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Virtual Manufacturing Empowers Digital Product Development
Recent progress in simulation methods for the manufacturing industry has reduced the need for expensive test hardware which could be used free of charge in manufacturing. Using manufacturing simulation tools starting at the design stage helps to optimize product development and corresponding manufacturing systems. Whenever there is the need for an early design input in order to ensure quality and manufacturing costs virtual manufacturing methods will have a profitable chance. For the case study "E-Coat Simulation" STAR-CCM provides an improved workflow from CAD-data and meshing to E-coat...
Optimization of Overlapping Mesh Calculations for Simulation of Paint Shop Manufacturing Process
Large painting systems like dip or robotic painting systems are generally characterized by their long process time and complex motions. Transient simulation of such systems using CFD resulted in unfeasible computation times and utilized significant computing resources. With the advent of overlapping meshes and motion superposition models, STAR-CCM+ attempted to address the challenges of simulating complex motions. In order to reduce the long computation time associated with such large models and to enhance the effectiveness of overlapping meshes, a new concept was introduced based on the...
Macro Scale Casting Simulation using STAR-Cast
The increasing demand from consumers for newer, cheaper and more efficient products is increasingly influencing the way products are designed and produced. Virtual manufacturing processes are recognized to be part of the solution to deliver better products. This goes also for casted goods. To accommodate the ever changing demands for a casting the simulation methods have to evolve as well. This means expanding the simulation scope both in terms of the complexity of the replicated boundary conditions and processes as well as the detail in which physical modelling is done. An overall...
A CFD Study of Particle-Laden Flow of a Tundish Water-Model
The flow of molten steel and the behavior of non-metallic inclusions inside the 6-Strand Tundish at Georgsmarienhütte GmbH were investigated. Considering that water models are generally accepted in supporting validation of CFD simulations, a scaled model of the Tundish was built. The water flow and the non-metallic inclusions behavior are compared with CFD simulation results. A VOF simulation with extreme density ratio (liquid water, air) was performed. The Eulerian Multiphase model and the Volume of Fluid model were implemented to calculate the behavior of water and air. The Lagrangian...
Dental Implant Cement Flow Simulations with STAR-CCM+
In recent years, cement-retained dental implant restoration (as opposed to screw-retained restoration) has seen a significant increase in popularity by virtue of its improved aesthetics, cost-effectiveness and reduced chair time. Although it is now common place for dentists to apply this method, excess extrusion of cement into the soft tissue surrounding the implant has been shown to cause long-term peri-implant disease when using this approach. Unfortunately, limited data are available to help understand how to achieve optimal cementation to avoid these health issues by controlling the...
A virtual automated process to aid Abdominal Aorta Aneurysm diagnosis and treatments
In the last few years several academic works have tested different simulation tools in order to understand the cause behind the rupture of aneurysms. However, these tools have limited or no impact on patients’ treatment. Due to this, the present work aims at developing a rule-based virtual automated process to aid Abdominal Aorta Aneurysm (AAA) diagnosis, which is useful in consequent treatment. Computational Fluid Dynamics (CFD) is the main tool employed to support the decision making process and the final therapy. So, CFD modeling is the main part of the entire workflow, which starts from...
Welcome to the STAR Global Conference 2014
Didier Halbronn, CD-adapco's VP of European Sales, opens the STAR Global Conference with a discussion of "Multidisciplinary Design Exploration" in which he will identify some of the highlights of the conference program.
Use of STAR-CCM+ for Heat Exchanger Product Development
The presentation will demonstrate the use of STAR-CCM+ to help develop a new type Charge Air Cooler (CAC) for heavy duty off-highway applications. A fin-tube type cross flow CAC requires very small mesh size in CFD model to capture its fin geometric characteristics and resolve the thermal boundary layer. Hundreds of millions of cells may be generated in the CFD model for a Conjugated Heat Transfer (CHT) study of the whole CAC unit, which will then require huge computing resources and make the CFD study very inefficient. The single and dual stream heat exchanger models in STAR-CCM+ require the...
Thermal Analysis & Design Improvement of an Internal Air-Cooled Electric Machine
Conjugate Heat Transfer analysis is performed on a split phase induction motor with internal fan-driven air-cooled topology by using the electromagnetic losses computed in SPEED and mapping them onto the real-world 3-D geometry in STAR-CCM+. Temperature dependent copper losses (I^2R) are modeled in both the stator winding and the aluminium rotor squirl cage. Simulation and measured temperatures are compared to show accuracy of this process. An improved, "vented" stator geometry is swapped into the STAR-CCM+ simulation to determine the potential impact of this design change upon the machine's...
Heat Transfer Through an Axial Fan with a Non-Homogeneous Temperature Source
Thermal protection is an important task in the development process of Mercedes Benz. Therefore a combination of heat exchangers and fans are applied for engine cooling. In some cases the set-up of fan and heat exchangers can cause a flow field, in which the temperature and velocity are strongly non-homogeneous in front of the engine fan. Under these conditions the thermal behaviour of the axial fan cannot be simulated in a proper way with the commonly applied quasi-steady Multiple Reference Frame model (MRF). For a reliable prediction of the thermal behaviour unsteady numerical simulations or...

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