Ansys Solutions 05 2006

Industry Spotlight
Oil and Gas

ANSYS 11.0 brings together powerful enhancements to broaden the role of simulation in product development.
The Fiat Panda reached fuel efficiency goals through aerodynamic studies performed with ANSYS CFX.
ANSYS Mechanical performs real-time analysis for jet engine turbine components based on in-service usage.
Contents
Industry Spotlight
5 Oil and Gas
Advanced simulation tools help meet growing worldwide needs for oil and gas as a critical resource for energy and materials in a wide range of products.
Departments
Editorial
The Spectacular Value of Being Right
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Industry News
Announcements and Upcoming Events
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Simulation at Work
Features
10 Expanded and Integrated
Development of an Innovative Snowthrower Steering System Meeting European Emissions for Trucks Meeting Market Requirements for Industrial Pumps Pressure Loss in Pipes with Sudden Contractions
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24 26 28 30 32
Solutions in ANSYS 11.0

ANSYS 11.0 brings together powerful enhancements to broaden the role of simulation in product development.
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Technology Update
Nonlinear Stabilization Features
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15 Latest Tools for Thermal
Analysis of Electronics
Tech File
Generating Interpolated Data with Beam and Shell Elements
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A wide range of ANSYS software is available to study cooling in electronics parts and systems.
36
Tips and Techniques

ANSYS Workbench Makes Simulating FSI Easier
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38 40
18 Simulation-Based Life-Cycle Cost Management

ANSYS Mechanical performs stress and thermal analysis for calculating as-flown fatigue life of critical jet engine turbine components.
Guest Commentary
Running CAE Activities as a Lean Business
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About the cover

The use of simulation plays a key role in enabling better exploration of new oil and gas fields, transportation of raw materials and transformation of this resource into everyday products. Read more in this issues Industry Spotlight article beginning on page 5.
21 CFD Helps Design an
Eco-Friendly Car
The Fiat Panda reached fuel efficiency goals through aerodynamic studies performed with ANSYS CFX.
For ANSYS, Inc. sales information, call 1.866.267.9724, or visit www.ansys.com. To subscribe to ANSYS Solutions, go to www.ansys.com/subscribe.
Editorial Director John Krouse jkrouse@adelphia.net Managing Editor Fran Hensler fran.hensler@ansys.com Designers Miller Creative Group info@millercreativegroup.com Art Director Dan Hart dan.hart@ansys.com Ad Sales Manager Beth Mazurak beth.mazurak@ansys.com Circulation Manager Elaine Travers elaine.travers@ansys.com Editorial Advisor Kelly Wall kelly.wall@ansys.com Editorial Contributors Liz Marshall Chris Reeves emm@fluent.com chris.reeves@ansys.com
ANSYS Solutions is published for ANSYS, Inc. customers, partners and others interested in the field of design and analysis applications.
Neither ANSYS, Inc. nor the editorial director nor Miller Creative Group guarantees or warrants accuracy or completeness of the material contained in this publication. ANSYS, ANSYS Workbench, CFX, AUTODYN, FLUENT and any and all ANSYS, Inc. brand, product, service and feature names, logos and slogans are registered trademarks or trademarks of ANSYS, Inc. or its subsidiaries in the United States or other countries. ICEM CFD is a trademark used under license. All other brand, product, service and feature names or trademarks are the property of their respective owners. POSTMASTER: Send change of address to ANSYS, Inc., Southpointe, 275 Technology Drive, Canonsburg, PA 15317 USA. 2006 ANSYS, Inc. All rights reserved.
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ANSYS Solutions
Volume 7, Issue 5 2006
Editorial
The Spectacular Value of Being Right

By reducing hardware test cycles, engineering analysis helps avoid bottom-line penalties of being wrong regarding time, cost and quality on individual projects and product launches. But the greatest benefit of a systematic Simulation Driven Product Development approach is the sustainable business value of being right year after year with steady streams of design innovations that capture the imagination and dazzle the market.
Save time, lower costs, maintain quality these are the benefits most companies go after with engineering simulation. For decades, thats been the name of the game: crank out products faster, cheaper, better than the competition. Using simulation, companies can spot and fix problems early By John Krouse in the cycle, thereby reducing Editorial Director the high cost and long delays ANSYS Solutions of going through numerous jkrouse@adelphia.net hardware tests. These proven benefits certainly are well documented. In one recent study, The Simulation-Driven Design Benchmark Report, the Aberdeen Group found that 100 percent of best-in-class manufacturers those meeting cost, revenue, quality and launch date targets 86 percent or more of the time use simulation in the design phase and average 1.6 fewer prototypes than all other manufacturers. With the help of simulation, these top performers, on average, were able to get the most complex products to market 158 days sooner with $1.9 million lower development costs. Manufacturers with the simplest products shortened launch times by 21 days and saved $21,000 in development costs. Most companies would jump at the chance to rack up these impressive numbers. Indeed, when it comes to time, cost and quality, failing to deliver on any one of these subtracts significantly from the bottom line. The penalty of being wrong is high, and the benefit of Simulation Driven Product Development in avoiding these deficiencies is unquestionable. But thats only part of the story and, certainly, no guarantee of market success. In fact, a well-designed, inexpensive, quality product launched incredibly fast can still be a total flop if its uninteresting and nobody wants to buy it. Thats why forward-thinking manufacturers aim for innovation continually capturing the imagination of the market with a steady stream of top-performing successful products. These companies listen to the voice of the customer, anticipate swiftly changing trends and know buyer expectations. Their products are innovative because they stand out from the crowd, and their development processes are innovative because these companies can quickly crank out successful designs one after another, year after year. In a recent study by Momentum Research Group, the number-one way for improving competitiveness cited by corporate decision makers was to increase the rate at which their organizations deliver product and service innovations. In another survey by The Boston Consulting Group in conjunction with BusinessWeek magazine, an overwhelming majority of senior executives named innovation as one of their top priorities. Unsurprisingly, Simulation Driven Product Development is at the foundation of many of these efforts in achieving repeatable and efficient design innovation. Instead of rushing to production, smart companies have learned that time saved by reducing the number of hardware tests near the end of development can be utilized early in the cycle to drive innovation. By using engineering analysis tools to evaluate alternative ideas, guide the design and refine concepts in the initial stages of product development, organizations front-load the process to cultivate the creativity and inventiveness necessary for true innovation. Leading-edge companies leveraging Simulation Driven Product Development know that the greatest value of the technology is that it enables them to pull ahead of competitors with innovative products and processes. They dont just avoid bottom-line penalties for being wrong; they get spectacular business value from being right adding money to top-line revenue streams, increasing brand recognition and sustaining ongoing profitability growth by hitting the bulls-eye, time after time, with unique and highly successful products.
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ANSYS Solutions | Volume 7, Issue 5 2006
Industry News
Recent Announcements and Upcoming Events

Top-Performing Manufacturers Using Simulation in Design Phase A recent Aberdeen benchmark study examines when and how companies use simulation during product development and correlates this usage with their performance. The study found that 100 percent of best-in-class manufacturers reported using simulation in the design phase, while only three out of four of the poorest performers do the same. The report also discloses best practices in using simulation that lead to superior product development performance. Aberdeen Group, Inc. provides fact-based research and insights focused on the global, technology-driven value chain. The report was made available to the public through partial underwriting by ANSYS, Inc. Moldflow Plastics Insight 6.1 Offers New Capabilities Moldflow Corporation, a leading provider of designthrough-manufacturing solutions for the plastics injection molding industry, released the latest version of its powerful and widely used plastics design analysis software. Moldflow Plastics Insight (MPI) 6.1 delivers new technologies and key enhancements to help users investigate and solve potential design issues, better interface with structural CAE software programs, reduce solution time and work more efficiently. One of the most significant new features in MPI 6.1 is the ability to predict birefringence (also known as double refraction), a phenomenon that causes optical defects in lens applications. This feature will allow designers of optical parts to eliminate such defects in applications ranging from automotive to consumer products to medical. For more information, visit http://www.moldflow.com. Microsoft and Bull Put High-Performance Computing Within Reach Microsoft Corporation and Bull SAS, one of Europes largest information technology companies, announced the availability of Windows Compute Cluster Server 2003 on Bull NovaScale R400 clusters, built from high-performance Intel Xeon processor-based servers. The partnership marries Microsofts highperformance computing (HPC) platform with the proven capability of Bull in HPC clusters, creating an easy-to-use, scalable infrastructure, featuring the best price-to-performance ratio.
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Windows Compute Cluster Server 2003 is Microsofts first software offering designed specifically to run parallel, HPC applications for customers solving complex computations. Bull, with deep expertise in designing and delivering HPC, has complemented its traditional offerings with Windows CCS 2003 solutions to address the needs of industrial users who need fast and easy turnkey solutions for their mechanical computer-aided engineering (MCAE) applications. For more information, visit http://www.bull.com. Linux Networx Delivers Immediate Productivity for Leading Supercomputing Applications Linux Networx announced the next member of the LS Series, Performance Tuned (LS-P) Linux Supersystems. The LS-P Series of turnkey, productionready systems delivers industry-leading application throughput and significant reductions in total cost of ownership for leading product design applications. LS-P systems are performance tuned for computational fluid dynamics (CFD), crash/impact analysis and structural analysis applications. Visualization software from CEI is supported as a tuned, integrated application on all systems. Linux Networx LS-P Supersystems eliminate the complexity associated with high-performance Linux clusters. They are delivered as state-of-the-art supercomputing systems that are production-ready within days of delivery. As turnkey systems, the LS-P family eliminates the expected customer time and expense associated with installing, integrating and tuning application software, as well as hardware and system software integration and tuning. For more information, visit http://linuxnetworx.com. TyanPSC Reaches 256 Gigflops for Personal Supercomputing TyanPSC, a business unit of Tyan Computer Corporation, launched the next generation in personal supercomputing: the Typhoon 600 series using Intel Xeon 5300 Clovertown processors. Leveraging Tyans experience of 2.5 million users, TyanPSC has designed a personal supercomputing platform that combines the best computational horsepower, the benefits of a personal or workgroup resource and the streamlined user experience that engineers and scientists expect from a PC. TyanPSCs next generation Typhoon personal supercomputer is an easy-to-
Industry News
deploy, easy-to-use turnkey system that delivers a stunning 256 GFLOPs in the office or any other environment while requiring only 15 amps from a standard wall outlet. For more information, visit http://www.tyanpsc.com. Icepak 4.3 Offers Enhanced Flexibility and Automation Icepak 4.3 electronics cooling design software introduces key new technologies in the thermal design of electronic systems. Direct representation of CAD geometries expands the ability of Icepak software to handle complex geometry with this new capability, providing additional flexibility and a higher degree of automation while modeling complex shapes in todays electronics components and systems. A new meshing technology has been introduced into the software for fast and optimal meshing of CAD geometries. Icepak 4.3 also introduces direct import of trace and via details from MCM/BRD and Gerber files of printed circuit board (PCB) layout along with a new method to accurately represent these details. For more information, visit http://www.icepak.com. Cooperation between Materialise and Fluent Results in 3Matic-for-FLUENT Materialise, the world leader in software development for rapid prototyping and industrial design applications, announced the first release of 3Matic-forFLUENT, a custom-developed batch geometry preconditioning module that is the outcome of the successful collaboration between Materialise and Fluent Inc. When combined with the Fluent TGrid 4.0 wrapper technology, 3Matic-for-FLUENT improves the CFD process of geometry to meshed model for a wide range of applications. Materialise 3Matic technology provides powerful geometry conditioning tools that have been used in rapid prototyping successfully for years. Last year, Materialise and Fluent teamed up to further develop this triangular meshing technology to meet the specific needs of FLUENT CFD software users. Materialise specialized Software Development Services team has worked closely together with Fluent on the automation process. For more information, visit http://www.fluent.com. Icewave 1.1 Software Offers Electromagnetic Compatibility and Interference Analysis Version 1.1 of Icewave electromagnetic compatibility and interference (EMC/EMI) analysis software incorporates enhanced model building capabilities and radiation computation for EMC/EMI analysis of
electronics systems. A new 64-bit solver allows users to solve complex systems without being restricted by memory limitations of 32-bit operating systems. Using its enhanced model sharing capabilities with Icepak thermal design software, Icewave 1.1 makes engineering workflows that require thermal and EM analysis easier than ever before. This capability allows system designers of high-performance electronics systems to dramatically reduce time from concept to market by simulating electronic design in a single CAD environment. For more information, visit http://www.icepak.com. ANSYS Addresses User Communities with Industry-Specific Conferences International Aerospace CFD Conference
June 18 19, 2007 Paris, France http://www.iacc.ansys.com The first International Aerospace CFD Conference (IACC) has been uniquely designed to bring together the international aerospace/defense computational fluid dynamics (CFD) user community for ANSYS CFX, ANSYS ICEM CFD and FLUENT products. The conference will offer keynote presentations from industry thought leaders, leading-edge applied CFD papers, best practice sessions for new technologies and a Partner Pavilion. European Automotive CFD Conference
July 5 6, 2007 Frankfurt, Germany http://www.eacc.fluent.com/ The biennial European Automotive CFD Conference (EACC) is a one-stop CFD conference for road, rail, racetrack and off-highway vehicle engineering. The third EACC offers a unique opportunity for updates on the latest technologies in computer-aided engineering (CAE) for the automotive industry. The conference will offer presentations from internationally renowned automotive companies, leading-edge applied CFD papers, best practice sessions for new technologies and a Partner Pavilion.
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Industry Spotlight
Oil and Gas

