Virtual Engineering - CFD and CAE

December 1, 2001

Virtual Engineering is rapidly being seen as the key to productivity and profitability in industry. More and more companies use CAE tools such as STAR-CD together with other CAE systems in preference to physical testing. The benefits are: reduced time to market, reduced cost and improved quality. The emphasis is not just on doing it, but doing it "quicker, cheaper and better"!

Virtual engineering is not a route that allows half measures. To avoid building multiple prototypes, all aspects of product development must be captured and closely integrated. For example, vehicle design engineers may need to simulate a crash, and at the same time optimise underhood thermal management. Only by working in a virtual CAE environment which integrates all aspects of the design process can prototyping be reduced. Moreover, this virtual approach must be fully integrated within a company's existing design verification process.

Integration for virtual engineering goes beyond making the design tools work together. Success also requires bringing diverse and specialised engineering expertise into the design process. Take power-industry heat exchangers - heat transfer and flow is simulated by CFD experts; however other engineers need to apply their very different skills to evaluate the structural reliability of the proposed design.

Where does CD-adapco fit into this picture? Whilst retaining strict confidentiality of client data, we are continually learning how to help clients solve generic engineering problems. We find ourselves enabled like "bees" to "cross-pollinate" expertise and thus achieve effective transfer of technology. To do this effectively, we aim to offer nothing less than a "full service".

Not only must we continue to develop highly functional, easy-to-use software, but we must also provide appropriate methodology and engineering services. In a nutshell - we want a team relationship with you, our clients, providing whatever you need, from software to engineering applications, filling the gaps in your expertise and training, providing manpower when needed, "empowering, then supporting".

The philosophy of cross-pollination is not new to us. The development of our flagship product, STAR-CD, has always been driven by the engineering applications of our clients, encountered through the engineering services of our offices in New York, Yokohama and London. For example, STAR-CD's moving mesh and spray simulation tools as applied to GDI engines, are now successfully being applied to improving diesel engines.

As the next stage in the establishment of the virtual engineering process, we are developing a set of expert system, "es-solutions". These are problem-specific tools and methodology with associated software, developed via our own engineering knowledge. "Methodology" in this context means everything that is needed to achieve an optimised engineering solution, including: what to consider and what to ignore, how to approach it, and how to judge when enough is done that a design can be accepted.

The expert system concept is also being extended to customisation. CD-adapco undertakes major simulation projects for clients, for example in external aero and underhood thermal management. This work enables the standard es-aero and es-uhood tools to be customised and allow the same clients to routinely solve similar problems in-house.

Amongst the new tools, es-fsi is one of the first really practicable systems for simulating fluid-structure interactions, whilst es-ice enables moving meshes to be set up quickly for in-cylinder calculations. Meanwhile, es-turbo offers solution methodology for aerodynamics, heat transfer and stresses for a cooled turbine blade, and is configurable for different turbines. For aircraft engines,it aims to achieve weight reduction with the highest safety, whilst for industrial gas turbines it is used to optimise reliability and is driven by the economics of fixed-price maintenance contracts. Other es-solutions are in the pipeline and will be announced over the next few months and years.

So, that's our vision - in the next decade CFD, with CAE tools in general and engineering expertise in particular, will increasingly be tied together in the exciting new world of virtual engineering. This affects your future as much as ours. We are planning to position ourselves one step ahead of this new way of working. When you are ready, we will be there to help you!

P S MacDonald, Director and General Manager
CD-adapco