Shape Optimization Using FRIENDSHIP-Framework

and STAR-CCM+
CAE Test Case with KRISO KCS and MTU 90 Diffuser

www.friendship-systems.com

Outline
Introduction
PART 1 KCS Case
Geometry
Integration
Optimization

PART 2 90 Diffuser
Parametric Model
Target
Optimized Result

Conclusion

Engineering software for optimal products | 09.05.2012 | 2

INTRODUCTION

Engineering software for optimal products | 09.05.2012 | 3

FRIENDSHIP SYSTEMS

Founded 2001 in Potsdam/Berlin

A GL Company, Marine Solution Part since 2009
Developes and Provides CAE Platform ( FRIENDSHIP-Framework )
Supports Technical Issues and Projects

Engineering software for optimal products | 09.05.2012 | 4

Daehwan Park
M.Sc. NAOE Pusan National University
Ph.D Student NAOE Technical University Berlin
Project Manager FRIENDSHIP SYSTEMS

Engineering software for optimal products | 09.05.2012 | 5

FRIENDSHIP-Framework
CAD
Integration Interface
Optimization Engine

CAD

FRIENDSHIP-Framework
the CAE platform

Optimization

Integration
CAD

Integration
Engineering software for optimal products | 09.05.2012 | 6

Optimization

FRIENDSHIP-Framework CAE Experience

CAD
Coupling Interface
Optimization Engine

FRIENDSHIP-Framework
the CAE platform

FINE/MARINE
ICEM + CFX
HydroMax

Neptune

WAVIS
FreSCO
POSEIDON
NAPA

Nu_SHALLO

STAR CCM+

RAPID
SHIPFLOW
In-House Code
Engineering software for optimal products | 09.05.2012 | 7

AUTOMATED MESH GENERATION

MACRO / JOUNAL

COMMAND FILE

Selected customers

DSME
HHI
SUNGDONG
STX
MOERI
Pusan National University
Mokpo National University
KAIST

Growing Interest from 2010 by Korean Industries

and Academic Field

Engineering software for optimal products | 09.05.2012 | 8

Cooperation between
CD-Adapco & FRIENDSHIP SYSTEMS

FRIENDSHIP SYSTEMS

CD-Adapco

POTSDAM

Nurnberg
IGES

STL FILES

JAVA MACRO

INTEGRATION
OPTIMIZATION

WIN-WIN Cooperation
CD-Adapco team has never used FRIENDSHIP-Framework
FRIENDSIHP SYSTEMS has never used STAR CCM+
Telephone, Email and Done!!!

Engineering software for optimal products | 09.05.2012 | 9

PART 1 KCS Case

Engineering software for optimal products | 09.05.2012 | 10

GEOMETRY

Engineering software for optimal products | 09.05.2012 | 11

Import KCS model in IGES patches

Main Principals
Lpp 230 M
B 32.2 M
D 10.8 M
Fn 0.26 (24 Knot)
Reference
Kim, W.J., Van, D.H. and Kim, D.H., (2001),
Measurement of flows around modern commercial ship
models, Exp. in Fluids, Vol. 31, pp 567-578

Engineering software for optimal products | 09.05.2012 | 12

Desingularization

Singularity in
Stern Valley
Engineering software for optimal products | 09.05.2012 | 13

Divide patches

Desingularization

Extract 4 edge curves

Engineering software for optimal products | 09.05.2012 | 14

Create coons patch

Singluarity disappeared

Desingularization

Singularity in
Bulb
Engineering software for optimal products | 09.05.2012 | 15

Subdivision

Desingularization

Singularity in
Bulb
Engineering software for optimal products | 09.05.2012 | 16

Regularity after
Subdivision

Desingularization

Duplicated IGES Patch

Cut the corner

Engineering software for optimal products | 09.05.2012 | 17

Fill Deck Surface

Produce deck surfaces from the given patches

Engineering software for optimal products | 09.05.2012 | 18

Water-Tight Trimesh

Tolerance 0.01
Adaptive Tesselation Error 0.01

Joint the patches with gaps

Engineering software for optimal products | 09.05.2012 | 19

Tolerance 0.07
Adaptive Tesselation Error 0.01

Water-Tight Trimesh
1_Trimesh

Trimesh Hull
2_Trimesh

2_Trimesh

2_Trimesh

2_Trimesh

Engineering software for optimal products | 09.05.2012 | 20

Water-tight Trimesh

Trimesh Deck

Trimesh Hull
Trimesh Transom
Engineering software for optimal products | 09.05.2012 | 21

Hydrostatics for Sactional Area Curve

Extraction offset groups from IGES surfaces

Engineering software for optimal products | 09.05.2012 | 22

Hydrostatics for Sactional Area Curve

SAC as input in Lackenby variation

Engineering software for optimal products | 09.05.2012 | 23

Lackenby Variation & Design Variables

Dv_dLcb

Image Trimesh

Dv_fbdyTanBeg
Engineering software for optimal products | 09.05.2012 | 24

Dv_fbdyTanEnd

Export STL
Export the varied image trimesh as STL format.
.exportSTL() or .exportColourSTL()

