Introduction: DHCAE Tools

Simulation solutions based on Open-source solver technology Engineering: CFD services with OpenFOAM® and CalculiX Software: Standard/ Customised: GUIs (CastNet), Extensions User Support Training: OpenFOAM®/our Extensions

DHCAE Tools GmbH Why open-source based: Competitive high level CFD tools : (Fluent/CFX/Star-CD) are expensive License cost at least 25 k US$/year base system, typically 40 k US$/year or more “Lost-CFD/FEA” are not always reliable restricted in functionality (no chance to grow) and model size Particular advantages of OpenFOAM: very well established, proven, no-black box high range of advanced models (e.g. multiphase (particles, free surface)) can be adapted to particular workflow very good performance for large models Drawback: Text file based, Linux only, hard to start

DHCAE Tools GmbH CFD for in house usage: Service: Close cooperation: E.g. base model setup by DHCAE Tools, further runs and modifications done by customer Engineers on-site would like to make use of CFD technologies: No CFD/OpenFOAM experts No Linux experts Used to work with GUIs Meshing and case setup: CastNet (GUI based) Solution: GUI to run the case: Important: Visual result control: Residual and even more important probes Why GUIs? Our experience: OpenFOAM feature (e.g. probes) will not be used if there is no possibility of an easy definition graphical visualization

CastNet-Meshing Geometry Input Meshing/ Case Setup Solving/Job Control Parasolid: (Nx, Solidworks, Solidedge,…) ACIS: (Inventor, SpaceClaim, TurboCAD,…) Granite Pro-E Creo Catia Discrete (stl, Nastran) universal Translator e.g. SpaceClaim CastNet: Direct CAD Kernel based geometry import: Models/assemblies CFD: Hybrid CFD-meshing or SnappyHexMesh-definition Case setup GUI for OpenFOAM: More than 30 solvers FEA: Second order elements, non-linear modeling e.g. contact Meshing/ Case Setup Local machine/cluster Direct export: Cloud Cluster on demand Fluid analysis: OpenFOAM Linux: ESI-versions OpenFOAM Windows: BlueCFD port Job control: runGui Structural analysis: CalculiX Linux: Standard linux version Windows: bconverged port Coupling: Data mapping (runGui) Solving/Job Control OpenFOAM: Paraview, Fieldview, EnSight, Tecplot (Windows or Linux) CaluliX: Linux: CGX Windows: CGX/Paraview Post- processing

DHCAE-Tools Our philosophy: More pragmatic then dogmatic We have to accept the reality of our customers. Not always but often: Commercial CAD systems with proprietary kernels Windows systems (IT says “NO” to Linux) New software must be productive from the first second GUI based working is preferred for certain tasks Can not be covered with OpenFOAM/CalculiX directly Combine proprietary solutions with OpenSource Try to share open source part of work (e.g. OpenFOAM-extensions) Major tools: CastNet: Preprozessor for OpenFOAM/CalculiX Rungui for CastNet Job-Control

CastNet for OpenFOAM® The outstanding features of the CastNet modeling environment are: Supporting a flexible and complete simulation environment for CFD and FEA on Windows and Linux operating systems including pre-processing, solving and post-processing Providing access to reliable, robust and high quality CFD and FEA-meshing based on CAD geometry Establishing a complete GUI based environment: Access to strong open source solver capabilities without editing text files or detailed knowledge of the keyword-structure Reducing the time from CAD model to ready-to-run case Allowing a reliable and stable CFD and FEA analysis by detailed job control Fully compatible: User can switch at any time from GUIs to text-based model setup User can extend the CastNet model output for specific needs

OpenFOAM® Interface CAD model based input CastNet allows a high quality geometry: import based on CAD kernel data. no need to repair the CAD geometry and volume information is preserved. The CAD import includes: • Direct access to Parasolid, ACIS and Granite (ProE/Creo) parts and assemblies. • CastNet generates internally a non-manifold model of complex assemblies resulting in conformal grids between the various regions (parts). region models, e.g. Porous, MRF, AMI rotating, CHT. different meshing approaches (e.g. free or extrude meshes) • Automated geometry improvement for meshing by suppression of sliver faces if needed.

