Escolar Documentos
Profissional Documentos
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PRODUCTS AND
TECHNOLOGY SPOTLIGHT
PAGE 9 SPEEDO MAKES
A SPLASH
PAGE 4
FLUID FLOW
SIMULATION
PAGE 17
MULTIBODY
DYNAMICS
PAGE 20
EDITORIAL
Don’t Isolate
Engineering Simulation
Leverage the tremendous value of the technology by tightly integrating
simulation into your company’s product development process.
The benefits of integrating simulation into engineering working against the full integration of analysis into product
processes are well known. By making analysis a routine part development processes and negating many of the potential
of design — especially up front in the cycle — companies benefits of the technology.
can spot and fix problems early, cut down on testing numer- Although such problems are rampant throughout the
ous physical prototypes, optimize product performance and simulation industry, some software has been developed
create innovative designs that often would not be feasible that takes the user community’s needs into consideration.
without the use of simulation to explore alternative concepts. Case in point can be found in this issue’s Spotlight on
Software vendors across the board have been touting this Products and Technology section covering the capabilities
message for years. Yet ironically — and unfortunately for the of simulation solutions from ANSYS Inc. An open architec-
CAE user community — software from many vendors does ture enables the software to work well with other programs
not support such integration. through bi-directional CAD associativity, and direct links to
One of the big problems is that many simulation other analysis solvers (including competitive programs)
programs are not interoperable with other software, and product lifecycle management (PLM) systems. The
especially with a broad range of CAD programs, other CAE software has been purposefully developed to be scalable
technologies and data management tools. Because the across a wide range of users and computers. This enables
architectures of these CAE programs are generally closed companies to deploy simulation solutions in a flexible
and rigid, programs simply don’t talk to one another and manner across the organization. It also enables users to
exchange information well. So users must go through ineffi- drill down as deep as they need to in a broad range of
cient and error-prone processes of converting data, disciplines — including the simulation industry’s most
reworking models, duplicating mesh representations and comprehensive multiphysics portfolio.
copying information from one system to another. In this way, innovative companies can implement
Another difficulty is that the programs often are aimed advanced simulation technology in a completely integrated
solely at particular user skill levels and specific types of manner using a single platform and common infrastructure,
analyses, or they may run only on certain computers. while competitors struggle with piecemeal analysis
Moreover, users may find that some software is not all it’s and fragmented workflow isolated from the rest of the
cracked up to be in handling the wide range of complex organization’s programs and processes. ■
problems and real-world applications that engineers routinely
encounter in their work. As a result, engineering simulation at
many companies may be performed sporadically in isolation
from other tools and groups throughout the organization — John Krouse, Senior Editor and Industry Analyst
Executive Editor Art Director Ad Sales Manager Designer About the Cover
Chris Hardee Susan Wheeler Shane Moeykens Miller Creative Group Speedo takes advantage
of simulation in designing
Managing Editor Editors Graphics Contributor Circulation Managers a new swimsuit.
Chris Reeves Erik Ferguson Maciej Ginalski Elaine Travers
Fran Hensler Sharon Everts
Senior Editor and Marty Mundy Editorial Advisor
Industry Analyst Kelly Wall Production Assistant
John Krouse Joan Johnson
Table of Contents
FEATURES
4 SPORTS
Simulating Swimwear for
Increased Speed
Speedo’s new full-body swimsuit takes advantage of simulation
technology in pursuit of gold medals and world records.
7 NEWS
4 ANSYS Signs Agreement to
Acquire Ansoft
The complementary business combination of ANSYS and
Ansoft will create the leading provider of best-in-class
simulation capabilities.
31 ELECTROMAGNETICS 42 ACADEMIC
Predicting Charged Particle Trajectories Simulation-Driven Teaching
Simulation helps researchers obtain electromagnetic field and Research
solutions for predicting charged particle trajectories in a wide Academic products from ANSYS at release 11.0 are
range of industrial, medical and research applications. helping train future engineers.
38 52
Simulating Swimwear
for Increased Speed
Speedo’s new full-body swimsuit takes advantage of simulation
technology in pursuit of gold medals and world records.
By Leigh Bramall, PR Specialist, ANSYS, Inc.
Most of us are familiar by now with the use of simulation in The LZR RACER suit is the result of three years of work
sports such as Formula One racing, NASCAR® and, more conducted by Aqualab, Speedo’s own in-house R&D group.
recently, America’s Cup yacht racing. The potential applica- Headed by Jason Rance, the Aqualab® group oversaw a
tions are obvious with aerodynamics on a racing car or research program that employed multiple partners — the Uni-
hydrodynamics on a yacht. But the use of simulation technol- versity of Otago in New Zealand, the University of Nottingham
ogy is spreading far beyond these more obvious applications. in the United Kingdom, the Australian Institute of Sport,
Swimwear designer and manufacturer Speedo® is a Optimal Solutions in the United States, NASA in the United
name synonymous with the pool and swimming competition. States and ANSYS. The outcome is a swimsuit that has
The company has an 80-year history of developing swimsuits 10 percent less passive drag than the FASTSKIN FSII suit and
for elite swimmers, all the while successfully maintaining its 38 percent less passive drag than an ordinary LYCRA® suit.
leading position in the industry. In the 1920s, Speedo made To begin the research, the team attempted to identify the
history with the Racerback — the world’s first non-wool suit. fabric with the least possible drag. They started by taking
More recently, the company introduced the full-body swim- body scans of more than 400 elite swimmers to provide
suit to the competitive swimming arena with its FASTSKIN® geometries for testing more than 100 different fabrics and
suit, which was designed to reduce drag and optimize suit designs. Work focused on developing two different
performance and was worn by the majority of competitors at fabrics: LZR Pulse®, an ultra-lightweight, powerful, lowdrag,
the 2000 Sydney Olympics. water repellent, fast-drying fabric to be used as the base
Computational fluid dynamics (CFD) first entered the woven material for the suit; and LZR panels made of a
sport of competitive swimming in a significant way with the low-drag, ultra-powerful polyurethane membrane to be
development of Speedo’s FASTSKIN FSII swimsuit, devel- bonded onto the base woven material to reduce drag at
oped for use at the 2004 Athens Olympics. February 2008 specific high-drag locations.
saw the further development of Speedo’s CFD program with To test the fabrics and create a suit with the lowest drag,
the global launch of its LZR RACER® suit ahead of the the Speedo researchers used one of the world’s most
Beijing games. Using FLUENT technology from ANSYS, Inc., advanced water flumes at the University of Otago. NASA
Speedo used CFD analysis to guide, test and refine the final also was employed, with the space agency evaluating the
design of the suit, bringing together a range of research with surface friction of fabric candidates in its low-speed wind
the goal of improving performance. tunnel. The wind tunnel was operated at 28 meters per
Pressure contours around an elite male swimmer wearing a LZR RACER suit in the glide position
Flow pathlines colored by local flow velocity around an elite male swimmer wearing a LZR RACER suit in the glide position
In the first ten weeks following its launch in February, swimmers wearing
the Speedo LZR RACER swimsuit set 35 world records.
