INTERNSHIP TRAINING REPORT 2019-

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ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of
any task would be incomplete without the mention of the people, who are
responsible for the completion of the internship, because it is epitome of hard
work, perseverance, undeterred missionary zeal, steadfast determination,
unperturbed concentration, dedication and most of all encouraging guidance. So,
with gratitude I acknowledge all those whose guidance and encouragement served
as a beacon of light and crowned our effort with success.

My humble pranam to SRI SRISRI DR. NIRMALANANDANATHA

MAHA SWAMIJI for his divine blessings

I am grateful to Dr. K.M. RAVIKUMAR, PRINCIPAL, for helping and

guiding us through our academic career.

I would like to thank Gp. Capt V. Rajan (Retd), HOD, Dept. of

Aeronautical Engineering for permitting me to undergo internship at S & I
Engineering Solutions.

I express my heartfelt thanks to the Management of S & I Engineering

Solutions and Dr. Nikhil Shende and Dr. Munikrishna N for providing me the
opportunity to undergo Internship in their industry/institution under their directions
and guidance.

I express my heartfelt thanks to my internal guide Prof. Dr. Nikhil Shende

and Dr. Munikrishna N for their guidance, support and technical expertise in
preparing this report.

I take the opportunity to express my deep sense of gratitude to my parents

and family, who introduced me to the Graduate Engineering studies and were a
constant source of moral support, love and encouragement throughout my studies.

I thank all those persons and all well-wishers who directly and indirectly
helped and motivated me to complete the internship successfully.

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ABSTRACT

During the course of the internship, we were introduced to the process of

CFD, through which we developed an appreciation of a good CFD process.
We were also introduced to different geometry creators, meshing tools, the
HiFUN solver, and various post processing tools. We were each given a test
case to validate the process we ultimately used for our project.

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LIST OF FIGURES
Fig. 1 – The CFD process
Fig. 2 – HiFUN Home page
Fig. 3 – Computational Domain
Fig. 4 - Discretized Domain, Clustered Grid Near Base And Coarse Structured
Grid Used In The Long Channel Before The Base
Fig. 5 (a), Fig. 5 (b) – Mach contours
Fig. 6 (a), Fig. 6 (b), Fig. (c) – Velocity Profiles
Fig. 7 – Skin Friction Co-efficient

LIST OF TABLES
Table 1 – Features of HiFUN solver

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CONTENTS
Acknowledgement
Abstract
List of Figures
Certificate

CHAPTER 1
INTRODUCTION
CHAPTER 2
INTRODUCTION TO HiFUN SOLVER
CHAPTER 3
PROBLEM STATEMENT
GEOMETRY CREATION
MESH CREATION
INITIAL AND BOUNDARY CONDITIONS
CHAPTER 4
RESULTS
MACH CONTOUR
VELOCITY PROFILES
SKIN FRICTION CO-EFFICIENT PLOT
CHAPTER 5
OUTCOME OF THE INTERNSHIP
CHAPTER 6
REFERENCES

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CHAPTER 1
INTRODUCTION
Computational Fluid Dynamics or CFD is the use of mathematics, physics
and computational software to solve problems of fluid flow over body surfaces
and through complex geometries. The process involves five steps – Geometry
creation, mesh generation, pre-processing, solving, post-processing.
Geometry Creation: This is first step to solve any problem in fluid dynamics.
The domain and geometry of the body are created in this step. Software like
CATIA, SolidWorks, etc. are used to create the geometry which are then
imported into other software which generate the required mesh. In some cases,
the geometry can be created within an all-in-one package like ANSYS, Su2, etc.
Mesh Generation: This is an important part of the CFD analysis, which
involves discretizing the domain into small parts for the solver to easily analyze
the fluid flow. The grids generated can be structured or unstructured, each with
its own advantages and disadvantages. The structured mesh is rigid and cannot
be sometimes used to properly divide the domain, while the unstructured
meshes are flexible and are most favored. Software like ICEM, ANSYS, etc.
are the most commonly used software. The mesh can also be fine or coarse
depending on the application, and user. The number of grids is a key
consideration because the higher their number, longer the computational time.
The mesh flow should ideally should be made in such a way that it intuitively
follows the flow pattern and the areas with large gradients are more refined.
The mesh generation generally ends with the specification of boundaries for the
domain and body under study.
Pre-processing: This is the most crucial step in the entire CFD process, as a
mistake here can lead to erroneous calculations in the solver, which gives a
completely different result than expected. It involves setting the boundary
conditions for the body, free-stream conditions for the domain, and is used to
specify the number iterations, the fineness of the calculations (given by the
Courant-Fredrichs-Lewy or CFL number), wall data, etc.
Solving: This step is at the heart of the entire CFD process. The solver is a
complex set of rules that solve Navier-Stokes’ equations or a different of the
same, such as RANS or Reynolds’ Averaged Navier-Stokes’. Other approaches
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are Large Eddy Simulation (LES), or Direct Numerical Simulation (DNS).

