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Clients using STAR-CCM+ for vehicle simulation have been growing at a steady rate. A wide range of applications are being used in the ground transportation sector, all the way from vehicle aerodynamics, passenger thermal comfort, to HVAC and component analyses. Clients today use STAR-CCM+ to optimize vehicle aerodynamic designs. Other clients are taking advantage of automation in STAR-CCM+ to achieve one day turn-around for front end cooling. The ability to run combined fluid solid models are allowing engineers to start modeling thermal cycles which in the past have been limited to just test...
To correctly simulate flow through the engine of a full-sized passenger bus in an open jet wind tunnel, Jacobs designed a Flow Control Device (FCD) for a recently commissioned open jet wind tunnel. The FCD is a wing to adjust the flow distribution around a vehicle. STAR-CCM+ surface wrapping technology was used to create a water-tight surface of a very detailed geometry of a bus in the wind tunnel. Pressure coefficients near the engine of the bus in ‘free air’ were used as the reference for the design of FCD in the wind tunnel. Experimental measurements during commissioning of the wind tunnel...
Archery arrows are complex, highly-tuned dynamical systems. Yet they are often designed based on tribal knowledge, anecdotal evidence and/or trial-and-error. Application of first-order aerospace analysis practices for a non-traditional, nonaerospace client specializing in the development of archery equipment resulted in the development of a new, high-quality product and superior insight into the physics that make it a success. This presentation will describe the concept development, analysis process and some key findings for an arrow fletching design cycle, as well as provide a brief overview...
In the ever accelerating pace of the product development cycle, the use of cloud based HPC and macro based automation has been playing a critical role in pushing the boundaries of Trek's engineering. This presentation will focus on Trek's design iteration process with STAR-CCM+ macro automation utility VSIM and subsequent CFD solving on a cloud cluster. The successful integration of the on-demand cloud HPC and local process automation lead to significant increase in productivity, such as improvements in analysis turn-around time reduction and rapid design iterations. This cost-effective, high...
Zipp Speed Weaponry used CFD simulation results, wind tunnel testing and their own creativity to rapidly develop a state-of-the-art product that succeeded in an already crowded bicycle racing wheel market. Their Firecrest wheels were a technological breakthrough that delivered 100% category revenue growth and the addition of over 120 new manufacturing jobs in Indiana in just two years, confirming their place as the established leader in this hotly contested market. With the help of Intelligent Light and CD-adapco, the company is working to rapidly develop a well-engineered, highly automated...
The presentation will be divided in the following sections: 1. Cervelo Product Line Cervelo's product line description and the importance of aerodynamics. 2. New Methodology With the success of the aerodynamic development of the P5, Cervelo is looking to implement the same methodology to the rest of the product line. 3. Cervelo Aerodynamic Development How was the previously defined methodology applied to a new product and the benefits in terms of ideas and turnaround time. 4. Future work A description of the opportunities that STAR-CCM+ has been able to open for Cervelo.
A comprehensive methodology has been developed to accurately simulate the functioning of air induction system for automobiles in STAR-CCM+. In this system, great emphasis has been placed in the physics of operation of air-filter (aids in restricting contaminants) and Mass Air Flow Sensor (MAFS) (measures the mass flow rate of air). Due to the unavailability of the flow properties in literature or with the manufacturer, the parameters porous viscous resistance, porous inertial resistance and porosity required for setting up porous medium (air-filter) were obtained from detailed experiments...
Behr GmbH & Co. KG is a leading supplier in the automotive industry in the field of thermal management. Radial blowers are a central component of the air-conditioning system of a passenger compartment. The target for the development of a radial blower is to increase the efficiency of the blower while reducing the noise level. This enables the provision of adequate air flow in all operating points. For supporting the development of radial blowers a CFD method based on transient DES simulations with STAR-CCM+ was developed. The development of the method was accompanied with various...
The conflicting requirements of better fuel economy, higher performance and lower emissions from an automobile engine have brought many new challenges that require development teams to look beyond conventional test and seek answers from simulations. One of the relatively unexplored areas of development where frictional losses have not been completely understood is the flow in the crankcase. Here computational engineering can play a significant role in analyzing flow field in a hidden and complex region where otherwise testing has serious limitations. Flow simulation in the crankcase poses...
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...

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