Advanced simulation tools help meet growing worldwide needs for oil and gas as a critical resource for energy and materials in a wide range of products.
By Robert Bayes Sales Manager ANSYS, Inc.
Oil and natural gas furnish about three-fifths of the worlds energy needs, fueling our homes, workplaces, schools and factories, and transportation systems. In addition, petroleum constitutes the raw materials for plastics, chemicals, medicines, fertilizers, construction materials and synthetic fibers. As a result, the industry has become a key element in our daily lives and an integral part of todays global industrial economy. Currently, the United States is the worlds largest consumer of oil and natural gas, using 25 percent of global production. In September 2006 alone, the total petroleum products delivered to the U.S. domestic market totaled 20.5 million barrels per day. Because of its critical importance worldwide, global demand for oil and gas is expected to increase by 22 percent in the next 10 years. Asia and its emerging markets of China and India lead this increase, with these two nations more than doubling their consumption since 1990. Moreover, Chinas Sinopec Development Research Institute predicts that Chinas oil consumption will double during the next 15 years to more than 10 million barrels per day. Capital expenditures in the
oil and gas industry also are on the increase. A Booz Allen Hamilton report indicated that of the 20 major companies they surveyed, 80 percent planned to increase capital expenditures over the next five years, including planned increases of 30 percent in 2006 alone.
Facing Risk and Uncertainty

Few industries are burdened with more uncertainty or more risk than oil and gas. From exploration to production to delivery, a wide variety of challenges are being met with engineering simulation. Drill-bit technology and offshore platforms have been improved, permitting faster, more effective drilling for longer periods in fields once considered inaccessible. In the past unthinkable, hydrocarbon reserves below 9,000 feet of seawater or imbedded in shale or sand now can be extracted. Technological innovations have enabled rigs to operate offshore and on land 24 hours a day to drilling depths of more than 10,000 feet.
World Marketed Energy Use, 1985 2025 (Projected)

400
Energy Use (Quadrillion BTU)
350 300 250 200 150 100 50 0 1985 1995 2005 2015 2025
Year
Source: Energy Information Administration, U.S. Department of Energy
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Industry Spotlight
Pipelines more than three feet in diameter carrying in excess of a million barrels of oil daily can withstand extreme conditions, including arctic and desert temperatures, as well as crushing and turbulent undersea forces. Giant tankers with evergreater capacities are designed to withstand huge compressive and shear forces, making these versatile carriers not only highly efficient but, above all, safer for crew and the environment. Refinery operations have been improved to more effectively process crude materials into specific products. In these areas, the use of simulation plays a key role in enabling better exploration of new oil and gas fields, transportation of raw materials and transformation of this valuable resource into products that people, companies and nations around the world depend on so heavily. Engineering analysis is indispensable in many of these applications and will undoubtedly prove to be critical as companies in the oil and natural gas industry face ever more demanding challenges in the decades to come.
High-performance, low-cost compute capability has made engineering simulation an everyday and indispensable tool for the oil and gas industry. JRME uses ANSYS Structural software to mesh huge models, such as this offshore spar and barge.
Offshore Platforms for Drilling Deeper

Ever since 1887, when the first offshore drilling rig was deployed 300 feet off the Pacific Coast, oil and gas producers have been forced to drill in progressively deeper waters to extract the resources their customers demand. And the deeper they drill, the more complicated the engineering problems. After about 1,300 feet, fixed oil platforms that sit on the ocean floor are no longer viable. Engineers solved this problem by creating floating platforms such as semisubmersibles, tension leg platforms (TLPs), spars, and floating production storage and offloading (FPSO) platforms that are held in place by moorings anchored to the ocean floor. All floating platforms must survive in the harsh environs of the open ocean. Designs must be engineered to withstand elements such as waves, ocean currents, salt water and wind. ANSYS software is used by many major offshore platform designers such as J. Ray McDermott Engineering (JRME) with facilities in the Americas, Middle East, Caspian and Asia Pacific for incorporating survivability into their products. Although initial engineering simulation work in the global oil and gas industry was limited to R&D and special projects, low-cost compute capability grew the demand for optimization. Worldwide competition prompted the need to optimize all aspects of platform design and produce a more efficient design to reduce total installed cost. JRMEs usage of ANSYS software exploded into everyday use on all designs.
Design of offshore platforms revolves around loading, calculation of stress and displacement, and assuring compliance with industry-developed standards. ANSYS Structural tools are used primarily to calculate stresses and deflections. JRME uses internal software and other commercially available tools to develop loadings and complete the necessary post-processing. They also develop translators to ensure streamlined communication between the various software tools to complete a proper design. Today, ANSYS technology is used on all new JRME designs. For a shallow water platform design, such engineering simulation may amount to only 10 percent of the engineering time and cost, but for a deepwater or floating platform it may be more than half the cost. As JRME engineers use the software, they improve productivity and identify additional uses, which further improves the companys productivity and lowers overall engineering cost.
Studying the Oceans Dance

The increasing worldwide demand for natural gas requires new concepts for gas import. Lightering, the process of offloading and transferring gas from large tankers to smaller ones, is economical and sometimes necessary at ports with narrow entrances, shallow waters or small berths. In addition, some communities mandate lightering so offloading facilities wont destroy the scenic view of the shoreline. Single Buoy Moorings (SBM), headquartered in the Netherlands with technical centers in Monaco and Houston, Tex., U.S.A., has developed a floating storage and re-gasification unit (FSRU) to enable
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offshore import of liquid natural gas, or LNG. Side-byside (SBS) mooring systems are developed for non-dedicated LNG carriers (LNGC) using standard manifolds and mooring equipment on the LNGC. Model tests were performed at the Maritime Research Institute Netherlands (MARIN) for in-depth verification and calibration of the hydrodynamics of two SBS vessels. The vessels were tested in 60m water depth against a large range of design wave systems for offloading operations. The objective of the calibration was to accurately reproduce the measured vessels motions in irregular sea-states and validate the latest hydrodynamic code developments. A fully coupled numerical model was built from the tested vessels characteristics using ANSYS AQWA multi-body hydrodynamic analysis software. The calculation of the relative slow-drift motions between the moored vessels is critical for the design of LNG transfer systems having limited design excursion envelopes. Due to the intermediate water depth (60m), the slow-drift forces are estimated from a fully populated difference frequency quadratic transfer functions (FQTF) matrix. In undertaking the model tests, the propagation of wave groups in a closed basin generates spurious long waves whose periods are in the vicinity of the natural period of the moored vessels. This significantly increases their response in the low-damped degree of freedom (surge). The low frequency wave elevation was measured and separated from the theoretical low frequency content of the wave field. The additional forces resulting from these spurious waves were calculated and imported into ANSYS AQWA as a time history. The calculated LNGC slow-drift surge motions obtained in head waves compare well with the experimental measurements.
The calibration of this numerical model takes into account the accurate description of the basin wave field and the latest developments concerning the interactions of two vessels in close proximity. SBM uses these results in designing safer equipment for offloading operations and developing novel side-byside mooring systems.
Quantifying Safety and Environmental Risks with Simulation

Every year, more than 120 million metric tons of LNG are shipped, worldwide, between 40 LNG-receiving and re-gasification terminals in the world; about 130 ships are currently in operation, 1,000 feet or so in length and holding the equivalent of 20 billion gallons of natural gas. With such statistics, the potential for explosion and fires and risk to life and the environment is of great concern. FLUENT CFD software is being used to address this challenge by modeling various LNG accident scenarios, bringing a higher level of objectivity to the risk-reward calculations. FLUENT technology has the ability to model combustion accurately along with the related flow of liquids and gases while tracking flow rates, temperature, pressure and species concentration. Using a scenario of a breached tanker and subsequent fire, the FLUENT simulation addressed different phases: the liquid natural gas, surrounding air and seawater; chemical reactions involved in combustion, in which methane and air react to form water and carbon dioxide; and the size of the hole from which LNG escapes. The goal of the simulation was to account for the spreading of cryogenic liquid on water, the evaporation process, the dispersion of dense gases, ignition, and combustion. A suitable boundary was defined within which the mathematical equations governing fluid flow was calculated. Analysts generated a mesh within the boundary of a sphere that surrounded the ship and
SBM performed model tests for in-depth verification of hydrodynamics with FSRU (left) and LNGC (right). Note the wave probes between the vessels to capture the wave elevation in the gap.
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LNGC surge motions calibration helps SBM to design safer equipment for natural gas offloading operations and develop side-by-side mooring systems.
Industry Spotlight
included both the ocean below and the atmosphere above the ship. Parameters including velocity, pressure and temperature were set before the CFD software solved the calculation iteratively. The results were then analyzed using tabular information and still or moving 3-D visualizations. In this model scenario, the largest danger is normally considered to be the thermal radiation generated by the blaze, and the simulation makes it easy to quantify the temperature at any location. The model can be adjusted easily to evaluate the impact of various scenarios, such as different weather conditions or a different size breach. Furthermore, its conclusions could easily be applied to any geographic area. Such information could prove invaluable in areas such as determining the location of future LNG terminals and emergency/disaster planning.
Improved Refinery Designs

