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Virtual Testing for Automotive Components & its Integration into the OEM´s Product Creation Process
InDesA operates a suite of virtual test benches for automotive auxiliary components, such as fans, pumps, compressors and heat exchangers. The objective is to speed up design iterations by verifying CAD designs directly by virtual performance testing and without the need of building prototype components for physical bench testing. As automotive components from suppliers are integrated into larger systems this is done within the OEM’s development process and software environment. Consequently the component’s performance data must be adapted to suit the requirements of other simulation...
Overset Grids Technology in STAR-CCM+: Current State & Future Developments
In this presentation the overset grids methodology implemented in STAR-CCM+ will be first described, including its distinct features compared to similar approaches known from literature (like applicability to arbitrary polyhedral grids and implicit coupling of all grids). Next the access to this feature through the user interface will be explained. The advantages of overset grids compared to alternative approaches when performing parametric studies or simulating motion of bodies relative to each other will also be discussed. Several examples of the use of overset grids for both steady-state...
Fine Tuning of a Fast Catamaran Design to new Operating Conditions utilizing CFD & Optimization
A 39m catamaran operating near the critical hump speed of 18 knots has been optimized through parametric variation. Design objectives included the quality of the flow on the propeller plane and the required power. The catamaran, which was originally designed for a much higher speed of 32 knots, already showed a relatively good performance for the new design speed. Applying STAR-CCM+ in combination with the parametric design and optimization platform FRIENDSHIP-Framework allowed a very economic adjustment, keeping the hull form mostly unchanged. The enhanced flow on the propeller plane was...
Adaptation of STAR-CCM+ Numerical Wave Tank to an Offshore Floater Design Tool
Advanced features of STAR-CCM+, such as Volume Of Fluid, DFBI and overset grid techniques have made it possible to simulate extreme waves and their interaction with floating structure to provide essential design information such as wave run up, air gap, green water and wave impact load. However, the application of the Numerical Wave Tank (NWT) for floater design remains challenging due to its computational cost, especially for the simulation of the floater response in irregular waves. Simulation of irregular waves by a NWT requires a computational domain large enough to simulate the nonlinear...
STAR-CCM+ Simulations of In-Situ Thermal Treatment of Oil-Shale
One of the many research areas at the University of Utah Institute for Clean and Secure Energy is to assist in the commercial utilization of the vast energy stored in domestic oil shale and oil sands resources. We are exploring in-situ thermal treatment technologies of oil shale development because of their potential for reducing environmental footprints. We are taking the novel approach of applying High Performance Computing (HPC) using STAR-CCM+ and Validation and Uncertainty Quantification (V/UQ) to perform Computational Fluid Dynamics (CFD) based simulations to quantitatively predict...
We often talk with our customers about their “grand challenges", trying to understand exactly what it is that keeps them up at night thinking: “if I could just _________, that would be a real game changer for my business!” Regardless of which industry they come from, their answers are often quite similar: The majority of these discussions relate to evaluating the performance of an entire system. An uncomfortable truth about modern engineering is that there really are no easy problems left to solve. In order to meet the demands of industry, it's no longer good enough to do "a bit of CFD" or "...
From CAD Data to E-coat Thickness: Learn the Special Knowledge to Do it with STAR-CCM+
Corrosion protection by E-coating is widely used in automotive industry, and simulation of this manufacturing process increases constantly because of the valuable information obtained in different phases of the development process of a car. Appropriate meshing strategies are necessary to meet the requirements to the simulations with respect to preparation speed and accuracy: In early design phase, it is recommended to use surface wrapper and remesher. When CAD data gets more precise at later stages, it becomes worth to invest in surface mesh preparation to obtain precise surface...
Virtual Manufacturing Supports Digital Product Development – Better Corrosion Protection by E-Coat Simulation in STAR-CCM+
With the recent progress in simulation methods for product development, the need for expensive test hardware, and therefore their availability, has been significantly reduced. This requires additional development and application of manufacturing simulation methods for virtual testing purposes. Early feedback based on manufacturing simulation results to the product design team will help ensure that manufacturing quality and cost requirements are met. STAR-CCM+ 8.02 provides an improved simulation process chain from CAD-data meshing to E-coat deposition including fill and drain behavior in...
Manufacturing Simulation for the Casting Industry with STAR-Cast
In manufacturing and product design, CFD is deployed for the design, validation, evaluation and optimization of the production process. The casting industry has adopted simulation to help with challenging castings, such as, to name just a few: designing the gating and the mold, minimizing necessary super heat, and finding the optimum pouring curve to reduce gas entrainment. It is with the aim of providing solutions for this whole range of casting applications that STAR-Cast was developed. With version 8.02, we will reveal a brand new STAR-Cast, now completely embedded within STAR-CCM+. STAR-...
Technology Review: Modeling & Simulation for Biomedical Device Design
Biomedical device design is facing increasing product complexity while prototype building and testing can take months. The inherent risk in new medical product development can be mitigated through a deeper understanding of the design properties and functions achieved through modeling and simulation. Modeling capabilities for the design of various devices from respiratory (inhalers), pacemakers, MIT/CT scanners, to cardiovascular and microfluidic devices will be discussed. The importance of Fluid Structure Interaction (FSI) modeling will also be addressed. The implicit coupling of STAR-CCM+...

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