Mindware

Knowledge Based Engineering

3D Shape Optimization Of Evaporator

Diffuser using Sculptor
Requested by:
Michael Schrumpf

Performed by:
Mohsen Battoei

December 05, 2005

Rev: 12/05/05 Slide 1

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 Mindware
Knowledge Based Engineering Objective
 The aim of this study is to optimize the shape of the evaporator
diffuser to maximize flow uniformity across the S-section of the
evaporator utilizing Sculptor.

 The baseline evaporator flow model was provided by Behr.

 The baseline is set up in Star-CD.
 The flow uniformity is defined as following:

Rev: 12/05/05 Slide 2

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 Mindware Sculptor set up
Knowledge Based Engineering
procedure

X1
X0
X2
 The model is imported into Sculptor. X3
 ASD (arbitrary shape deformation) volume is X4
defined around the objective. X5
 Some control points are grouped together.
 6 individual Design Variables (DV) are
defined as X0, X1 , X2 , X3, X4 and X5.
 The DV’s are fixed in Y and Z directions.

Rev: 12/05/05 Slide 3

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 Mindware Sculptor set up
Knowledge Based Engineering
procedure—contd.

 The grouped control points are selected

as DV’s in Analysis Variables menu.
 Sculptor reads in the baseline analysis
results into the “Analysis Function Dialog”.
 The uniformity index is selected to be
maximized.
 The number of optimization iteration is set
to 2.

Rev: 12/05/05 Slide 4

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 Mindware
Knowledge Based Engineering
Results in Sculptor

 Totally 16 analysis are computed for 2

optimization iteration in Star-CD.
 The flow uniformity index increased by
5.15 % in 96% compared with baseline 91.13%.
 The pressure drop decreased by 1.2 % in 744 pas
compared with baseline, 753 pas.

Rev: 12/05/05 Slide 5

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 Mindware Velocity contour on
Knowledge Based Engineering
the S-section

Rev: 12/05/05 Slide 6

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 Mindware Velocity contour on
Knowledge Based Engineering
the S-section

Rev: 12/05/05 Slide 7

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 Mindware
Knowledge Based Engineering
Velocity contour

Rev: 12/05/05 Slide 8

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 Mindware The baseline and
Knowledge Based Engineering
optimized shapes

Rev: 12/05/05 Slide 9

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 Mindware
Knowledge Based Engineering
Animation

Rev: 12/05/05 Slide 10

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 Mindware
Knowledge Based Engineering
Summary

 The model is set up for optimization in Sculptor.

 For the first optimization study several design variables are considered.

 Star-CD CFD commercial software is used as the solver.

 The preliminary results of flow uniformity shows a 5.15% increase when

compared with the baseline case. (Baseline 91.13 % , optimized 96%)

 The pressure drop shows a 1.2% decrease when compared with the baseline
case. (Baseline 753 pas, optimized 744 pas)

 It is expected that further optimization is achievable by defining additional

control points around the objective.

 The total 16 analysis are done in 5 hours.

Rev: 12/05/05 Slide 11

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