Multiphysics with ANSYS

Fluid Structural Interaction

Michael Tooley
ANSYS Inc.

1 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Agenda

Introduction

1-way Thermal and Structural FSI

2-way Thermal and Structural FSI

FSI Examples

Conclusion and Questions

2 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Multiphysics Simulation
Multiphysics simulation delivers a deeper understanding of product
performance by considering the interaction of multiple engineering
disciplines.

Structural-
Mechanics
Systems and
Electromagnetics Embedded Software
Fluid Dynamics

3 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Multiphysics Simulation from ANSYS

Modern product development trends are driving the need for

greater investigation of multiphysics effects.
Our unique approach is a collaborative workflow in a framework
that provides automated data exchange and optimized solver
interactions between best-in-class single physics solutions.

4 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 ANSYS Multiphysics At A Glance

FSI: Pressure/Force Electromagnetics Thermal

Fluid Cooling Coupling
FSI: Thermal Stress

Low and High

Structural Fluid Flow
Frequency
Analysis Analysis
Electromagnetics

Electromagnetics
Thermal Fluid Cooling
Thermal Stress Coupling

External Data Electromagnetics

Thermal Stress Coupling

5 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Agenda

Introduction

1-way Thermal and Structural FSI

2-way Thermal and Structural FSI

FSI Examples

Conclusion and Questions

6 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 1-way CFD to Steady Thermal via Drag-and-Drop

Transfer HTC or temperature

from CFD to a Thermal system
Use CFD results to give more accurate
HTC boundary conditions for Thermal
analyses in Mechanical
Use this when Fluent/CFX was not a
CHT calculation

Wall HTC

Heat Transfer Coefficient from CFD used for a thermal analysis in Mechanical.

7 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 1-way CFD to Structural via Drag-and-Drop

Transfer solid temperature

fields from CFD (CHT) to
Mechanical to calculate
thermal stresses
Steady-state

Volumetric
Temperature

Thermal stresses are calculated in Mechanical using a volumetric temperature transfer from CFD CHT results

8 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 1-way CFD to Structural via Drag-and-Drop

Transfer pressure and viscous

forces from CFD to Mechanical
to calculate deformations and
stresses
Steady-state

Surface Force

Deformations and stresses are calculated in Mechanical using force loads from the CFD results

9 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 1-way via External Data

1-way transfers to Mechanical

Steady or transient (sort of)
Support for a wide range of
variables
Surface and Volumetric transfers
No schematic connection, so no
automatic update, but is easy to
use separate projects
Source data can come from any
solver

10 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 External Data vs Direct Connection

External Data Drag-and-Drop

Easy to use, but need to export/import files
manually
Imported data is static during Project / Design
Point updates
Works with separate projects
Very easy to use drag-and-drop connection
Works with Project Update & Design Points
Needs a single project

Flexible choice for variables to transfer Pre-defined list of variables to transfer

Good performance Need to enable Octree mapping (beta) to get

good performance
Transient load transfer is not easy to use No support for transient load transfer

Surface and Volume transfer Surface and Volume transfer

Profile Interpolation and Conservative Mapping Profile Interpolation only

(in R16.0)
Extensive mapping validation Some mapping diagnostics

11 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 External Data vs Drag-and-Drop
Force Transfer
Coarse mesh(41976 nodes, 23393
elements)

Direct schematic link: some error in force sums

External data: globally very accurate (total force is same as CFD result)

12 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 External Data vs Drag-and-Drop
Force Transfer
Super fine mesh(1636428 nodes,
1124862 elements)

Direct schematic link: almost same value

External data: globally very accurate (total force is same as CFD result)

13 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Other 1-way Load Transfers

Transient 1-way Force can be passed from ANSYS CFD to Mechanical

Time Domain: ACT extension available on customer portal
A text format of transient CFD force can easily be mapped to the Mechanical
model and used as transient load
Frequency Domain
A Fourier Transform of the transient CFD force can be used as load in a
harmonic response analysis