Engineering software for optimal products | 09.05.2012 | 25

Integration

Engineering software for optimal products | 09.05.2012 | 26

Integration

Definition

Configuration

Computation

(Define Input &

Output)

(Set Input Values)

(Compute and
Read Output)

Engineering software for optimal products | 09.05.2012 | 27

Integration
Definition
Java Macro

Template files

Integration
Editor

Sim File
Deck.Stl

Entries

Input Files

Hull Stl
Transom Stl

Result Files
Result Table
(CSV)

Screenshot 1
Screenshot 2

Engineering software for optimal products | 09.05.2012 | 28

Integration
Definition

Example : JAVA Macro Integration

Engineering software for optimal products | 09.05.2012 | 29

Just import java macro file

Integration
Configuration
Deck.Stl
FRIENDSHIPFramework

Hull Stl
Transom Stl
Result Table
(CSV)
Wave Elevation

STAR CCM+

Wave Center
Profile

Drag
Convergency
Streamline

Engineering software for optimal products | 09.05.2012 | 30

Integration
Computation

Argument for POD license

Set argument

Set the executable path

Engineering software for optimal products | 09.05.2012 | 31

"-power -podkey
98XXX/x3xXX3Xd/91X9XX== -licpath
[email protected] -batch
automationScale.java setup.sim"

Integration
Computation

Engineering software for optimal products | 09.05.2012 | 32

Test Computation

Very small Max. Physical Time (6e-2)

Check if STAR-CCM+ is integrated.c

OPTIMIZATION

Engineering software for optimal products | 09.05.2012 | 33

Automated Optimization

Optimum Design

FRIENDSHIP-Framework Optimization Engine

Form Variation
< 1. Writes>

Decision Making

< 2. Triggers>

< 6. Reads>

*.csv
*.png

STLs
JAVA Macro

SIM

< 4. Run>
< 3. Reads>

STAR CCM+

Engineering software for optimal products | 09.05.2012 | 34

Mesh Gen &

Computation

< 5. Writes>

Computation Environment in CD-Adapco

Maximum Physical Time
20.0
6 Threads
Linux
Duration per Computation
About 2 hours

Selected Max. Physical Time 20

Full Max. Physical Time 30
Engineering software for optimal products | 09.05.2012 | 35

Geometry Scaled
Scaling is implemented in JAVA macro.
Model Scaled in 1/31.6
Lpp 7.27
B 1.02
D 0.34
Fn 0.26
Rn 1.4x10^7

Engineering software for optimal products | 09.05.2012 | 36

Global Search with Sobol

Design variables
Dv_dLCB
[ -0.01, 0, 0.01 ]
Dv_fbdyTanBeg [ -30, 0, 30 ]
Dv_fbdyTanEnd [ -30, 0, 30 ]

Objective
Drag force

Variants number
20

Engineering software for optimal products | 09.05.2012 | 37

Select the best variant

Original
Selected
Dv_dLCB = 0.00125
Dv_fbdyTanBeg = - 3.75
Dv_fbdyTanEnd = - 18.75
Drag original 44.2
Drag selected 43.55 (-1.5%)

Setions at regular stations

Engineering software for optimal products | 09.05.2012 | 38

PART 2 MTU 90 Diffuser

Engineering software for optimal products | 09.05.2012 | 39

90 Diffuser
Integration via Case Study
In collaboration with
MTU Friedrichshafen GmbH
Diffuser: engine component
which turns flow of around 1kg/s,
direction change of 90
Hot exhaust gas at approximately 500C
Design study for curved part
Compare with CFD results of a diffuser which is in service

Engineering software for optimal products | 09.05.2012 | 40

Parametric Model

Design Variable

Engineering software for optimal products | 09.05.2012 | 41

Elbow Shape by Volume Parameter

Target
Pressure Drop at Bend Exit
Uniformity Index at Bend Exit

Engineering software for optimal products | 09.05.2012 | 42

Optimized Result

Objective

Original Model

Pressure Drop [mbar]

(The Lower The Better)

Uniformity Index
(The Higher The Better)

MTU Trial and Error

Automated Optimization

47

15

14

0.51

0.86

0.87

Engineering software for optimal products | 09.05.2012 | 43

Optimized Result

Engineering software for optimal products | 09.05.2012 | 44

Conclusion & Outlook

Auto-Mesh and JAVA Macro of STAR-CCM+ is main feature of this
CAE process.
Integration is done in 5 minutes.
Global search leads designers to the further intuition.
Enlarge CAE cases between
STAR-CCM+ and FRIENDSHIP-Framework

Engineering software for optimal products | 09.05.2012 | 45

Thank you very much for your attention

FRIENDSHIP SYSTEMS GmbH
Benzstr. 2
14482 Potsdam
Germany
[email protected]

www.friendship-systems.com