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SIMULATION TECHNOLOGY:
SPEED UP YOUR ITERATIVE PROCESS
Jan Buytaert
Senior Systems Engineer
Consultant PhysicsLab
CONTENT
WHY USE
SIMULATION TECHNOLOGY?
Problem statement & illustrations
• design trials
• Innovation
• becomes more complex and multidisciplinary,
• and consequently more challenging and expensive.
1 Confluence concept
2 Simulation parameters
Design space
3 Simulations
4 Prototypes & experiments
5 Design choice
Time
2.3 Simulation technology, speed up your iterative process
CONFIDENTIAL
9
sim
breadboard
• Example
• PCB air fan cooling
• Multi-physics model (CFD & Heat transfer)
• Design verification
• of a physically non-testable case
• Example
• Cooling of a reaction vessel
• Multi-physics model (CFD & Heat transfer)
• Problem solving
• by design optimization
• Example
• Beer bottle interlayer
• Structural model
• Problem solving
• by design vs cost optimization
• Example
• Beer appliance door
• Structural model
• Optimization of performance
• Optimization of amount of material/weight economically
• Reducing testing costs
WHAT IS
SIMULATION TECHNOLOGY?
The finite-element method
• Simulation
• The imitation of the operation of a real-world process or system over time.
• Requires that a model be developed (containing geometry + loads).
• Simulation technology
• Physical model versus …
• … abstract mathematical model
2.3 Simulation technology, speed up your iterative process Engineer Michael Burm
CONFIDENTIAL
31
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times
• Geometry
• Draw from scratch or start from a CAD model
• Remove unnecessary detail & use symmetry
• Meshing
• Subdivide a large problem (i.e. a CAD geometry)
into smaller, simpler, parts, called finite elements.
• fine meshing = good resolution = long calculation times
mesh
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
• Geometry
• Meshing
• Boundary conditions
• Mimic the physical loads and constrains
interacting with the model
• … forces, displacements, pressure, fixations, heating/cooling …
• Idealization/simplification is needed ~ approximation
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible
• Geometry
• Meshing
• Boundary conditions
• Finite-element method solving
• Matrices of partial differential equations
• Analytical solving = mission impossible (too many variables, degrees of freedom, equations)
• Approximate solution
• Calculation time …
• Convergence to a solution …
safety factor
stress
HOW TO
USE SIMULATION TECHNOLOGY?
Insights
• Challenges
• Optimal meshing of the geometry
• Breaking down a problem into subsystems for simulation
• The art of idealization (stripping away of unnecessary complexity)
• Applying realistic boundary conditions
• Interpreting the results correctly
Model set-up
Solution process
Solution verification
Solution validation
Post-processing
Report writing
Analysis specifications
Solution validation
Geometry creation
• Physical testing
It should be remembered that test Solution validation
"Nobody trusts a computer simulation except the guy who did it,
and everybody trusts experimental data except the guy who did it.
Why not combine the two and get results
everybody can mistrust a little."
- T. Kordyban -
• Conclusions
Simulation technology serves agility in innovation
• Speed-up your innovative process
• Model and load case variations can be readily made
• At a reduced testing cost
• Concretize your product/process
Gate: Go/No-Go
• Facilitated design space exploration
Gate: Go/No-Go
and the converge towards a chosen design
• Simulations and physical testing both have value
• User-centric development
• Specification/discussion load cases
• Robustness/safety factor for use cases
EXAMPLES
SIMULATION TECHNOLOGY
From beer to Darwin’s evolutionary theory
• Example
Chimney with different flows inside
• Multi-physics model
• Particle tracing
• CFD
• Example
Gravitational oil drain
• CFD model
• Design optimization
• Design verification
• Example
Biomechanical structural analysis of bird beak evolution
• Structural model
• Mechanical stress, fracture risk and beak evolution
• Conceptual understanding
QUESTIONS?