Contents

I. Create geometry.......................................................................................................................................1
II, Setup boundary condition physic continua and initial conditions...........................................................5
III. Generate Mesh.......................................................................................................................................8
IV. Setup Solver and Visualizing Results.......................................................................................................9

I. Create geometry
1. Expand Geometry-> Right click 3D-CAD Models-> New

This step is used for open 3D-CAD tool in STAR CCM+

2. Right click XY plane in Features-> Create Sketch-> Click icon to create rectangle sketch

Select starting point at original point and select ending point at any location.

3. Select horizontal edge and change starting point into (0,0) and ending point is (39 in, 0

4. Select vertical edge and change starting point into (0,0) and ending point is (0,77in)

5. Click Ok

6. Right click Sketch 1 -> Extrude-> Change distance into 1.5 in-> Click Ok

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Now, you have a geometry of solar plate

7. Right click ZX plane in Features-> Reference Geometry-> Plane by transformation

Chaage value of translation vector into (2.5, 19.5,0) in-> Click Ok

8. Right click Plane 1-> Create Sketch-> Select icon to generate a circle-> Change center to (0,0)
and radius: 0.125 in -> Click ok

9. Right click sketch 2-> Extrude-> Change Direction Type to Reverse-

Change Body Interaction into None-> Click Ok

10. Expand Body Groups-> Rename Body 1 to Solar Plate, rename Body 2 to Nozzle

11. Zoom in Inlet of nozzle geometry and select the face-> Right click on the surface-> Rename-> Write
name: Inlet-> Click Ok.

12. Zoom in top surface of solar plate-> Right click on the surface-> Rename-> Write name: Top Wall->
Click Ok.

13. Right click on Top of Solar Plate-> create sketch-> On face-> Click icon to create rectangle
sketch

Select starting point at original point and select ending point at any location.

-> Select horizontal edge and change starting point into (0,0) and ending point is (39 in, 0

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-> Select vertical edge and change starting point into (0,0) and ending point is (0,77in)

-> Right click Sketch 1 -> Extrude-> Change distance into 1 cm-> Change Body Interaction into None->
Click Ok

13. Click Update 3D-CAD and after that Close 3D-CAD

Now you back to simulation screen.

Expand Geometry-> 3D-CAD Models-> Rigth click 3D-CAD Model 1-> New Geometry Part-> Click Ok

14. Rigth clcik Scenes-> New Scene-> Geomerty

Now, you can see the geometry of Solar Plate and Nozzle.

14. - Expand Geometry-> Right click Part-> New Shape Part-> Cone ->

Start Coordinate: [0.49529999999999996, 0.023319370754540318, 0.06035610114335164] m,m,m

End Coordinate: [0.49529999999999996, 0.631513519026245, -0.28239492238479824] m,m,m

Start Radius: 0.05 m

End radius: 0.1 m

-> Create-> Close

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15. Expand Geometry-> Part-> Multiple select Nozzle, Solar Plate, Body 3 and Cone -> Right click on
them-> Transform-> Rotate-> Change Axis Vector into (1,0,0) and Angle is -30 deg-> Click Apply-> Close

For 45deg model, the value of angle is -45 deg. For flat model, you skip step 15

You can do this by push Ctrl + slect both of them

16. Create Background for environment

Expand Geometry-> Righ click Part-> New Shape Part-> Block-> Change Corner 1 into (-1,-1,-1.2) and
Corner 2 into (2,3,1)-> Select Create-> Close

17. Expand Geometry-> Part-> Block-> Surface-> Right click Block Suraface-> Split by angle-> Ok

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18. Multiple select Block, Nozzle and Solar Plate

You can do this by push and hold Ctrl + click on them

Right click on them -> Create Mesh Operation-> Boolean-> Subtract-> Select Target Part: Block-> Ok

19. Expand Geometry-> Operations-> Subtract-> Excute

20. Expand Geometry-> Part-> Right click Subtract-> Rename into Background

Now, you finish prepare geometry for the simulation.

II, Setup boundary condition physic continua and initial conditions

1. Multiple select Solar Plate and Background-> Right click on them-> Assign Part to Region-> Change
option following to the picture

Select Apply-> Close

2. Right click Continua-> New-> Physics continua

Expand Physic 1-> Right click Model-> Select Model->

Properties Enabled Models

Space Three Dimensional
Material Gas
Flow Segregated Flow
Equation of state Constant Density
Time Implicit Unsteady Time
Viscous Regime Turbulent
Reynold-Averaged Turbulence K-Epsilon Turbulence

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 Optional Models Gravity
Segregated Fluid Temperature
Lagrangian Multiphase
Then, click Close

Rename Physic 1 into Air Physic

-> Expand Air Physic-> Lagrangian Multiphase -> Right click Lagrangian phases-> New

-> Expand Phase 1-> Right click Model-> Select Model->

Particle Type Material Particles

Material Solid
Equation of State Constant density
Optional Particle Forces Drag Force
Two-Way Coupling
This step is used for set up material of dirt