Surface shear stress contours on an elite male athlete in the glide position
ANSYS, Inc. and Ansoft Corpora- development and delivery of new and
tion, a global provider of electronic innovative products to the marketplace;
design automation (EDA) software, it also is expected to give ANSYS one
announced on March 31 that a definitive of the most complete, independent
agreement was signed in which ANSYS engineering simulation software off-
will acquire Ansoft for a purchase price erings in the industry. This reaffirms and
of approximately $832 million. Ansoft is strengthens the ANSYS commitment to
a leading developer of high-performance open interface and flexible simulation
EDA software, which is based on more solutions that are driven primarily by
than 25 years of research and develop- customer demand, flexibility and choice.
ment by world-renowned experts in With more than 40 direct sales offices
electromagnetics, circuit and system and 21 development centers on three and allow designers to evaluate their
simulation. Engineers use Ansoft continents, the combined company will entire product.”
products to simulate high-performance employ approximately 1,700 people. “This merger brings together two
electronics designs found in mobile “We are very excited about the great companies with a shared vision
communication and Internet devices, state-of-the-art technologies that Ansoft and strong engineering focus,” said Dr.
broadband networking components and adds to the simulation capabilities of Zoltan J. Cendes, the founder, chairman
systems, integrated circuits, printed ANSYS,” said James E. Cashman III, of the board and chief technology officer
circuit boards and electromechanical president and chief executive officer of of Ansoft Corporation. “The combina-
systems. Products from Ansoft are used ANSYS, Inc. “Both companies have a tion of our R&D teams, complementary
by blue chip companies as well as small strong commitment to their customers technological strengths and commit-
and medium-sized enterprises around and employees, share a passion for ment to quality will enhance our ability
the world. the development of innovative products to deliver comprehensive, innovative,
The acquisition of Ansoft is the first and services, and have a history of world-class simulation software tech-
foray for ANSYS into the broader EDA world-class execution. It expands our nologies that customers demand.”
software industry and will enhance the offerings into electronic designs, a “We are excited about bringing two
breadth, functionality, usability and critical area. Now we can bring the rich- great Pittsburgh-based companies
interoperability of the combined ANSYS est engineering calculations to predict together to create an exciting oppor-
portfolio of engineering simulation solu- how a product will perform in the real tunity for aspiring engineers, computer
tions. The combination is expected to world. Electronics and the electro- scientists and professionals to join us
increase operational efficiency and magnetic field are obviously a big part of in our mission to democratize the
lower design and engineering costs that. With Ansoft, we can take a com- use of simulation across the globe,”
for customers, as well as accelerate plete system and the entire environment added Cashman. ■
Engineering Simulation
for the 21st Century
Five key principles guide the development of
simulation products and technology at ANSYS.
By Chris Reid, Vice President, Marketing, ANSYS, Inc.
Technology is the lifeblood of ANSYS, Inc., and the basis facet of life — from the cars we drive to the energy we use, the
for everything we offer our customers. For more than 35 products we buy, the air we breathe and even the devices we
years, ANSYS has been a pioneer in the application of finite insert into our bodies to maintain our health.
element methods to solve the engineering design challenges How have we accomplished this near 40-year run of
our customers face. During that time, the evolution of our groundbreaking achievement in engineering simulation and
industry, products and technology has been nothing short of modeling? Staying true to our vision and strategy has
amazing. Fueled by a corresponding increase in the power- certainly been a major factor. Unlike others, ANSYS has never
to-price ratio of the computing world, the problem size wavered from its core business of engineering simulation
and complexity of simulations have grown to impressive software. Instrumental to that vision is our commitment to
dimensions. The net effect of this is evident in almost every advanced technology — the cornerstone of our business and
value to our customers. After all, it is our products and infrastructure, saving implementation time while
technology that enable companies to create the most providing measurable benefits in speed and robustness
innovative and globally competitive products for as well.
their industry. The old adage “one size fits all” is certainly not
Also instrumental to our vision are five principles the case in the world of engineering simulation.
that guide the development of our products and tech- Despite the common threads that appear everywhere
nologies. The first is unequalled depth. Simply stated, simulation is used, there are also real differences.
for each of the key areas of simulation and modeling Some industries, such as automotive and aerospace,
technologies — whether it be mechanical, fluid flow, are mature in their use of these tools, while others,
thermal, electromagnetics, meshing or others — we such as healthcare, are relative newcomers. Compa-
offer a depth of capability that is second to none. This nies within the same industry can be at markedly
depth has been created over time by reinvesting in different stages of adoption, and users within any one
the research and development of new technologies, company may have vastly different needs or experi-
and supplemented by key acquisitions and partner- ence with simulation tools. There is a need for
ships along the way. Today, the results speak for flexibility. Customers must be able to adopt the
themselves in the richness of what we offer our cus- appropriate level of simulation and know they will
tomers, regardless of their specific simulation have latitude in how they move forward.
requirements. At ANSYS, we call this engineered scalability —
The second guiding principle is unparalleled guiding principle number four. Why “engineered”?
breadth. In this regard, ANSYS has assembled a Our scalability is by design and is specifically engi-
complete range of simulation capabilities — from pre- neered into the technology we have developed. The
processing to multiple physics to knowledge depth of our technology allows customers to choose
management. Our customers see this as a tremen- the appropriate level of technology for their needs yet
dous benefit, because they know we can provide a scale upward as their requirements evolve and grow.
solution for each specific area of analysis and that we If the customer is a small company with just a desktop
provide rich depth across our entire portfolio of prod- or modest compute resources, or if it is large with
ucts and technologies. Some companies, perhaps, hundreds of machines in large-scale compute clus-
can lay claim to this in one or two areas, but we offer ters, our software runs efficiently and brings value. In
this depth and breadth for the full range of simulation a similar vein, if the number of users is very small or in
and modeling techniques. the hundreds, scalable deployment has been factored
In offering both technological depth and breadth, in. Likewise, if the customer is an infrequent user, a
our customers are able to run simulations that designer who wants to perform a simple simulation or
are more sophisticated, more complex and more an expert analyst, we have the appropriate level of
representative of the real world. Utilizing such a tool for each of those levels of experience. Underpin-
comprehensive multiphysics approach — our third ning this seamless range of capability — from the
guiding principle — enables engineers to simulate and automated to the most sophisticated and customiz-
analyze complete systems or subsystems using true able — is the same advanced technology, scaled up
virtual prototyping. Increasingly, companies realize that or down accordingly.
a multiphysics approach is essential to attain the most Technology isn’t of much use to the customer if it’s
accurate and realistic simulation of a new product or extremely inflexible to apply, scalable or otherwise. All
process design. At ANSYS, we not only provide of it must be usable in a way that makes sense for the
the technologies to do this, but we make them all company and its design and development processes,
interoperable within the unified ANSYS Workbench as well as alongside other programs it may have
environment. Thus, the user can configure a selected for their engineering systems strategy. The
multiphysics analysis and avoid the need for cumber- vision needs to be flexible and adaptive, not rigid and
some file transfers or intermediate third-party constraining. In this regard, ANSYS adheres to a fun-
software links. Our technology inherently provides the damental tenet of adaptive architecture — the fifth
guiding principle. We recognize the mission-critical situation. We can be the backbone, coexist peer-to-
nature of what we provide and also how crucial it is peer or be a plug-in, whatever the need may be.
