Topology-Optimization for internal Fluid Flow: TOSCA Fluid
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CFD topology optimization for channel flow Task: Find a geometrical proposal for a channel within a fluid design space:
For each fluid cell decide:
? Inflow
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“Should this cell belong to the channel or not?”
Outflow
Each fluid cell is a design variable!
Millions of design variables possible
General optimization schemes are not feasible 2 © FE-DESIGN GmbH, www.fe-design.com Corporate proprietary, Approval for distributing and copying required
OC-based Topology Optimization
The Optimality Criterium is to avoid flow recirculation
An achieved consequence is (for many technical flows) a reduction of pressure drop
Redesign Rule: Elimination of local backflow and recirculation by blocking out of backflow areas
provides an “optimization” approach by means of “improvement”
FE-DESIGN – the optimization company
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Topology optimization with TOSCA Fluid
Outflow 1
• Define the Design Space (e.g. CAD) Outflow 2
• Meshing “as usual” • Define your Boundary Conditions • Run the Optimization
Inflow
FE-DESIGN – the optimization company
Design Space
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Topology optimization with TOSCA Fluid
Outflow 1
Free Flow Outflow 2
Transition Area (defining new channel shape) Prevented Flow
Inflow
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Design Space
Optimized Channel Shape
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Topology optimization with TOSCA Fluid
Direct run time communication with the CFD solver
CFD Solver Solution Process Shared-Memory
Only one single CFD solver-run for complete optimization process
Optimization and Flow Result
TOSCA Fluid Optimization
Time resp. Iteration
suitable for large real world applications
FE-DESIGN – the optimization company
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TOSCA Fluid – Result Reconstruction Methods STL-Surface
Optimization result and Designspace
IGES-Cuts FE-DESIGN – the optimization company
CAD-Reconstruction based on IGES-Cuts 7 © FE-DESIGN GmbH, www.fe-design.com Corporate proprietary, Approval for distributing and copying required
TOSCA Fluid – Graphical User Interface
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TOSCA Fluid – Example Projects
EGR-Cooler:
Pressure Drop Reduction: 20%
Efficiency Enhancement: 11 %
Engine Air Intake / Filter System:
Pressure Drop Reduction: 42%
Flow Uniformity Enhancement: 56%
Intercooler Intake Hose:
Pressure Drop Reduction: 20%
Commercial Vehicle HVAC Duct:
Pressure Drop Reduction: 25 %
Flow Split Enhancement: 6%
... Courtesy Opel
FE-DESIGN – the optimization company
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TOSCA Fluid – Feature Overview
TOSCA Fluid.topology Version 2.2 features
Reduction of flow recirculation and vortices by topology optimization of the flow domain
Reduction of the pressure drop and related phenomena
Efficient, fast optimization by direct runtime coupling of the optimization to the CFD solver
Support of
STAR-CD V4.0x solver with .ccm / .ccmg databases STAR-CCM+ V6 solver ANSYS Fluent V12 solver
Parallel operation support
GUI and pre/post processing interfaces
LinuX x86_64 Support
FE-DESIGN – the optimization company
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TOSCA Fluid Key Notes (1)
New and unique technology for fast and efficient topology optimization of internal fluid flow systems
Simulation driven design, fast and easy design optimization impacting all development stages
Use of your favorite CFD-solver and existing models for optimization, no parameterization necessary
Unmatched efficiency for large, real world industrial applications
High innovative strength due to new and potentiality inspiring designs and large solution spaces
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Optimization process
Resulting design proposal (60% less pressure drop compared to a standard design)
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TOSCA Fluid Key Notes (2)
Based on Daimler Technology
Technical and support hotline by experienced CAE and optimization staff
Easy setup of optimization problems using the graphical user interface (GUI)
No model parameterization is required
Straight forward pressure drop reduction (noise diminution), flow homogenization and several other optimization tasks
initial Design
available Designspace
Optimization
General reduction of development time and development cycles which saves your costs New conceptual Design, ∆p ↓26 %
FE-DESIGN – the optimization company
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