The hottest EFD software accelerates vehicle desig

2022-10-20
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EFD software accelerates automobile design white paper (Chinese version)

as we all know, the computer simulation/virtual model technology in the form of CFD (Computational Fluid Dynamics) greatly reduces the product cost and accelerates the time to market. However, many operators have not realized that the progress of software is making it easier for small and medium-sized enterprises to make profits. Thanks to software such as EFD (Engineering Fluid Dynamics), we no longer need to hire or train CFD experts, outsource analysis to consulting companies, or test multiple physical prototypes. Today, in companies of any size, generally trained design engineers can use their existing knowledge to successfully conduct fluid flow and thermal analysis, thus greatly reducing the number of prototypes required

this breakthrough is achieved because EFD simplifies the process of establishing and running fluid flow or thermal analysis. Of course, in some demanding applications, advanced professional knowledge and elegant appearance are required. Adjust CFD lattice division and solution settings to solve by convergence. However, our experience shows that using existing knowledge, design engineers can solve 80% - 90% of the analysis work they encounter without special CFD training. This makes CFD no longer limited to the field of experts, and becomes the mainstream trend, representing the fundamental changes in the design process. Just as CAD's transition from 2D to 3D requires a leap in thinking, so does EFD - and the results may be more important

using existing knowledge, design engineers can solve 80% - 90% of the analysis work they encounter without special CFD training

based on these factors, the application scope of CFD has been greatly expanded. Although many operators in the automotive industry may think that fluid flow analysis is specifically used to study the gas flow in the appearance of cars, this is actually the beginning of EFD applications. Another significant application that may come to mind is to study the fluid in the valve to determine the size of the valve. However, EFD is being used to optimize the design and manufacture of a wide variety of parts, such as pumps, braking systems, filters, fuel cells, manifolds, lamp tubes, transmissions, and many other components. It is worth noting that the heat conduction in the device or processing process is inevitably affected by the fluid flow effect. Therefore, EFD is also good at analyzing the thermal effects of components and systems of various sizes

EFD may save millions for just one project.

the minimum of any hardware or software purchased by an engineering team is: can I save my time and money? EFD software package, generally speaking, the cost of obtaining a permanent license can be recovered in its first application project, and then make profits year by year

the convincing evidence for the above time and cost theory is a study conducted by Aberdeen group (engineering decision support: driving better product decisions and accelerating the speed of products to market). This study compares 190 companies for the first time through several key performance indicators, which are related to meeting cost/revenue goals and determining product launch dates. Then the companies it studies are divided into three groups: "top", "industry average" and "laggards"

there is no doubt that the strategy adopted by industry pioneers is to replace physical prototypes with virtual models as much as possible. The average number of virtual models used by these industry pioneers is 7.3, while the laggards only have 2.8. The following table shows the time and cost saved in the case of less 1.1 physical models. According to the complexity of products and the number of virtual models, laggards need more physical prototypes. The average physical model of the industry pioneer is 2.7, while the laggard is 3.8. As shown in Table 1: for products with low complexity, the cost saved is close to 10000 US dollars; For high complexity products, the savings are more than onemillion dollars. Table 1 time and cost saved in the case of less than 1.1 physical models table

source: Aberdeen group, 2007

Table 1: the research of Aberdeen group shows that the less physical prototypes are used, and using virtual models in the software as much as possible can greatly save time and money

financial income also extends the service life of the product. As stated by the AutoSim Consortium (a project funded by the European Commission), compared with the launch on time, the six-month products in the evening market, even if included in the budget, will reduce the revenue by an average of 33% in five years. Moreover, as shown in Table 1, as long as one physical prototype is reduced, the development cycle can be reduced by 14 to more than 100 days

now, the key information is that almost all design and engineering teams can save these time and costs

EFD promotes CFD to become a mainstream engineering design tool

any engineering team can use computers to simulate engineering systems, and there are no new changes in the following concepts. For centuries, scientists have used mathematical models to describe our world. Newton and Leibniz developed different calculus to add dynamics to the model. In fact, using a relatively simple model, Newton predicted the orbit of the planet. This feat is revolutionary. It even challenges the human view of the universe. In the following decades and centuries, researchers found formulas to describe various physical phenomena in the field of machinery, mechanism, chemistry and even the whole electromagnetic wave. For the flow of fluid or gas, the most basic relationship is the Navier Stokes equation first proposed in the early 19th century. Although the real problem is very complex and the role of Navier Stokes equation is limited, it is difficult to find an analytical solution, so it is necessary to find a rough approximate numerical method. This is the computational fluid dynamics that I am familiar with when I use this Ayong computer automatic control system to complete the process of tension experiment