that our technology fits within the customer’s overall Five simple phrases — unequalled depth, unparal-
system. There can be CAD systems, selected third- leled breadth, comprehensive multiphysics, engineered
party codes for niche applications, or legacy and scalability and adaptive architecture. These five tenets
in-house software, all of which remain critical compo- are what drive our product development strategy with
nents of the overall process. We need to coexist with every dollar we invest. We also think they are the reason
these and, in fact, enable them to be included in the that 96 of the top 100 industrial companies on the
overall workflow as painlessly as possible. FORTUNE Global 500 list, as well as another 13,000
Many companies are investing in product lifecycle customers around the world, use technology from
management (PLM) systems. These constitute a major ANSYS. The ANSYS simulation community today is
investment and require data exchange with the the world’s largest, and by continuing to pursue our
simulation software. The ANSYS Workbench platform strategy of Simulation Driven Product Development and
and the new ANSYS Engineering Knowledge Manager adhering to these five guiding principles, we see no
(EKM) technology are designed to provide functional reason why our vision of placing simulation tools in the
coexistence with PLM systems, which actually hands of every engineer shouldn’t become a reality in
improves their value to the customer. Adaptive the near future. ■
architecture means what it says — ANSYS products Images courtesy Tusas Engine Industries, Silesian University of Technology, Cummins,
Inc., FluidDA nv, Modine Manufacturing Company and © 2008 Owens Corning
and technology can adapt to the customer’s specific Science & Technology, LLC and the Gas Technology Institute. Used with permission.
Putting Engineering
Knowledge to Work
New technology enables efficient sharing of rich simulation
information and provides enterprise-wide benefits.
By Michael Engelman, Vice President, Business Development, ANSYS, Inc.
The last three decades have witnessed the evolution of Simulation data Other
computer-aided engineering (CAE) from a tool used by management
Pressure data for airflow over an aircraft wing is extracted using ANSYS EKM data Comparison reports provide users, even those without a technical and simulation
mining capabilities. background, with the ability to examine simulation results.
expertise is critical to enabling innovation. It empowers users other types of product data. An SPDM system is comple-
to build on previous experience and fosters continual mentary to a PLM system and can add significant value when
improvement and collaboration of the expert analysts and designed to work in close conjunction with PLM.
design engineers. Effective process management tools that The ANSYS Engineering Knowledge Manager (EKM)
capture simulation best practices, deploy managed simula- technology, now in its initial release, is aimed at meeting these
tion tasks and processes, and plug into internal applications challenges with extensive capabilities: archiving and manage-
within a unified environment are essential to achieve these ment of simulation data, traceability and audit trail, advanced
goals — though they must also require minimal effort and search and retrieval, report generation and simulation com-
maintenance costs. parison, process/workflow automation, and capture and
Managing simulation data and processes within this deployment of best practices. It is a Web-based SPDM
context is a specialized subset of the broader product framework aimed at hosting all simulation data, workflows
lifecycle management (PLM) vision. This discipline is based on and tools, whether in-house or commercial, while maintaining
the digital management of all aspects of a product’s lifecycle, a tight connection between them. While providing seamless
from concept and design through manufacture, deployment, integration with simulation products from ANSYS — including
maintenance and eventual disposal. Unfortunately, those the ability to automatically extract and organize extensive
needs that are specific to simulation and SPDM are often information about ANSYS software–based simulation files
overlooked or poorly addressed by today’s PLM systems. This when they are uploaded into the repository — the ANSYS
is a result of SPDM being more demanding than the file/ EKM tool is an open system that can manage any type of
document-centric approach of PLM and related product data in-house or third-party simulation products, files or infor-
management (PDM) systems. Simulation data is richer, more mation as well. Moreover, it is a scalable solution that can be
complex and typically many orders of magnitude larger than effectively used by small workgroups, distributed teams of
engineers or the entire enterprise.
With tools and developers that have histories stretching
back to the formative years of simulation, ANSYS under-
stands the complexity and challenges of simulation. ANSYS
EKM technology was created with an appreciation that
access to simulation; developing effective processes for
incorporating simulation into individual, workgroup and
enterprise-wide efforts; and managing simulation efforts
within a larger development or industrial process is a compli-
cated effort — one that can be made simpler. Having access
to the right tools, developed by a team that has devoted years
to understanding the challenges of simulation, can streamline
the incorporation of virtual product development efforts into
traditional workflows and environments. Adding ANSYS EKM
tools to the capabilities of the family of products from ANSYS
Process workflows can be mapped out and displayed in diagram style, as shown here.
Among other possibilities, each step may be customized by the user to include empowers organizations of all sizes to better achieve the
automated substeps, assign team members tasks and iterate to the next step. goal of Simulation Driven Product Development. ■
ANSYS Mechanical parametric model of a gasket is automatically changed for each of the 10,000 DOE analyses performed.
-2.75E+0
Gasket Force
which variabilities of key parameters
-3.15E+0
impact product performance.
The process is accomplished in
-3.28E+0
four major phases: process automation,
design exploration, design optimization
and robust design. Utilizing the ANSYS -3.24E+0
4.0
Workbench environment, process auto-
0E
E-2
2.4
-3
mation ensures that simulation tasks
E-2
2.20
0E
8.0
-3
are well defined and flow automatically
E-2
2.28
0E
-8
-4
E-2
2.36
file
.00
to extract and evaluate key perform-
Pro
-2
E
E-2
2.44
-
.40
Groo et
4
ance variables. ve D sk
0E
2.52 Ga
epth
-3
ANSYS DesignXplorer software
then performs the DOE, running numer-
ous (usually thousands) analyses using ANSYS DesignXplorer software generated a response surface showing sensitivity of each input variable to contact force.
various combinations of these param-
eters. The ability to quickly and for analysis and to set up parametric
effortlessly execute such an extensive models in mechanical solutions from 1000
study on this wide range of parameters ANSYS — is essential for ANSYS
Probability Density
target performance requirements. the ANSYS DesignXplorer tool in DFSS Upper Gasket Groove Depth (in)
ful sampling functions and probabilistic between the cell and approximately 400
design technology. It also provides valu- 200 bipolar cooling plates. In designing
200
able output in the form of probability the fuel cells for commercial use in
design functions, scatter plots and harsh environments, the goal was to 0
0 1 2
response surfaces that are critical in lower the failure rate of the gaskets,
Plate Interface Gap (10-3 in)
DFSS. Seamless interfaces with para- which tended to leak on occasion —
Probability density functions of parameters that
metric computer-aided design (CAD) even in a carefully controlled research vary with each analysis iteration
programs — used to import geometry lab setting.
Probability Density
depth and the opposing plate’s 200
0.01
recessed pocket groove depth — that 150
determined the overall compressive 100
0.008
force of the gasket under a given bolt 50 0.026
2
Gas
load. These were considered to be 0 ket 0.024 0 x10-3
t
-2 -1 0 1 2
Gro
ove 0.022 -2 Offse
ile
randomly varying parameters with Gasket Profile Offset x10-3
Dep
th et Prof
k
Gas
given mean and standard deviations
0.026 0.026
as determined through probability
density functions generated by the
Gasket Groove Depth
The ANSYS CFX solver uses finite elements (cell vertex The ANSYS CFX-Flo tool is a version of ANSYS CFX
numerics) to discretize the domain, similar to those used in software that limits the physics accessible by the user to the
the mechanical analysis side of the business. In contrast, models most commonly used by design engineers. It is com-
the FLUENT product uses finite volumes (cell-centered patible with other applicable ANSYS Workbench add-ins.
numerics). Ultimately, though, both approaches form The reduced complexity and cost of ANSYS CFX-Flo make it
“control volume” equations that ensure exact conservation a good choice for design departments in organizations that
of flow quantities, a vital property for accurate CFD simula- already use ANSYS CFX software or other products com-
tions. ANSYS CFX software focuses on one approach to patible with the ANSYS Workbench environment.
solve the governing equations of motion (coupled algebraic The FLUENT for CATIA V5 product offers many of the
multigrid), while the FLUENT solver offers several solution same benefits of FloWizard and ANSYS CFX-Flo software.
approaches (density-, segregated- and coupled pressure- Completely embedded into the CATIA V5 system, it is fully
based methods). Both solvers contain a wealth of physical compatible with the standard, full FLUENT solver. It is most
modeling capabilities to ensure that any fluids simulation useful for companies that use CATIA V5 in their design
has all of the modeling fidelity required. departments and FLUENT software in their analysis groups.
