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 CAD
Edited by Paul Dvorak
How CFD
streamlines fluid
designs
Fluid-analysis software lets
engineers see inside products
to spot and solve troublesome
flow problems.
Mark Kacik
Principal Engineer
Moen Inc.
Cleveland, Ohio
C
FD or computational-fluid
dynamics was once the
realm solely of PhDs and
aerospace companies. But
software developers have
done a good job simplifying it so CFD programs
can be used by a wider range of engineers and for a
variety of tasks. At our company, for example, we
use CFD to improve fixtures such as showerheads
and valves, and faucets by predicting spray and flow
patterns, reducing them in size, increasing their ef-
ficiency, and letting them do more. The software
lets us pay close attention to fluid dynamics early in
a product’s development.
CFD software lets engineers refine designs
through several iterations in as little as a day. Fea-
tures such as interactivity with MCAD, easier-to-use
meshing algorithms, and user-friendly GUI’s have
placed the analysis software into a daily-use toolbox
for design engineers. Understanding how it differs
from the structural analysis of finite elements and
knowing what to look for in charts and images lets
design teams get more out of the technology.
WHERE CFD WORKS WELL
Optimizing a product is an iterative process in-
volving design, prototyping, testing, refining the de-
MACHINE DESIGN
Moen’s Revolution
showerhead with
Freedom Dial represent a
product with complex internal
waterways and several functions in a
small package. The dial lets users select a
steady stream of water, a pulsing massage, or a
variation in between. An analysis with CFD
software assisted engineers with modifications
that met design goals and customer expectations.
sign, and reentering the loop. CFD de-
creases development time and effort by
substituting electronic prototypes for physical ones.
Although design loops have lengthened with more
activity, build-and-test cycles have drastically short-
ened. Overall, the product-development cycle is
much shorter than before even though engineering
content has increased.
Structural finite-element analysis, unlike CFD, is
an absolute approach. This means numerical re-
turns from FE analyses feed directly into the design
decisions, so accuracy is crucial. Although the
same often applies to CFD, it’s more likely that plots
and images will be studied for energy-consuming
eddy currents, vortices, large pressure drops at
transitions, cavitation, and flow separation. The
software has tools to help find each of these. De-
signs are compared based on incremental or rela-
tive improvements to these dynamic phenomena,
eventually producing a better design.
64 • OCTOBER 24, 2002 www.machinedesign.com
CAD

The image shows the

cross section and internal
volume of a spray head.
CFDesign, computational-
fluid-dynamics software
from Blue Ridge
Numerics, Charlottesville,
Va., (www.cfdesign.com)
shows performance-
reducing asymmetrical
flow in the nozzle as a
wide range of velocities
with the color transitions
from green, yellow, then
red and back to green.
The outlet is at the
screen bottom. Such
insight to flow conditions
is impossible with tradi-
tional flow analyses.

But getting the most out of CFD software means size conflicts with the need for proper nozzle
scrutinizing results for subtle indications of undesir- shape, velocity, and direction. A pleasing or appeal-
able phenomena that are sometimes hidden by a fea- ing spray often requires fully developed flow at the
ture called autoscaling. A few problems are so obvi- nozzle exit. This means flow near the nozzle exit
ous they seem to jump off a chart or graph. More of- should ideally have a near uniform velocity distri-
ten, users have to scrutinize analyses to find them. bution. Tight package constraints, complex geome-
try, and winding passageways leave little room to
PROBLEMS AND SOLUTIONS follow conventional guidelines, which generally re-
As with most products, consumers expect more quire a minimum of six diameters of straight length
functions in faucets and shower systems, yet in to establish a symmetrical, developed flow profile.
smaller packages. This more-and-smaller trend CFD provides a way to visualize flow problems by
places conflicting demands on design teams. generating velocity and pressure plots, both
Showerheads are an example in which package aligned with and normal to the flow axis. The plots
let designers mini-
mize the condi-
tioning section
A redesign of the length. For in-
previous flow stance, a plot of
passage shows how vorticity (the angu-
the velocity profile lar velocity of a
in the nozzle exit fluid) can identify
might be made more a vortex or strong
uniform with the eddy currents.
addition of lobes Based on CFD re-
and widening an sults, one could in-
entrance sert flow straight-
passageway. CFD eners such as fins
software shows a or other geometry
more uniform changes that help
velocity, an correct asymmet-
indicator of a more ric profiles rather
appealing spray than adding a sta-
pattern. bilization length.
Particle-trace plots
(highlighted paths
of theoretical indi-
MACHINE DESIGN 66 • OCTOBER 24, 2002 www.machinedesign.com
 CAD

The colored area is a

small section from a
handheld spray head.
The four narrow
passageways at the top
are a few of 40 that
lead to outlets. A
velocity distribution
plot is used to refine a
manifold (the
rectangular section
below the four outlets)
and manifold feed to
obtain a uniform
distribution in nozzles
and reduce high
velocities (high-
pressure drop) in the
manifold feed.

