Topology-Optimization for internal Fluid Flow: TOSCA Fluid

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CFD topology optimization for channel flow

Task: Find a geometrical proposal for a channel within a fluid design space:

For each fluid cell decide:

?
Inflow

Outflow

Should this cell belong to the channel or not? Each fluid cell is a design variable! Millions of design variables possible

...
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General optimization schemes are not feasible

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OC-based Topology Optimization

The Optimality Criterium is to avoid flow recirculation An achieved consequence is (for many technical flows) a reduction of pressure drop Redesign Rule: Elimination of local backflow and recirculation by blocking out of backflow areas provides an optimization approach by means of improvement

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Topology optimization with TOSCA Fluid

Outflow 1

Define the Design Space (e.g. CAD)

Outflow 2

Meshing as usual Define your Boundary Conditions Run the Optimization

Inflow

Design Space

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Topology optimization with TOSCA Fluid

Outflow 1

Free Flow
Outflow 2

Transition Area (defining new channel shape) Prevented Flow

Inflow

Design Space

Optimized Channel Shape

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Topology optimization with TOSCA Fluid

Direct run time communication with the CFD solver Only one single CFD solver-run for complete optimization process

CFD Solver Solution Process

Optimization Shared-Memory and Flow Result

TOSCA Fluid Optimization

Time resp. Iteration

suitable for large real world applications

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TOSCA Fluid Result Reconstruction Methods

STL-Surface

Optimization result and Designspace

IGES-Cuts
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CAD-Reconstruction based on IGES-Cuts

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TOSCA Fluid Graphical User Interface

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TOSCA Fluid Example Projects

EGR-Cooler:
Pressure Drop Reduction: 20% Efficiency Enhancement: 11 %

Engine Air Intake / Filter System:

Pressure Drop Reduction: 42% Flow Uniformity Enhancement: 56%

Intercooler Intake Hose:

Pressure Drop Reduction: 20%

Commercial Vehicle HVAC Duct:

Pressure Drop Reduction: 25 % Flow Split Enhancement: 6%

...
Courtesy Opel

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the optimization company

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FE-DESIGN GmbH, www.fe-design.com
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TOSCA Fluid Feature Overview

TOSCA Fluid.topology Version 2.2 features

Reduction of flow recirculation and vortices by topology optimization of the flow domain Reduction of the pressure drop and related phenomena Efficient, fast optimization by direct runtime coupling of the optimization to the CFD solver Support of
STAR-CD V4.0x solver with .ccm / .ccmg databases STAR-CCM+ V6 solver ANSYS Fluent V12 solver

Parallel operation support GUI and pre/post processing interfaces LinuX x86_64 Support
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TOSCA Fluid Key Notes (1)

New and unique technology for fast and efficient topology optimization of internal fluid flow systems Simulation driven design, fast and easy design optimization impacting all development stages Use of your favorite CFD-solver and existing models for optimization, no parameterization necessary Unmatched efficiency for large, real world industrial applications High innovative strength due to new and potentiality inspiring designs and large solution spaces
FEFE-DESIGN
the optimization company
Resulting design proposal (60% less pressure drop compared to a standard design) Optimization process

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TOSCA Fluid Key Notes (2)

Based on Daimler Technology Technical and support hotline by experienced CAE and optimization staff Easy setup of optimization problems using the graphical user interface (GUI) No model parameterization is required Straight forward pressure drop reduction (noise diminution), flow homogenization and several other optimization tasks General reduction of development time and development cycles which saves your costs
New conceptual Design, p 26 % available Designspace

initial Design

Optimization

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the optimization company

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FE-DESIGN GmbH, www.fe-design.com
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