Transfer into OpenFOAM text file OpenFOAM® Interface Transfer into OpenFOAM text file CAD Geometry association

CastNet capabilites The solvers include the following modeling capabilities: Steady-state/transient analysis compressible or incompressible flows and media With or without heat transfer including radiation Multiphase flow (VOF/Euler-Euler/Lagrangian particle tracking) Dynamic meshes (sliding meshes or sloshing applications) Conjugate heat transfer analysis CastNet provides a strong user support for OpenFOAM® during the case setup: The case setup is strongly simplified by solver templates to each application CastNet gives warnings in case E.g. if gravity is required by the selected solver, but the definition is missing, a warning will appear. CastNet defines the boundary by patch, not by field. CastNet helps the user with many defaults in the background. E.g. CastNet thermo-class automatically, valid time loop parameter for the chosen solver. These defaults can be modified by the user in a configuration file.

CastNet capabilites Further CastNet functionalities for OpenFOAM® usage are: • Simple configuration of settings for parallel runs. • Probes definition and post processing output options. • Fully automated setup for conjugate heat transfer and sliding mesh applications. • Convenient definition of boundary conditions using derived OpenFOAM® patches. • Easy and stable initialization with potentialFoam before the final run. • Definition of local initial conditions, e.g. specification of volume fractions in particular regions. • Support of baffle faces, fan faces, cyclic boundary conditions and two-dimensional modeling. • Time dependent boundary conditions and support of groovyBC. • Definition for incompressible (Newtonian/Non-Newtonian), multiphase or thermophysical materials. • Second solver run for particle tracking.

CastNet capabilites Rungui: Detail Job monitoring during runtime

CastNet capabilites Access to many OpenFOAM functions, e.g. Postprocessing tools

CastNet capabilites The runGui is a job control system for OpenFOAM®. • To enable a reliable CFD analysis by a detailed job control. • To facilitate the usage of OpenFOAM® : Modifying solution settings during runtime. • To provide an easy access to OF meshing, pre- and post-processing features. • To allow an easy exchange of data between CalculiX and OpenFOAM®. These goals are reached by the following outstanding features: • One click button for case setup from the CastNet output • Job control by automated residual and probes plots controlled by CastNet settings • Modifying solver settings during the run, e.g. by changing schemes and solution settings without stopping the solver GUI based OpenFOAM features: Mesh manipulations such as mesh extrusion, mesh scaling and wall refinement mapFields: Mapping of results from one case to another Wall results such as wall shear stress, YPlus-values etc

Meshing in CastNet Internal mesher: Hybrid meshing (Simmetrix meshing technology): Excellent boundary layer meshing Hex-Core meshing Extrude regions Perfect geometry representation External mesher support: SnappyHexMesh (OpenFOAM meshing technology): Hex dominant polyhedral meshing Fully integrated in CastNet workflow Works well with bad geometry input (no solids, many sliver faces etc.)

CastNet CAD input and meshing Effective and fast model generation (less than one days) CAD-model based Reliable CFD-meshing Reliable boundary layer meshing Combination of extrude meshing/free meshing

Meshing feature CastNet hybrid meshing Boundary Layer meshing Extrude meshing Hex Core Meshing

Meshing feature SnappyHexMesh Edge Refinement in CastNet for SnappyHexMesh Associated with geometry edges

Meshing feature CastNet For SnappyHexMesh Face Refinement in CastNet for SnappyHexMesh Associated with geometry faces

Meshing feature CastNet For SnappyHexMesh Boundary Layer definition in CastNet for SnappyHexMesh Associated with geometry edges

Meshing feature CastNet For SnappyHexMesh

Examples Examples of technical applications: Meshing and case setup in CastNet OpenFOAM capabilities Working fields and extensions of DHCAE Tools

Example: Chemical Engineering Chemical plant engineering Meshing setup and OpenFOAM case definition

Chemical Engineering Direct setup for porous zones

CastNet Meshing Porous Zones (Filter) Porous Zones (Rotor)

