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Delft, November 4

th
2010
Actiflow: Using OpenFOAM

Technology for Aeroconsulting


OPENFOAM

is a registered trade mark of OpenCFD Limited, the producer of the OpenFOAM software
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Today the following items will be presented to you
Actiflow: an engineering company with a focus on aerodynamics
The reasons why Actiflow chose OpenFOAM as the main CFD solver
Examples on the use of OpenFOAM by Actiflow
Development of steady state electrohydrodynamics solver ehdFoam
Active automotive aerodynamics
Other examples of the use of OpenFOAM within Actiflow
Introducing CFDDesk, the Dutch OpenFOAM support system
Concluding remarks on OpenFOAM technology as used within Actiflow
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow is an engineering company with a focus on aerodynamics
Actiflow is founded in 2005 as a spin-off of Delft University of Technology
We offer various services:
Design Engineering (including prototyping and testing)
Aero Consulting
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow is young and dynamic, providing accurate and fast results
Actiflow is flexible and thinks with the customer
We are experienced in a large range of fluid flow problems
We can perform several tasks in the design and prototyping phases and assist product
development
Next to computational facilities we also have experimental facilities in our workshop
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow chose OpenFOAM technology based on several
characteristics
OpenFOAM is open source and allows parallel calculations without licensing costs
OpenFOAM is, generally speaking, as accurate as or even better than commercial CFD
codes
Solvers can be modified for specific needs
Special boundary conditions and applications can easily be created and implemented
Full control over the solving algorithms without hidden filters and limiters
Large amount of models, algorithms and solvers are available
State of the art development work is going on all around the world
Assistance with common problems via the forum
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
A solver for steady-state electrohydrodynamics, ehdFoam, was
created in order to model an innovative air purifier
For one of the customers, Virus Free Air (VFA), a new solver had to
be created
Their innovation is an electric air purifier based on corona wind
There was a need to compute the flow of charged particles in the
design stage of the electronic air purifier
In order to model this flow a solver was created based on available
solvers: electroStaticFoam and simpleFoam
To model the corona wind effect a new boundary condition, corona
discharge boundary is created:
Several types are created, depending on the application and
conditions
For post-processing the Lagrangian particle solver was modified to
the electrostaticParcelFoam, which calculates particle paths of
charged particles in an electrically charged fluid influenced by
electrostatic forces, gravity, buoyancy and drag
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
ehdFoam, solver for steady-state electrohydrodynamics
Source: N. E. Jewell-Larsen et al., Modelling of corona-induced electrohydrodynamic flow with COMSOL
Multiphysics, ESA Annual Meeting on Electrostatics, 2008
Corona discharge is defined as the electrical discharge brought on by
the ionization of a fluid surrounding a conductor, which occurs when
the electric field strength exceeds a certain value.
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The model uses these equations, involving two-way coupling of
fluid and electric field
Continuity
Momentum
Turbulence Modeling
Gauss law
Conservation of charge
( )
( )
2
2
0
from turbulence model
0
1
0
t C
t
C
C e C C
u
p
u u u E
V
J E u D


=
= + + +

=
= + + =




Electrostatic body force
Convection of charge density
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The model equations are implemented in ehdFoam as follows
Pressure-velocity coupling uses the
SIMPLE algorithm
Turbulence is modeled using the
OpenFOAM RAS models
Electrostatic equations are solved
before the SIMPLE loop
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The electrostaticParcelFoam model equations are defined
similarly
Location of particle
Forces acting on the particle
Aerodynamic force (drag only)
Electrostatic force
Gravitational force
Buoyancy force
(
( )
0 0
' '
' 0 0
2
3
( )
( ) '
( )
2
4
3
s t s s
p
p p p
p s s
p D E g b
D
D p p
E p
g p
b p
F s
x t x u ds ds
m
F F F F F
C Re r
F u u u u
F Eq
F m g
F r g


= =
= =

= + +

= + + +
=
=
=
=




Particle charge needs to be determined
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The electrostaticParcelFoam model equations are defined
similarly
Saturation charge
Current charge, if q(0)=0
Time needed to reach 0.5 q
max
from q(0)=0
Substitution, q(t*)=0 (definition)
New time derivative to be used
( )
2
max 0
max
0
*
max
max
2
*
4 p
( )
1
4
q r E
q
q t
t
E
J
q
t
q q
q q
t
t