These two core CFD solvers represent more than 1,000 Industry-Specific Fluids Simulation Tools
person-years of research and development. This effort Flexibility and generality are important, but sometimes
translates into the key benefits of fluid flow analysis soft- not required for specific applications. In addition to providing
ware from ANSYS: experience, trust, depth and breadth. general-purpose CFD and rapid flow modeling products,
The fluids core solvers from ANSYS are trusted, used and ANSYS makes fluids simulation even more accessible and
relied upon by companies worldwide. focused with its industry-specific analysis tools. These prod-
ucts are often called vertical applications because of the way
Rapid Flow Modeling they integrate all the steps for the analysis of a specific type
ANSYS addresses the fluid flow analysis needs of of system into one package. The technologies offer industry-
designers, who work on the front lines of their company’s specific functions as well as employ the language of the
product development process and often need to make industry in which they are used.
important design decisions quickly with no time to set up and Turbomachinery is one of the world’s single most
solve complex mathematical models. For these time-limited successful CFD vertical applications, due to the similarity of
engineers, ANSYS offers a choice of rapid flow modeling the geometry and physics across a broad range of rotating
(RFM) products. RFM technology from ANSYS compresses
the overall time it takes to do a fluid flow analysis by
providing a high level of automation and focusing on only the
most robust physical models. Three RFM tools are available:
FloWizard, ANSYS CFX-Flo and FLUENT for CATIA®
V5 software.
FloWizard software integrates all steps in the fluids
process into one smooth interface. Computer-aided design
(CAD) files can be sent to the FloWizard product, flow
volumes extracted, models set up, calculations completed
and HTML reports generated. FloWizard software is fully
compatible with the FLUENT product, making it a good
choice for designers in companies that use FLUENT tech-
nology in the analysis department. Airflow in a datacenter as simulated using ANSYS Airpak software
Multibody Dynamics:
Rigid, Flexible and
Everything in Between
Advances in simulation solutions for machine features
accommodate more complex designs.
By Steve Pilz, Product Manager, ANSYS, Inc.
As simulation
capabilities grow,
an engineer’s
Simpler is better — that’s what ability to simulate
we’ve all been told. The more compli- more complex
machines
cated something is, the more ways increases.
there are for it to break. This seems
logical and is something we should
consider as we invent new machines.
The challenge is that simple machines
do simple things and often can only
do one thing well. A simple bottle
opener, for instance, probably isn’t
the best tool for anything other than
opening bottles, but it does what
it was designed to do. Complicated
machines — both mechanical and bio-
logical — have more parts, and often were adequate for Images:
motorcycle © iStockphoto.com/Paul Griffin bicycle
can be used to do more than one thing. many years, but © iStockphoto.com/Artsem Martysiok
As an example, the adult human body eventually general
typically has 206 bones and can be surface contact was Joints were first released
used for all kinds of things from opening released to address with the COMBIN7 element,
bottles to competing in triathlons. the limitations. With this which was used to model only
Inventing machines that can do a variety new functionality, parts undergoing pinned, or revolute, joints. At
of things requires that the machines large rotations, deformations, sticking, ANSYS 10.0, major advances to joint
have multiple parts that work together, sliding and a host of other real-world technology were made via the
preferably without failing. Simulation behaviors could be modeled. MPC184 element, which could be
tools in the product portfolio from General surface contact became used to model multiple joint types,
ANSYS help make designing useful popular and widely used. It also such as those that are translational,
machines easier and faster, as well as became more robust and efficient with cylindrical, spherical, slot, universal,
more fun. each successive ANSYS release for general or fixed. Joint elements
mechanical applications and is now are particularly interesting to those
Joints considered mature, proven technology. involved with the design of multiple-
When machines were simpler, One problem with the widespread use part machines because they can be
there were fewer options, and multiple of general surface contact, however, used to enable large rotations and
parts could be connected in mech- is that sometimes it is more than is translations between parts at a very
anical software from ANSYS only required. The relatively new capability low computational expense. To illus-
using shared nodes, beam elements, to connect parts via joints has some trate the potential computational
coupling, constraint equations and potentially huge advantages that can savings of using joints, a metal hinge
node-to-node contact. These methods be applied to many situations. is used as an example. (Figure 1.)
Ear
Pin
Base
Figure 1. Hinge model Figure 2. For this hinge model, general surface contact joints are used in three locations.
First, where the ear meets the base, frictionless surfaces prevent translation along the
axis of the pin and still allow rotation of the ear and base against each other at the joint.
Second, bonded surfaces between the pin and the base prevent the pin from spinning or
translating relative to the base. Then lastly, frictionless surfaces between the ear and the
pin allow the ear to rotate freely about the pin.
There are many ways to set up a model for a metal hinge, but the Doing that, the model can be solved in a fraction of the time it took to
two used in this investigation are a traditional general surface contact solve without the use of joints. Second, as can be seen from the element
approach and a revolute joint approach (Figure 1). To simplify, the parts listing in Figure 4, even in a model in which contact surfaces are not
are set to be rigid so that problem size changes can be compared specified, there are still contact elements — which come from use of
more easily. For each approach, a single CPU laptop is used to run the joint or MPC184 element — but far fewer of them.
the simulations.
In the general surface contact approach, to enable rotational free-
doms but constrain all translationals except one, three contact surfaces TYPE NUMBER NAME TYPE NUMBER NAME
are required (Figure 2) and one remote displacement, which rotates 1 1 MASS21 1 1 MASS21
the hinge 90 degrees counter-clockwise. Using a few user-defined 2 1 MASS21 2 1 MASS21
3 1 MASS21 3 1 MASS21
mesh specifications for surface contact size (body and edge sizing), the 4 1 CONTA176
4 1 CONTA176
problem consisted of 7,188 elements (Figure 3) and took 2,249 5 1 TARGE170
5 1 TARGE170
seconds to solve. 6 180 CONTA174
8 1 TARGE170 6 2 CONTA176
By changing from a general surface contact approach to a revolute 9 178 CONTA174 7 1 TARGE170
joint–based approach, there are three rigid parts and two joints 10 180 CONTA174 8 1 CONTA176
connecting those parts to each other at the hinge: one revolute joint 11 178 TARGE170
9 1 TARGE170
12 576 CONTA174
between the ear and the pin, and one fixed joint between the base and the 13 1 CONTA176
10 2 CONTA176
pin. The pin could be suppressed since it won’t perform any function once 14 1 TARGE170 11 1 TARGE170
it is replaced with a revolute joint, but it is included in the model to make 15 832 CONTA174 12 1 MPC184
16 1408 CONTA174 Figure 4. Element description for hinge
the run-time comparison equivalent with the general surface contact
17 1408 TARGE170 joint modeled with a revolute joint
approach. The total problem size, as expected, is far smaller, uses only 14 18 288 CONTA174
elements (Figure 4) and requires a solution time of only 1.625 seconds. 19 832 CONTA174
20 288 CONTA174
So what have we learned? First, if detailed contact information
21 832 TARGE170
at the hinge pin is unimportant, it is a lot more efficient to replace Figure 3. Element description for hinge
thousands of contact elements with a single revolute joint element. joint modeled with general surface contact
Figure 6. Folding arms of John Deere agricultural sprayer model to be subjected to time–history loading
Image courtesy Brenden L. Stephens, John Deere
CH43 - Vert1 Displ FBK (Displacement) CH44 - Vert2 Displ FBK (Displacement) CH45 - Vert3 Displ FBK (Displacement)
CH46 - Long1 Displ FBK (Displacement) CH47 - Lat1 Displ FBK (Displacement) CH48 - Lat2 Displ FBK (Displacement)
115.
