Visualization of flow and heat.
Our simulations enable:
Used tools:
Before, between, and after immersion in coating processes, components or car bodies are cleaned in spray zones. The spraying process can cause additional liquid to enter the interior of the components. Since the alignment of the conveyor technology often remains constant during this phase, drainage can be examined and verified in the simulation.
Contamination simulations enable precise prediction of particle behavior based on flow fields. Both fine dirt particles (Lagrange) and coarser particles (Discrete Element Method) are analyzed. Particular attention is paid to the probability of impact and the blocking behavior of the particles. For maximum flexibility, a wide range of physical influences such as particle shape, size, and adhesive forces can be taken into account.
To ensure optimum corrosion protection and precisely identify problem areas, painting processes such as cathodic dip coating (CDC) are supported by simulation. Multiphase simulation (VOF) and modeling of the painting process (e-coating) can be used to determine both the resulting layer thicknesses and air inclusions as well as their interaction, while the overset mesh approach allows the exact modeling of the dipping movement in the tank.
Calibration cycles are used to ensure a high degree of accuracy in terms of layer thicknesses.
Efficient meshing processes enable highly automated work flows, so that the most complex geometries can be prepared and calculated with millimeter precision in a comparatively short time.
Phase transitions are of great importance, especially in the field of hydrogen engines, which can be modeled using suitable condensation and/or boiling models. In combination with fluid-film modeling, a complex multiphase problem can also be evaluated in a single-phase and thus comparatively quickly and cost-effectively. In addition, the determination of critical temperature ranges enables predictions with regard to possible icing.
When carrying out immersion processes, various issues are evaluated using CFD and FE calculations. For example, when components are immersed and removed, the resulting pressure differences are investigated, which cause external and internal parts to be pressed together or apart. This entails the risk of plastic deformation and adhesive failure. Pressures, forces, component movements and deformations can be analysed and optimized in order to minimize potential risks.
After the dipping process, residual liquids often remain in the dipped components. A VOF simulation is used to prevent these residual liquids from being carried over into subsequent tanks or burning in the dryer. This determines the remaining liquids, which can then be removed through suitable openings or movements of the conveyor system.
The simulation also provides valuable insights into the flow situation in the tank. Based on the prevailing process conditions, targeted measures can be taken to optimize the flow around the components in order to make the entire process more efficient and reliable.
Our specially developed co-simulation is used for calculation methods in which the coupling between two continua with different time scales must be evaluated. This approach reduces calculation time while maintaining the same quality of results. Examples include couplings between transient air flows and solid components that exhibit very sluggish thermal behavior. Cooling and heating processes can also be evaluated cost-effectively using this approach.
In the course of e-mobility, calculation methods are needed to calculate the cooling performance on the windings of electric motors. Due to the different state variables of the oil, these are highly complex calculations. Rotating oil jets break down into smaller and smaller droplets that form oil clouds because of the speed of rotation and the impact on the windings. An oil film forms on the windings and the walls, which ultimately collects at various points. Simultaneously, heat transfer and electromagnetism take place.
The ability to combine different hybrid multiphase models enables efficient evaluation within a single simulation. Heat transfer and electromagnetism can be added as well.
The lubrication of gears in gearboxes as well as the splash lubrication in the field of machining are typical applications for complex multiphase simulations with moving parts. Here, wetted surfaces, drag losses, heat dissipation and other parameters can be determined in order to avoid wear problems or to understand existing damage patterns.
Continuous quantities of oil from the oil sump or oil jet are finely atomized and distributed by rotating parts. Precise numerical discretization and modelling of adhesion properties enable the recording of even the smallest quantities of oil and their interaction. In addition, multiphase simulations can be used to model filling processes, such as those that take place in cooling circuits or batteries, for example to localize and eliminate air pockets.
In a drying process, components are dehumidified through the use of thermal methods. For example, in a convection dryer, a car body is heated to a target temperature, which depends on the application. This is necessary to burn in process materials. By using co-simulation, the process can be modeled with different time scales, which enables the movement through the oven system and the simultaneous heating of the components. The movement in the fluid (calculation region stationary) is solved, while the heat conduction in the component (time-dependent/transient) is calculated in a second region (solid). This method enables a precise evaluation in order to economically optimize the product and system with regard to target conditions and energy efficiency.
And finally, with a mapping method the component temperatures can be projected onto finite element meshes, which serve as boundary conditions for a thermomechanical distortion calculation.
The key to a long service life of power electronics lies in their effective cooling in order to maintain the maximum permissible temperatures. For the development and optimization of cooling systems, calculation methods are required that can model all heat transfer mechanisms (heat conduction, free/forced convection, heat radiation) as well as active cooling air flows, often generated by fan wheels. Rotating components can be modeled using a simplified, stationary and very efficient moving reference frame (MRF) approach.