After oil has been discovered, extracted and transported, it enters a weblike maze of pipes, tubes, towers and tanks the refinery. While refining is a complex process, the goal is straightforward: to take crude materials and transform them into the products used for a wide variety of purposes. For oil, that usually means heating homes, fueling vehicles and running industry. Petrobras, the government-owned oil company in Brazil, is one of the fifteen largest oil companies in the world. Their research arm, The Research Center of Petrobras (CENPES), joined with Engineering Simulation and Scientific Software Ltda. (ESSS) in the year 2000 to develop projects using computational fluid dynamics (CFD) on upstream and downstream applications. ESSS is an engineering consulting firm and ANSYS support distributor in South America that offers custom CAE software solutions.
Petrobras/CENPES uses ANSYS CFX to research inter-phase heat and mass transfer phenomena. This washing zone in a coke fractionation shows the behavior of vapor and liquid through the baffles.
FLUENT software was used to model an LNG tanker explosion after a starboard breach. This images shows the LNG flame approximately two seconds after the start of the fire, illustrated through contours of temperature on an iso-surface of CO2.
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LNG flame after about seven seconds
At CENPES, several studies require a thorough understanding of inter-phase heat and mass transfer phenomena. Some of these studies form the basis of new refinery projects such as coker and vacuum fractionators. These fractionators are used to separate the heavier ends of the raw crude oil into its component parts, such as kerosene, diesel napthalene, etc. Petrobras and CENPES have established a technical imperative to improve the efficiency of these fractionators. To this end, with the assistance of ESSS, Petrobras/CENPES enhanced the configuration of feed inlet device fractionation towers and empty spray sections as well as tower internals. Such enhancements are based on the study of spray injection characteristics with complex physics and boundary conditions using ANSYS CFX software. Further, to understand the best feed nozzle angle, spray distributions and operating conditions, these enhancements take into account the heat and mass transfer between the different phases. Improvements were made to the collector pans and liquid distributors in the kerosene and light diesel sections using free surface models. Petrobras/CENPES also has been performing advanced studies that involve multiphase/multicomponent flows and free surface models applied using EulerianEulerian and EulerianLagrangian techniques. Researchers have employed a wide range of models and boundary conditions to determine the optimal design of these fractionators. The positive results presented so far have encouraged Petrobras to increase their use of ANSYS CFX software to solve a variety of additional engineering problems. Even with complex phenomena, using engineering simulation has produced very good outcomes; Petrobras/CENPES has been able to implement improvements without the use of expensive, time-consuming experimental tests.
ocean floor or extracting the last bit of usable hydrocarbons from a barrel of crude oil, ANSYS technology continues to help these companies solve their diverse engineering problems. s
The author wishes to thank Paul Schofield of ANSYS, Inc. and Marcus Reis of ESSS for their efforts and contributions to this article.
A Flash from the Past

Ancient cultures used crude oil in a variety of ways: to inlay mosaics in walls and floors, to line water canals, to seal joints in wooden boats and to build roads. As early as 1500 BC, the Orient used specific oils as a technique for lighting, burning it slowly so it wouldnt explode. The Chinese were the first to discover underground deposits of oil in salt wells; they transported the liquid in extensive pipelines made of bamboo to use as a lighting source. The Romans found a new use for the substances: they converted flaming containers of oil into weapons of war. The control and availability of oil and gas played a major role in both World Wars. The use of oil replaced coal as the worlds primary source of industrial power early in the twentieth century. Then in the 1950s, world oil consumption began to grow at a rate of 7 percent annually; the forecast at that time indicated that oil reserves were equivalent to sustaining a short 30 years of production, leading many to fear that oil resources would be exhausted by the year 2000. In the 21st century, oil and gas production is now so high-tech that many of its techniques are used in other industries, including space exploration programs.
Targeting New Horizons

Technology will continue to advance global exploration, production and delivery of oil and gas: getting more out of each well, finding new pools, developing cost-effective materials and disturbing less of the environment. Global warming, government regulations, oil spills, sabotage and prolonged severe weather will undoubtedly shape the industry as well. Each new discovery or invention will lead to a new set of challenges. But one thing is certain: Engineering simulation will be leveraged in a variety of applications in the oil and gas industry. ANSYS software has been a valued tool that many companies in this industry have depended upon for years. Whether its modeling the extreme pressures of the
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Expanded and Integrated Solutions in ANSYS 11.0

10
Images courtesy Aavid Thermalloy, ICT Prague and Silesian University of TechnologyInstitute of Thermal Technology.
New release brings together powerful enhancements and new technologies to increase productivity and broaden the role of simulation in product development.
By Barry Christenson Manager, Product Marketing ANSYS, Inc.
ANSYS, Inc. is rolling out the latest version of its family of engineering simulation solutions with new tools and capabilities that enable users to complete jobs efficiently and fully leverage Simulation Driven Product Development for a wide range of applications. The release represents the leading edge in integrated, best-in-class engineering simulation functionality, including advanced analysis, meshing, optimization, multiphysics and multibody dynamics. With the worlds largest simulation community utilizing this software, ANSYS 11.0 brings together technologies from existing businesses and recent acquisitions, making significant advances in : s Developing and delivering best-in-class solver technologies s Providing integrated coupled physics for complex simulations s Exposing meshing technologies in a common meshing application, customizable for the users physics and solver requirements s Effectively handling larger problem sizes by supporting leading-edge hardware and software platforms s Evolving ANSYS Workbench as the best environment for CAE integration s Establishing state-of-the-art computational fluid dynamics technology within the ANSYS software suite
The goal of our focused software development road map is to provide customers with the most advanced and reliable engineering simulation solutions available in the industry. The following highlights illustrate some of the key new technologies in ANSYS 11.0 that will increase user productivity and enable companies to continue broadening the role of simulation in the product development process.
Variational Technology for Solver Speedup

The second ANSYS variational technology implementation speeds up the solution and has been applied to two distinct types of mathematical problems: nonlinear solutions for structural and thermal analysis as well as harmonic analysis. These capabilities are referred to as VT Accelerator. This capability provides a 2X to 5X speedup for the initial solutions, depending on the hardware, model and type of analysis used. VT Accelerator makes re-solves 3X to 10X faster for parameter changes, allowing for effective simulationdriven parametric studies of nonlinear and transient analysis in a cost-effective manner. Users can make the following types of changes to the model before a VT Accelerator re-solve: s Modify, add or remove loads (constraints may not be changed, although their value may be modified) s Change materials and material properties s Change section and real constants
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Change geometry, although the mesh connectivity must remain the same (that is, the mesh must be morphed)
VT Accelerator, at version 11.0, enhances the solution of the following types of nonlinear applications: s Nonlinear structural static or transient analysis not involving contact or plasticity s Nonlinear thermal static or transient analysis
Mesh Morphing
By working with a mesh and not the solid model, the ANSYS Mesh Morpher allows parameterization of models created from CAD data, nonparametric geometry data such as IGES or STEP, or mesh files such as the ANSYS .cdb file. Read a mesh into FE Modeler and then create an initial configuration to synthesize geometry from the existing mesh. At ANSYS 11.0, the ANSYS Mesh Morpher allows four different transformations: Face Translation, Face Offset, Edge Translation and Edge Offset. A wide
Today it is quite common to go from CAD geometry to a finite element mesh. At 11.0, within FE Modeler, you can transform a mesh (left) into geometry (right) and then, with the ANSYS Mesh Morpher, make it parametric thereby making design studies and optimization possible.
variety of configurations can be created with these transformations. For example, a Face Offset of a cylindrical surface is equivalent to changing the radius. These translations determine target configurations and automatically define transformation parameters.
Optimization
ANSYS DesignXplorer has a powerful new suite of design of experiments (DOE) tools. Automatic design points can be generated two ways: Central Composite Design (CCD) or Optimal Space-Filling. CCD provides a traditional DOE sampling set, while the objective of Optimal Space-Filling is to gain the maximum insight with the fewest number of points. New meta-models can accurately represent highly nonlinear responses such as those encountered in CFD or structures. After sampling, ANSYS DesignXplorer provides four different meta-models to represent the simulations response: Full Second Order Polynomial, Kriging, Non-Parametric Regression and Neural Network. Kriging has two variants, pure Kriging and Radial Basis Function.
With the new body-fitted Cartesian meshing algorithm in ANSYS 11.0 software, a user can generate a pure hex mesh on even the most complicated geometries.
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Workbench environment. The latest release also provides a single post-processing tool. ANSYS Workbench significantly reduces the time to obtain solutions to complex multiphysics phenomena. The General Grid Interface technology of ANSYS CFX software has been utilized to deliver FSI load transfers between ANSYS and ANSYS CFX that are both conservative and profile-preserving. The robustness and accuracy of all FSI solutions are improved. This breakthrough in interface load transfer technology is clearly one of the benefits of having experts in FEA and CFD working side-by-side, on the same team, sharing technology. The range of fluid structure interaction cases has expanded with release 11.0.
TurboSystem Vertical Solution

ANSYS DesignXplorer VT softwares new fitting methods, such as nonparametric regression, are powerful enough to capture very complex responses, as this example shows.
Once you have the simulations responses characterized, ANSYS DesignXplorer supplies three different types of optimization algorithms: Screening (shifted Hammersley), Multi-Objective Genetic Algorithm (MOGA) and Nonlinear Sequential Quadratic Programming (NLPQL). At 11.0, ANSYS DesignXplorer offers a full suite of sampling, modeling and optimization routines to address a wide variety of applications.
Fluid Structure Interaction

The integration of ANSYS and ANSYS CFX technologies in ANSYS Workbench has taken another step forward. With version 11.0, users will be able to set up, solve and post-process a two-way fluid structure interaction (FSI) simulation completely in the ANSYS
Using the ANSYS fluid structure interaction capability, a thermalstress simulation can be performed within ANSYS Workbench. For this gas engine exhaust header, thermal loads were passed from ANSYS CFX software to ANSYS Mechanical software to determine the heat transfer between the fluid and the solid body. From this information, the user determined stresses and ultimately performed a fatigue analysis.
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The ANSYS Workbench environment provides an integrated geometry design and analysis system that links all elements of the rotating machinery design process. ANSYS Workbench is the integration platform for advanced physics capabilities that enable designers to model rotating machinery such as pumps, compressors, fans, blowers, turbines, expanders, turbochargers and inducers. The integration of ANSYS solutions into the design process can take weeks out of the CAE process by eliminating manual file transfer, result translation and re-analysis time. The first step in the turbomachinery design process is to obtain a preliminary design using initial sizing software, given the performance criteria and sizing constraints. PCA Engineers Limited is providing initial sizing software for centrifugal compressors and pumps that will be included in ANSYS BladeModeler at 11.0. Vista-CC Design is a rapid mainline design program that when given the compressor duty mass flow, pressure ratio and geometric constraints configures the compressor scantlings, vane inlet and exit angles, velocity triangles. It also provides essential non-dimensional performance parameters, such as specific speed and specific flow rate on which design decisions can be based. The inclusion of 1-D sizing tools, automated meshing, streamlined work flow and automatic report generation all contribute to a simulation-driven design and analysis system that will enable users to develop better turbomachines. The integration of these tools is an example of the ANSYS ongoing commitment to develop powerful solutions for specific industry requirements.
Integrated Meshing Technologies

ANSYS 11.0 delivers more examples of meshing technology integration and provides physicsANSYS Solutions | Volume 7, Issue 5 2006
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features both on the surfaces as well as into the volume. Boundaries are created with mapped or swept blocks providing a pure hex mesh on the boundaries with transitions to tetrahedral or hex dominant/core in the interior. This flexibility of mapped, swept and free blocks provides the freedom to use structured hex mesh in the most important regions of the model while getting a high-quality automatic mesh in regions of less concern.
The ANSYS TurboSystem solution provides integrated tools for designing and simulating a wide range of rotating machinery within the ANSYS Workbench environment.
based meshing solutions that tailor the mesh for mechanical, electromagnetics, CFD or explicit dynamics simulation. Best-in-class meshing technology from ANSYS, ANSYS ICEM CFD and ANSYS CFX has been exposed within the ANSYS Workbench environment to leverage the strengths of the various algorithms to provide an intelligent, flexible and robust solution to meshing. Based on the defined physics filter, various controls are automatically defined, such as mesh size, mesh transition, mesh uniformity, mesh speed, mesh quality and refinement controls for proximity and curvature. Advanced user controls then are available to exert influence over the mesh when required. This intelligence in meshing allows even the novice user to get a good mesh suited for the defined physics while providing the flexibility of additional controls to improve the solution speed and/or accuracy. The multiple meshing methods, available through advanced options, also provide backup meshing approaches to improve the overall robustness of the meshing solution. In 11.0, a common mesh data structure has been implemented that provides additional flexibility in the interaction among applications within the ANSYS Workbench environment. This development provides increased bi-directional communication for interaction between solvers (FSI, implicit/explicit, etc.) as well as a more unified approach to meshing (geometry synthesis, advanced meshing). This common mesh data structure also provides a method for integrating third-party mesh utilities within the ANSYS Workbench framework. New in ANSYS ICEM CFD and AI*Environment 11.0 is a multi-zone volume meshing tool tailored for external aerodynamic applications. This new meshing approach provides the flexibility and control of a blocking (structured meshing) approach with the ease of use of an automatic (unstructured) meshing approach. This semi-automatic multi-zone meshing algorithm allows a user total control over the mesh
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New mesh methods have been added to provide a uniform mesh with control over minimum edge length as required for the Explicit Dynamics simulation. Physics preferences allow the software to key off the physics requirements and apply smart defaults to the mesh.
Inflation layer controls are available to put prism layers on surfaces of primary importance in the simulation. This allows a CFD user to capture the boundary layer with a biased mesh to capture the Y+, or a structural user to create uniform orthogonal mesh on key surfaces for improved accuracy in the simulation.
ANSYS ICEM CFD and AI*Environment 11.0 products also address the age-old question, Should I mesh with tets, or should I spend the extra time to create a hex mesh? You can do both with the new body-fitted Cartesian meshing approach that gives a pure hex mesh in less time than traditional tetrahedral meshing algorithms. Options also exist for a hybrid mesh with tets and pyramids to reduce the constraints on the mesher and provide easier methods to edit the mesh. The uniformity of the hex mesh that is generated from this approach makes it perfect for explicit crash analysis or any simulation in which uniform hex mesh is of interest.
Linear and Nonlinear Dynamics

