Reshaping the Future of CFD Using Mesh Morphing

A cool title, isn’t it? Hello ANSYS blog readers! This is my first time in this blog as a guest blogger. You will notice a brief resume of mine together my photo as the author of this post, but let me introduce myself so that you can understand why I am here writing about mesh morphing to the ANSYS audience.

I am a Professor at University of Rome, with good experience in fluid structure interaction (FSI) and Fluent customization using UDF programming. Five years ago, driven by a Formula 1 Top Team, I developed a powerful mesh morphing tool crafted by tough specifications. Managing any kind of mesh, precise, fast and parallel! Nothing at that time was able to do this kind of job. We tried to go with (RBFs) Radial Basis Functions mesh morphing, one of the most promising techniques. And we made it. Continue reading

How Can You Get More From An Oil Pump?

Imagine you have an oil pump in your car that has its outlet blocked. The pump is trying to throw the oil out but since the outlet is blocked the pressure in the pump keeps increasing. The excessive pressure that develops in the pump can be catastrophic to its strength and therefore life. This is precisely what happens when you try to operate the pump under extreme cold conditions, when the viscosity of the lubricant increases so much that the pump almost behaves as if its outlet has been blocked.

pumpsThis is a very common design scenario for pump manufacturers. Estimation of what is called as “shut-off” pressure and its implications on the structural integrity of the pump are key concepts that every pump manufacturer should bear in mind while designing pumps. Interestingly, simulations today allow manufacturers to develop deep understanding of such phenomenon and help them to design pumps, that perhaps they could not have, with just physical testing and prototyping. Continue reading

Optimizing Auto Combustion Using Predictive Simulation Technologies

Spray-droplet visualization at the start of injection for a Diesel sector-mesh simulation

Spray-droplet visualization at the start of injection for a diesel sector-mesh simulation

Today’s automotive community is increasingly called upon to think strategically and form unique relationships that expand its reach in a new era of cross-industry collaboration. We’re eager to share our excitement about Reaction Design’s new role at ANSYS (especially as it applies to developing optimal auto combustion processes) and reveal our shared vision for our more powerful and predictive simulation technologies.

We’re looking forward to telling you about it at the upcoming SAE 2014 World Congress and Exhibition, being held April 8 through 10 at Detroit’s Cobo Center. A must-attend for the automotive engineering community, this event represents an unparalleled opportunity to explore new technology through both technical sessions and the Innovators Only Exhibition. Continue reading

Why I Love Working with the Infiniti Red Bull Racing Team and Simulation

On March 27 at 4 pm GMT, 12 pm EST, I will have the pleasure to participate in an exclusive, one-time, non-recorded webinar hosted by SAE international with Al Peasland (Head of Technical Partnerships, Infiniti Red Bull Racing) and Nathan Sykes (Team Leader for CFD and FEA, Infiniti Red Bull Racing).

The RB10 Red Bull Racing Formula 1

The RB10 Red Bull Racing     Formula 1

Since the birth of the Infiniti Red Bull Racing (IRBR) Formula 1 team almost 10 years ago, simulation has played a vital role in assisting the team to develop its cars aerodynamics through its CFD software and services. I have been the technical account manager for the IRBR account for over 6 years. In addition to developing and solidifying our technology relationship, I have witnessed first hand the impressive integration of ANSYS software into a Formula 1 CFD process. I take great joy (and pride!) working tirelessly and collaboratively with IRBR to deliver technology that has proved superior in concept and execution, ultimately helping to design the cars that have delivered the quadruple championships, which have been awarded to the team over the last four consecutive years. Continue reading

Electric Machine Design Methodology

In 2009, the University of Wisconsin-Milwaukee, with full support from ANSYS, deployed an initiative to the region’s industrial community by launching the ANSYS Institute for Industrial Innovation (AI3). Recently, ANSYS and the university launched a video about common interests and partnership activities that tells the story behind the institute.

As you heard in the video, the institute at UWM is a portal for industry to engage with academia to foster economic growth and development of regional industries and educational institutions, leveraging world-class CAE capabilities including CAD, FEA and system simulation platforms. AI3′s framework provides an infrastructure that spans the product development cycle from concept to functional prototype. Continue reading

Advanced Design of Electric Motors

Electric motors consume nearly half of all global energy, so the drives need to be highly efficient. Electric machines include materials that can vary drastically in price over a relatively short period of time due to market demands and a limited supply of the raw materials. Traction motors used in hybrid electric vehicles (HEV/EV) utilize rare earth permanent magnets. Changing a design parameter, such as the shape or size of the magnets, most likely will have consequences on performance such as a reduction in efficiency or will introduce a change in torque quality.

Original and optimized design

The modified design and the original design provided by Magna Electronics. The modification included the reduction of the magnet length and decrease of “V-angle” of the magnets.

Engineers who design interior permanent magnet (IPM) machines most often create a 2-D plot of the efficiency and torque of the machine versus its rotation speed, known as an efficiency map. The goal is to reduce the magnet size and maintain the maximum torque and efficiency for the entire speed and torque range. An efficiency map can be created by taking measurements in the test environment of the output torque, input power and output power. Of course, this means that the traction motor first must be designed and manufactured.

Also, at this late stage of the design cycle, making design changes to improve performance is costly and takes another round of prototyping. Consequently, IPM traction motor engineers utilize simulation tools that quickly, yet very accurately, predict the performance of the traction motor and drive product development. Engineers who are responsible for the electromagnetic design of IPM electric motors usually employ the finite element method (FEM).

Continue reading

Witnessing Engineering Simulation in Action

During the last few weeks, I had the opportunity of a lifetime to witness two competitive sport clients race with machines that were developed using ANSYS fluid dynamics engineering simulation tools. I can guarantee you that I was like a kid in candy store!

Emirates Team New Zealand - America's Cup

In September, I was on vacation in San Francisco to see the America’s Cup and had the chance to see Emirates Team New Zealand race. As you might recall, they won the Louis Vuitton Cup — but unfortunately not the America’s Cup. Even so, seeing those monsters race on the SF Bay was phenomenal. What a spectacle! Amazing sailing, impressive engineering.

Emirates Team New Zealand - San Francisco Bay

These are just a couple of the photos I took at the event. One shows the boat after the race. I thought it was a cool picture because it showed how massive it is. The other shows the actual wing.

If you want to know more about the America’s Cup and fluid dynamics simulation, please listen to the designer team of Emirates Team New Zealand talk about it here. Continue reading

Bringing the Hyperloop One Step Closer to Reality Through Simulation

It sounds like something out of Star Trek or Buck Rogers, but the notion of a super-fast (think speed of sound or faster) ground-based transportation system isn’t science fiction.

About a month ago, Elon Musk, the visionary behind ANSYS customers SpaceX and Tesla, formally proposed the Hyperloop, which would transport people via aluminum pods enclosed inside of steel tubes. These pods would travel up to 750 miles per hour, shrinking travel time between cities. (A trip from Los Angeles to San Francisco would be only 30 minutes!)

But as it often happens when a true innovator steps forward with a new idea, the critics descended. They claimed the Hyperloop was nothing more than mere fantasy, that it wouldn’t be practical. Even Musk himself admitted that prototypes were needed before he could turn the Hyperloop into reality.

I’ve been personally interested in the idea of this potential mode of transportation for some time now. In my opinion, the technologies needed for implementing tube transportation are extremely simple, compared to some of the highly sophisticated machines such as commercial airliners or spacecraft that humans routinely construct today.

So, using ANSYS technology, we put Musk’s Hyperloop designs to the test. The upshot? The Hyperloop will indeed work – with some tweaks. Continue reading