previous software versions have been widely used to solve various problems of commercial CFD software. Software suppliers have been committed to improving lattice tools and solvers in the past 10 years. Next, the ongoing step is to balance these improvements and make new breakthroughs. Therefore, the advent of EFD (Engineering Fluid Dynamics) software is as important as introducing commercial software to the world for the first time

the skills required to operate EFD software are only the knowledge of CAD system and product physics, which most design engineers have mastered

only in the 1950s, with the emergence of computers, did CFD Research really begin, but research is based on programs developed and written by researchers, that is, codes we are familiar with, generally in academic circles or government supported projects. These procedures are generally written for a single case. Until the 1980s, commercial programs began to appear, and the use of CFD expanded, but these programs need to be operated by professionals, who must understand the skills of correctly setting software, such as obtaining good grids, selecting the best solution and adjusting operations. However, with these software packages, if engineers can define geometric models, determine physical conditions and describe some initial parameters, they can still simulate the flow field

previous software versions have been widely used to solve various problems of commercial CFD software. Software suppliers have been committed to improving lattice tools and solvers in the past 10 years. Next, the ongoing step is to balance these improvements and make new breakthroughs. Therefore, the advent of EFD (Engineering Fluid Dynamics) software is as important as introducing commercial software to the world for the first time

the key word here is "Engineering" - this software is designed for daily design engineers rather than experts. It removes all obstacles to the mainstream use of CFD. Until now, the biggest obstacle is that traditional CFD software requires users to have a deep understanding of computational fluid dynamics in order to obtain accurate results. In contrast, EFD's breakthrough advantages include its use of local 3D CAD data, automatic definition of flow space and generation of grid grids for it, and management of flow parameters based on object features - all of which are combined and processed through convenient wizard instructions, and engineers do not need to understand the computational part of CFD. On the contrary, they can focus on the hydrodynamic performance of products, which has become part of their responsibilities, because they are well-trained and experienced. The skills required to use EFD software are only to understand the CAD system and product physics, and the vast majority of design engineers already have these two skills

picture 1: EFD not only makes engineers still in a familiar software environment, but also can automatically perform many steps, while traditional CFD software packages need to master a lot of professional knowledge to complete

an important aspect of distinguishing EFD is that it is seamlessly integrated into the mechanical CAD software package familiar to engineers. After installing EFD software, all menus and commands that need to run flow or thermal analysis are integrated into the CAD software package. EFD combines the functions of CAD and CFD closely (see Figure 1), and its main advantages are:

· engineers do not need to export files from the CAD environment to the analysis software package, and spend time to establish the "ready CFD" geometric model. This process takes either days or hours. On the contrary, EFD uses Engineering Dr. Liu to give a detailed lecture on the three industry standards from the scope of application, classification, requirements, experimental methods and mark packaging. The same geometric model generated by the instructor in the mechanical CAD software package, including any modification of the model, is automatically imported into EFD analysis

· EFD software automatically determines the fluid region you are interested in, while traditional CFD software requires users to define their own calculation region of interest

· EFD software is clearly set up, divided and solved. CFD is too flattering. It provides a wide range of options, but it is not needed in most cases. EFD software can automatically select the appropriate solution results and set the solution method to get the solution. Engineers also don't have to worry about how to determine the time and place of the change of flow characteristics, because EFD supports laminar transition turbulence simulation

· it is only necessary to set the boundary conditions once. Due to the unified operating environment and corresponding to the geometric shape, these parameters remain unchanged, unless the engineer modifies them

· similarly, EFD accelerates the iterative design process; Engineers can quickly and easily apply what they have learned to analysis and design improvement. Using traditional CFD software, the lattice must be regenerated every time the geometry changes, which usually involves time-consuming manual intervention. In contrast, when the geometry changes, the EFD software runs immediately, automatically generates a new lattice, and works under the previously defined boundary conditions. Therefore, the speed of completing this step is greatly accelerated from changing geometry to running solution and inspection results

in general, due to the close combination of CAD and CFD functions, EFD significantly accelerates the workflow, and there is no need to perform many manually set steps when running the analysis

Figure 2: fluid flow analysis of intake pipe in pro/engineer wildfire environment - EFD software can analyze the changes of physical design

when in the conceptual stage, manufacturers conduct simulation through EFD, so that they can discuss the design scheme, find design defects, optimize product performance, and then start detailed design or

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