New at release 11.0, ANSYS expands and consolidates its wide array of advanced structural dynamics capabilities into a single ANSYS Workbench environment. Linear and nonlinear structural dynamics and stress analysis now are seamlessly integrated into ANSYS Workbench Simulation, bringing frequency response and time history dynamics of rigid and flexible structures and mechanisms together. In a single setting, users now can select a range of
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behaviors: from linear to advanced nonlinear and from fully rigid to fully flexible responses, and all combinations in between. Other process-streamlining features include support for simple and advanced joints and constraints, geometry-based automatic joint detection, nonlinear materials and contact, kinematic analysis, and associativity with CAD system geometries.
ANSYS AUTODYN explicit analysis software for modeling nonlinear dynamics now is available as an integrated tool in the ANSYS Workbench environment. In this simulation, the golf ball is created as a parametric model via ANSYS DesignModeler and modeled with multi-layer, hyperelastic, Lagrangian components. The sand is modeled using the Smooth Particle Hydrodynamic (SPH) method contained in ANSYS AUTODYN.
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Structural dynamics and stress analysis are seamlessly integrated into ANSYS Workbench Simulation.
Image courtesy Dale Earnhardt, Inc. Engineering.
The efficiency of the expanded ANSYS dynamics solution makes it ideal for: s Interactive part and assembly joint definition and verification s Determination of assembly dynamic response under pure rigid body assumptions s What-if studies through parametric model changes in the CAD system or ANSYS DesignModeler s Rapid evolution from rigid dynamic analysis to partial or fully flexible analysis s Consolidating the complete dynamics analysis in one user environment ANSYS Workbench
Finite element (FE) solvers for computational structural dynamics Finite volume solvers for fast transient computational fluid dynamics Mesh-free particle solvers for high velocities, large deformation and fragmentation (SPH) Multi-solver coupling for multiphysics solutions including coupling between FE, CFD and SPH A wide suite of material models incorporating constitutive response and coupled thermodynamics Serial and parallel computation on shared and distributed memory systems Links to parametric CAD, ANSYS Design Modeler and meshed models as a native ANSYS Workbench application, permitting rapid parametric studies without manual model updating
Integrated for Overall Product Development Simulation

Other exciting new features in ANSYS 11.0 software are too numerous to list here. (See below, ANSYS Community: New Release Information.) The ANSYS dedication to solver technology, simulation process integration and usability revolution will be clearly visible in many areas of this release and in future updates as well. s
Explicit Dynamics
ANSYS AUTODYN software is a uniquely versatile explicit analysis tool for modeling the nonlinear dynamics of solids, fluids and gases and their interactions. At release 11.0, ANSYS AUTODYN will be available for the first time as an integrated tool in the ANSYS Workbench environment. Tightly coupling ANSYS AUTODYN with tools such as ANSYS Meshing and ANSYS DesignModeler provides an environment in which rapid decisions can be made based on results provided only by an explicit dynamics simulation. With a graphical interface that is easy to use and is fully integrated into ANSYS Workbench, ANSYS AUTODYN allows setup, running and post-processing of problems and includes benefits such as: s Associativity to solid geometry from CAD tools or ANSYS DesignModeler
ANSYS Community: New Release Information

We urge all customers to review the release information on the ANSYS customer portal; in addition, we encourage you to visit the ANSYS Community Forum area. This section in the forum contains detailed examples and how-to guides for many new features, all designed to help you start using these technology enhancements quickly. To access the area, visit the ANSYS Workbench Forum or ANSYS CFX Forum area and then select All Forums from the menu on the left. Select ANSYS 11.0 Forum, which is displayed in the list.
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Latest Tools for Thermal Analysis of Electronics

A wide range of ANSYS software is available to study cooling in ICs, components, PCBs and complete electronics systems.
By David Rosato Product Manager ANSYS, Inc. Rajesh Nair Manager, ICE Division Fluent Inc.
In the rapidly changing electronics industry, designers are cramming ever-increasing capabilities into smaller and smaller products such as cell phones, PDAs and laptops. Moreover, electronics is being integrated into an expanding variety of formerly all-mechanical products. This pushes the limits of air cooling to protect sensitive circuitry from its number-one enemy: excessive heat build-up. In these demanding applications, there is little time for mechanical, thermal and electrical simulation in launching quality electronic products to meet narrow windows of market opportunity and there is absolutely no room for failure. In this fast-paced, high-stakes industry, ANSYS tools are used in meeting these challenges for thermal analysis relating to chips, components, printed circuits and complete systems.
Thermal Analysis
The electronics industry can be segmented into four general areas: chip, component, printed circuit board (PCB) and system. The chip is the part of the package that has active circuitry on it and where the majority of the heat is generated. Chips typically are made of silicon, gallium arsenide (GaAs) or gallium nitride. Active features on a chip can be smaller than a micron. Many companies use the special features of ANSYS TAS software to thermally simulate GaAs power amplifiers. This feature allows RF design engineers to easily define the geometry. The full chip model is generated automatically with details to the sub-micron level. Typical solve time is less than a minute.
Temperatures of a four-BGA package-on-package were determined by ANSYS PTD.
Simulating Electronic Components

To thermally simulate electronic components, ANSYS offers ANSYS PTD, or Package Thermal Designer, software. For ball grid array (BGA)-type packages,
ANSYS PTD has direct interfaces to Cadence APD and Sigrity UPD, the leading ECAD tools used to design these components. Every part of the design is imported from these tools, leaving little to be defined by the user. Three-dimensional models usually can be automatically generated and solved in a few minutes. ANSYS PTD tools can simulate almost any package style including BGA, multi-chip, leaded and leadless. Package-on-package (PoP)- and packagein-package (PiP)-type devices can also be simulated. These devices integrate multiple individual parts into a single package. Complex geometry such as leadframes can be imported through DXF or DWG MCAD files. The component can be placed on a JEDEC board, and standard thermal characterization tests can be simulated accurately. With the easy-to-use
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environment, direct ECAD interfaces, fast geometry processing and model solving, simulations that once took days can now be done in minutes. tools like ProEngineer or ECAD tools (Cadence, Mentor ) if necessary. Predefined object models like heat sinks, integrated circuit packages, PCBs, fans and blowers allow users to rapidly build a system prototype even before designs are committed to CAD. A variety of advanced physical models including those for turbulence, flow and temperature resistance modeling, radiation, shell conduction, and heat exchanger models make Icepak software the state of the art in thermal modeling. Network modeling options allow the user to optionally represent complex IC packages using simple RC-type network models. Automated meshing algorithms take user input in the form of local (object-based) and global sizes and generate a high-quality mesh. Assembly-level meshing allows the user to include minute details in a system-level model yet keep the model sizes small and solution times short. The backend solver, provided by Fluent, is robust and fast.
Studying Printed Circuits

At the printed circuit board level, ANSYS offers ANSYS TASPCB technology. Like ANSYS PTD, ANSYS TASPCB has interfaces with the ECAD tools used to design them. ANSYS TASPCB software imports every layer, trace, plane and via in the board. As components get smaller and their power dissipation increases, the local thermal behavior of the PCB to which they are attached becomes more important. A PCB can have as many as 20 to 40 layers with tens of thousands of traces and vias. Each of these is a local heat transfer path. ANSYS TASPCB software accounts automatically for every one of them in the 3-D model of the board that is automatically generated. As power dissipation on the board increases and operating voltages decrease, the current going through the planes and traces increases. This causes a voltage drop in the traces and planes that turns into heat. ANSYS TASPCB can calculate this voltage drop and automatically make the dissipated heat part of the overall thermal solution. The solution also accounts for how the electrical resistance of copper significantly changes with temperature by increasing the heat generated with increased temperature. The 3-D models generated by ANSYS TAS, ANSYS TASPCB and ANSYS PTD software can be exported to ANSYS Mechanical software and the ANSYS Workbench environment. Temperature results are included, permitting thermalstress simulation. A simplified version of the ANSYS TASPCB board with components and power can be exported to Icepak software, the electronics cooling design tools that are now part of the ANSYS suite from the companys recent acquisition of Fluent Inc. The component geometry from ANSYS PTD also can be exported to Icepak for system-level analysis.
Evaluating IC Package Designs

Icemax software is an advanced parasitic extraction tool for analyzing complex IC package designs. Increasing circuit and transistor density has led to problems of cross-talk and signal integrity that cannot be easily analyzed using design rules or correlations at the package level. The Icemax modeling interface is trivially simple. It eliminates the major bottleneck in the modelbuilding process by being compatible with all EDA platforms that are used across the IC design industry. A full three-dimensional model is generated in a matter of minutes from industry-standard layout data using
System-Level Design and Optimization

Icepak software is interactive, object-based thermal management software for performing thermal design and optimization at the system level. The technologys model-building features include search and selection from libraries of pre-defined parts and components, placement and sizing using the mouse, and use of complex geometries including direct import from CAD
Temperature and air flow in this server system with blowers and heat sinks were predicted by Icepak software.
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because of stringent regulations regarding electromagnetic emission and specific absorption rate (SAR). Issues related to cross-talk are experienced when EM radiation from one device interferes with the operation of another device. Additionally, use of cooling devices like heat sinks in order to solve thermal problems at the packaging level result in these devices behaving like antennae, thereby compounding the problem of minimizing EM radiation. Furthermore, a thermal solution for a system usually tries to maximize the flow through the system by ensuring larger intakes and exhausts from the system; however, this works at cross-purposes with an EM system design that tries to minimize radiation from the system by closing off or minimizing the size of these openings. Icewave technology shares its CAD import capabilities with Icepak, thereby allowing import from a variety of CAD tools and formats. Model-building capabilities are similar to those of Icepak, allowing users to build relevant parts like heat sinks, enclosures, vents, sources and lumped elements quickly and efficiently without having to start with basic entities. Mesh generation is fully automated. Advanced material models such as dispersive dielectrics and frequency-dependent skin effects on conductors also are available. s
Icemax was used to extract SPICE models for this multi-chip module.
super-fast geometry processing engines. Modelbuilding tasks then get reduced to a simple sequence of events that include importing layout information; assigning material properties; and including additional information like wire bonds, solder bumps and solder balls. This is performed through a wizard-style interface that leads the user through the steps required to complete the 3-D package geometry. The user merely needs to specify the operating frequency, the net (or the entire package) to be simulated and the number of neighbors to be included in the simulation. Package designers, engineers and researchers involved in IC package design can easily generate detailed, reliable RLC information for the entire package in a matter of minutes. Output can be generated in matrix, SPICE or IBIS formats for signal integrity, power integrity and simultaneous switching noise analysis. The output is ready for circuit simulation.
Full Wave Simulation for EMC and EMI