Transient Force

Time or Frequency
Domain
Turbulent structures around a cone flow meter Deformation of the flow meter due to fluid forces

14 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Vibroacoustics and Modal Analysis

Pressures and velocities from fluids

can be used for additional analysis in
Mechanical
Vibroacoustics: Noise generated by
turbulent pressure fluctuations create
minute vibrations that transmit through
materials and propagate as sound
Modal and harmonic analysis: Check Pressures (FFT)
vibration frequencies, interactions and
sinusoidal loading of structural parts

Modal Analysis Free Vibration Harmonic Analysis Sinusoidal Load,

Response @ Frequency Domain
15 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary
 Electromagnetics
Maxwell Mechanical
Fluent

Torque 2D_cooling_inside
213.75
Curve Info avg
Moving1.Torque
156.4067
Setup1 : Transient
Moving1.Torque_22_deg
181.9289
Imported

16% drop in
200.00 Moving1.Torque_2eme_it_52deg
157.3518
Imported
Moving1.Torque_3eme_it_53deg
156.4067
Imported

predicted Single physics simulation, assuming a

Torque (N)

180.00

performance magnet temperature of 22C

Y1 [NewtonMeter]

160.00

3-way Multiphysics simulation shows that

140.00
the actual magnet temperature: 53C

123.75
2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
Time [ms]

Time (ms)
16 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary
 Agenda

Introduction

1-way Thermal and Structural FSI

2-way Thermal and Structural FSI

FSI Examples

Conclusion and Questions

17 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 2-way Structural

2-way Force/Displacement

Earthquake structural and sloshing

response for a liquid storage tank

18 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 2-way Thermal

2-way Thermal coupling

between CFD and
Mechanical
Less common: usually a CFD
CHT simulation is preferred
In some cases the physics
available in Mechanical is
required
Thermal-electric
Thermal shells
Coarser meshes
Long thermal transients
Etc
Flow and heat transfer in a thermal-
electric generator

19 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 2-way Thermal-Structural

Force-Displacement and Thermal

coupling

Bi-metalic strip flow deflector. Fluid pressure

and thermal loads are coupled with the
Labyrinth seal. The seal gap depends on the
thermal-structural solution for the deflector.
structural rotational forces, fluid pressure loads and
thermal stresses caused in part by the hot fluid.
20 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary
 Agenda

Introduction

1-way Thermal and Structural FSI

2-way Thermal and Structural FSI

FSI Examples

Conclusion and Questions

21 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 2-way FSI for Dynamic Seals

HALOTM seal courtesy of ATGI (www.atgi.us)

2-way FSI model of non-

contacting seal for
turbomachinary applications

Goal: Simulate how reduced

fluid pressure in the leakage
path is pulling down the seal.
Calculate leakage flow rate,
pressure profile and
structural deformations.

Transferred quantities:
Force & Displacements
22 2011 ANSYS, Inc. September 2, 2015
 Pressurized
oil inlet

Journal Bearing Solution Shaft Housing

Load

Static Analysis:
Calculate the equilibrium position with full 3D
Elasto-Hydrodynamics (EHD) and Thermo-
Elasto-Hydrodynamics (TEHD) analysis
Fluid film pressure and film thickness
Cavitation, structural deformations
Temperature distribution

Journal and
Attitude
ANSYS Workbench Shaft
angle

Guo assumed 25
Published Results
micron eccentricity
and did not include
EHD effects

Guo, Z.L., Hirano, T., Kirk, R.G., 2005. Application of CFD analysis for
rotating machinery. part I. hydrodynamic, hydrostatic bearings and
squeeze film damper. Journal of Engineering for Gas Turbines and
Power, 127(2): 445-451. [doi:10.1115/1.1807415]
23 2011 ANSYS, Inc. September 2, 2015
 2-way CFD-Mechanical Thermal-Structural
Coupling