73.15
50.
25.
0.
-25.
-50.
-78.17
0. 11.5 23. 34.5 46. 57.5 69. 80.5 92. 103.5 115.
Figure 7. Time–history loading at six different geometric locations along the sprayer model in Figure 6
Image courtesy of Brenden L. Stephens, John Deere
is extremely well suited to solving time that it previously would have and flexible, as they would be if made
multi-jointed assemblies, such as the taken to simulate a single concept. from rubber.
folding arm agricultural assembly A more in-depth explanation of the
(Figure 6). This scheme is adept at ANSYS Flexible Dynamics use of ANSYS Structural, ANSYS
handling complex time–history input Is the ANSYS Rigid Dynamics Mechanical or ANSYS Multiphysics
(Figure 7) and is extremely fast com- tool all that is needed to fully under- products running flexible nonlinear
pared to more traditional solvers. Solve stand a prototype of a machine? dynamics simulations is necessary to
time, even for complex assemblies, is What happens if the parts deform? demonstrate the steps required to take
typically measured in seconds and Will they break? Will they fatigue and an all-rigid dynamics model and turn it
minutes rather than in hours and days. fail after a short time or only after into a partially or completely flexible
One caveat worth mentioning is that, extreme use? If parts bend, twist and model. This translation from a rigid to a
at release 11.0, parts need to be flex, will the machine still perform its flexible model includes material assign-
connected with joints rather than intended function? ment, meshing and solver setup.
contact when using the ANSYS Rigid The ANSYS Rigid Dynamics Without writing a spoiler to any future
Dynamics capability. If contact is capability, for all its strengths, articles on this subject, this is remark-
required to accurately represent the doesn’t provide a complete picture ably easy to do.
part interactions, flexible dynamics of a machine’s performance. In a The simple machines have already
simulation is required. thorough machine prototype inves- been invented. We don’t really need a
The ANSYS Rigid Dynamics tool tigation, the next step is a flexible more efficient bottle opener. With the
should be used first on any complex, dynamics analysis, which allows addition of more realistic and faster
multi–part assembly with connections. some or all of the machine’s parts to modeling solutions — achieved by com-
Fast solution times can help users behave as they would in the real bining the ANSYS Rigid Dynamics
quickly find joint definition problems, world — flexing, twisting and deform- module and ANSYS Structural, ANSYS
inadequate boundary conditions, over- ing. Flexible dynamics allows users to Mechanical or ANSYS Multiphysics
constraints and other problems. With examine parts to identify whether software — complicated machines can
the time saved, multiple design ideas they are stiff and light, as they would be less prone to failure and produce
can be analyzed in the same amount of be if made from titanium, or heavy fewer career-limiting disasters. ■
Nonlinear Simulation
Provides More
Realistic Results
When parts interact and experience large deflections and extreme
conditions, nonlinear technology is required to simulate real-life situations.
By Siddharth Shah, Product Manager, ANSYS, Inc.
In today’s competitive environment in which everyone but for those with moving parts or
strives to develop the best design with the best perform- that involve friction, it is unwise to
ance, durability and reliability, it is unrealistic to rely on linear make this assumption.
analysis alone. Analyses must be scaled from single parts
and simplified assembly-level models to complete system- Geometry
level models that involve multiple complex subassemblies. In certain situations, the
As more parts get added to a simulation model, it becomes deflections of a structure may be
more difficult to ignore the nonlinear aspects of the physics, large compared to its physical
and, at the same time, expect realistic answers. dimensions. This usually results
In some situations involving single- or multiple-part in a variation in the location and
models, analysis with linear assumptions can be sufficient. distribution of loads for that struc-
However, for every assumption made, there is some ture. For example, consider a
sacrifice in the accuracy of the simulation. Ignoring nonlinear- fishing pole being bent or a large
ities in a model might lead to overly conservative or weak tower experiencing wind loads.
design in certain situations, or might result in the omission of The loading conditions over the
Top-loading simulation
unexpected but valuable information about the design or per- entire body of the structure will
of a plastic bottle
formance of the model. It is essential to understand when and change as the structure deflects.
when not to account for nonlinearities. The Also, in certain slender types
following are some situations in which non- of structures, membrane stresses may cause
linearities are commonly encountered. the structure to stiffen and, hence, reduce
displacements. One example of this is fuel
Contact tanks used for satellite launchers and
Currently, auto-contact detection spacecraft. If accurate displacements
in ANSYS Workbench Simulation are to be computed, geometry non-
allows users to quickly set up con- linearities have to be considered.
tact (part interactions) between
multiple entity types (solids, sheets, Material
beams). However, in cases in which Material factors become increas-
two parts interact with each other, the ingly important when a structure is
parts might stick or slide against required to function consistently and
each other instead of remaining reliably in extreme environments —
static. Also, their stiffness might such as structures that must operate
change depending upon whether at high temperatures and pressures,
they touch each other or not, as provide earthquake resistance, or
is seen with interference or snap- be impact-worthy or crash-worthy.
fit cases. Ignoring sliding may be Frictional contact between the rotor and the brake
Plastics, elastomers and composites
acceptable for a large class of problems, pad in a brake assembly are being used as structural materials
with increasing frequency. These materials resources and manpower. For many, the
do not follow the linear elastic assumption of software appeared cumbersome, chal-
stress–strain relationships. Structures made lenging and intimidating. It was acceptable
with these materials may undergo appre- and often preferable to get by with physical
ciable changes in geometric shape before testing alone. That is not the case today,
failure. Without accounting for this material however. Nonlinear structural simulation is
behavior, it can be impossible to extract no longer an intimidating tool, but rather
meaningful and accurate information from one that ANSYS has made available to all
their simulations. engineers by fusing its complex physics
In the past, nonlinear analysis was asso- into an easy-to-use interface in the ANSYS
ciated with heavy investment in training, Workbench environment. ■
Medical check valve
Turbomachinery Coupling
Bibby Transmissions Group — a long-time ANSYS DesignSpace user — has
been a world leader for many years in the design and manufacture of couplings
“Through the ANSYS Workbench
for use in industrial markets. The company’s high-speed disc couplings, designed
by its TurboFlex division, have been a popular choice for transmission couplings platform, we have a tool that
among the power, chemical, steel and water treatment industries.