Methods or models used to solve these equations are the Spalart-Allmaras, k-
omega, k-epsilon, Transition SST, etc. For simplicity one or two equations
models such as the Spalart-Allmaras or k-omega models are commonly used.
Since the solver solves these differential equations using numerical methods,
the main challenge is to get a faster result with minimum error (as numerical
methods are just an approximation). The numerical methods used are Newton-
Rapson method, Runge-Kutta method, generalized minimal residual method
(GMRES), Backward Differential Formulae 1, 2, 3. (BDF1, BDF2, or BDF3).
The solver runs for the number or iterations specified or until the solution
converges. The solver generally has a provision to view convergence or residue
plots, integrated data plots, etc. During the course of this internship, we were
trained to use the home-grown High-resolution Flow solver on UNstructured
meshes or HiFUN.
Post-processing: This is the final step in the CFD process. Here, we can
visualize the flow pattern, physical properties at different places, variation in
the them as time progresses, and plot the different graphs required by the
problem under analysis. In a nutshell, it provides the user with a tool with
which he/she can relate the solved problem with real scenarios.

Geometry Creation

Grid Generation

Pre-processing

Solving

Post Processing

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FIG.1 THE CFD PROCESS
CHAPTER 2
INTRODUCTION TO HiFUN SOLVER
HiFUN or High resolution Flow solver on UNstructured meshes is a general
purpose flow solver that uses unstructured data based algorithms. The code is fine
tuned to solve problems pertaining to the aerospace industry and can be extended
to the automobile industry.
Mesh elements
Spatial Accuracy
Numerical flux formula
Viscous discretization
Non-conformal Block Interface algorithm
Moving wall boundary condition
Multiple rotating frames of reference algorithm
Algorithm to simulate porous media
Turbulence Model
Wall function
Convergence acceleration
Parallel Processing
Higher order time accuracy
Grid Adaptation
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Hexahedron, tetrahedron, prism and pyramid
Achieved through Green-Gauss procedure or
method of least squares
Supports a number of numerical flux formulae
but allows the user to determine, based on his or
her choice
Allows for robustness of the solver even in highly
skewed cells
Handles non conformal grids at the interface of
two blocks
Possible to simulate both translating and rotating
walls
Handles multiple rotating frames of reference for
any problem
The flow solver is capable of solving problems
involving porous media
Supports Spalart-Allmaras and k-omega
turbulence models
The standard equilibrium wall function gets
automatically activated for turbulent calculations
if grid density is not adequate near the wall
Rapid convergence through a matrix-free implicit
procedure
A four layered approach to data handling ensures
there is no degeneration of data handling
A dual time stepping procedure is used to achieve
second order time accuracy both on stationary
and moving grids
Sensors based on error estimator and error
indicator is used as a hybrid strategy.
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HiFUN is suited for serial applications, which

Migratory Memory Algorithm implies a machine’s solving capability is
substantially enhanced
TABLE.1 FEATURES OF HiFUN SOLVER

A general-purpose flow solver that uses unstructured data algorithms. Developed at

the Department of Aerospace Engineering, Indian Institute of Science, Bangalore,
problems pertaining to aerospace as well as the automobile industry can be solved.
The solver is capable of solving problems at a wide range of Mach numbers, from
airship aerodynamics to aerodynamics of hypersonic air vehicles.

FIG.2 HiFUN HOME PAGE

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CHAPTER 3
PROBLEM STATEMENT
I. GEOMETRY CREATION
Many aerospace applications involve base flows, such as missiles, rockets and
sometimes even aircrafts, despite their aerodynamic shape. In this project, we try to
determine the properties of the standard case of an incompressible Driver-
Seegmiller base flow, which is used for the validation of the HiFUN solver which
is also used for our project. Seegmiller’s incompressible base flow is a standard
case used for validating CFD solvers.
This study focuses on the incompressible flow over a backward-facing step,
measured experimentally by Driver & Seegmiller. The geometry has a step height
to tunnel exit height ratio of 1:9 which helps to minimize the freestream pressure
gradient due to sudden expansion. The experimental configuration also had a step
height to tunnel width ratio of 1:12 to minimize three-dimensional effects.
Computational domain and Grid Used: A single-zone mesh was generated to
model the region from x/H = -105 to +50. The grid was clustered to the solid
surfaces such that y+ = 1. The grid was also clustered in the streamwise direction
near the recirculation region to improve resolution.

