2008 International

ANSYS Conference

Strongly Coupled FSI Simulation

Moving Compressible Pressure Pulse through a Tube

Daniel L. Cler,
US Army RDECOM/ ARDEC/
WSEC/ Benet Labs

Overview
Background
Problem Description
Objectives and Assumptions
Workflow
Results
Future Work
Conclusion

A Collage of Real Life Multiphysics

Applications
Examples of multiphysics
are plentiful
Realistic FSI analysis is
needed to address design
and performance issues.

Courtesy of Pluere

Total deformation contours

on a pump impeller in a
coupled structural and flow
analysis

Wing flutter, engine noise,

VIV, oil exploration, offshore
structures, air crafts and
components, defense
equipment, pumps, valves,
arteries, bones, ...

Typical torsional
blade modes:
impact of gas on
swept surfaces

ANSYS Adv.v1,n3,2007,
Coupled FSI of bio-med valve

FSI of distributor header

Courtesy: CADFEM
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Background
Multiphysics Solutions: State-of-the-Art
Much has been achieved
In-depth single discipline solutions
Ability to make these solutions communicate
Efforts to facilitate communication at data level
MPCCI, dedicated solvers, and communicators

Multi-disciplinary applications need real world collaboration

of discipline specialists
Analysis tools need framework to share multiple data fields that
represent the true physics

Technology maturity is providing new opportunities

Need for improvement stays ahead of the progresses made

Hardware and software capabilities entice practitioners

with increased demand of complex real life analysis
towards Simulation Driven Product Development
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Current Reality
Integrated Process in Workbench

Base level coupling

Geometry Model
CHT Solid Mesh

CFD with CHT

Thermal Stress Setup
Thermal Loads from CFX

Thermal Stress
Solution

 Consider a problem with flow physics involving

High speed compressible flow in a tube
From pavement / concrete digger to oil well drills
From BB guns to more serious defense equipment
From musical instruments to pneumatic control equipment...

P / T Spikes

A Sample Engineering Case

Time

Very high cyclic pressure and thermal loads over long time

Simple principle
Use potential energy of compressed fluid through systematic release
in kinetic form
Focus on optimized delivery of an object or a force on a target
The release segment of these cycles involve a reaction force

Engineering challenge
Minimize the reaction impact without any degradation on the forward
motion, direction and force fields

Important to analyze the response of the tube material

Accuracy of the target motion, direction and force fields
Long term fatigue behavior of the equipment (tube)
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Engineering Solution
Consider a lightweight structure attached at the
end of the tube to reduce the recoil action
Loads on the new attachment device
Pressure pulse from inlet end of the tube
Thermal loads from the source of the pressure
pulse

Design objective
Maximize braking by smart design to
minimize forces and moments (torques) on
the tube
Smartness defined by minimum space and
material use without loss of strength or life

Engineering Solution
The case studied here is a muzzle block
The attachment geometry is for exemplification
only and is not for any real equipment or any
design
The total engineering of such system require
analysis of multiple fields of physics
Propulsion system, material science, aero-acoustics,
turbulence, fatigue life estimation, stress-concentration
and micro-cracks, solidification, heat treatment,
machining, surface finish, etc.

This study focuses only on analysis of coupled FSI

problem to demonstrate maturity of the analysis tool

Objectives
Explore the state of the art in simulation for two-way fluid structure
interaction to predict the pressure, thermal loads, on the fluid side and
deformations of the structures
Multiple loading cycles in a single analysis
Objective is NOT to do all the detailed simulation of 1 cycle

Requirements:

Two way coupled, unsteady, FEA & CFD analysis

Robust, easy to use, flexible
Automated with minimal user intervention
Optimization tools

Develop the initial Proof-of-Concept !

Feasibility study
Focus on correctness of physics by establishing proper coupling

Assumptions
Fluid simulation
Blow down simulation
No moving solid-load in the tube
Typical chamber pressure is compensated

Half geometry, vertical symmetry

Fluid material properties
NASATM 4647 ; NASA/TP-2002-211556

FEA simulation
Flexible multi body dynamics
Tube inlet is fixed in space
Solid material properties
Alloy Steel
http://www.efunda.com/materials/alloys/alloy_home/steels_properties.cfm
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Workflow and Data Transfer

Pre-processing
ANSYS Simulation: Solid mesh, mechanical simulation setup
ICEM CFD: Fluid mesh
ANSYS CFX-Pre: CFD, FSI simulation setup

Solver and Execution

ANSYS Multiphysics: A single integrated, fully coupled environment
FEA Solver: ANSYS Simulation
CFD solver: CFX-Solver

Data Transfer
CFD to FEA: Wall heat flux and total force
FEA to CFD: Wall temperature and displacement
Data transfer between ANSYS and CFX solvers is fully automated

Post-processing
ANSYS CFX Post
Solid and Fluid field variables can be post processed together

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Fluid Domain and Mesh

Mesh Generated using ICEM CFD
Blocking concept, hexahedral mesh
Initial proof of concept mesh
Number of Nodes 49322

