Rubn Jacob D.

Industrial Designer, University of Valparaso, Chile Master in Design, Management and Development of New Products Master CAD CAM CIM PhD Candidate in Design, Manufacturing and Management of Industrials Projects Polytechnic University of Valencia, Spain

13th EAEC European Automotive Congress

Establishment methodologies for CFD analysis using NX, and proposals for redesign the carbody for competition Shell Eco-marathon

this presentation

NX simulation
1.

Theoretical Framework Goals and research structure. S tablishment of procedures for CFD analysis. Redesign proposals and outcomes achieved Final considerations

2.

3.

3Ds Max -Vray

4.

5.

Current Vehicle

Introduction and theoretical framework

aerodynamics + FEM + CFD

Aerodynamics is the branch of fluid mechanics that studies the actions that appear on solid bodies when exist a relative motion between them and the gaseous fluid that surrounds them. Aim: to improve the capacity of the vehicles to penetrate the air with the smaller possible effort... Through the modification of the forms and surfaces.

aerodynamics+ FEM + CFD

The method of the finite elements consists of taking a body and dividing it in small elements that together correspond with the original body in their geometry. (discretization) For a smallest element, better match with the real geometry and more accurate results

aerodynamics coefficient

solid bodies the forces between them are registered and operating in the contact point. Fluid and solid surface following, around the solid, maintaining close contact between all "points" The forces in this system must be considered in all points of the solid surface, actually almost infinite, determined by the size of molecules of the fluid.

aerodynamics coefficient

Due of complexity of effects of air over vehicle this relations between forces it are made depend of only one variable (coefficient) Cx coefficient it is obtained from a specific formula with a unique unknown value: "force in X (Fx), obtained through CFD analysis or wind tunnel experiments

research approach and empirical work.

research hypothesis

NX sofware and its solver NX THERMAL / FLOW is appropriate and sufficient for the development of CFD analysis to provide accurate and useful information in the process of development and optimization of a land vehicles aerodynamics, and makes possible to approach a specific method to continue to follow for implementation.

general aim

Perform CFD analysis process of the carbody in development for the Shell Eco-Marathon vehicle, using the NX platform and propose, ba sed on the results, ideas for the optimization of its shape and aerodynamic performance.

specifics goals

1. Perform a proper proceedings.

documentation

of

the

2. Establish a clear and strong method for the proper conduct of this type of analysis in NX 3. Generate documentation that serves as an introduction to the field of CFD analysis for professionals with no experience or training in the area but with the need to perform this type of simulations. 4. Define the scope and actual capacity to perform CFD analysis of NX platform regarding its accuracy and usability, and compared to others software applications.

method followed for the conduct of CFD analysis

basic method for development CFD analysis in NX

1.Preparation of the Model. preparation of the 3D model in the native software which has develop the modeling process 2.Generating "Wind Tunnel" Representation in NX. create the parallelepiped representing the wind tunnel in the system. Must be large enough so that the flow around the vehicle is not disturbed by the walls

basic method for development CFD analysis in NX

3.Meshing the vehicle. Meshing the geometry of the vehicle to study with proper size of element 4.Boundary Conditions Determination. This stage of the process determined the fluid velocity equal to the vehicle in the real world, the area of inlet and outlet flow, the fluid domain (space filled by the fluid), the target zones of flow and surfaces contact of the vehicle.

basic method for development CFD analysis in NX

5.Solution Calculation. needed to perform the necessary iterations and the calculation of equations for the solution according to the conditions imposed. 6.Presentation of the Results. once the calculation of the solution is over, you get the graphical presentation of results, can be seen the flow using streamlines, colored fields and scales, and numerical data

presentacin de los resultados

Proposals of modifications and results.

analysis conditions in final model

Velocity of Fluid/ vehicle: 30 km/ h Turbulence model: k- (K epsilon) Mesh of vehicle: type subdivision, element size 25 mm over STEP model, 2D mesh with element type TRI3 Thin Shell. Solution: Flow/ stationary state. Solution units: Meter/ Newton. Flow Mesh: 0,060,03-0,01 Tunnel model dimension 6000 mm lenght, 2000 high y 3000 width. Accuracy on previous test analysis: 0,01 (sphere)

outcomes from simulation and analysis of final model

Extract of file *.log from NX analysis of final vehicle 3D model Fx= 3,319 Newtons
x-comp y-comp z-comp |R| -----------------------------------------------------------------GLOBAL FLOW SURFACE CG location (m): CP location (m): Total Force (N): Total Torque (N-m): Shear Force (N): Shear Torque (N-m): Pressure Force (N): Pressure Torque (N-m): 1.371E+00 1.160E+00 4.365E+00 -2.070E-04 1.046E+00 2.373E-05 3.319E+00 -2.307E-04 2.511E-05 3.358E-03 1.159E-01 2.856E-02 4.762E-01 2.053E+00 4.825E+00 2.388E+00 1.046E+00 3.214E-02 3.902E+00 2.355E+00

2.388E+00 -1.787E-02 6.276E-04 6.139E-03

3.214E-02 -6.243E-04 1.152E-01 2.047E+00

2.355E+00 -1.725E-02

outcomes from simulation and analysis of final model

Air density= 1,204 kg/ m3 Velocity= 30 k 50 km/ h= 9 14 m/ s Projected frontal area: 0,304 m2 Projected lateral area: 1,284 m2