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FIG.3 COMPUTATIONAL DOMAIN

II. MESH GENERATION

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FIG 4. DISCRETIZED DOMAIN, CLUSTERED GRID NEAR BASE AND COARSE

STRUCTURED GRID USED IN THE LONG CHANNEL BEFORE THE BASE

• Domain size = -150 to 50 meters

• Grid Size = 196854 cells
• y+ = x+ = 6.548e-6 meters

III. BOUNDARY AND INITIAL CONDITIONS:

• Mach number = 0.128 • Pressure at inlet = 2505.37 Pa
• Freestream pressure = 1246.192 Pa • Inlet nuTilda = 9.6568e-05
• Freestream temperature = 300.0 K • Thermal conductivity = 0.0242
• Dynamic Viscosity = 1.7894e-05
• Ratio of modified turbulent viscosity = 1.341946

CHAPTER 4
RESULTS
I. MACH CONTOURS

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FIG.5 (a) MACH NUMBER CONTOUR; (b) ZOOMED IN NEAR THE BACKWARD STEP

II. VELOCITY PROFILES:

2.5

1.5
y/H

0.5

0
0 0.2 0.4 0.6 0.8 1 1.2
U/U inf

Experiment HiFUN

FIG.6 (a) x/H = -4.0

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3.5

2.5

2
y/H

1.5

0.5

0
-0.2 0 0.2 0.4 0.6 0.8 1 1.2

U/Uinf

Experiment HiFUN

FIG.6 (b) x/H = 1.5

3.5

2.5

2
y/H

1.5

0.5

0
-0.4 -0.2 0 0.2 0.4 0.6 0.8 1 1.2
U/Uinf

Experiment HiFUN

FIG.6 (c) x/H = 2.5

III. SKIN FRICTION CO-EFFICIENT:

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0.04

0.04

0.03
Skin Friction Co-efficient

0.03

0.02

0.02

0.01

0.01

0
0 200 400 600 800 1000 1200

x/H

HiFUN Experiment NPARC k-omega

FIG.7 COMPARISON OF SKIN FRICTION CO-EFFICIENT

CHAPTER 5
OUTCOME OF THE INTERNSHIP
As per my experience during the Internship, SandI has friendly employees and a
motivating work culture which is supported by a concrete environment and
infrastructure, starting from the staff level to the management level.
There is lot of team work followed in every task, be it hard or easy and there is
always a very calm and friendly atmosphere maintained. There is a lot of scope for
self-improvement as great communication and support is found.
This internship was a useful experience for me. I have gained exposure to how an
aerospace industry, more specifically, the CFD domain functions. This internship
helped me explore my interest in the domain of computational fluid dynamics. I
learned how to develop an industrial level application mesh on 2D and 3D
geometries. This internship taught me how an CFD solver works and what it takes
build your own CFD solver. It was an amazing experience to work on the
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indigenously developed CFD solver HiFUN. This internship taught me how to

work in a team. I made few contacts while working in this organization, and above
all, working with the Directors of the company helped me learn a lot. Soham was
a very cooperative and helpful person, and he helped us learn how to develop a
good quality mesh over certain geometries. Munikrishna sir and Nikhil Sir were
great guides during our internship, and they constantly motivated us to do our work
sincerely.
SandI is a great company to learn and explore domain of interest using real time
projects. It has been a great experience to work in such a reputed organization.

CHAPTER 6
REFERENCES AND BIBLIOGRAPHY
[1] . https://turbmodels.larc.nasa.gov/backstep_val.html
[2] https://www.grc.nasa.gov/WWW/wind/valid/backstep/backstep01/backstep01.html
[3] https://www.grc.nasa.gov/WWW/wind/valid/backstep/backstep02/backstep02.html

[4] Smith, H. E., "The Flow Field and Heat Transfer Downstream of a Rearward Facing Step in
Supersonic Flow," ARL-67-0056, March 1967.

[5] Garrard, G. D. and Phares, W. J., "Calibration of the PARC Program for Propulsion-Type
Flow," AEDC-TR-90-7 (AD-A224253), July 1990.

[6] Ebrahimi, H. B., "CFD Validation and Evaluation for Reacting Flows, Part III", AIAA-95-
0735, Reno, NV, Jan 1995

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