CFD Flow Simulation

CFD Simulation – Benefits in Engineering

CFD simulation (CFD = “Computational Fluid Dynamics”) is used to design and optimize flow-carrying components and bodies subjected to flow. CFD simulation mathematically models fluid flows and flow patterns. Visualizing flow paths with CFD software reveals weaknesses in flow guidance, which in turn allows for the optimization of product and process efficiency.

Flow simulation or flow analysis provides a detailed view of where flow losses or pressure losses occur. If measurements are not possible or too time-consuming, CFD simulation is the right development tool for optimizing pressure losses.

Reduce flow losses / pressure losses

What are the specific benefits of a CFD flow simulation? Technical devices and vehicles that are surrounded by or have gas, air, or liquids flowing through them are ubiquitous today: cars, vans, and trucks, as well as turbochargers, pumps, piping, vacuum cleaners, and clothes dryers, etc. What all these devices have in common is that their energy consumption depends directly on flow losses.

Flow loss or pressure loss occurs due to flow separation (recirculation), which can lead to a complete flow separation. Flow separation is caused by, among other things,

• abrupt changes in the flow pattern
• irregular cross-sectional expansions
• components located within the flow path

This causes the flow pattern to “break up.” In addition to pressure loss, another negative consequence can be noise generation. A CFD simulation identifies these undesirable flow patterns and enables the targeted optimization of flow-critical components.

M.TEC: Service Provider for CFD Simulation

As a provider of CFD simulation and fluid flow simulation services, M.TEC simulates various media with their respective viscosities, such as air, water, oils, gels, and adhesives. CFD simulation can also be used to model the mixing of different media (e.g., a multi-component adhesive or an air-fuel mixture).

The M.TEC Simulation & Calculation team specializes in fluid dynamics analysis. With extensive knowledge of the underlying physical principles of fluid mechanics, we quickly deliver simulation results along with the correct interpretation, enabling adjustments to be made to the CAD data. M.TEC develops flow-optimized concepts and derives appropriate measures from the results of the flow simulation—to optimize your component or product.

Frequently Asked Questions About Flow Simulations with M.TEC

Types of cfd simulations or flow simulations

Steady-state simulation

Steady-state simulations or sometimes referred to as stationary simulations are useful in cases where flow properties such as velocity, pressure, and temperature do not change over time and the system is in equilibrium. The flow may have reached a steady state without fluctuations, or the changes may be minimal and have no effect on the flow properties. If a system or process under investigation is expected to reach a steady state or approach a steady state, a steady-state CFD simulation can be used to analyze the flow behavior and find a solution to a problem within the system. These CFD simulations are useful for design optimization, in early design phases, and in cases where the average flow behavior is sufficient.

Unsteady Simulation

Flows with varying flow parameters—such as variable flow rate and time-dependent phenomena like vortex shedding, oscillating flows, flow separation, high turbulence leading to altered flow behavior, phase changes, and varying fluid volume—can be analyzed using an unsteady/transient CFD simulation. In this case, the variation of flow parameters over time is examined, and changes in the flow are analyzed over time. This helps identify flow behavior and determine necessary modifications to the system under investigation.

Thermal Simulation or Heat Transfer Simulation

In thermal CFD simulations (heat simulations), heat transfer (convection or thermal processes) and flow within the system between different materials—whether solids, liquids, or gases—can be analyzed. In addition to surfaces with constant or fluctuating temperatures, heat sources or heat sinks can also be included in the system.

This type of CFD simulation enables a detailed analysis of temperature distribution and heat flux, which are crucial for optimizing thermal management in electronics, HVAC systems, automotive components, and other industrial processes.

Fluid-Structure Interaction

Fluid-structure interaction in CFD simulations accounts for the interaction between fluids and deformable solids. In cases where fluids exert significant forces (pressure and shear forces) on the structure, it is important to account for the effects on the structure. The deformed structure also influences the flow and ultimately alters the fluid forces acting on the structure. Fluid-structure interaction plays a crucial role in the detailed analysis of the interaction between the flow and the structures in the flow field. Some examples where fluid-structure interaction plays an important role include pneumatic control systems (valves), biomedical applications for studying blood flow in arteries/artificial hearts, wind turbines/tidal power plants, weather monitoring systems, wind tunnel tests in the automotive/aerospace industry, or other products.

Multiphase Flow

This type of CFD simulation involves multiple immiscible fluids (gases or liquids) or different phases of a single fluid (e.g., water and water vapor). Multiphase CFD flow simulations help analyze the interaction between different fluids or phases. Depending on the system or process being analyzed, the flows can be modeled with a sharp interface between the fluids or as a mixture of fluids. Examples of applications for multiphase CFD simulations include fluid transport tanks, the analysis of gas concentrations in work areas, mixing processes in the manufacturing industry, etc.

Particle Transport

CFD simulations can be used to investigate particle flow in systems and analyze particle distribution within the system under consideration. The influence of the flow field on the particles is taken into account to analyze particle transport within the system. The Lagrangian particle method and the discrete element method (DEM) are common methods for investigating particle transport in fluid systems.

Phase Change Simulations

CFD simulations can be used to study phase changes between solid, liquid, and gaseous states, such as melting, freezing, evaporation, and condensation. This eliminates the need for extensive monitoring systems and allows the necessary modifications to be made to a system to resolve existing issues before production. Examples of cases where CFD simulations of phase changes can be used include steam stacks, heat exchangers, turbomachinery, and more.