vidual fluid particles) are also useful in spotting dition is the blending of hot and cold streams.
vortices and eddy currents. More noise is created where the streams impact
Another problem comes in manifolds that feed head on, rather than meeting at an angle. Velocity
dozens of nozzles, as in a typical spray head. Mani- plots identify such areas and guide designers to
fold-feed design must assure that each nozzle has geometries that soften the blending of multiple
the same pressure. To assist, CFD software can gen- flows.
erate a plot of static pressures to help guide these A few undesirable flow characteristics are more
designs toward an appealing and soothing spray difficult to spot because they are so subtle on
pattern. graphs. Small vortices in a flow channel that feeds a
Low water-supply pressure presents another nozzle is one example. Vortices can be spotted in
challenge. It calls for products with efficient wa- plots of velocity normal to the flow axis. Vorticity
terways. CFD provides graphic plots of total pres- (angular velocity) images also provide a sense of
sures and velocities that identify energy-consum- swirling liquid. Velocity plots may show these
ing phenomena, such as
strong eddy currents, geo-
metric transitions with high- Particle traces help identify energy-consuming eddy
loss coefficients, and con- currents and highlight flow asymmetries due to inertia.
centrated points of high ve-
locity and highly asymmetric
flow profiles.
Noise is another design is-
sue. Static-pressure plots let
designers identify localized
negative pressure zones
prone to noise-emitting cavi-
tation, a condition in which
vapor bubbles form and col-
lapse. A tool that generates
so-called ISO surfaces, those
at a selected pressure value,
highlights areas or surfaces
of interest.
Noise is also generated
when two or more flow
streams converge. The most
frequent example of this con-
MACHINE DESIGN 67 • OCTOBER 24, 2002 www.machinedesign.com
 CAD

noisemakers, but
the velocity values
are on a much
smaller scale than
forward velocity
and may be shaded
or hidden by an au-
toscaling feature.
Autoscaling adjusts
for high values
present in regions
of the model that
are often not of
concern. In doing
so, it shades or
masks the presence
of lower vorticity
levels in the area
studied. The auto-
scale feature can be
disabled and the
scale manually ma-
nipulated as Water enters the showerhead on the left and hits a turbine shown in black in the
needed to gain center. The red on the right is the cross section of an annular manifold. The outlet is
deeper understand- not visible but near the bottom of the image. The pressure-distribution contour helped
ing of the fluid be- the design team optimize the turbine blade.
havior. Additionally,
particle-trace plots
are effective tools for unmasking vorticity. When improperly applied, an analysis will likely
Along with displaying fluid behavior, CFD is a fail after running for hours. Then it’s necessary to
subtle but significant learning tool. Engineers and stop the analysis, locate the problem, refine the
designers can see fluid flow in a way never before mesh, and restart the solver. Automating the find-
possible. Working with the charts and plots, a de- ing and repair of mesh and solution failures would
sign team comes to understand flow behavior in be a big advance for CFD packages.
complex channels. Proper model construction is also key to suc-
cess where intricate geometry exists. Assuring con-
ROOM FOR IMPROVEMENT tiguous linking of features and not merging com-
Although CFD software has developed into a plex geometric shapes will make an analysis more
practical tool for daily use, there is room for im- robust.
provement. For example, to run analyses, one must CFD automation does not replace the need for
create models of the waterways. That’s not easily hand calculations or detailed up-front engineering
done. With solid models, the analyst has to turn that pays attention to geometry that minimizes en-
solids into voids, and internal spaces into defined trance and exit losses, flow straightness, or proper
volumes using their CAD package. Future versions convergence and divergence angles. By supple-
of the CFD software used here reportedly will have menting proper engineering practices with the
some of this capability. Users then have to recog- CFD tool, the end result is an optimized design as
nize and remove certain details such as slivers — well as a more reliable product. What’s more, test
small, stagnant volumes adjacent to seals. If left in, and prototype activities drop off, thereby shorten-
the mesher will pack these small volumes with ing entire projects. ■
many small elements, generating large models that
are prone to failure during mesh generation and WE WANT YOUR FEEDBACK.
take unnecessarily long to solve. Removing slivers
and irrelevant details speeds meshing and solving. Did you find this material interesting? Circle 723
Another time-consuming task in the process is Do you want more information of this type? Circle 724
finding and correcting mesh-related problems. Ar-
eas with intricate geometry, complex fluid dynam- Comment via e-mail to mdeditor@penton.com
ics, or both need a finer mesh than other parts of What related topics would you like to see covered? What
the model. Properly applying a good mesh depends additional information on this topic would you find useful?
on experience, careful judgment, and finesse.
MACHINE DESIGN 68 • OCTOBER 24, 2002 www.machinedesign.com