Icewave software is a time-domain 3-D full wave simulation tool for EMC and EMI analysis of electronic products. Icewave uses a robust finite-difference time domain (FDTD) field solver to solve complex real-world electromagnetic (EM) radiation and propagation problems. EM radiation problems have become increasingly important for the average consumer
Icewave was used in determining the electric field in this electronic enclosure.
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Simulation-Based Life-Cycle Cost Management

ANSYS Mechanical performs stress and thermal analysis for calculating as-flown fatigue life of critical jet engine turbine components.
By David Stapp President Peregrine Consulting, Inc. U.S.A.
Finite element analysis (FEA) is widely used in the design of new turbine products. The technology historically has been weighted toward the start of the products life, the point at which optimizations are necessary and the design is still in flux in other words, before production begins. Later in product life, the use of FEA has, by and large, been limited to dispositioning discrepant hardware or conducting life updates, as turbine components in the field approach their original life limits on-wing. Recently, the philosophy of life management of aging aircraft turbine engines and airframes has changed. A new paradigm called condition-based maintenance (CBM) is the new focus. This approach diagnoses a parts remaining health and life by analyzing measurable phenomena such as sudden temperature or performance excursions, or minute but detectable vibration signatures. The aim is to identify indicators that precede significant component life events, such as creep or fatigue failure.
The promise of reducing life-cycle costs is based on the premise that the consequences of a crack or imminent failure detected with CBM can be averted through comparatively inexpensive maintenance before more costly component field failures occur. Using the same premise, reliable prediction and early detection of component failure also will make it possible to keep expensive critical components on-wing longer.
Why ANSYS Software was Selected

The key word here is reliable, and the best way to ensure reliability is to embrace FEA as a key life-cycle cost management tool. Peregrine Consulting, Inc. has been engaged in research for three years under a contract with the U.S. Air Force to address the challenges in making possible (and even economical) real-time stress and life analysis of turbine components for as-flown conditions.
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Peregrine Consulting, Inc. created this complex model of the high-pressure turbine rotor through ANSYS pre-processing capabilities. Detailed analysis accounts for effects such as frictional contact, stress-stiffening and large deformations.
Peregrine chose ANSYS Mechanical as the core solver because of its broad capacity for customization and its abundance of tunable parameters, as well as the fact that ANSYS, Inc. is a true veteran of aircraft turbine design and analysis. The software has been the tool of choice at turbine OEMs since the early 1980s. When Peregrine Consulting set about developing ground-breaking technology, we decided that using a proven tool as a core element would ease the substantiation process and guarantee the usability of legacy data, a significant advantage. ANSYS also has shown substantial commitment to continual improvement of its solver technologies. Case in point: Improvements in the Distributed ANSYS product allow us to run solutions efficiently in parallel across multiple CPUs. Enhanced scalability of solver performance directly impacts the return on investment of managing turbine field life, and ANSYS has demonstrated a commitment to being first-to-market with new solver features.
Analyzing Parts As-Manufactured, As-Flown

In analyzing turbines for true in-service usage conditions, determining what missions should be analyzed, especially for military turbines, is a significant undertaking. In addition, it is a discipline that is revisited frequently over a turbines life-cycle. Defining a representative sample of expected missions for a fighter aircraft turbine is no small task. Since
throttle excursions may be abrupt and unpredictable from flight to flight, arriving at methods to calculate fatigue damage to critical components takes considerable manpower and engineering judgment. Calculating as-flown, as-manufactured fatigue damage for each part and each flight reduces reliance on engineering judgment. It will extend on-wing component life for a considerable population of turbines while catching outliers that could result in a premature failure. To be sure, managing analysis and data on this scale is a challenge, but with little associated risk and substantial cost and reliability benefits to be gained. Considering the high cost of turbine components and the cost of taking valuable assets out of service for repair, there is a tipping point at which the life-cycle cost savings derived from acquiring and managing data on that scale is worthwhile. At Peregrine Consulting, we believe the time has arrived to economically run near-real-time analysis of as-flown missions for every turbine in the field. The implications to the safety of military aircrews and the flying public, as well as the impact on the life-cycle costs of very expensive assets, could be dramatic.
Multiphysics Engine Simulation

Peregrine Consultings three-year development effort has resulted in a prototype of the core application for Turbine Field Life Analysis Multiphysics Engine Simulation (TFLAMES): a specialized data processing
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Condition-based maintenance uses FEA to predict component life for components in jet turbine engines such as the F414 powerplant for the F-18E/F Superhornet aircraft.
and process management program that calls upon ANSYS tools to do the heavy lifting of frictionalcontact rotor assembly stress analysis. Our prototype features the high-pressure rotor of the F414 turbine, the Navys engine for the F-18E/F Superhornet. We combined disparate models created separately (most of them by our own engineers) into a single high-pressure rotor model, eliminating the cut boundary condition issues normally associated with turbine rotor analysis. Previously, this was an untenable approach for a frictional analysis due to the large element count and the difficulty of reaching solution convergence. But with efficient solvers, proprietary techniques and cost-effective highperformance compute platforms, full turbine rotor analysis of as-manufactured geometry becomes an economical reality.
Analyzing Actual Aircraft Missions

A question arises once the model is defined: How does one analyze an actual aircraft mission? The typical turbine-powered aircraft already stores the flight mission data in its engine controller, so getting information about flight conditions (such as ambient temperature and pressure, airspeed, turbine rotor speeds, etc.) is relatively straightforward. TFLAMES will screen input for data problems, determine suitable data sets for analysis and then convert that data for use as input to heat transfer and stress analysis. Once a complete set of stress and temperature results for a single mission is at hand, fatigue damage
for each critical turbine location can be calculated at a level of accuracy not previously achievable. In fact, TFLAMES will make it possible to understand the effect of a wide range of factors that may impact turbine component life, such as pilot practices, manufacturing tolerances and aberrations, mission complexity, material fatigue capability and environmental conditions. In this way, data mining of the results will yield new understandings of the key factors that lead to long component lives. By combining Peregrines proprietary simulation acceleration techniques with low-cost, highperformance servers and the ANSYS software capability to process runs across multiple CPUs, it has become economical to run full rotor transient analysis capturing nonlinear effects such as frictional contact, stress-stiffening and large deflections in a period of time measured in hours rather than weeks a major step forward in life assessment technology. The TFLAMES approach to product life-cycle cost management can be employed when the asset is expensive to maintain or difficult to access, or when in-service conditions are hard to pin down: areas such as space vehicles, satellite structures, permanent space platforms and even planetary infrastructure assets of the future. s
Peregrine Consulting, Inc. (www.peregrineconsulting.com) provides design and analysis consulting services for the aerospace industry in areas such as turbine engine development, unmanned aerial vehicle design, engine systems integration and fatigue life studies.
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CFD Helps Design an Environmentally Friendly Car

Fiat Panda MultiEco show-car uses aerodynamic studies to reach fuel efficiency goals.
By R.Tregnago, Head of Aerodynamic and Aeroacoustics, Vehicle Division E. Ribaldone, Senior CFD Engineer R. Putzu, Junior CFD Engineer Centro Ricerche Fiat, Italy
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Fiat considers the Panda MultiEco to represent the future of environmentally friendly cars. Introduced during the 2006 Geneva Motor Show, this concept car exhibits leading technology to reduce emissions and decrease fuel consumption by combining an innovative powertrain architecture, the use of eco-compatible materials for the exterior and interior, and aerodynamic improvements and optimization. Developed within the Fiat Group (Fiat Auto, Fiat Powertrain Technologies and Centro Ricerche Fiat), these solutions will bring great benefits to consumers. Thanks to lower fuel consumption and the use of lowcost methane, the Panda MultiEco reduces relative cost per kilometer by an impressive 63 percent. Aerodynamic studies of the Fiat Panda MultiEco were performed by Centro Ricerche Fiat (CRF), an industrial organization whose objective is the
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promotion, development and transfer of innovation to provide a competitive advantage to clients and partners. These include the different companies in the Fiat Group, automotive suppliers, companies from other sectors of industry, small and medium-sized enterprises (SMEs), and national and international research agencies. Priority areas for R&D at CRF include energy and environment, safety and wellbeing, and sustainable growth. The core competence of CRF is centered on land transportation, which includes advanced vehicles and propulsion systems, innovative components and their associated manufacturing processes, and methodologies for product development. For this project, the goal with regard to aerodynamics was to achieve a drag coefficient for the Panda MultiEco that was lower than the standard Panda vehicle. The design concept for the MultiEco was based on the Panda 4x4, because the height of the 4x4 more easily allowed the introduction of methane (compressed natural gas or CNG) tanks in place of differential and rear-wheel powertrain shafts. However, the Panda 4x4 has the highest drag coefficient of the entire Panda family; therefore, reaching the target reduction was quite challenging. Aerodynamicists of Centro Ricerche Fiat and designers from Centro Stile Fiat worked together from very early in the design process to try to reconcile style with aerodynamic requirements. Considerable effort was spent improving the underbody aerodynamic efficiency. Fully detailed geometry models were considered, using computational grids generated with ANSYS ICEM CFD software. The cases were run using grids consisting of
Panda MultiEco represents the future of environmentally friendly cars, according to developer Fiat. The company used ANSYS technology to analyze the concept cars aerodynamics.
All images courtesy Centro Ricerche Fiat.
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Flow streamlines (colored by velocity) along the vehicle underbody
Velocity contour on a slice plane through the vehicle underbody
several million tetrahedra and prisms. CFD simulations of underbody components using ANSYS CFX meshing software focused on highlighting and reducing the most significant contributors to aerodynamic drag. The results were useful in designing fairings, shields and a rear diffuser. The huge amount of CFD analysis throughout the vehicle development process also allowed definition and refinement of details like the rear spoiler and front bumper. A first study was performed on a Panda 4x4 car. This case was considered as an aerodynamic reference for subsequent tests. Further analysis, performed on several Panda MultiEco concepts, were useful in highlighting critical regions and components that affect flow behavior. In particular, the presence of the gas tanks on the underbody of the CNG vehicle was shown to have significant impact on the overall vehicle aerodynamic performance. Increasing this performance was achieved by optimizing dam shape
and dimension, introducing and optimizing a rear spoiler, conveniently shielding the underbody cavities, and designing an appropriate rear diffuser. Important reductions in drag were obtained both on the underbody and the rear car body. The ultimate relative reduction of the drag coefficient was estimated to be 18 percent of the initial Panda 4x4 value, providing an absolute drag coefficient that met the desired value. Virtual simulations performed with ANSYS CFX played a fundamental role in supporting engineering decisions during the project. Moreover, using CFD allowed CRF to save time and money by avoiding the prototyping and testing costs that would have been incurred for experimental investigations in an aerodynamic wind tunnel. The use of ANSYS CFX during the design cycle of the fuel-efficient Fiat Panda MultiEco was instrumental in allowing the team to reach the aerodynamic goals. s
Reducing drag on the underbody of the Panda MultiEco was an important consideration in ensuring reduced fuel consumption. This graphic shows the velocity field on a slice plane through the vehicle.
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Normalized drag forces, comparison between Panda 4WD and selected Panda MultiEco designs
Simulation at Work
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Development of an Innovative Murray/Briggs & Stratton Snowthrower Steering System