3. Right click Continua-> New-> Physics continua

Expand Physic 1-> Right click Model-> Select Model->

Properties Enabled Models

Space Three Dimensional
Material Solid
Time Implicit Unsteady Time
Optinal Models Segregated Solid Energy
Equation of State Constant Density

Then, click Close

Rename Physic 1 into Solid Physic

-> Expand Solid Physic-> Model-> Solid-> Al-> Thermal Conductivity-> Constant-> 1260

4. Expand Region-> Background-> Change Physic Continuum into Air Physic

5. . Expand Region-> Solar Plate-> Physic Continuum into Solid Physic

If you do not see Properties, let click Window-> Properties

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6. Expand Region-> Boundaries-> Nozzle.Inlet-> Type: Velocity Inlet-> Physic value-> Velocity
Magnitued: 210.5 m/s

-> Expand Region-> Boundaries-> Multiple select Block.Block Surface, Block Surface 1,2,3,4,5,6 -> Change
Type into Pressure Outlet

-> Right click on them-> Edit-> Phase Condition-> Phase 1-> Change Type into Phase Impermable->
Expand Physic Conditions-> Lagrangian Specification-> Change Method into Specify for Boundary

-> Expand Physic Value-> Statistic Temperature-> 31C

7. Expand Phase Condition-> Physic Conditions-> Mode-> Active Mode: Escape-> Click Close

The step is used for defining that the when the dirts move out Backgorund, it will not back to Background

8. Setup initial dirts:

Right click Injector-> New-> Select Injector 1-> Lagrangian Phase: Phase 1-> Type: Surface Injector->
Input: Solar Plate. Top Wall.

-> Expand Injector 1-> Conditions-> Flow Rate Distribution-> Method: Per Parcel Stream-> Enable Radom
Injection

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-> Expand Injector 1-> Value-> Particle Diameter: 4e-5-> Injection Point Dnesity: 500/m2

Now you have to define a function for injector. The idea for put dirt on the surface is creating injection
during only first timestep.

Expand Tool-> Field Function-> New-> Scalar-> Rename User Field Function 1 into MFR-> Change
Definition into ${Iteration} < 6 ? 6.4516E-7 : 0

The function is if-else function. That mean when iteration is smaller than 6, the value of MFR is 6.4516E-
7 and if the iteration is higher than 6, this value is 0. One timestep equal 5 iterations.

-> Back to Injector 1-> Values-> Mass Flow Rate-> Method: Field Function-> Scalar Function: MFR

9. Setup initial condition

-> Expand Continua-> Air Physic-> Initial Conditions-> Statistic Temperature-> Value: 31C

-> Expand Continua-> Solid Physic-> Initial Conditions-> Statistic Temperature-> Value: 33C

->Expand Nozzle.Inlet-> Physic Value-> Statistic Tempere-> Value: 25C

10. Create Interface

Interface is used for transform data between 2 regions. In the simulation, we have 2 regions with
different physics continua so we have to create interface between them.

-> Expand Background-> Boundaries-> Expand Solar Plate-> Boundaries

-> Multiple select Solar Plate. Default (in Background) and Default (in Solar Plate)-> right click on them->
Create interface

-> Multiple select Solar Plate. Top Wall (in Background) and Top Wall (in Solar Plate)-> right click on
them-> Create interface

III. Generate Mesh

1. Expand Geometry-> Part-> Right click Solar Plate-> Create Mesh-> Automated Mesh-> Active Surface
Remesher, Automatic surface repair, Polyhedral Mesher-> Click Ok

Active Surface Remesher, Automatic surface repair are tools that used for repair mesh automatically,
Trimmed Cell Mesher is a type of mesh in STAR CCM+

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 The first is tetrahedral mesh, the second one is trimmed mesh, the last one is
polyhedrall mesh. In the simualtion, you can choose any type of mesh. However, to reduce time of
simulation, trimmed mesh is recommed because it is formal mesh while tetrahedral and polyhedral is
unformal mesh so it take more time to do simulation. Beside that, the geometry of the system is not too
complicated.

2. Expand Goemetry-> Operation-> Automated Mesh -> Default Controls-> Base size:0.2 m

3. Expand Geometry-> Part-> Right click Background-> Create Mesh-> Automated Mesh-> Active Active
Surface Remesher, Automatic surface repair, Polyhedral Mesher, Prism Layer Mesher-> Click Ok

The prism layer mesh model is used with a core volume mesh to generate orthogonal prismatic cells
next to wall surfaces or boundaries. This layer of cells is necessary to improve the accuracy of the flow
solution.

-> Expand Goemetry-> Operation-> Automated Mesh 2-> Default Controls-> Base size: 5 cm

Bae size is reference value that use for define properties of mesh

-> Right click Custom Controls-> New-> Surface Control-> Part Surface: Nozzle

-> Expand Surface Control-> Controls -> Traget Surface Size: Custom, Minimum Surface Size: Custom,
Prism Layers: Custom, acitve Customize Total Thickness

-> Expand Value-> Target Surface Size-> Parcentage of Base: 5

->Expand Custom Prism Value-> Prism Layer Total Thickness-> Parcentage of Base: 5

->Minimum Surface Size-> Parcentage of Base: 1

-> Right click Custom Controls-> New-> Surface Control-> Part Surface: Solar Plate.