Chemical Engineering Roof section

Come to results rather in days than weeks Chemical Engineering Come to results rather in days than weeks

Chemical Engineering Filter plant with hundreds of regions (CAD-Part)

Chemical Engineering Filter regions separated with baffle faces

Chemical Engineering

Chemical Engineering

CastNet-Meshing ExampleQuench Usage of extrude regions to avoid tetrahedral elements Based on Parasolid-assembly: Parts are transferred into regions conformal mesh transition

CastNet-Meshing Boundary Layer from extrude to free mesh regions

Particle Evaporation

Particle Evaporation Strong interaction: Heattransfer Momentum: Temperature distribution OpenFOAM Other CFD-Solver Strong interaction: Heattransfer Momentum: Density Spray resistance

DHCAE Tools’ Filter solver Increasing resistance due to particle hits is considered in iteration loop

DHCAE Tools’ Filter solver-Macro Modelling

DHCAE Tools’ Filter solver-Meso Scale Modelling

CFD-Development and Verifications Filling processes with free surfaces

Filling process

CFD-Development and Validation Rotating Meshes with AMI

Valve

Valve

VOF Mixer with SHM in CastNet Mixer case setup for SnappyHexMesh

VOF Mixer with SHM in CastNet

ACMI with translational regions

CalculiX CalculiX is a non-linear structural solver developed by Guido Dhondt und Klaus Wittig at MTU. CalculiX is originally developed on Linux as an open source system. CastNet supports the original Linux version as well as the Windows port provided by bConverged. In structural mechanics with CalculiX CastNet supports: Linear and non-linear statics/dynamics Non-linear analysis: Non-linear geometry: Large displacement, contact Non-linear material: Plasticity, hyper elasticity Linear frequency analysis Buckling

CastNet Support for  CalculiX Wide number of boundary conditions and loads are available such as fixations, prescribed displacements, concentrated and distributed surface or volume loads. CastNet supports volume shell elements, beam, spring elements two dimensional element formulation. Furthermore a coupling to CFD-results is available: Pressure distributions estimated in OpenFOAM® can be transferred to CalculiX as surface load. Volume temperature fields from a conjugate heat transfer analysis can be transferred from a solid OpenFOAM® region to CalculiX volume. By this thermal stresses and displacements can be calculated in CalculiX.

CastNet Support for  CalculiX CalculiX has been added to CastNet in 2013 (new SimModeler platform) to complete the open-source solver based tool environment for a reliable stress analysis Special meshing Feature for FEA: Manifold/non-manifold models Second Order Elements – Curved non curved Postprocessing Support: Translator to Paraview provided by DHCAE Tools

CalculiX-Example CHT-Example OpenFOAM-Calculix: Red: Fluid Region (considered in OpenFOAM only) Green: Solid Region: (considered in OpenFOAM as solid for CHT in Calculix for stress analysis)

CalculiX-Example: Combination with OpenFOAM CHT CHT-Mesh for OpenFOAM Solid Region for CHT (OpenFOAM) Fluid Region for CHT (OpenFOAM)

CalculiX-Example CalculiX case setup

CalculiX-Example CalculiX mesh: -Second order elements for reliable FEA

CalculiX-Example CalculiX results mapping of OpenFOAM temperature load for thermal stresses

CalculiX-Example Final data transfer from OpenFOAM to CalculiX in Rungui

CalculiX-Example Consistent postprocessing for all results in Paraview

CalculiX/Abaqus(CSM) FSI Workflow CastNet: Case setup (CFD/CSM) OpenFOAM (CFD) Mesh update No pressure/WSS Transfer Forces FSI-coupling CalculiX/Abaqus(CSM) Displacement converged? yes DAtaconversion (vtk)-Post-process: Paraview

CalculiX-Example

Conclusion Open-Source solver technology can substitute commercial CFD/FEA system in many fields: Not only license costs but also strong features Very good integration into workflow Very strong solution capabilities Additional GUIs may help: - Make use of the solver capabilities - More reliable job control resulting in more accurate results - Time effective case setup and control Thank you for your attention !