=
=
+
=
=

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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The first test case was a 2D Wire Flow
Validation of the solver, comparison with an experiment and simulation with COMSOL
(N. E. Jewell-Larsen et al., Modelling of corona-induced electrohydrodynamic flow with
COMSOL Multiphysics, ESA Annual Meeting on Electrostatics, 2008)
Single coronating wire with 14 collecting wires
Coronating wire potential: 8000 V
Collector wires potential: 0 V
Jewell-Larsen et al. ehdFoam
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The results of the test case are satisfactory
The final goal of the solver is accurate prediction of the flow field due to corona
discharge
The solver recreates the electric, charge density and velocity fields that were observed
in the paper during computation and experiment
Jewell-Larsen et al. ehdFoam
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The solver and postprocessing utility where later applied to an
actual design
The objective of the solver was an actual application of corona wind in an air filter
Challenging 3D Case: very small needles, rather large domain
Circular tube, with carefully placed needles
Movie shows charged particles enter a filtering tube and how they are affected by the
electric and velocity fields
Air is sucked into the tunnel due to corona discharge effect
Particles are effected by the charged needles and secondary flow is induced
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The base of Actiflow is automotive application of active aerodynamics
Actiflow applied boundary layer suction on:
Formula Renault front wing
Ferrari F430 diffuser
Using OpenFOAM, Actiflow simulated boundary layer suction on:
Bluff body equipped with a diffuser
Ahmed Body
Several commercial car models
Using OpenFOAM, Actiflow simulated base bleed on:
Ahmed Body
VW Golf V
Several other commercial
car models
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
A procedure for active aerodynamics analysis was developed
The procedure starts with analysis of the flow around the standard geometry
The flow field is investigated and the geometry is adapted for base bleed and suction
panels
Without flow control, the simulation is carried out again, to check the consistency
Active flow control simulations are carried out to find promising configurations
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Results obtained with the Ahmed body are promising
With a parameter variation, the configurations can be optimized for drag reduction or lift
reduction/downforce increase
Using an optimal design the lift of the body can also be influenced positively
Finally there are geometrical design loops incorporating the active flow control system
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
OpenFOAM results for active automotive aerodynamics are
within engineering accuracy and fast
Remarks considering the accuracy of the results are the following:
The correct trends are captured
No cooling flow, simplified wheels, cleaned geometry
Simulation of bluff body flow remains challenging for RANS
Actiflow is investigating LES/DES, but it is not yet applicable in design loops
Simulations are good for conceptual design, road/wind tunnel tests are used for the
final design
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow is active in different fields of application
Our main fields
Automotive
Wind Energy
Building Physics
Medical
Other
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow uses OpenFOAM for several other flow phenomena
Building Physics:
Wind hindrance
HVAC design
Office Buildings
Church renovation
(Conjugate) Heat transfer
Heat flux sensor design
Heat transfer with floor heating
Medical solutions
Innovative infant incubator
Wind energy
Development of small wind turbines
Active flow control on large scale wind turbines
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Actiflow uses OpenFOAM for several other flow phenomena
Ship hydrodynamics:
Investigation into the occurrence of cavitation
Turbomachinery:
Pumps, ventilation systems
Consumer goods:
Senz Umbrellas
Smoke and toxic contents dispersion
Welding smoke: Clean Air
Diesel generator exhaust fumes
Factory planning
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Setting up Dutch OpenFOAM support desk for other companies
Together with Vortech, Actiflow offers the possibility to set-up OpenFOAM support for other
companies
Several levels of support will be created
First line support: Fast response for small problems (telephone/email)
Second line support: In depth analysis of the problem, may take more time
Consultancy is another option:
We help decide whether the use of OpenFOAM is beneficial
Support with installation, updating and organization
Development of solvers and utilities for specific problems
Advice on model choice and solution method
With the experience of Vortech and Actiflow, the steep learning curve becomes more
gentle
The support system is still young, so any comments will be appreciated
More information can be gathered at Vortechs and our stand and in the flyer
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
The website will be used as a portal for support and is online
http://www.cfddesk.nl/
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Actiflow: Using OpenFOAM Technology for Aeroconsulting
Concluding remarks on the use of OpenFOAM for
aeroconsulting
Due to the versatility of OpenFOAM, Actiflow can consult a large variety of customers
After several years of experience we have confidence in our simulations and the solutions
to problems we solve
The open source format allows to create or adapt models as needed and helps
understanding the working method of the software
With OpenFOAM we can accurately solve complex problems from different fields within the
timeframe of an engineering design process
With our experience we can help others start enjoying the many benefits of OpenFOAM
Actiflow BV
Zinkstraat 22
4823 AD Breda
The Netherlands
contact@actiflow.com
www.actiflow.com
Tel: +31 765 422 220

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