In a fuel injector leakage path high pressures and high

temperature gradients both influence the leakage path
gap and flow rate Leakage
Path
CFD and Mechanical are coupled via System Coupling
Mechanical uses coupled field
elements to solve both
thermal and structural
degrees of freedom

Fuel injector leakage path

solved using Fluent and
Coupled Field Elements in
Mechanical

24 2011 ANSYS, Inc. September 2, 2015

 2-way Coupling for Porous Jumps and
Thin Porous Zones
Targets thin porous structures that deform due
to fluid pressures
Automotive and industrial filters
Porous membranes (biomedical)
This is not suitable for thick porous structures
because volumetric forces are not considered
Only surface forces on the upstream and
downstream sides are passed to Mechanical

25 2011 ANSYS, Inc. September 2, 2015

 2-way FSI Analyses of a Jumper Pipe with
Multiphase Fluid Flow

Goal: Calculate long term fatigue

caused by internal and external
flow conditions.
FSI analyses enables better
prediction of stresses and
vibration frequencies for various
flow conditions

ANSYS products used

CFX, Mechanical & nCode

Other Industrial Applications

Process equipment, slug flow
Nuclear piping

26 2011 ANSYS, Inc. September 2, 2015

 2-way FSI Analysis of a Reed Valve

Hyperelastic reed valve

Goal: Study the deformation of

the open valve for different
operating pressures and different
hyper elastic materials

ANSYS products used

Fluent
Mechanical

Other Industrial Applications

Compressors for A/C
equipment
2-Stroke engine

27 2011 ANSYS, Inc. September 2, 2015

 2-way FSI for a Mass Flow Meter

2-way FSI simulation of a Coriolis Flow

Meter. The phase shift between the
upstream and downstream bends
depends on the mass flow through the
device

Goal: Create a simulation model that

correctly capture the phenomena. This
model can than be an important tool
in the design process

ANSYS products used

Fluent
Mechanical

28 2011 ANSYS, Inc. September 2, 2015

 Thermal-Mechanical Fatigue in an
Exhaust Gas Recirculation Cooler
Exhaust Gas Recirculation (EGR)
Coolers are subject to Thermo-
Mechanical Fatigue (TMF)
Fatigue due to cyclic thermal and
mechanical loading
Results from complex physical
interactions
An accelerated thermal shock test is
the standard test for estimating
life of components subjected to
cyclic thermal loading
Simulation can mimic accelerated
thermal shock test and provide
deeper insight into the damage
mechanisms Typical profile for boundary conditions (BCs) in
the transient thermal shock test
29 2011 ANSYS, Inc. September 2, 2015
 Representative EGR Cooler
Coolant Inlet

High temperature EGR gases enter

through inlet Coolant Outlet

EGR gases pass cooling tubes and exit

through outlet
EGR Inlet
EGR components experience high
temperature gradients, resulting in
stress and fatigue
EGR Outlet

EGR Geometry
EGR Mesh

30 2011 ANSYS, Inc. September 2, 2015

 General Multiphysics Simulation Process

Determine Thermal Boundary

CAD Conditions (CFD-CHT)

Modify design if
required Transient Thermal Analysis
(Mechanical)

Fatigue Analysis for Single Cycle Stress Analysis for Single Cycle
(ANSYS nCode Design Life) (Structural)
31 2011 ANSYS, Inc. September 2, 2015
 ANSYS Workbench Project Schematic
Surface Heat Flux and Heat
Transfer Coefficient (HTC) data
for Cold and Hot conditions
Fatigue Analysis
Steady State Thermal
for Cold condition Structural Analysis
used as initial state for
Transient Thermal

Volume
Temperature
data for Cold
condition used Transient Thermal
as initial solution with initial
condition Cold condition and
thermal cyclic
loading

Detailed Structural
Analysis on a part of
EGR using Submodel

Fatigue Analysis on
the Submodel

Validation of Thermal
mapping from Fluids
to FEA
32 2011 ANSYS, Inc. September 2, 2015
 CFD-CHT Results
Low Thermal Load (Cold) Cycle
High Thermal Load (Hot) Cycle
Steady state flow with CHT
analysis performed for high
and low thermal load
conditions to determine
heat transfer coefficients
for replicating the thermal
shock test in ANSYS
Mechanical.

