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Simulating and Optimizing Mixing Processes



During this presentation we will discuss the challenges vehicle manufactures face when designing manifolds for engines.

Some of the challenges inherent with manifold systems are high temperatures and the uniform mixing of two gases. These issues will be analyzed simultaneously through simulation using Mentor Graphics' CFD analysis software for mechanical engineers FloEFD. The presenter will show that expensive prototypes, test equipment and time to market can all be reduced dramatically with the early implementation of embedded CFD software into a users existing MCAD system. In addition to the speed at which the designer can complete the design, the ultimate product will be less expensive while maintaining optimal performance.

To illustrate this, the presenter will demonstrate how easy it is to prepare a product design for analysis, analyze it and then evaluate the detailed results, The presenter will then go on to show you how to perform "what-if" analysis by simply modifying the MCAD geometry and viewing the simulation results for the new model.

What You Will Learn

  • Perform analysis using a FloEFD wizard and a familiar CAD interface
  • Visualize mixing processes in a virtual 3D environment
  • Understand the impact of design changes and how it can effect the mixing of fluids/gases
  • Export detailed reports to Microsoft's Word and Excel

About the Presenter

Presenter Image Joe Proulx

Joe Proulx has worked for Mentor Graphics Mechanical Analysis, formerly Flomerics, as a consultant engineer since July 2005 and is currently an application engineer. He also participates in training, customer support and consulting.

Joe's prior employment was with Sycamore Networks where he was responsible for all aspects of designing the cooling of the company's products. Along with the use of thermal simulation software, Joe was able work in a thermal lab complete with a thermal imaging camera, wind tunnel, multiple hot wire anemometers, thermocouples and other ubiquitous lab equipment.

Before that, Joe was employed by Degree Controls as thermal consultant. Degree Controls is a complete thermal solutions provider. Joe was responsible for handling customer's thermal needs from computational thermal analysis to physical flow and temperature measurement.

Prior to his position at Degree Controls, Joe was employed by Cabletron Systems in Rochester, NH. While there, Joe worked as a thermal analyst utilizing FloTherm and a complete thermal lab.

Joe graduated from the University of New Hampshire in 1995 with a Bachelor of Science degree in mechanical engineering.

Who Should View

  • Design Engineers
  • Mechanical Engineers
  • Product Design Managers
  • Engineers who are currently using MCAD and are interested in a CAD-embedded analysis solution

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Q and A Transcript

Q: How does the mesh react when you have a very large volume with a very small thickness?
A: FloEFD employs a specific local mesh refinement technology for thin solid volumes in large computational domains. This technology fully resolves the geometry with a high-quality grid without the need of an extensive fine mesh in and around the thin volume.
Q: Can I simulate flow inside a rubber co-extrusion die?
A: Yes, FloEFD users are able to stipulate material types.
Q: Can I mix non-Newtonian fluids as well?
A: Yes, but the fluids must be of the same material type; for example; power law fluid 1 mixes with power law fluid 2.
Q: Please clarify; you can mesh this object directly within the CAD environment?
A: Yes, the user stays in the CAD tool's environment. The software for gridding is embedded within the CAD software and is done automatically when the model is run.
Q: Our products are very complicated. Can FloEFD mesh them and provide accurate answers?
A: Yes, FloEFD includes meshing technology that is able to process complex real-life designs. It uses hexahedral mesh cells in the computational domain. This cell shape is the most efficient one regarding computational efforts necessary to obtain required accuracy. In addition, it is very robust and enables fast solution times.
Q: How much computing power do you need to run FloEFD?
A: FloEFD runs on both 32 and 64bit Windows Operating Systems. It requires a minimum of 2GB of RAM to run.
Q: How many different fluids can FloEFD handle?
A: FloEFD can handle 10 different fluids and an almost infinite number of temperatures. (the limit on the number of different temperatures is only limited by the hardware running the software)
Q: I have CATIA v5r17, can I get FloEFD for this?
A: Yes, the FloEFD version required is called FloEFD V5. You can find additional information under:
Q: Can you specify pressure gradient at an outlet?
A: Yes, you can do that.
Q: Can you explain how the minimum gap size controls the minimum mesh size?
A: Using information about the model geometry, such as the minimum gap size, FloEFD further constructs the mesh by means of various refinements, i.e. splitting of the basic mesh cells into smaller cells, thus better representing the model and fluid regions.

Q: You mentioned that FloEFD outputs detailed reporting to Word and Excel, what version of Microsoft Office does the software use?
A: FloEFD supports Microsoft Office 2000, XP, 2003 and 2007 for the reporting capabilities.
Q: Can FloEFD simulate long-pipeline systems (interconnected or not)?
A: FloEFD solves for flow and heat transfer in 3D so it can definitely solve for pipeline systems, depending on the system size though. Complex systems may be difficult to solve depending on available computer power.
Q: Can FloEFD analyze transient conditions or time based events or is it just steady-state?
A: Yes, FloEFD can also solve a transient analysis.
Q: How about the thermal properties of the porous media? - can we account for those?
A: Yes, you can attach a material property to a porous media and it will conduct heat.
Q: How long does it take to learn your software?
A: New FloEFD users comes up to speed very quickly as the software does not have a steep learning curve. Users who have knowledge of the subject matter are able to fulfill analysis requirements with FloEFD even if they did not get a chance to attend a training class. We would still recommend getting trained whenever possible as our technical staff will advise you how to introduce FloEFD into your development process to maximize the benefits of using this design evaluation tool on a day-to-day basis. As a first step, we recommend that you download the 60-day trial version of FloEFD from our website so you can test the technology first-hand.
Q: The design office I work in use a Siemens NX CAD system. Can I use your software with our CAD models?
A: Yes, FloEFD reads native CAD data directly from major CAD systems such as Siemens NX, SolidEdge, Autodesk Inventor, etc. without the need for prior data conversion and is fully embedded in to Pro/ENGINEER, CATIA v5 and SolidWorks.
Q: What about external analysis?
A: Yes, FloEFD can do external analysis. For example, the software can be used to compute drag and lift coefficients.
Q: Does FloEFD automatically use multi-processors or does it need a special license?
A: FloEFD by default, allows a user choose the amount processors they want dedicated to running the software and does not require extra licensing to do so.
Q: Can FloEFD model both multi-flow and multi-phase?
A: FloEFD handles mixing fluids as long as they are miscible. It does not currently handle multi-phase flow.
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