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Chapter 1

Introduction to CFD

Introduction to
ANSYS Polyflow

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Introduction to POLYFLOW training

Training Manual

Agenda Day 1

8:30 Introduction to CFD 14:00 Polyflow B

9:30 Polyflow A 14:30 Tutorial 5

11:00 Example 15:30 Evolution

11:30 Tutorial 1 16:30 Tutorial 8

12:30 Lunch 17:00 Break for the day

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Introduction to POLYFLOW training

Training Manual

Agenda Day 2

8 30 Time
8:30 Ti dependent
d d t Flows
Fl 14 00
14:00 I t d ti to
Introduction t Rheology
Rh l

9:30 Tutorial 7 15:00 CFD Post

10:30 Adaptive meshing 16:00 Workshop

11:30 Tutorial 9 17:00 Break for the day

12:30 Lunch

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Introduction to POLYFLOW training
What is CFD? Training Manual

Computational fluid dynamics (CFD) is the science of predicting fluid flow,


heat and mass transfer, chemical reactions, and related phenomena by
solving numerically the set of governing mathematical equations
Conservation of mass
Conservation of momentum
Conservation of energy
Conservation of species
p
Effects of body forces (e.g. gravity)
Etc.

The results of CFD analyses are relevant in:


Conceptual studies of new designs
Detailed product development
Troubleshooting
Redesign

CFD analysis complements testing and experimentation by reducing total


effort and cost required for experimentation and data acquisition.
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Introduction to POLYFLOW training
How Does CFD Work? Training Manual

ANSYS Polyflow solver is based on the


finite element method
Domain is discretized into a finite set of Control
elements Volume*

General conservation (transport) equations


for mass, momentum, energy, species, etc.
are solved on this set of control volumes
Fluid region of pipe flow is
discretized into a finite set
of control volumes.

Unsteady Convection Diffusion Generation Equation Variable


Continuity 1
Partial differential equations are X momentum u
discretized into a system of algebraic Y momentum v
equations Z momentum w
Energy h
All algebraic equations are then solved
numerically to render the solution field

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Introduction to POLYFLOW training
CFD Modeling Overview Training Manual

Problem Identification
Problem Identification 1. Define your modeling goals
1. Define goals 2. Identify the domain you will model
2. Identify domain
PreProcessing and Solver Execution
Pre-Processing 3. Create a solid model to represent the
domain
3. Geometry
4. Design and create the mesh (grid)
4. Mesh
5. Set up the physics (physical models,
5. Physics material p
properties,
p domain properties,
p p
6. Solver Settings boundary conditions, )
6. Define solver settings (numerical
e Model

schemes, convergence controls, )


Solve 7 Compute and monitor the solution
7.
Update

7. Compute solution

Post-Processing
9.

Post Processing 8. Examine the results.


8 results
8. Examine results 9. Consider revisions to the model.
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Introduction to POLYFLOW training
1. Define Your Modeling Goals Training Manual

Problem Identification
1. Define goals
2. Identify domain

What results are you looking for (i.e.


(i e pressure drop,
drop mass flow rate,
rate
extrudate shape, flow balance, ..), and how will they be used?
What are your modeling options?
What physical models will need to be included in your analysis?
temperature, gravity, viscous heating, free surface)?
What simplifying assumptions do you have to make?
E.g. simplify the geometry
2d vs. 3d
Symmetry

What degree of accuracy is required?


Mesh
M h resolution
l ti

How quickly do you need the results?


2d vs. 3d
3d, mesh
h resolution,
l ti etc.
t

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Introduction to POLYFLOW training
2. Identify the Domain You Will Model Training Manual

Problem Identification
1. Define goals
2. Identify domain

How will you isolate a piece of the


complete physical system?

Where will the computational


domain begin and end?
Domain of Interest
Do you have boundary condition
as Part of a Larger
information at these boundaries? System
y ((not modeled))
Can the boundary condition types
accommodate that information?
Can you extend the domain to a
point where reasonable data exists?
Domain of interest
isolated and meshed
for CFD simulation.
Can it be simplified or approximated
y
as a 2D or axisymmetric p
problem?