ITI Manta used ANSYS Mechanical in designing components for optimal fatigue life.
A name known in households since 1920, Murray, Inc. is a global manufacturer of lawn, garden and outdoor power equipment that includes snowthrowers, lawn tractors, walk-behind mowers, gas-powered edgers, mini-cultivators and high-wheel trimmers. Headquartered in Brentwood, Tenn., U.S.A., the company takes pride in offering products that provide consumers the latest technology, greatest durability and top designs for the money. Products are powered by engines from Briggs & Stratton, the worlds largest producer of air-cooled gasoline engines for outdoor power equipment. Briggs & Stratton expanded its product portfolio with the recent acquisition of Murray, Inc. One of Murrays newest products is the Power 2 Steer, a heavy-duty snowthrower with a unique steering system that enables consumers to make turns easily, compared to competitive equipment that forces users to squeeze a trigger, which releases drive power to one of the two wheels. This action requires considerable dexterity and effectively reduces traction by 50 percent, because only one wheel is being driven. In contrast, consumers can turn the Murray Power 2 Steer simply by adding pressure to the handle. This engages a proprietary clutch assembly that provides the proper variable-speed driving force to the wheels for easy turning and steering. In this way, the Power 2 Steer gives twice as much power as the competition because traction is maintained on both wheels, not just one.
ANSYS Mechanical software was used by ITI Manta in its simulation-driven design approach for developing parts such as this snowthrower auger shaft.
Hitting the Window of Opportunity

Murray had only a few short months to get the Power 2 Steer into production before the company lost business from one of its strategic snowthrower retailers. Hitting this narrow window of opportunity just before the snow season would be difficult, because the effect
of the new clutch assembly on stress and deflection levels needed to be evaluated for components and subsystems throughout the snowthrower, such as the drive shafts, bearings, subframe and sheetmetal main chassis. Designing these components for the necessary strength was critical to ensure adequate fatigue life of components without adding prohibitive cost and material. The tight product development schedule left no room for numerous physical prototype test cycles.
Simulation-Driven Design
To meet the production deadline, Murray turned to ITI Manta for engineering analysis of the structure and
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design of critical components and subsystems. ITI Manta is the test, analysis and design business within product development consulting firm International TechneGroup Incorporated (ITI, www.iti-global.com). The firm used ANSYS Mechanical software to determine von Mises stress and structural deflection in a simulation-driven design approach, in which flaws are spotted, alternatives are explored and product performance is refined early in the conceptual stage of development before detailed design is created and the first prototype built. Using this approach, component designs were optimized based on minimizing stress and deflection levels and, thus, optimizing the target fatigue life. Hardware prototypes then were built to verify the design. ANSYS software was essential in the simulationdriven design approach used in analyzing and developing components and assemblies for the Murray Power 2 Steer snowthrower, explains Brian Lewis, product development manager at ITI. Parametric capabilities allowed us to quickly change models to study alternatives without remeshing from scratch. Also, the software worked extremely well with other packages in providing a convenient way to integrate structural analysis into a virtually seamless product development process from concept through release to manufacturing.
Significant Benefits
By parameterizing simulation models, ITI Manta engineers were able to quickly modify the designs to meet the various operational requirements and iteratively arrive at an optimal product configuration. In this way, the design was completed on time to meet the seasonal product launch. Since its introduction, sales volume for the Power 2 Steer snowthrower has continued to grow thanks to the steerable feature, which the company describes as extremely successful in selling profitably over the competition. Product cost was minimized thanks to component designs that minimized the amount of material used. In the long term, greater durability will continue to strengthen the companys brand value in providing customers with products designed and built to last for decades. s
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Simulation at Work
The Euro 4 baseline exhaust system
Surface mesh used for the baseline system
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Pathlines colored by velocity magnitude illustrate the flow through the baseline design and an alternative design.
CFD Helps Light-Duty Trucks Meet New European Emissions Regulations

FLUENT simulation optimizes flow distribution in catalytic converters while reducing system backpressure.
By Alessandro Verdi, IVECO Engineering Andrea Renzullo, Alessio Tarabocchia, Giorgio Villata Cornaglia R&D, Italy
The European Union has introduced emissions regulations for various vehicles during the past several years. In 2006, the Euro 4 regulations were targeted at new light-duty vehicles with the goal of reducing NOx emissions and harmful particulates. To meet the new emissions targets, after-treatment devices have been added to the exhaust system of the IVECO Daily line of trucks and vans, one of the most popular lines of light-duty vehicles in Europe. Engineers from IVECO and the Exhaust System Division of Cornaglia worked together to design the new exhaust system, using FLUENT software CFD to optimize the flow distribution in the catalytic converter (referred to as cat) while keeping the system backpressure under control. A baseline exhaust system was studied first, focusing upstream of the muffler, where higher temperatures exist and the main contribution to the system backpressure occurs. The geometry then was modified and new calculations were performed to optimize the following parameters: s the flow uniformity index, , evaluated on inlet sections of the pre-cat and main-cat monoliths and defined as the average of the deviations between the mean and local flow velocities s the system backpressure, or difference between the static pressure on the inlet section of the system and the ambient pressure A 600,000-cell mesh was generated using GAMBIT, geometry and mesh generation software that is now part of the ANSYS suite from the recent acquisition of Fluent Inc. The pipes and monoliths were modeled with hexahedral elements, while the conical sections were modeled with tetrahedra. Steady-state
calculations were performed using the k- turbulence model with non-equilibrium wall functions. The ideal gas law was used for the exhaust gases, and heat transfer at the walls was included. The monoliths were treated as porous regions, and the upstream muffler static pressure, measured on an engine bench, was used for the exit condition. Mass flow rates of 20 percent, 60 percent and 100 percent of the maximum flow rate of the IVECO F1C JTD engine were used as inlet conditions. Four geometric configurations were analyzed to study the effect of different designs on the flow uniformity index and backpressure reduction. One configuration was found to perform the best overall, causing the most uniform flow for all but one flow condition and a 12 percent reduction in backpressure compared to the baseline. The predicted improvement was confirmed by experimental tests, and this configuration was subsequently adopted for serial production. The Cornaglia exhaust system, optimized by this study, is currently mounted on the IVECO Daily light-duty vehicles throughout Europe. The use of CFD for the optimization process reduced the development time and the cost of prototype manufacturing. s
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Simulation at Work
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Meeting Market Requirements for Industrial Pumps

ANSYS tools for rotating equipment help designers decrease pump size by 33 percent while boosting performance for a power savings of 5 percent.
By Anil Patel, Assistant General Manager Kiran Patel, Design Engineer, CFD Analysis Center Jyoti Ltd., India
Jyoti Ltd. has continuously widened its range of pumps to meet the growing and constantly changing requirements of the industrial pump market. Computer-aided engineering as well as pump model testing facilities are instrumental in helping the company develop pumping systems with superior hydraulic and mechanical performance. Jyoti uses ANSYS turbo system products to quickly and efficiently bring these new products to market. Established in 1943, Jyoti Ltd. is a leading engineering company offering reliable quality products and services to clients in India as well as the international market. The company serves a wide range of industries, including power generation, transmission and distribution; agriculture; water supply and sewage systems; defense with a focus on naval and marine establishments; railways; and core industries such as steel, cement, paper, sugar, fertilizers, chemicals and petrochemicals. Engineers at the CFD Analysis Center at Jyoti were asked to assist in the design and development of
Testing facility at Jyoti Ltd. R&D Center, where CAE and pump model testing facilities are used to develop pumping systems with superior hydraulic and mechanical performance. Engineers there used ANSYS technology to design a new pump based on an existing design.
All images courtesy Jyoti Ltd.
a new pump based on an existing design. This pump was required to have increased efficiency as well as reduced manufacturing costs. Because ANSYS, Inc. provides an integrated system for design and analysis that can greatly reduce the amount of time between
ANSYS CFX simulation of the old version of the pump (left) and the new version (right). The new design increased efficiency and decreased cost.
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Blade loading at 5 percent span for old design (left) and new design (right)
Blade loading at 95 percent span for old design (left) and new design (right). The figure on the left shows stator blade loading for the old design at which the pressure on both side surfaces of blade cross. This would cause higher head loss and decreased performance. This design flaw has been corrected in the new design on the right and has improved the performance of stator.
design iterations, ANSYS turbo system products were used for this project: ANSYS CFX computational fluid dynamics software, ANSYS BladeModeler blade design tool and ANSYS TurboGrid rotating machinery meshing product. These tools have long been in use within the rotating machinery community to reliably provide performance results. Theoretical design of rotor and stator was completed using a conventional method, and then the design was transferred to ANSYS BladeModeler. The design was improved using ANSYS CFX analysis until the CFD analysis result parameter trends met the specified requirements. After several iterations and analysis using ANSYS CFX, the hydraulic performance of the equipment was greatly improved. This improvement
will lead to power savings of approximately 5 percent. Of even greater importance, the total weight of equipment as well as the material costs for these components was reduced by 33 percent, which is considered a major breakthrough for Jyoti. In addition, simulation using ANSYS CFX software provided additional insights into the effect of incidence angle and secondary flow in the stator on the equipment performance. This resulted in performance improvements by optimizing secondary flow in the stator and minimizing the incidence angle. In this way, through use of the integrated system of rotating machinery tools from ANSYS, Jyoti was able to both improve performance of the pump and decrease costs. s
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Old pump design (left) and new pump design (right). The new design is 33 percent lighter than the old design and is considered a major breakthrough at Jyoti.
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Simulation at Work
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Pressure Loss in Pipes with Sudden Contractions

ANSYS CFX was used to validate an experiment correlating pressure loss and flow characteristics.
By Dr. Francesca Iudicello, Thermofluids Engineer ESDU International plc, London, UK
IHS ESDU International provides validated engineering design data, methods and software that form an important part of the design operations of companies large and small worldwide. ESDU has more than 65 years of experience in providing engineers with the information, data and techniques needed to continually improve fundamental design and analysis. Guided and approved by independent international expert committees and endorsed by key professional institutions, ESDU methods are developed by industry for industry. ESDU International provides validated, up-to-date engineering data to design engineers and teachers of design in the aerospace, mechanical, chemical and structural engineering fields. ESDUs Thermofluids group has developed methods for calculating pressure losses in internal flow systems for more than 37 years. These are industrystandard methods based on the analysis of high-quality experimental data, analytical methods and lately validated using ANSYS CFX software. Within ESDU, computational fluid dynamics (CFD) is used to supplement and support experimental methods of data collection. Pipes with sudden contractions exist in many engineering applications, including nuclear reactor cores and pipe fittings. To design such systems, the pressure loss and the extent of the flow separations must be determined to avoid placing sensitive equipment in the recirculation regions. There has been an increasing need to predict pressure loss reliably for cases in which experimental data is not available, not reliable or inconsistent. There is little reliable experimental data on pressure loss in sudden contractions, especially for round- and chamfer-edged sudden contractions. For CFD to reliably predict pressure losses and flow characteristics in internal flow systems, it is essential to capture the important flow mechanisms for a wide range of geometrical configurations and flow conditions. The pressure loss and flow
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characteristics correlations, recently developed by ESDU, are based on rigorously validated CFD data for sharp-, round- and chamfer-edged sudden contractions in laminar, transitional and turbulent flow regimes. CFD validation studies in support of these correlations were carried out using ANSYS CFX 10.0 software. ESDUs Thermofluids group was advised to use ANSYS CFX by the members of ESDUs Fluid Mechanics, Internal Flow Panel, who have a deep knowledge of fluid mechanics and long experience in the design of internal flow systems. Under the guidance of this panel, ESDU is developing best practice guidelines for the use of CFD in the prediction of pressure loss and flow characteristics in internal flow systems.
Analysis of Turbulent Flow

The ANSYS CFX solver proved to be very robust, and it converged to a high accuracy within a reasonable number of iterations even with meshes that are not high-quality. The resulting predictions were validated against well-documented, reliable experimental data using a rigorous procedure that reduced the sensitivity to mesh size and distribution, advection schemes, timedependence, residuals levels, turbulence modeling and near-wall treatment, and flow boundary profiles and location. This procedure was applied to all geometrical configurations and flow conditions tested. Three turbulence models were tested: the k model with scalable near-wall treatment as well as the k model and SST with automatic near-wall treatment. The closest agreement with the experimental data was obtained using the SST model (automatic) for the flow separation details, and with the k model (automatic) for the pressure loss. The validated ANSYS CFX predictions were within the experimental uncertainty. The results confirmed that it is essential that the pressure loss coefficient, determined from the pressure drop across the upstream and downstream pipes of the contraction, is calculated in
Images courtesy ESDU International plc.
the regions of fully developed flow outside the region of influence of the contraction. These could be up to 110 diameter lengths (for high Re laminar flow) downstream of the contraction plane.
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Better Understanding of Correlation

