Tag Archives: CFD

Move from wind tunnel testing to simulation-driven design offers typical automakers more than 500% ROI

Moving from wind tunnel testing of physical prototypes to simulation-driven design processes can offer typical automotive OEMs more than 500% ROI (return on investment), according to research from Tufts University’s Gordon Institute for engineering management. Continue reading

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Flow field around Tesla Model S simulated with Exa software identifies areas of higher drag in red. Source: Tesla and Exa Corp.

Aerodynamic optimization of a high-speed train

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Source: Optimal Solutions Software

The high-speed train market in recently industrialized countries is one of the most hotly contested engineered-product markets in the world, with even the smallest advantage important in gaining a competitive edge. In particular, fuel consumption is a critical factor in design, sales and maintenance of these vehicles. In this project, a manufacturer of high-speed rail vehicles needed to maximize efficiency, reduce emissions and decrease design time.

Seeking a more efficient engineering approach that would let it maximize the number of designs that could be tested within the project schedule, the manufacturer selected Sculptor from Optimal Solutions Software. By specifying key design parameters, the software allows hundreds of designs to be generated in a matter of minutes—a radical improvement over the company’s previous process, in which this phase of the project took months. Continue reading

Aerodynamic and structural optimization of a turbofan

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Geometry of existing fan. Source: FEA-Opt

Optimizing turbofan designs is challenging because of the need to deal with both aerodynamic and structural performance. While designing a fan with high performance and efficiency is important, strength and reliability of the structure are also critical. Further, integrating parametric CAD, CFD and stress analysis is not a trivial task and usually takes extensive effort.

In this project SmartDO and ANSYS were utilized together to optimize a turbofan. The technical services team at SmartDO’s developer, FEA-Opt Technology, helped the customer build a parametric model with ANSYS DesignModeler, construct the CFX and mechanical analysis block, and integrate SmartDO with ANSYS Workbench. SmartDO was able to increase the mass flow of the fan by almost 14% while slightly reducing the maximum stress under aerodynamic and structural loading. These results showed promising possibilities for further design development. Continue reading