Development of Tools to Automate

the Analysis of Turbo-Machinery

Tom Lincoln / Jaideep Bangal
Cooper Standard / Altair Engineering, Inc.

Executive Summary

Cooper Standard (CS) Corporate Overview

History of CFD at Cooper Standard
Cooper Standard adoption of AcuSolve for enhanced CFD efficiencies
and accuracy
Additional AcuSolve Applications at Cooper Standard

About Cooper Standard

Our Mission
Provide outstanding service, support
and innovative solutions to our
customers benefiting all stakeholders

Headquarters:

Novi, MI

Established:

1960

Employees:

21,500+

Locations:

70+ in 19 Countries

2010 Top 100

Global Suppliers:

Rank 62

2010 Top 100

North American Suppliers:

Rank 35

of Cooper Standard.
2011 Sales:

$2.85 B

History

2012
2011
2010
2007
2007

1960

1999

2000

2004

2005

2006

Strategic Footprint
Key
Headquarters
Sales / Administration
Technical Center
Manufacturing
Manufacturing / Technical Center

North America

Europe

Asia Pacific

South America

Joint Ventures
Cooper-Standard Saiyang Wuhu 94% /6%
Cooper-Standard NISCO 40% / 60%
Cooper Hubei Jingda 37% / 63%
Metzeler India 74% / 26%
Cooper Hasco China 47.5% / 47.5% / 5%
Guyoung Tech Korea 20% / 80%
Cooper Standard France 51% / 49%
Nishikawa Tachaplalert Cooper Limited 20% / 80%

Countries
Australia
Belgium
Brazil
Canada
China

Czech Republic
France
Germany
India
Italy

Japan
Korea
Mexico
Netherlands
Poland

Romania
Thailand
United Kingdom
United States

2012 - Located in 19 Countries

2004 - Located in 14 Countries

Global Customers

RENAULT

HYUNDAI

Breadth of Product & Segments

Thermal Management Key Capabilities

Heating and cooling

management systems for
hybrids, electric vehicles and
internal combustion engines

Electromechanical Devices
Thermal Devices
Thermal Integration

Technology

Automotive News PACE Award

Honorable Mention

Electric Water Valve Assembly

Thermoplastic Rear Door Glass

Seal Assembly

Metal to Plastic Fluid Connection with

Overmolded Anti-Rotation Retainer

Day Light Opening (DLO) System

Society of Plastics Engineers

Global Six Sigma Award Best

Achievement of Design for Six
Sigma

Coolant Water Valve

Over 500 Patents Globally

Daylight Opening Modules

Engineered Stretched Plastics
Occupant Detection Systems
Low Fuel Permeation Nylon Tubing
Quick Connect Fluid Couplings
Core process methods

Most Innovative Use of Plastic: Finalist

Electric Water Valve Assembly

Transmission Thermal Valve Assy

Electric Brushless Pump

cooperstandard

Cooper Standards History With Pumps

Cooper Standard identified a market for electrically driven coolant

pumps.
Development began in 2005, CFD was used from the start.
Cooper Standard offers pumps to replace the vehicle main water pump
and auxiliary supplemental flow.
Wattages range from <20 W to 1 kW.

Early CFD Analyses August 2005

Combination Tet and Hex
cells
Uniform mesh size
Significant time to set-up
manually

CFD Analyses June 2010

~5M cells ranged from 0.2 mm to 2 mm
Manual set-up required a full day and 610 hours to converge each flow point

Comparison Between Measured Data and

CFD Prediction
1.20
1.00
Pressure Gain

0.80
0.60
Measured
Pressure
Gain
Predicted
Pressure
Gain

0.40
0.20
0.00
5000

7000
9000
Flow Rate

11000

13000

Early CFD - Challenges

Results were good but

Model set-up would take 8+ hours

Each flow point would take 4 10 hours to converge

6 flow points for one pump = 40+ hours

Meshing was manual and required expertise to generate a good mesh

AcuSolve Process Automation

Import CAD /
HM mesh

Process intelligence

Fast setup: 4

Auto meshing

Auto solving strategy

steps

Define
Solids
Stationary Fluid
Rotational Volume
Angular velocity
Rotation axis

Boundary
Conditions
Inlet / Outlet

Automeshing

Auto time step

calculations

SOLVE

Auto Time steps calculation

Setup multiple flow points

and run it batch mode

10
minutes
Setup time

Cooper Standard Pump Analysis

Goal: Predict pump performance,

Flow Curve

Reduce Setup and Solution time

Enable CSA Engineering team to

analyze designs early

Pump Meshed Model

Meshed Impeller

AcuSolves Rotating Machinery Process

First run
Very fast setup and solution
Helped understand process and setup before adding more
details
Setup Time: 1 hour from receipt of CAD impeller
Solution Time: 12 flow points 10 hours
1.200

Test
First Run

Pressure Gain

1.000
0.800
0.600

Boundary Layer = 1.4 mm

Mesh Size 7 mm

0.400
0.200
0.000
0.000

0.200

0.400

0.600

Flow

0.800

1.000

1.200

16

AcuSolves Rotating Machinery Process

Refined Mesh
Analysis converged in 9th iteration
AcuSolve results matched test results
Setup Time: Unchanged
Solution Time: 12 flow points-24 hours

Pressure Gain

1.200

1.000

0.800

0.600

Test Pressure Gain

Final Converged Run

0.400

Boundary Layer = 0.1 mm

Mesh Size 2 mm (on Impeller)

0.200

0.000
0.000

0.200

0.400

0.600

Flow

0.800

1.000

1.200

17

AcuSolve Results

Contours of Static Pressure

Contours of Velocity

AcuSolve Results

Velocity Profile

Pressure Distribution fluid

volume

Pressure Distribution

AcuSolve Results

Contours of Pressure on
Planes Cut Through a Pump

Contours of Velocity on
Planes Cut Through a Pump

AcuSolve Results

Pressure Distribution

Velocity Profile

AcuSolve Results

Pressure Distribution

Velocity Profile

AcuSolves Rotating Machinery Process

1-hour setup
Automeshing ensures optimized mesh near critical flow/impeller
features
Accurate results
Standardized inputs built into the tool
5 flow points can be run in 10 hours on a 4 core laptop
The tool is being rolled out to the Product Engineers to handle
increased demand

23

Additional Collaboration - Thermal Analysis

Pump
Cooper Standard engaged Altair in a consulting project to set-up the
initial AcuSolve models
Altair transferred knowledge to Cooper Standard for future product
development

3D CAD Model

Simplified FEA 3D Model

Additional Collaboration - Thermal Analysis Pump

IR Camera Image

AcuSolve Thermal Analysis results

AcuSolve predicted high temperature component locations and were later

confirmed by IR camera

AcuSolve Results

Thank You