Engineers at Bibby found that with linear analysis assumptions, material allows us to increase the per-
yielding occurred around clearance holes where the flexible coupling was
mounted and also when the coupling was rotating near its operating speed. formance of our products. Drastic
Knowing that they were not capturing material behaviors related to contact and
preloading conditions, engineers at Bibby felt a need to model the material plas-
ticity and calculate plastic strains and deflection. This analysis was undertaken to
reductions in weights and inertia
ensure that the loading-induced plasticity was localized and did not induce
global failure for the coupling. The simulation required nonlinear modeling of con- of the couplings have been
tact in which the couplings used an interference fit, material behavior for the hub
and spacer, and bolt preloading for the couplings. achieved without compromising
Bibby engineers successfully set up this model within the ANSYS Workbench
Simulation tool using the previously mentioned nonlinearities and were able
to accurately predict the observed behavior. In addition, they were able to
the strength of the unit. Lateral
identify operating speed — not torque as had been previously believed — as the
dominant factor that influenced the observed plastic deformation. This valuable vibration of couplings is now
information could not have been obtained by physical testing alone.
being estimated to a level of
Thanks to Wilde FEA Ltd. for assistance with this article.
The assembly model includes pretension bolted The von Mises stress exceeds the yield
joints and BISO material for the hub and spacer. limit of 700 MPA, and yet it is localized.
High Performance
from Multiphysics
Coupled Simulation
Engineers use ANSYS Multiphysics to study the
mechanical strength and thermal performance of
an innovative thermoelectric cooler design.
By Robin McCarty, Senior Engineer for Product and Process R&D,
Marlow Industries, Texas, U.S.A.
Conductor P N Conductor
Heat-producing device
Cold ceramic
Solder
hot side of the device was fixed on the bottom surface. equivalent traditional multistage device and a planar multistage
Maximum principal stress was used to evaluate and com- device. Each device consisted of three stages equivalent with
pare the TEC designs because it can be directly related to thermoelectric element dimensions and thermoelectric element
the failure of a brittle material, such as bismuth telluride. count per stage. In the model, three different currents were eval-
The testing team identified the thermoelectric element uated, and the maximum principal stress located in the most
with the maximum stress and then refined the finite element highly stressed thermoelectric element was noted.
mesh in that area to ensure that stress convergence had Through these analyses, Marlow configured planar
been obtained for the structural simulation. Using a plot designs with maximum principal stress levels comparable to
of maximum principal stress distribution in a typical TE the traditional multistage devices. Thermal performance
element, the engineering team found that the maximum also was nearly equivalent. The correlation between the
stress occurs on the corner of the TE element, which stress results for the traditional multistage and planar multi-
correlated to where Marlow historically had seen cracking stage devices provided confidence in the new planar
in thermoelectric elements that resulted in device failure. multistage design concepts. This type of evaluation would
To validate the new planar multistage designs, Marlow not have been possible without the multiphysics simulation
evaluated the mechanical stress levels for a thermoelectrically capabilities available in software from ANSYS. ■
Sailing yacht developed by Perini Navi A cross section of the mast Shell model used in analysis of local buckling phenomena
In the extremely selective large sail- In this context, Perini Navi devel- reduction in keel weight, thus increas-
boat market, Perini Navi sailing yachts oped a pilot project to take advantage ing the overall sailing performance of
have long been acknowledged for their of automatic optimization techniques the boat. Other important factors that
high performance in terms of balance, based on virtual prototyping. The stimulated the project included the
speed, reliability and safety, as well as project was born out of Perini Navi’s potential cost savings associated with
their aesthetic details and passenger collaboration with EnginSoft of Flo- using less aluminum for the mast and
comfort. With 42 yachts launched rence, Italy, and was concerned with lead alloys for the keel, an easier prod-
around the world since 1983 and many the optimization of the main mast uct construction due to a reduction in
more under construction at its ship- structure for a special series of new the weight and thickness of the mast
yards in Italy and Turkey, Perini Navi heavy cruiser motorsailers ranging in plates, greater sailing comfort resulting
now meets more than half of the global length from 50 to 60 meters (164 to 197 from the reduction in the boat’s tilting,
demand for sailing yachts greater than feet). The goal of this effort was and overall shorter time to market.
50 meters in length — the so-called to identify the solution best able to min- The mast design methodology
megayachts. To meet the growing imize the mast’s weight while consisted of first analyzing the global
requirements of its customers, Perini maximizing strength to avoid specific buckling factors on the transverse
Navi has found it necessary to combine global and local buckling factors. and longitudinal planes. Starting with
the distinguishing and well-consolidated Accurate modeling using structural models developed by Perini Navi in
features of its yachts with constant simulation offered the possibility of not ANSYS Mechanical software for struc-
improvement in technical solutions over only a weight reduction of the mast tural simulation, EnginSoft analysts
a wide range of conditions. structure but also a large balancing parameterized the models using the
Mast deformation related to the first (left) and third (right) Deformation that results from localized buckling
buckling factors for the global structure in the mast
Predicting Charged
Particle Trajectories
Simulation helps researchers obtain electromagnetic field solutions
for predicting charged particle trajectories in a wide range
of industrial, medical and research applications.
By Andreas Hieke, CEO, GEMIO Technologies, Inc., California, U.S.A.
Finite element model of quadrupole tip region Isosurface plots of electric field
electrodes, isolators and current- Among such constraints are: In one recent study of a complex
carrying conductors. Such variations • Degree of spatial accuracy of trajectory problem, physicists at
usually break certain symmetries in the the final position of a trajectory GEMIO Technologies, a company that
device or particular spatial ratios that are • Long-term stability of a solution utilizes advanced numerical methods
frequently assumed in the mathematical (trajectory) to design ion optical devices for life
expression. In these cases, simulation is science applications, used ANSYS
• Execution speed of the compu-
usually the only option that can provide Emag capabilities for the simulation of
tation (the ability to simulate a
more depth of understanding for the an RF quadrupole, a system of four
very large number of trajectories
situation. For many practical problems, parallel rods that can act as a guide or
using techniques such as Monte
the electromagnetic simulation capabili- filter for charged particles. Very good
Carlo simulation)
ties provide field solutions for extremely mathematical approximations for the
complicated geometries with sufficiently • Degree of smoothness of a electric field inside an infinitely long
high accuracy. trajectory [3] quadrupole can be developed, and
Charged particle trajectory simu- • Relevance of coupled effects stability conditions for trajectories can
lations based on these field solutions (particle-field coupling such as be derived [4]. However, no accurate
need to satisfy different and frequently space charge, induced currents, mathematical relationships are avail-
conflicting requirements. The experi- etc.) and other more advanced able characterizing the electric field
enced computational physicist, therefore, effects, usually relevant only in and particle behavior at the tip of a
must carefully balance these demands high-energy physics applications quadrupole. As a result, researchers
and choose the appropriate numerical are heavily dependent on simulation at
methods and techniques for the that critical location.