The ANSYS CFX results have helped us understand why the previous ESDU correlation for the pressure loss coefficient in turbulent flow was significantly higher than the ANSYS CFX predicted values. The original ESDU correlation and other commonly used correlations are biased toward the widely used experimental data of Benedict. This information is reputed to be very reliable. However, the location at which the downstream static pressure measurements were carried out is reported to be at the flow reattachment point and is assumed to be in fully developed flow. This assumption is not correct, as CFD calculations and measurements show that the flow becomes fully developed at least 20 diameter lengths downstream of the contraction plane. It reattaches at about one diameter length. Consequently, ANSYS CFX predictions are lower than Benedicts data in the fully developed region but in close agreement at the flow reattachment point. Comparisons of the ANSYS CFX predictions with the pressure loss coefficient correlations in commonly used engineering handbooks showed that although some discrepancies are evident, they are in good agreement with Bullens experimental data, which is considered reliable. Traditionally, the ESDU database has been experimental and analytical. After the successful validation work on sudden contractions, ANSYS CFX data will play a great role in the improvement of existing pressure loss correlations for internal flow systems. The results obtained with ANSYS CFX software, in some cases, proved to be more reliable than previously accepted references. These CFD predictions explained the discrepancies and have provided guidelines for experiment. The success of the validation work for the pressure loss across sudden contractions has given ESDU the confidence to use ANSYS CFX for other internal flow components, such as orifices and valves. s
Flow schematic to determine pressure loss and extent of flow separation
Typical ANSYS CFX results vs. experimental data were within the experimental uncertainty.
CFX results vs. Benedicts experimental data. ANSYS CFX predictions are lower than Benedicts data in the fully developed region, but in close agreement at the flow reattachment point.
References ESDU 05024, Flow through Sudden Contractions of Duct Area: Pressure Losses and Flow Characteristics, 2005-DEC-01. ESDU TN 06023, CFD Validation Studies for Pressure Loss and Flow Characteristics in Sudden Contractions, ISBN: 1 86246 600 9. DOI: 10.1912/ESDUtn06023. www.esdu.com
ANSYS CFX results vs. handbook correlations and Bullens experimental data. ANSYS CFX predictions are in good agreement with experimental data.
Technology Update
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Sample Problem: Collapsed Fuel Container

The nonlinear stabilization technique can be used in a wide range of unstable problems, including some that would be difficult to solve with conventional FEA methods. Figure 1. Fuel container example geometry and boundary conditions
Understanding Nonlinear Stabilization Features

Enhancements in ANSYS Mechanical handle nonlinear problems such as buckling, structural wrinkling and other large-deformation analysis in which material behavior becomes unstable.
By Roxana Cisloiu and Jin Wang ANSYS, Inc. Development
In large-deformation analysis, two major problems can cause convergence difficulties and reduce simulation accuracy (especially in static analysis with implicit solvers): mesh distortion and structural instability. A special nonlinear technique called rezoning was released in ANSYS 10.0 for the first of these problems, allowing users to repair the distorted mesh (limited to 2-D for now) and continue the simulation. In addition, a nonlinear stabilization technique developed as an enhancement in ANSYS 11.0 allows for state-of-the-art simulations of unstable nonlinear problems such as post-buckling, snap-through, structural wrinkling and other analysis in which materials become unstable.
Numerical Damping for Large Deformations

An unstable structure usually is characterized by a load-displacement curve in which the deformations
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can become very large during a small load increment. The newly developed tool in version 11.0 deals with such instabilities by providing a numerical damping scheme invoked by the STABILIZE command, which activates or de-activates stabilization from one load step to another or after a multiframe restart during a load step. The stabilization feature can be thought of as adding an artificial damper or dashpot element at each node of an element for which this feature is available. Stabilization is achieved by reducing the large displacement of the node by adding to the force equilibrium equations a damping force (stabilization force) proportional to the pseudo-velocity of the node. Since it is usually difficult to predetermine the stability of a structure, it is more efficient and accurate to run the nonlinear analysis without stabilization while saving the restart files. Then, if the analysis fails to converge due to instabilities, the stabilization can be
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Figure 2. Final deformation at which ANSYS diverges without stabilization
Figure 3. Final deformation obtained using the new nonlinear stabilization tool in ANSYS 11.0
activated during a restart analysis from any substep except the last converged one. If the behavior of a problem is known to lose stability very soon after the load application, then the stabilization can be turned on at the beginning of the analysis. The stabilization force can be controlled via an energy dissipation ratio (STABILIZE,,ENERGY) or a damping factor (STABILIZE,,DAMPING). ANSYS provides the user with the option of applying the stabilization force by keeping the damping factor unchanged during each substep of a load step (STABILIZE,CONSTANT,) or by gradually reducing it to zero at the end of the load step (STABILIZE, REDUCED,). The specific value that has to be applied to achieve both convergence and correct deformation patterns is determined through a trial-and-error process.
first and then unloaded significantly, resulting in a small elemental potential energy but large stabilization energy.
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When the above conditions are not fulfilled, the results still might be valid if a large part of an elastic structure undergoes rigid body motion, as in a snap-through simulation. But the results have to be used extra carefully.
Sample Problems
The nonlinear stabilization technique can be used in a wide range of unstable problems. It is illustrated here in several examples (Figures 1 through 8) that could not have been solved otherwise in a practical manner with conventional FEA methods.
Collapsed Fuel Container

The model (Figures 1, 2 and 3) represents half of a five-liter fuel container modeled with SHELL181 elements with reduced integration as well as two pairs of contact elements defined on both the inside and outside surfaces of the bottle. The material considered is elastic, and applied boundary conditions and forces are shown in Figure 1. The initial simulation without stabilization diverges at time 0.38 and no significant deformation is visible, as can be seen in Figure 2. A restart analysis is performed from the substep before the last converged one with stabilization turned on with the constant option and controlled by a damping factor of 1.5. Using stabilization, the analysis can be carried out up to the point at which the bottle is almost fully collapsed, as shown in Figure 3.
Accuracy of the Analysis

Since artificial stabilization forces are introduced into the problem, users are advised always to check the accuracy of results obtained with this technique. This can be done in the following ways:
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Compare the stabilization energy to the potential energy. The stabilization energy should be much less than the potential energy for an acceptable result. If the previous condition is not satisfied, the user can further compare the stabilization forces to the applied loads and reaction forces. An acceptable result requires that these forces be much smaller than the others. Such a case can occur when an elastic system is loaded
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Technology Update
Sample Problem: Local Pipe Buckling
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Figure 4. Pipe geometry and boundary conditions
Figure 5. Equivalent stress at the last converged substep without stabilization
Figure 6. Final equivalent stress obtained with stabilization
Local Pipe Buckling

This model (Figures 4, 5 and 6) represents a thinwalled pipe modeled with SOLID186 elements that is subjected to a large, pure bending deformation. The material is chosen as elasto-plastic with a TB,BISO definition. The geometry of the model, boundary conditions and applied pressures are shown in Figure 4. The initial analysis is run without stabilization and diverges at time 0.75 due to the instabilities developed as a result of the local buckling of the pipe. As can be noted in Figure 5, this stage shows very little
deformation compared to the initial configuration, and buckling is not yet initiated. Therefore, the analysis is restarted at time 0.62 and stabilization is turned on with the constant option, and a specified energy value of 0.04 is used. The model is solved to completion. The final deformation obtained with stabilization is shown in Figure 6.
Wrinkled Thin Membrane

The choice of this example (Figures 7 and 8) to test the performance of the stabilization feature was motivated
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by two reasons: the challenges that any finite element software faces when simulating the development of the out-of-plane deformations in thin-film membranes and the availability of experimental data for comparison in published literature (Alexander Tessler, David W. Sleight and John T. Wang, Nonlinear Shell Modeling of Thin Membranes with Emphasis on Structural Wrinkling, 44th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Norfolk, Virginia, AIAA 2003-1931, April 7 10, 2003, pp. 11). The model represents a square thin membrane (Mylar polyester film) modeled with 100x100 SHELL181 elements. The model is clamped along the bottom edge and subjected to an in-plane shear loading along the top edge, as shown in Figure 7. Because there is no mechanism that can initiate the out-of-plane, buckled deformation, a well-known procedure is used that consists of imposing pseudorandom imperfections at each node in the out-ofplane direction. The imperfection magnitudes are dependent on the membrane thickness and are very small so that they do not influence the final deformed configuration. The imperfections, material data and geometry employed are the same as in the above referenced literature. Since the structural instabilities are initiated soon after the load application, the stabilization feature is activated from the beginning with the constant option and an energy value of 0.5. The out-of-plane deformations, as shown in Figure 8, were found in close agreement with results available in the literature in terms of number of wrinkles, their orientation and amplitudes.
Sample Problem: Wrinkled Thin Membrane
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Figure 7. Square thin-film membrane example geometry and loading
Summary
The new nonlinear stabilization technique shows significant potential for use in solving many of todays formidable tasks such as post-buckling and other shell, beam and solid structures with instabilities. The novel stabilization technique proves to be a very powerful tool with very few limitations, and it can be used together with nearly any other nonlinear solution technique (except arc-length method). The addition of nonlinear stabilization together with the recently introduced rezoning feature has greatly amplified the power of ANSYS nonlinear capabilities. It has proven itself as an important step in the advancement of simulating complex engineering processes. s
Figure 8. Out-of-plane deformations
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Tech File
36
Generating Interpolated Data with Beam and Shell Elements

Convenient macros provide a way for ANSYS software to help study nontraditional problems.
By John Crawford Consulting Analyst
One day I found myself thinking of the many types of engineering problems that you can solve with ANSYS software, ranging from electromagnetics to heat transfer, from forced vibration to harmonic analysis, and many more. All these have one characteristic in common: They are all physical phenomena found in nature. This isnt surprising, since ANSYS technology was developed to solve physical problems using the finite element method, which it happens to do very well indeed. However, I started to consider the possibility of using ANSYS for problems that fall outside these traditional applications. Are there any problems for which finite element analysis (FEA) might be suitable that are not necessarily physical in nature? I remembered that when I use ANSYS software to model something simple like a cantilever beam, it calculates a deformed shape that describes a parabola: the most efficient, least complex shape that results from the systems boundary conditions, or known values. Given the values of the deflection and slope at one end and the deflection at the other, ANSYS calculates a path for the beam that matches
the classical equation of Y=A+BX+CX 2, in which A=B=0 and C=M/2EI (M=bending moment, E=elastic modulus and I=area moment of inertia). Just as a parabola is the most efficient equation for describing a system that has three known values bounding it, ANSYS calculates the shape that is the most efficient and minimizes the potential energy stored in the beam.
More Data Points and Higher Orders

Using ANSYS software to calculate the path of the exponential curve described by a simple second-order equation may seem a little like hitting a pin with a sledgehammer, but it offers the potential to solve more complex problems. We could solve a second-order polynomial without any trouble using traditional means, but it becomes increasingly difficult to solve for the constants in a polynomial as data points are added and the order of the equation increases. Since finite element analysis offers an alternative way to solve for the value of Y as a function of X for any number of given data points, I decided to write a macro (curve.mac) that generates a beam model that passes through a series of points and plots the deformed shape. The example shown in Figure 1 has eight sets of values for Y at X=0, X=1 X=7. ANSYS technology calculates the minimum potential energy solution for this set of boundary conditions, which also happens to be the shape of the least complex curve that passes through these points. This is the same curve we would obtain if we could solve for a seventhorder polynomial equation. Its nice to be able to see the curve that passes through these points on the screen, but we often find the equation of a curve because we want to know the value of Y for any value of X. The finite element model doesnt present us with an equation for this curve, but we can use the functions in /POST1 to calculate the value of the displacement Y and the slope DY/DX for
Figure 1. Generating a least-complex curve between sets of twodimensional points