Transient methods are physically more accurate and offer advantages in terms of the quality of results, but require more computing time. Transient effects can also be resolved using the actually rotating volume mesh.
Cooling calculations enable statements to be made about cooling air volumes, component temperatures and relevant heat paths. This allows the complete understanding of the system and the identification of optimization potential.
When mixing single-phase substances, we rely on the Large Eddy Simulation (LES) in our calculation methods in order to model the turbulent behavior with high accuracy while maintaining a balanced relationship to the simulation costs.
Both stationary and transient calculations are carried out for turbocharger and compressor simulations. Characteristic diagrams are generated by the simulation. In addition, the limit ranges can be defined in which the surge and choke lines are reached. It is also possible to evaluate the thermal behavior and localize failure weak points.
Jet mixing nozzles are fittings that enable agitator-free mixing of large tanks, for example in the food industry, based on the principle of a water jet pump. Their advantage lies in their suitability for the CIP process (Cleaning-in-Place), where the system can be cleaned hygienically in an automated manner without manual intervention. For the design and implementation in the plant, it is important to understand both the operating principle of the nozzle inside the vessel and its pressure drop during use.
By means of a series of CFD simulations, it is possible to efficiently and relatively cost-effectively investigate the entire product range of several nominal diameters under different load cases in various tanks. By visualizing the flow the fitting can be optimized with respect to pressure drop and secondary flow.
Bringing structures into shape.
Our simulations enable:
Used tools:
The installation of the battery assembly generates deformations in the entire shell. Especially unfavorable tolerance fields of the battery and the shell can further increase this deformation. It is essential to prevent the deformation in different tolerance positions. Furthermore, forces in the screw connections resulting from the tolerance field can be determined.
When assemblies are joined using thermal and mechanical joining processes, such as spot and laser welding, clinching or roller hemming, stresses and plastic deformations occur. Joining simulation allows these processes to be analyzed in detail. It enables the prediction of stresses and deformations so that targeted optimization measures can be developed for individual components and equipment. This allows existing production problems to be identified and solved efficiently. In addition to digital product development, joining simulation helps to minimize the use of hardware and increase quality.
The positioning and implementation of the vehicle body on different skids creates changing deformation states due to its own weight. Attachments (weight variations) that are added during the development process can additionally be secured.
Lifting the hood on one side causes the assembly to twist. This is indicated by a narrowing gap between the mudguard and hood. A collision or contact must be avoided.
The fixed glass roof is joined to the shell using an adhesive connection. It is inserted at defined points using grippers.
The stresses and absolute deformations of the adhesive must be prevented during the assembly process and the gripper positions optimized. The glass roof and the mounting on the shell are examined and secured.
Rolling is a forming process in which a workpiece is plastically deformed by the movement of rollers and can be used to manufacture assemblies. Simulations deepen the understanding of the process and analyze the influence of critical process parameters on the quality of the assembly. In addition, experiments for the quantitative evaluation of the assembly can be simulated so that direct validation is possible.
In an example of massive forming wire winding, the wire wrapping process of a winding machine is simulated. Such simulations are used for CAD modeling of the wires, which prevents errors during manual winding creation in CAD from occurring. In addition, the simulation enables the actual process of the automatic production machine to be modeled digitally. This saves costs on the one hand by shortening the design time, and on the other hand digitally depicts how an electric motor coil winding machine works.
The diversity of our calculation methods requires flexible and adaptable automation solutions that are tailored to the individual needs of our customers. We develop independent programs that automate pre- and post-processing for CAE applications and are visualized for the end user with a user-friendly graphical interface.
Through targeted process automation we increase efficiency, reduce costs and minimize errors. In this way, we enable reliable delivery dates and the highest quality standards for all our customers.
Used programming languages:
The EnSight Toolbox supports employees in efficiently importing simulation results into Ansys EnSight and automating the creation of post-processing objects (such as section planes, vector displays, isosurfaces and isovolumes, etc.). The data sets are imported in a process-specific manner via a GUI, whereby up to six simulation results can be compared with each other.
Furthermore, a JSON importer enables scenes from Siemens Star-CCM+ to be reproduced in EnSight. The created scenes are saved in States, allowing them to be customized by employees.
The ANSA Batch-Mesh function enables employees to automate and optimize the meshing process for simulations. This feature allows large volumes of geometries to be processed efficiently and consistently, improving the quality and accuracy of simulation results.
Through a user-friendly GUI, various mesh parameters and settings can be configured to meet the specific requirements of each simulation. The Batch-Mesh function also supports the parallel processing of multiple geometries, significantly reducing overall processing time.