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Introduction to POLYFLOW training
3. Create a Solid Model of the Domain Training Manual

Pre-Processing Solid steel


3. Geometry
extrusion die
4. Mesh
geometry
5. Physics
y
6. Solver Settings

How will you obtain a solid model of the


g
fluid region?
Make use of existing CAD models?
Extract the fluid region from a solid part?
Create from scratch?
Can you simplify the geometry?
Remove unnecessary features that would Extracted
complicate meshing (fillets, bolts)? fluid cavity
Make use of symmetry or periodicity?
Are both the solution and boundary conditions
symmetric / periodic?
Do you need to split the model so that
boundary conditions or domains can be
created?
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Introduction to POLYFLOW training
4. Design and Create the Mesh Training Manual

Pre-Processing A mesh divides a geometry into


3. Geometry
many elements. These are used by
4. Meshing the CFD solver to construct control
5. Physics
y volumes
6. Solver Settings
What degree of mesh resolution is required in
each region of the domain?
The mesh must resolve geometric features of
interest
i t t and
d capture
t gradients
di t off concern, e.g.
velocity, pressure, temperature gradients
Triangle Quadrilateral Can you predict regions of high gradients?
Will you use adaption to add resolution?
What type of mesh is most appropriate?
How complex is the geometry?
Can you use a quad/hex mesh or is a tri/tet or
Tetrahedron Hexahedron y
hybrid mesh suitable?
Are non-conformal interfaces needed?
Do you have sufficient computer resources?
How many cells/nodes are required?
How
H many physical
h i l models
d l will
ill be
b used?
d?
Pyramid Prism/Wedge

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Introduction to POLYFLOW training
Tri/Tet vs. Quad/Hex Meshes Training Manual

For flow-aligned geometries,


quad/hex meshes can provide
higher-quality
higher quality solutions with fewer
cells/nodes than a comparable tri/tet
mesh
Quad/Hex meshes show reduced
numerical diffusion when the mesh is
aligned with the flow.
It does require more effort to
generate
t a quad/hex
d/h mesh h

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Introduction to POLYFLOW training
Tri/Tet vs. Quad/Hex Meshes Training Manual

For complex geometries, quad/hex meshes


show no numerical advantage, and you
can save meshing effort by using a tri/tet
mesh or hybrid mesh
Quick to generate
Flow is generally not aligned with the mesh

Hybrid meshes typically combine tri/tet


elements with other elements in selected
regions
For example, use wedge/
prism elements to resolve
b
boundary
d layers.
l
More efficient and accurate
than tri/tet alone.
W d ((prism)
Wedge i ) mesh
h
Tetrahedral mesh
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Introduction to POLYFLOW training
Multizone (or Hybrid) Meshes Training Manual

A multizone or hybrid mesh uses


different meshing methods in different
regions. For example,
Hex mesh for fan and heat sink TET
Tet/prism mesh elsewhere

Multizone meshes yield a good


combination of accuracy, efficient HEX
calculation time and meshing
g effort.

When the nodes do not match across


the regions
regions, a non-conformal
non conformal interface
can be used.

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Introduction to POLYFLOW training
Non-Conformal Meshes Training Manual

Non conformal meshes are useful Non-conformal


for meshing complex geometries interface
Mesh each part then join together

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Introduction to POLYFLOW training
Set Up the Physics and Solver Settings Training Manual

Pre-Processing For a given problem, you will need to:


3. Geometry
Define material properties
4. Mesh
5. Physics
y
Fluid
6. Solver Settings Solid
Select appropriate physical models
For complex problems
solving a simplified or 2D Isothermal, non-isothermal, gravity, viscous
problem will provide heating,
heating etc.
etc
valuable experience with the Prescribe operating conditions
models and solver settings Prescribe boundary conditions at all
for your problem in a short
boundary zones
amount of time.
Inlets, outlets, wall temperatures, heat fluxes, etc.
Provide initial values or a previous solution
Set up
p solver controls
Set up convergence monitors

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Introduction to POLYFLOW training
Compute the Solution Training Manual

Solve The discretized conservation equations are


7. Compute solution solved iteratively until convergence.

Convergence
C is
i reached
h d when:
h
Changes in solution variables from one iteration
to the next are negligible.
Residuals provide a mechanism to help
monitor this trend.
trend
Overall property conservation is achieved
Imbalances measure global conservation

The accuracy of a converged solution is


dependent upon:
Appropriateness and accuracy of physical models.
Mesh resolution
Numerical errors

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Introduction to POLYFLOW training
Examine the Results Training Manual

9. Update Model
Examine the results to review solution
and extract useful data
Post Processing Visualization Tools can be used to

9
8. Examine results answer such questions as:
What is the overall flow pattern?
Are there recirculation zones?
What is the free surface shape?
Is a blow molded part fully formed?
Are key flow features being resolved?