simulation. In this study, first the researchers
created a finite element model
representing the 3-D geometry of the
quadrupole tip region. They used
the simulation results to generate
3-D isosurface plots of the electric
field resulting from applying various
potentials to the rods. The simulation
also provided information about the
electric potential and magnitude of the
electric field in a cross section of the
quadrupole. The numerical values
obtained from the simulation solution
are remarkably accurate and require
little numerical effort while using fairly
Electric potential (left) and electric field magnitude (right) for a cross section through the quadrupole coarse discretization. At the axis of the
quadrupole, the predicted potential
has a relative error of less than 10-8, of several hundred volts. Researchers tools must be carefully evaluated and
while that of the predicted electric field executed the computation in an exter- tested to gain trust in the results.
is only 10-6 relative to the maximum nal module written in FORTRAN™ and If executed correctly, charged particle
value inside the quadrupole. based on the field solutions obtained simulations provide a valuable solution
A particular advantage to having a with ANSYS Emag technology. They that substantially reduces physical
numerical simulation model is the then imported the resulting data back testing in the development of these
ability to test the response to certain into software from ANSYS for post- systems. Furthermore, simulation con-
conditions that are, effectively, impos- processing. tinues to represent the only effective
sible to study in most experimental The particle trajectory simulation method to study configurations for
setups. In addition, such ideal condi- indicated that the particle remains on which no analytical mathematical
tions provide a method to test the a nontrivial but stable trajectory in a expressions are available. ■
accuracy of the simulation, because plane orthogonal to the quadrupole
frequently the expected result is axis for a few orbits but, in some rare Dr. Andreas Hieke is an internationally recognized
expert in computational physics and the founder
known. In the case of an RF quadru- instances, is suddenly ejected from the of GEMIO Technologies. The author welcomes
pole, for example, a particle that is plane. From a slightly different angle, reader feedback and may be contacted at
perfectly orthogonally injected into the the simulation indicated tetrahedrons ahi@ieee.org or ah@gemiotech.com.
multipole with certain suitable initial of nodes in which disturbances of the
conditions (location, speed and timing) trajectories occur. Following careful References
will remain on a stable, periodic tra- investigation of this unexpected effect, [1] Hieke, A., “Ion Dynamics in Electro-
jectory forever. A numerical simulator the researchers determined that Pneumatic Fields — a Key to Modern
Biotechnology,” ANSYS Solutions,
must be able to replicate such particle it was caused by an unusual numerical Spring 2005, pp. 13–17,
capture effects and provide stable problem in the external FORTRAN http://www.ansys.com/assets/testimonials/
long-term solutions. This is somewhat module that executed the trajectory ion-dynamics.pdf.
comparable to orbital injection of a integration. After the team corrected [2] Humphries, Jr., S., “Principles of Charged
satellite around a planet — although this numerical issue, the effect no Particle Acceleration,”
http://www.fieldp.com/cpa.html.
gravitational forces are only attractive longer occurred, and subsequently the
and obviously static in nature, whereas team has used this approach to obtain [3] Hieke, A., “3-D Electro-Pneumatic Monte
Carlo Simulations of Ion Trajectories and
charged particle capture in multipoles stable trajectories for at least 105 RF Temperatures During RF Quadrupole
requires RF electric fields, and the cycles. Injection in the Presence of Gas Flow
resulting trajectories are of more com- As this study demonstrates, Fields,” 52nd ASMS Conference on Mass
Spectrometry and Allied Topics, Nashville,
plicated shapes compared with the ANSYS Emag simulation features are
TN, May 23–27, 2004.
elliptical orbits of satellites. capable of providing electric and mag-
[4] Paul, W., “Electromagnetic Traps for
Based on certain values for these netic field solutions with very high Charged and Neutral Particles,” Nobel
conditions, the GEMIO team comput- accuracy, making these solutions suit- Lecture, Physics, 1989,
ed the trajectory of an orthogonally able as a basis for different types of http://nobelprize.org/nobel_prizes/physics/
laureates/1989/paul-lecture.htm.
injected particle. For this analysis, the charged particle trajectory simulations
quadrupole operates at RF frequencies in a wide range of applications. As
on the order of 1 MHz with potentials always, the numerical behavior of such
Particle trajectory as predicted based on ANSYS Emag E field solutions Tetrahedrons indicate nodes in which disturbances of trajectories occur.
Flush
with Success ANSYS CFX simulation results showing the free surface
movement through the valve during discharge
A toilet discharge valve is optimized to reduce
household water consumption and maintain performance.
By Miguel Francisco and António Gameiro Lopes, Mechanical Engineering Department, University of Coimbra, Portugal
Vítor Costa, Mechanical Engineering Department, University of Aveiro, Portugal
Adapting A High-Speed
Train to Winter in Russia
Simulation helps prevent traction problems for
rail travel during extreme weather conditions.
˘
By Philipp Epple, Stefan Becker, Caslav Ilic, Branimir Karic, Irfan Ali and Antonio Delgado, Institute of Fluid Mechanics,
Friedrich-Alexander University, Erlangen-Nuremberg, Germany
Uwe Endres, Burkhard Halfmann and Sven Pook, Siemens AG, Erlangen, Germany
Understanding the
Dangers of Aneurysms
Simulation is used to validate measured
blood flow in cerebral aneurysms.
By Christof Karmonik, Research Scientist, Richard Klucznik, Director of Interventional Neuroradiology,
Hani Haykal, Director of Neuroradiology and Goetz Benndorf, Director of Interventional Neuroradiology Research,
The Methodist Hospital Research Institute, Department of Radiology, Houston, Texas, U.S.A.
Cerebral aneurysms are arterial outpouchings in the peripheral visual deficits, loss of balance and coordination,
brain that result from weak spots in the vessel wall. Rupture or other neurological deficits (depending on the location of
of a cerebral aneurysm can be dangerous for a patient and the aneurysm), often cerebral aneurysms are asymptomatic,
occurs most commonly between 40 and 60 years of age. especially if they are small in size.
When an aneurysm ruptures, blood leaks from the ruptured When an aneurysm is detected, treatment options other
wall into the subarachnoid space, or the brain itself, poten- than conservative management include surgical clipping or
tially causing serious damage. This may lead to major minimally invasive therapy that approaches and occludes, or
permanent neurological deficits or even death. While it is blocks, the aneurysm using endovascular techniques. Both
estimated that approximately 3 percent to 6 percent of the treatment options are associated with an overall morbidity
general population have cerebral aneurysms, there is a rup- and mortality of about 11 percent. Because not all aneurysms
ture in only eight in approximately 100,000 person-years. will rupture and bleed, it would be highly beneficial to under-
The overall prognosis is poor for the patients with aneurysm stand the underlying mechanisms that lead to rupture in
rupture — 50 percent will die one month after rupture and order to minimize risk to the patient. Currently, there is
an additional 20 percent will be unable to live on their own. no medical imaging modality that can provide complete
Aneurysm growth and rupture depends on multiple quantitative information about hemodynamic parameters,
factors: geometrical factors such as aneurysm size and such as wall shear stresses and dynamic pressure.
shape or the ratio of the aneurysm dome height to the neck In order to better understand the dynamic forces of blood
width; biological factors such as decreased concentration flow within an aneurysm and the conditions that may cause
of structural proteins of the extracellular matrix in the rupture, an interdisciplinary team of researchers at The
intracranial arterial wall; and hemodynamic factors, espe- Methodist Hospital Research Institute (TMHRI) in Houston,
cially wall shear stresses. While patients with unruptured Texas, is studying hemodynamics using computational fluid
aneurysms may have symptoms such as headache, dynamics (CFD) simulations with FLUENT software. More
The 3-D model created by the NOVA system of the cerebral vasculature using the MRI TOF images Pathlines of blood flow during time of average inflow
(bottom) shows the anatomical location of the aneurysm. The yellow plane illustrates a scan plane for
recording the inflow waveform in the left anterior cerebral artery. The DSA model was then used to
create a surface model used by the GAMBIT tool.
