated in a relatively small number of industries such as automotive,
aerospace, and power generation producing high-value products in which fluid flow has an obvious and major impact
on performance. This has led to the belief among many that CFD only adds value to these high-value products.
Actually, fluid flow has a major impact on the performance of a wide range of products performance which can be
significantly improved by analysis. Every product which interacts with a fluid or gas and every production process
involving fluids or gases is a potential subject of analysis. This helps explain why today CFD is being used to improve
products as diverse as swimming pools, toilets, lawn sprinklers, gas meters, production printing system, disk drives,
and oil filters.

+ 2,841

...

5. CFD softwares ability to integrate CFD into the design process allows design
engineers to focus on the physics of the problem, which in most cases, they
already understand well and generate results more quickly.

Mentor Graphics
www.mentor.com

Speak Your Mind

Name *
Email *
Website
POSTCOMMENT

Solar Power

EE World

Print Subscription

Design World

Solar Power World reaches executives,


managers, engineers, installers and

EE World Network of sites feature industry


experts covering product news and

Stay Informed. Stay Smart. Stay Ahead.


You're invited to qualify for the fastest

>> Advertising

technical professionals involved in the


design, manufacturing, development, and
installation of solar power projects.

reviews, EE video, how-to articles, best


practices in electronics design and
electronic datasheet resources.

growing design engineering publication on


the market today. Click button below for
additional information.

>> Engineering Jobs

Visit website

Visit website

New/Manage Subscription

>> Contact
>> Site Map

You might also like