Shape evolution from initial to final 3D model

Shape modification

Frontal area value

Fx

Cx

SCx

1 2 3 4 5 6

0.316 m2 0.305 m2 0.303 m2 0.307 m2 0.306 m2 0.304 m2

3.991 N 4.151 N 3.968 N 3.497 N 3.463 N 3.319 N

0.291 0.313 0.302 0.262 0.261 0.251

0.091 0.095 0.091 0.080 0.079 0.076

Specific improvements to reach to final shape

Frontal zone of vehicle :

Drag forceX in 30 km/ h simulations is 3,991 N for initial model and 3,319 N, for the final model

Highest pressures are 6,516x10-5 and 4,642x10-5 N/ mm2 for initial and final models respectiively.

Specific improvements to reach to final shape

Rear zone of vehicle: This area consists of the "tail" of the vehicle, is wanted so smooth and integrated as possible to allow the fluid to move smoothly and remains attached to the vehicle, delaying the point at which is "take off" from the carbody

The streamlines show how modification affects live so slow smooth the flowseparation from wall of the vehicle

the and the

conclusions of research and empirical work

25

vehicle meshing process

Valores tiempos - Fx - Fuerza total

20

15

10

FEM Meshing element size ( mm)

Time for meshing the fluid (min and sec)

Calculation time for the solution (min and sec)

Result for Fx (Newtons)

Results for resulting total force XYZ (Newtons)

Tiempo Malla Fluido Tiempo de Clculo

140 90 70 60 50

6.00 6.00 6.00 6.00 6.00

12.01 12,11 19.56 20.14 20.08

2,988 3,200 3,194 3,268 3,381

5,479 5,073 5,042 4,960 5,067

0
10 60 110 Fx Fuerza total (resultante) Tamao de elemento mallado vehculo

40 30 25 20
10

6.00 6.00 6.00 6.00

6.00

20.37 21.42 21.45 21.00

22.15

3,413 3,378 3,354 3,377

3,382

5,111 5,085 5,041 5,086

5,102

Fixed conditions: Type of Fluid meshing element is relative, values 0.06 for the fluid and 0.03 for the limits, 0.015 for the fluid in contact with the vehicle. Analysis at 30 km/h Turbulence Mod. k-

According to the fidelity factor of the mesh representation with respect to the original form (mesh matching) have been considered the values from 40 to 20 mm as the acceptable range for the sizeof either element meshing type sub division or cobble (which do not affect the result)

Fluid mesh, type of element size relative

Size of mesh elements of the fluid is relative(fluid boundaries - the area in contact with the vehicle)
0,9 0,2 0,1 0,50 0,10 0,05 0,25 0,05 0,035

Time for meshing the fluid (min and sec)

Calculation time for the solution (min and sec)

Result for Fx (Newtons)

Results for resulting total force XYZ (Newtons)

0.30 1.00 2.00

1.00 2.54 6.42

5,077 4,385 3,867

6,457 6,071 5,637

0,12 0,04 0,020

0,06 0,03 0,015 0,04 0,02 0,012

4.00
6.00 10.00

8.09
21.45 26.49

3,584
3,354 3,298

5,234
5,041 4,927

The optimal calculation time-element size-accuracy relation is close to the value 0.12 (0.04 to0.02 for its limits and the area in contact with the vehicle).

Fixed conditions: Type of Element of Fluid Meshing is relative, Size of FEM mesh element for the vehicle 25 mm., Analysis at / h Turbulence Mod. k-

Fluid mesh, type of element size absolute

Size of mesh elements of the fluid Absolute (fluid - boundaries - the area in contact with the vehicle)
250 150 - 75 200 95 - 60

Time for meshing the fluid (min and sec)

Calculation time for the solution (min and sec)

Result for Fx (Newtons)

Results for resulting total force XYZ (Newtons)

0.30 1.00

1.09 2.07

4.635 4.336

6.047 5.732

170 75 - 50 150 50 - 40 85 - 65 - 35
75 - 55 - 30

3.00 2.30 4.00

5.00

3.05 8.48 16.11

19.22

4.310 3.794 3,480

3,224

5,721 5,294 5,074

4,801

Fixed conditions: Type of Element of Fluid Meshing is Absolute, Size of FEM mesh element for the vehicle 25 mm., Analysis at / h Turbulence Mod. k-

For type of element size "absolute" values 150-50-40 be chosen as the ideal for optimal relationship between precision and calculation time, and 8565-35 as optimal values when we want more accuracy at the expense of increased computing time.

hypothesis state

NX are suitable and adequate for the development of these tests. The software provides accurate and reliable results, consistent with one another when external conditions change. The way to show numerical data can be improved to be more understandable. CFD simulations carried out have proved useful in the development process and optimize aerodynamics of the vehicle.

future research

There is no about the implementation road" by NX.

information of "Rolling-

Confirm the trends discovered and generate specific documentation for NX, no longer exists. The type of mesh element must be studied in a similar way to define its impact on theaccuracy and computational time. The boundary layer should be integrated into the analysis.

Establishment methodologies for CFD analysis using NX, and proposals for redesign the carbody for competition Shell Eco-marathon

Rubn Jacob D. - Vicente Colomer R.