Numerical Reporting Tools can be used


to calculate quantitative results:
Forces and Moments
Average heat transfer coefficients
Surface and Volume integrated quantities
Flux Balances
Examine results to ensure property conservation Flow Balance
and correct physical behavior. High residuals
may be caused by just a few poor quality cells.
cells Contact time

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Introduction to POLYFLOW training
Consider Revisions to the Model Training Manual

9. Update Model
Are the physical models appropriate?
Is the flow unsteady?
Post Processing
Are there 3D effects?

9
8. Examine results

Are the boundary conditions correct?


p
Is the computational g enough?
domain large g
Are boundary conditions appropriate?
Are boundary values reasonable?

Is the mesh adequate?


Can the mesh be refined to improve results?
Does the solution change significantly with a refined
mesh or is the solution mesh independent?
mesh,
Does the mesh resolution of the geometry need to be
improved?

Effect of mesh resolution on exit


velocity variation at a die exit
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Introduction to POLYFLOW training
POLYFLOW Workflow under Workbench 2 Training Manual

Start ANSYS Workbench

Drag the Fluid Flow (POLYFLOW)


system from Analysis Systems
group in the Toolbox onto
preview drop target shown in
the Project Schematic.
Same for the extrusion or blow
molding

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Introduction to POLYFLOW training
Import the Geometry Training Manual

Right-click on Geometry cell A2 and select Import Geometry

Import the geometry file (CAD model or a previous DesignModeler


.agdb
db file)
fil )

You can also link the POLYFLOW simulation to an existing


DesignModeler session.

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Introduction to POLYFLOW training
Generate a Mesh Training Manual

Right-click on Mesh cell and select Edit.


Meshing opens and loads geometry

Select Mesh under Model in Outline


Note that Preferences are automatically set
for POLYFLOW, because Meshing was opened
from a POLYFLOW system.

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Introduction to POLYFLOW training
Define Boundary and Cell Zones Training Manual

Create boundary zones using Named


selections.
Select the surface which will
represent the boundary you wish
to set.
Right-click the selection and select
Create Named Selection
Selection.
Name the selection and click OK.
die exit
bs.1, bs.2, etc

You will also need to define the


regions of the flow containing fluid
and solid (if any)
any).
Fluid, solid regions
Different regions for different remeshing
More details will be presented later
sd.1, sd.2, sd.3, etc

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Introduction to POLYFLOW training
Set Up and Run POLYFLOW Training Manual

Edit the Setup cell to set up the model options


Boundary conditions
Solver settings
Solution
Post processing

Once run, the solution will be post processed in CFD-Post for post
processing
Contour and vector plots
Profile plots
Calculation of forces and moments
Animation of unsteady flow results
Free surface shape

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Introduction to POLYFLOW training
Demonstration of POLYFLOW Software Training Manual

Start POLYFLOW (assume the mesh


has already been generated).
Set up a simple problem.
Solve the flow field.
Postprocess the results.

Online help and documentation is


available

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Introduction to POLYFLOW training
Navigating the PC at Fluent Training Manual

Log in to your workstation


Login name: ansys
Password: ansys

Directories
Tutorial mesh/case/data files can be found in
c:\Student
\ Files\fluent\tut\
\ \ \
We recommend that you save your work into a central working folder:
c:\users
Working
W ki folder
f ld shown
h on the
th desktop
d kt isi a shortcut
h t t tot c:\users
\

To start POLYFLOW and/or Workbench, use the desktop icons.

Your support engineer will save your work at the end of the week.
It is recommended that you restart FLUENT and/or Workbench for
each tutorial to avoid mixing solver settings from different
workshops.
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