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-> Expand Surface Control 2-> Controls -> Prism Layer: Custom-> Enable: Customize Number of Layer,
Customize Total Thickness, Customize Distribution.

-> Expand Value-> Custom Prism Value-> Number of Prsim Layer: 4-> Prism Layer Stretching:1.2-> Prism
Layer Total Thickness-> Percenatge of base: 20

-> Right click Custom Controls-> New-> Volumetric Control-> Part: Cone-> Expand Voulemetric Control->
Expand Control-> Surface Resher-> Enable Customize size-> Polyhedral Mesher-> Enable Customize
Polyhedral Mesher-> Expamd Value-> Custom Size-> Percentage of Base: 15

Now, you finish setup properties of mesh. Then click the icon to genertate mesh

-> Right click Scenes-> New-> Mesh

IV. Setup Solver and Visualizing Results

1. Expand Solver-> Implicit Unsteady Time-> Time-Step 0.01 s

-> Expand Stoppinf Criteria-> Maximum Physical Time-> Maximumum physical time 30s

2. Righ click Derived Parts-> New Part-> Section-> Plane-> Active No Displyer->

Origin: 0,1,0 and Normal: 0,1,0 -> create

-> change Normal into 1,0,0 and Origin: 19.5 in, 0,0 -> Create -> Close

Now you have 2 section planes

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3. Right click Scenes-> New Scenes-> Scalar-> Click Scene/Plot -> Expand Scalar 1-> Part-> Active all
Derived Parts-> Scalar Field-> Function: Temperature-> Unit:C

4. Back to Simulation-> Right click Scenes-> New Scenes-> Scalar-> Click Scene/Plot -> Expand Scalar 1->
Part-> Active all Derived Parts-and Lagrangian Phase> Scalar Field-> Function: Velocity

-> Right click Scalar Scene 2-> New Displayer-> Surface-> Expanf Surface 1-> Part-> Active boundary of
nozzle and solar plate-> Click Ok

5. Expand Injector-> Injector 1-> Input-> Active these surface

5. Click the icon to intialize solution and click the icon to run simulation

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- Right click Report -> New Report-. User-> Maximum-> Rename to Maximum Temperature-> Unit: C->
Field Function: Temperature-> Part: Solar Pate

- Right click Report -> New Report-. User-> Minimum-> Rename to Minimum Temperature-> Unit: C->
Field Function: Temperature-> Part: Solar Pate

- Plot number of particle on solar plate

-> Expand Tools->Right click Filter-> New-> Select Filter-> select Relationship below tree Body 3

-> Click to commit change and close

-> Right click Field Functions -> New-> Scalar-> Rename to Mass of particle -> Definition:
insidePart(@Filter("Filter"), 1e-5)? ${ParticleMass}:0

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Ideal: The above function mean that if the particle is belong to Block 3, mass of particle is visualized
while is not belong to Block 3. mass of particle is 0. After that, using sum function to calculate total mass
of particle. Next, Calculate number of particle via function: total mass/ mass of a particle

-> Right click Report-> New Report-> User-> Sum-> Rename to Total Mass-> Field function: Mass of
particle-> Part: Phase 1

->Right click Report-> New Report-> User-> Expression -> Rename to Number of Particle-> Definition: $
{TotalMassReport}/9.054488906666263E-11

-> Multiselect Maximum Temperature, Minimum Temperature, Number of particle, Total Mass-> Create
Monitor and Plot Report-> Multi plot

- Plot velocity from nozzle

-> Right click Derived Part-> New Part-> Probe-> Line

Point 1: [0.49845088230717705, 0.030174558845527652, 0.05226386901643078] m,m,m

Point 2: [0.49845088230717705, 1.7519803634995912, -0.9218237272511167] m,m,m

Resolution: 50

-> Right click Plots-> New Plots-> XY Plots-> Rename to Velocity on Probe Line

-> Expand Velocity on Probe Line-> X Type-> Vector Quantity-> Value: 0,1,-0.5

-> Y Types-> Y Type 1-> Scalar Function: Velocity: Magnitude-> Line Probe -> Line Style-> Change Style to
Straight line

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- Create Solution histories to save results

-> Right click Solutions Histories-> New-> Rename to History1

Function: Pressure, Temperature, Velocity

Part: Select all of part

-> Solver -> Implicit Unsteady-> Timestep: 0.01s

-> Stopping Criteria-> Maximum physical time: 30s

-> Maximum Steps-> Disable

-> Save and Initialize simulation -> Run

+ For independent mesh test

-> Expand Geometry-> Operations-> Automated Mesh 2-> Change Base to 3cm and 4 cm-> Save as for
each model

5. Click the icon to intialize solution and click the icon to run simulation

After finishing simulation, expand Plots-> Right click on each file -> Export

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Import the data into a excel file and create diagram to compare them.

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