CFD Result Temperature Field for two operating conditions

33 2011 ANSYS, Inc. September 2, 2015
 Mechanical Analysis
Transient thermal analysis uses CFD-CHT steady-state
cold analysis temperature as Initial State
Convection is applied on all external faces
Imported convection load: HTC data from CFD-CHT

Convection BC on external faces

Thermal Analysis

Stable cycle

HTC data import

Temperature Graph
34 2011 ANSYS, Inc. September 2, 2015
 Stress Results
Frictionless Support

Imported Body Temperature

Equivalent Stress
Stress Analysis

Imported Body Temperature

from stable cycle
Time History of Equivalent Stress

Imported Body Temperature from a stable cycle during the Transient

Thermal analysis applied
Frictionless Supports defined as shown in the right top image

35 2011 ANSYS, Inc. September 2, 2015 Submodel

 SN Life Full Model
Fatigue Results
Fatigue Analysis

Global Model

Creep Damage
Full Model

Creep Damage SN Life

Temperature Mapping Load/Stress Mapping

Hybrid Load Generator

Stress Life approach used for the global model

Strain Life approach used for sub-model since
SubModel
elasto-plastic material is used for static analysis
and results show plastic strain

36 2011 ANSYS, Inc. September 2, 2015

 Solenoid Design

Problem:
Must meet pneumatic valve design requirements
Force vs stroke requirements while
maintaining size
Reduce closing time
Fulfill thermal management constraints
Solution:
ANSYS Multiphysics can be used to:
Speed up the design process
Courtesy of NassMagnet, Hannover
Increase the level of design accuracy
Optimize the performance of the solenoid

37 2011 ANSYS, Inc. September 2, 2015

 Solenoid Results Comparison
Using fluid dynamics to determine the
heat transfer coefficient (HTC)
improves simulation accuracy.
2-way coupling between Maxwell
and Steady-State Thermal with losses
and temperatures exchanged
1-way temperatures Maxwell to
Fluent for HTC calculation.
1-way HTC from Fluent to Steady-
State Thermal

38 2011 ANSYS, Inc. September 2, 2015

 Agenda

Introduction

1-way Thermal and Structural FSI

2-way Thermal and Structural FSI

FSI Examples

Conclusion and Questions

39 2011 ANSYS, Inc. September 2, 2015

 Multiphysics Bundles
Multiphysics Bundle Included Solvers

ANSYS Mechanical CFD ANSYS CFD, Mechanical

ANSYS Mechanical Emag Maxwell ANSYS Mechanical Emag , Maxwell 3D

ANSYS Mechanical CFD Maxwell ANSYS Mechanical Emag, CFD, Maxwell 3D

ANSYS CFD includes ANSYS Fluent

and ANSYS CFX
Share ANSYS HPC keys between
ANSYS CFD and ANSYS Mechanical
As of R16, the multiphysics
bundles also include: SpaceClaim,
Design Explorer, and AIM

40 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary

 Multiphysics Simulations with ANSYS

Many Physics, One Vendor

Consolidated CAE partner
Streamlined installation, licensing, and
technical support FLUID
DYNAMICS
Multiphysics Made Easy
Automated setup and workflows
Analyze the whole system STRUCTURAL
Flexible Solutions MECHANICS
1-way data transfer
2-way co-simulation
Single solver solutions ELECTRO-
MAGNETICS
Combine ANSYS with 3rd party tools
Performance & Advanced Modeling
Best-in-class physics modeling SYSTEMS &
Highly scalable HPC MULTIPHYSICS
Design exploration and optimization
41 2013 ANSYS, Inc. September 2, 2015 ANSYS Confidential & Proprietary
 Questions?

42 2011 ANSYS, Inc. September 2, 2015