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In order to meet the required Exhaust Gas Recirculation rate, EGR modules contain nowadays heat exchangers. Typically, single-pass or two-pass coolers are used. When an EGR cooler with a two-pass inlet is considered, a mass flow split ratio of 0.5 per duct is a required condition for obtaining a maximum cooler efficiency. The needed partition of the exhaust flow upstream of the cooler is achieved by using flowsplitter geometries. This presentation deals with the optimization of a flowsplitter. The objective of the study was to obtain a design with an improved flow balance. Furthermore, a...
An overview of the challenges of FSI will be presented along with the capabilities available in the STAR-CCM+ to meet those challenges. The topics will include Data mapping techniques, Protocols and formats for exchanging data between CFD and CSM codes, Coupling methods for stability and accuracy, Techniques for dynamic fluid mesh evolution, and Validation of FSI results. A technical overview under each of these topics will be provided. A range of examples which demonstrate the STAR-CCM+ FSI capabilities and validate the accuracy will be shown. The examples span analytical and experimental...
In this talk, we'll focus on how leading companies are streamlining the virtual product development process by implementing four enabling technologies, namely: Process automation Scalable Computation Efficient Design Exploration, and Sensitivity & Robustness Assessment We will highlight how the HEEDS technology from Red Cedar Technology is being used to accelerate design processes, improve workflow between CAD and CAE, discover better designs, and identify the most robust designs for manufacturing. Key case studies in automotive, aerospace, life sciences and energy will be used to...
The use of multi-user architectures for collaborative design has been explored on several types of engineering software. The client-server architecture of STAR-CCM+ allows collaborative simulation set-up for Computational Fluid Dynamics models. Simulation operations are completed by the server and commands are sent to the server by the client. By using the client-server architecture, users can partition the workload of the simulation set-up and decrease the time required to prepare a simulation prior to solving. Five models are tested to measure the time savings that can be achieved through a...
This presentation describes the aeraulic optimization of an electrical box cooling. This equipment is present on the roof of a railway train. The challenge is to provide cooling powered only by airflow around the train, without adding fans or any other system with a cost in term of mass, deterioration of the reliability and the overall price of the equipment. We must therefore reach a sufficient air flow to perform this function. In the first stage, STAR-CCM + is used to analyze the air flow around the train and especially around the studied box. In a second step, the study focuses on...
Solenoid valves are electromechanical valves that are used to control the flow of liquids and gasses. These valves are controlled by an electric current which runs through a solenoid. The electric current, when activated, provides an electromagnetic (EM) force which enables the motion of a plunger that shuts off or opens fluid flow. From a computational fluid dynamics perspective, modeling the valve closing poses severe numerical challenges due to fluid mesh pinching. Apart from this, accurate evaluation of electromagnetic and fluid dynamic forces and an understanding of their interaction...
The last decades of automotive development have become a race driven by emission regulations, fuel efficiency and customer requirements. To meet future rrequirments, more and more virtual development is required to further accelerate the proces. One of the most significant trends in engine development is downsizing, which leads to smaller engines with higher power output and therefore much higher thermal loading. To reach a high levels of reliability and engine life an optimized and very effective cooling system is needed. 3D CFD has become a valuable and efficient tool to guide the IC engine...
The Eu6 silencer developed by Scania has a complex structure with different chemical and physical phenomena taking place inside it, varying from simple flow through filters to the mixing and chemical reactions of the urea spray. The silencer function is controlled by a number of sensors which are not heat tolerant. The heat received by these sensors is a function of how the heat is propagated through the structure of the silencer and the external flow field. The external flow field in turn varies from the normal steady-state cruising conditions to an extreme case of sudden hot shut down of...
Thermal stress is one of the major failure modes of EGR Coolers due to high temperature gradients at shell and tube heat exchanging regions. For adequate risk assessment highly accurate temperature field determination is required to be able to run further durability analyses for detection and prevention of several thermally induced failure modes. The most practical and accurate way of providing detailed temperature filed is including and solving several physical processes all together by implicitly coupling them using STAR-CCM+. The physical processes that are incorporated are gas and coolant...
Acoustic design of automotive air induction and exhaust systems is commonly based on empirical methods, linear acoustics (transfer matrix methods) and one-dimensional, non-linear CFD simulation. In addition hardware testing is adopted for the calibration of components like mufflers and resonators. Finally with the intake or exhaust system mounted to the engine, bench testing is used to verify targets for noise regulation and to confirm brand sound characteristics. Today 3D CFD simulation is still rarely used for acoustics analysis of intake and exhaust systems, mainly due to the required...

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