FLUID Domain

Chamber:
High pressure, high
temperature

Outer domain:
External flow
Muzzle block

Barrel

Ground
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Solid Domain and Mesh

Mesh Generated using ANSYS Simulation
Easy to use, highly automated and fast!
Hex mesh in the barrel
Tet mesh in the muzzle block

Pulse
Source

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Workflow Snapshots
Mechanical Simulation Setup
Boundary Conditions : Solid

Material: Steel Alloy

Analysis Type : Flexible Dynamics
Coupled Field Element
Solve for thermal and structural stresses

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Workflow Snapshots
CFD Simulation Setup

Material properties

Source term approach for

initial high P and T

Density: Ideal Gas mixture

Temperature dependent
properties
NASATM 4647;
NASA/TP-2002-211556

Mass and energy sources

corresponding to 820 atm and
1120 K at pulse source
Applied at the first time step of
each cycle

Physical Models
SST K- turbulence model
Natural convection

Adaptive Time stepping

Time step size ramp up from
7e-6 s (min) to 0.25 s (max)

Initial condition

B.C. types

1atm and 300K, zero velocity

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Green : Opening
Red
: FSI interface
Cyan : Ground
Open face: Symmetry

Workflow Snapshots
FSI simulation set-up in ANSYS CFX Pre
FSI Simulation Setup
External coupling
Interface load transfer

CFD solver controls

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Workflow Snapshots
FSI simulation start-up using ANSYS CFX-Solver

CFX Solver input

ANSYS Solver input

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MFX Multi-Field Solver

Supports Simulation between
Multiple Executables
FEA CFD

ANSYS Multi-Field Solver

Sequential load transfer coupling

Third Party Coupling Scheme Not

Required
Uses Client/Server architecture
TCP/IP
Heterogeneous Networks
(LAN/WAN/Internet)

MFS
Coupling within a
single executable

MFX
Coupling between
multiple executables
ANSYS/CFX

Supports Large Models

Coupling of structural,
thermal, electric and
electromagnetic fields
in ANSYS Multiphysics.

Solution on Two Machines

CFX Solution can use Parallel
Processing

Supports Nonconformal Meshes

Transfers Surface Loads
Automatically Morphs CFD Mesh
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FSI
Other combinations in
future releases!

Results
Solvers output CFX & ANSYS

Cooling period
b/w the pressure
pulses ~10sec

CFX Output

ANSYS Output
Total force (N) Fx, Fy, Fz
on FSI interface

Maximum mesh
displacement (m) in the
Fluid Domain

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Workflow Snapshots
Post Processing

Coupled simulation post-processing in ANSYS CFX Post

Common Graphical User Interface
Can analyze intermediate time step data
Easy to create/save animations
Geometry definition

Post surfaces

Animation controls

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Results CFD
16 - Cycles

Mach no. @ Symmetry Plane

Temperature @ Symmetry Plane

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Results CFD
5 - cycles

Pressure iso-surface, 0.1 atm(g)

Temperature iso-surface, 500K

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Results Mechanical
7- cycles

Temperature on the Muzzle block

Temperature on FSI interface

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Results Mechanical
5 - cycles

Structural deformation x25000

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Future Work
Appropriately finer mesh
Inclusion of additional physics
Radiation model
Real gas effects
Including moving solid loads
Moving solid considered rigid
Approximated by a moving
interior plane in layering
Fully coupled 1-DOF solids motion
Significant time saving

Source terms to model energy

impulse of the cartridge detonation
Improve run time performance
Effects of tightness of the convergence criteria on solution accuracy

Ensure parallel performance

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Conclusion
Two way coupled FEA & CFD
Demonstrate seamless two way fluid/thermal and structural coupling
for high speed compressible flow simulation

Easy to Use
Single, intuitive environment for the entire FSI simulation setup

Robust
Minimal user intervention for the FSI run
Robust FEA and CFD solvers, even with larger time step size

Automation with minimal user intervention

Full automation through scripts possible

Flexible
Ability to add advanced models to include more physics

Optimization
Design Explorer in Workbench

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Questions and Answers

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Multi-field Solver Field Interface

Loads Transferred Across Field Interface

Physics Fields

SEND

Structural Displacement
Thermal

Temperature, Heat
Generation, Heat Flux

RECEIVE
Force, Temperature
Displacement, Heat
Generation

Electric Field Force, Heat Generation Displacement, Temperature

Magnetic Force, Heat Generation Displacement, Temperature
Fluid

Surface Force, Surface

Temperature

HF Electromagnetic Heat Generation

Displacement, Surface
Temperature
Temperature

Please refer to ANSYS coupled field analysis guide for thorough details.
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MFX Multi-field Solver

ANSYS Master

CFX Slave

Do Mapping

Time Loop

Time Controls

Time Loop

Stagger Loop

ANSYS
Solver

Stagger Loop

Stagger Controls (ANSYS to CFX)

Load Transfers
Stagger Controls (Bidirectional)

End Stagger
Loop

End Stagger
Loop
End Time
Loop

CFX
Solver

End Time
Loop

Time Controls
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