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Figure 2. Shell elements showing given set of Y values as a function of X and Z points
any given X coordinate. So I wrote a macro called yfuncx.mac that does this. The accuracy of these values is dependent on the resolution of the mesh that is used, but, for practical applications, it is quite easy to get an answer that is accurate enough for our needs. Using ANSYS software in this manner gives us the ability to obtain Y and DY/DX for any location along any line for which we have boundary condition data, regardless of how complex the curved line might be.
are applied in the Y direction that correspond to the known values of Y, and the model is solved and postprocessed. Figure 2 shows the shape of the surface that passes through the eight XZ locations for which Y values in which data was given in the macro.
Extending the Reach of FEA

Using classical methods to solve for a surface that passes through eight points in space is not easily accomplished, but ANSYS software can do it very easily. Whether we have eight points or 800 points doesnt really matter; we still can use ANSYS to generate a surface that passes through all of these points. Once the surface is generated, its a simple matter of using ANSYS post-processing capabilities to obtain the value of Y for any X and Z coordinates. I wrote a macro that automates the steps needed to do this (yfuncxz.mac). Its reasonable to assume that the range of nonphysical problems that can be solved by ANSYS software is not limited to the two examples I have shown. Its very likely that there are other applications for finite element analysis that reside outside the physical domains in which we usually operate. If you have used ANSYS to successfully solve a nontraditional problem, feel free to send me an email at techfile@cox.net and tell me about it. The macros mentioned in this column can be downloaded from the ANSYS Solutions Web site, www.ansyssolutions.com. s
Handling Two Variables

Calculating values as a function of one variable is useful, but it would be much better to be able to do this for two variables. We often want to interpolate data that is a function of two variables, such as temperatures spread across a surface as a function of X and Y, or displacement at a specific location as a function of two varying loads. It can be difficult (and sometimes impossible) to use classical methods to arrive at the equation that describes the surface that passes through several points. Could FEA help us solve problems like this? Building upon the idea of using ANSYS to calculate Y as a function of X, its a relatively simple matter to extend this to a second dimension and calculate Y as a function of both X and Z. I wrote a macro (bumps.mac) that generates a shell model for a given set of Y values that are a function of X and Z. Hardpoints are defined as the XZ locations at which Y values are known, the area is meshed, displacements
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Tips and Techniques

Figure 1. Transferring loads one-way from ANSYS CFX to ANSYS software Figure 2. Thermal analysis with loads mapped from ANSYS CFX feeds a thermal condition for a static structural analysis.
Geometry courtesy CADFEM GmbH.
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ANSYS Workbench Makes Simulating FSI Easier

Enhancements in version 11.0 streamline setup of fluid structure interaction problems.
ANSYS 11.0 software offers enhancements that streamline setup of fluid structure interaction (FSI) problems within the ANSYS Workbench environment. Outlined below are two simple examples, with the hope that readers will apply these techniques to real applications of their own. FSI simulations can be broadly categorized as one-way or two-way coupled. One of the most common applications of one-way FSI is the solution of thermalstress problems, in which significant thermal stresses in the solid are induced by thermal gradients in the flow field. In many of these cases, the resulting deformation of the solid is small, and the flow field is not greatly affected. In our example, well pick up after the CFD heat transfer simulation is complete and the FEA problem has been partially set up in ANSYS Simulation. Loads from ANSYS CFX software can be applied to the FEA model, as illustrated in Figure 1:
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By Judd Kaiser, ANSYS CFX Technical Solutions Specialist ANSYS, Inc.
Select the CFX boundary region name that corresponds to the selected faces. This step requires some care: It is important that a CFX boundary condition exists that corresponds to the desired faces in the ANSYS Simulation environment.
After inserting a new Steady State Thermal analysis, select the desired face(s) of the model, right-click and select Insert, CFX Temperature. In the Details view, select CFX Surface, Import and select the desired CFX results file. If a results file already exists in the project, it will be chosen automatically.
To perform a one-way FSI thermal stress analysis, a steady-state thermal analysis is performed first (with a temperature load applied from ANSYS CFX), and the resulting temperature distribution is applied as a thermal condition for a static structural analysis. (See Figure 2.) For cases in which the structure deforms so significantly that it affects the flow field, two-way FSI is needed. Industrial examples include aerodynamic flutter of wings, buffeting of car hoods, transient wind loads on buildings and bridges, and biomedical flows involving compliant blood vessels and valves. For cases such as these, both ANSYS and ANSYS CFX software must be run concurrently with loads transferred between solver iterations. The process for setting up a two-way FSI case in the ANSYS Workbench 11.0 environment is summarized as follows:
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Define the FEA model in ANSYS Simulation.
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Figure 3. Inserting a fluidsolid interface in Simulation
Figure 4. Post-processing of the coupled ANSYS CFX and ANSYS solutions is performed in CFX-Post. Shown is a model of a three-lobe valve for a biomedical application.
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Select the faces in which loads will be transferred between the CFD and FEA simulations, then right-click and insert a Fluid Solid Interface in the same manner as you would insert any other constraint or load. (See Figure 3.) An interface number and default name (FSIN#) is assigned to each interface to connect the fluidsolid interface in ANSYS CFX-Pre. When the FEA setup is complete, the FSI simulation is not executed from the ANSYS Simulation environment. Instead, select the Solution object in the Simulation tree and select Tools, Write ANSYS Input File.
Finally, under the Solver branch of the Outline tree, double-click on Solver Control. This is where detailed solver controls are set for the CFX solver as well as coupling controls for communication with the ANSYS Multi-field solver. Under the External Coupling tab, details such as the number of stagger iterations, solver execution order, coupling underrelaxation and coupling convergence target are set.
In ANSYS CFX-Pre, there are four basic steps to completing the FSI problem setup:
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Double-click on Simulation Type in the Outline tree. Under Basic Settings on the Simulation Type tab, set External Solver Coupling to ANSYS Multi-field and select the ANSYS inp file that was written out from ANSYS Simulation. Typically, two-way FSI applications involve mesh deformation. Double-click on the relevant fluid domain in the Outline tree and, under General Options, set Mesh Deformation to Regions of Motion Specified. For each boundary condition, mesh deformation options are set under the Boundary Details tab. For the FSI interface boundary condition, set Mesh Motion Option to ANSYS Multi-field.
With both the FEA and CFD setup complete, write the CFX solver definition file. New in ANSYS software version 11.0, the CFX solver manager can be used to launch and monitor the coupled ANSYS CFX and ANSYS simulation. The Define Run window references both the ANSYS CFX definition file and the ANSYS input file. During the run, the text output from both solvers and graphical convergence monitors are available for review. When the coupled solution is complete, both the CFD and FEA results can be simultaneously postprocessed in ANSYS CFX-Post, as shown in Figure 4. The ability to load multiple results files, including ANSYS results, is new in 11.0. For transient results, the time step selector will automatically synchronize the fluid and solid results to a common time value. Creation of transient animations, including the production of mpeg movie files, is straightforward. Also new in version 11.0, displacements can be magnified in CFX-Post to visually emphasize deformation. s
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Guest Commentary
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Running CAE Activities as a Lean Business

Todays competitive pressures require companies to develop metrics, quality standards and operational models in leveraging the full power of simulation as an integral part of product development processes.
By Mark Zebrowski, CAE Consultant U.S.A.
Searching for Central Focus

For many companies, identifying whats centrally important for computer-aided engineering (CAE) in their operations has been elusive. As a tool for functional performance evaluation, the technology has been used in the engineering community since the mid-1970s and has experienced exceptionally rapid growth during the last decade. Its effectiveness as a tool to replace physical testing varies widely from company to company and across various functional attributes. As with many computer-based approaches, some companies are not sufficiently confident in CAE to move from the current levels of physical testing to more of a predictive simulation-driven environment in which the technology is used as the principle method to prove-out designs in the upcoming fully digital world. Instead, CAE often is relegated to the sidelines of product development as companies wait in anticipation for software providers to come up with that one thing in terms of features and functions that will show them the way to improved quality, reduced cost structures and quicker time-to-market for innovative products.
In the 1991 movie City Slickers, actor Billy Crystals character, Mitch Robbins, is a big-city ad salesman having a mid-life crisis. For his birthday, he goes on a dude-ranch holiday, driving cattle from New Mexico to Colorado. On the cattle drive, grizzled, no-nonsense trail boss Curly Washburn (played by Jack Palance) teaches Mitch how to be a cowboy. In the process, Curly tells Mitch about the value of ignoring lifes many distractions while focusing on whats centrally important. As Curly points out, if you stick to a single purpose, everything else falls into place. The trick is figuring out that one thing you should focus on, which is often right under our noses, yet we fail to recognize it.
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Stuck in a Time Warp

This narrow view, focusing on tactical elements only, has its roots in the early days of CAE, when companies were concerned about details such as element formulations, mesh generation speeds and compute power. Thats what we all focused on back then. Discussions at conferences centered on who had the best isoparametric technology, the fastest CPUs and other technology-related topics of endless debate. Some remain stuck in this time warp, still searching for newer and better technology when experience has shown that tactical solutions alone wont solve a companys strategic and operational problems. Significant changes in CAE implementation come about when you begin to broaden your view in considering whats really important for CAE: the overriding strategy of establishing optimal simulation processes and integrating them into the overall product development process. Such a self assessment shows that the one thing companies must focus on in leveraging the full power of CAE is a shift in thinking in treating CAE not just as a technology but as a robust, repetitive and consistent business process in which the product is a cost-effective stream of superior, highquality and timely designs. In this broader view, the role of CAE is elevated to that of a general engineering tool, not just one to be used exclusively by craftspersons and dedicated analysts.
Evaluation systems that include various quality elements and do not solely emphasize cost or speed
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If organizations begin to view their virtual prototyping/CAE activities as a business operation, they will realize that they absolutely need a set of principles and operations that will help expand its scope of activities over time, increase its level of funding within the company, continuously improve the services it provides to those relying on simulation results and provide an ever-increasing ROI to the parent organization. All this directly relates to issues that any successful business must address: growth, market share, customer satisfaction, budgeting and profitability.
Focusing on a Business Model

The next step is to ask What business do I choose for a model? For me, the answer was right under my nose. I was privileged to work for a company that was, for about 20 years, a recognized leader in CAE. One of my assignments was to lead a group of about 40 technical leaders in a study of what improvements would allow CAE to lead design. One of the books recommended to me was The Machine that Changed the World (by Womack, Jones and Roos) discussing how craft production processes were replaced by mass production and then by lean production. So for CAE, the one thing for us became this: Run it like a business, a lean business. As a growth strategy, lean CAE supports fast-to-market product planning, allowing development of emerging market segments. It becomes the first choice for experimentation, development, target cascading, validation and final verification of designs due to higher confidence in its predictive capability and its expanding scope of application. Finally, it is continuously improved by dedicated personnel driven by both business and accuracy metrics. Running CAE as a lean business in this manner leverages the full power of simulation as an integral part of product development processes and as a competitive advantage to companies adopting this strategy. s
Overriding Strategies
Running CAE as a business has a variety of characteristics common with most business operations:
s
A business model having measured inputs and outputs, with a known return on investment (ROI) A business plan with an evaluation of the present and future business conditions, including a technical and operational plan for sustaining and growing the business Well-defined series of processes, with supporting documentation, with process flexibility when allowed as well as rigidity when required Metrics keyed to the final product the accurate prediction of functional performance A quality operating system (QOS) to guide enhancements and improvements An operational model that looks beyond detailed CAE tasks (getting data, building a math model, post-processing, etc.) toward the more important process steps in the engineering prediction process
Mark Zebrowski (mzebrowski@sbcglobal.net) spent 32 years working on various CAE, NVH and vehicle attribute programs at Ford Motor Company and was a technical manager for 12 years prior to his retirement in 2005. Currently, he is an independent consultant specializing in the business justification of CAE and integration of analysis into efficient product development processes.
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