mfr [kg/s]
-0.001 -0.001
-0.002 -0.002
1
-0.003 -0.003
0 500 1000 0 500 1000
L A2
R A2 time [ms] time [ms]
0.003 0.003
mfr [kg/s]
mfr [kg/s]
0.002 0.002
0.001 0.001
0 0
0 500 1000 0 500 1000
R A1 time [ms] L A1 time [ms]
Measured volumetric blood flow waveforms at the two arteries providing inflow into the CFD mesh showing the location of the two cross-sectional
aneurysm (R A1: segment of the right anterior artery and L A1: segment of the left anterior planes where pcMRI flow patterns have been acquired; cross
cerebral artery), and also at arteries carrying the outflow away from the aneurysm (R A2 and sections display the absolute magnitude of the blood flow
L A2: segments of the same arteries) velocity, with red indicating fastest flow.
specifically, this group has performed unsteady compu- could be identified in both the profiles measured with
tational fluid dynamics simulations of an anterior pcMRI and the cross sections derived from the CFD simu-
communicating artery (AComA) aneurysm and has calcu- lations. These regions reflect the multi-directionality of the
lated pathlines and velocity profiles at different time points blood flow inside the aneurysm, corresponding to the rota-
in the cardiac cycle. The results obtained with the CFD tional flow motion. The absolute values of the measured
analysis were compared with blood velocity measurements velocities were lower than the ones calculated with CFD in
performed using phase-contrast magnetic resonance both cross sections, a fact that most likely is due to an
imaging (pcMRI), a noninvasive imaging technique that inherent measurement uncertainty caused by partial
allows the visualization of velocity patterns of flowing blood volume averaging, in which the MRI signal is averaged
and the quantification of the volumetric blood flow rate. over the slice thickness of the scan plane (5 mm), while the
At first, researchers created a stereolithographic (STL) CFD cross sections are mathematical planes with zero
file of the surface of an AComA aneurysm. This model was thickness.
based on both a 3-D dataset of the cerebral vasculature of In conclusion, the TMHRI group showed that the
the patient acquired with time-of-flight magnetic resonance velocity values calculated inside a cerebral aneurysm by
imaging (MRI TOF) and a 3-D dataset acquired with digital CFD with patient-specific input boundary conditions were
subtraction angiography (DSA). Afterward, this STL file was in good qualitative and quantitative agreement with actual
imported into GAMBIT software and the model was meshed velocity values measured with pcMRI and NOVA. These
using 61,663 tetrahedral volume elements. results are encouraging and point to the huge potential of
Researchers then defined inflow boundary conditions CFD simulations to better understand the hemodynamic
as velocity inlets and outflow boundary conditions as pres- effects in cerebral aneurysms that lead to rupture so
sure outlets. The values of the volumetric flow rate for inflow as to assist in making clinical decisions about the need
into the aneurysm were based on the volumetric flow rate for surgery. ■
waveform measured with pcMRI in combination with the
noninvasive optimal vessel analysis (NOVA) system, a tech-
nology for the quantification of volumetric blood flow rates.
Also, researchers recorded the outflow of the aneurysm and
velocity profiles inside the aneurysm at two perpendicular pcMRI
planes, or cross sections, using the same technique. 40
For the CFD simulation, blood was modeled as an
incompressible Newtonian fluid with a density of 1,050 [cm/s]
kg/m3 and a viscosity of 0.004 kg/ms. To ensure elimination
of initial transients in these unsteady cases, the researchers
-25
simulated five cardiac cycles. Results are reported from
the fifth cardiac cycle. Mathematical cross sections were
CFD
defined inside the CFD mesh at the same locations at which
> 65
the velocity profiles were measured using the NOVA system.
The CFD simulation illustrated the pathlines in the aneurysm
[cm/s]
during average inflow and also showed a swirling motion of
the flow inside the aneurysm, a flow pattern that is typical
of these vascular pathologies. -30
Lawrence revisits the plate-with-a-hole, pressure vessel and format, as well as model files and a material database used in
bracket problems, and solves them using a 2-D or surface some of the tutorials and exercises. The book ends with a
model. In each case, results for the solid and simplified short chapter on the role of FEA in engineering and issues
models compare well. Other tutorials include analysis of related to its appropriate use. This chapter raises several
natural frequencies, buckling, heat transfer and thermal issues worth chewing on, such as absolute versus compara-
stresses. tive answers, establishing goals for the analysis, interpreting
Instructions in the tutorials are terse, so the reader must results and performing failure analysis.
peruse both the text and menu snapshots to be able to In the educational setting, there are two important
successfully complete the tutorials, as the two are not aspects in learning to use the ANSYS Workbench environ-
redundant. In some cases, the menus on my computer were ment to obtain reliable engineering solutions. First, students
slightly different from the ones shown in the book, even need to develop the necessary skills to use the software
though I was using version 11.0. With some digging around, interface in order to set up and solve a variety of engineering
however, I was able to compensate for these differences problems. Second, they need to understand the underlying
and proceed with the tutorials. concepts to apply the software correctly in order to obtain
validated results. Either book will help students learn the
ANSYS Workbench Software: Tutorial with Multimedia CD interface, with Lawrence’s book additionally addressing
While Lawrence’s book focuses on ANSYS Workbench more advanced topics such as contact, assemblies and
applications, Dadkhah and Zecher’s book integrates fatigue loading. Dadkhah and Zecher’s book has more
discussion of basic finite element modeling concepts with substantial discussion of the underlying concepts and, thus,
tutorials using the ANSYS Workbench platform. Fundamental is more suitable for the novice. Both books certainly are
concepts considered include stiffness matrices, loads and recommended additions to your engineering bookshelf. ■
supports, solid elements, 2-D/axisymmetric models, and
mesh refinement/quality. The chapter on stiffness matrices For further information on the books ANSYS Workbench Tutorial
by Kent Lawrence and ANSYS Workbench Software: Tutorial with
analyzes a system with two springs, so shape functions are Multimedia CD by Fereydoon Dadkhah and Jack Zecher, contact
not covered. the publisher, Schroff Development Corporation, at 913.262.2664,
Discussions about modeling concepts are accompa- or visit www.sdcpublications.com.
nied by tutorials that focus on illustrating the concepts in
ANSYS Workbench applications. For instance, discussion
of mesh refinement and quality precedes a tutorial on using
convergence to improve results for the normal stress in the
fillet region of a T-section. This lets readers see the
concepts in action in an actual FEA calculation.
Most tutorials deal with fundamental problems, such as
a straight beam, plate-with-a-hole and cylindrical pressure
vessel. This allows the authors to check their FEA results
against hand calculations or handbook results, which they
are very diligent about. This is a sound pedagogical
approach to teaching the fundamentals to an FEA novice,
and it will help instructors emphasize the importance of
verifying FEA results.
Dadkhah and Zecher present tutorials on solid
modeling using the ANSYS DesignModeler tool at the start
of the book. This material covers some of the same territory
as Lawrence’s book. FEA chapters include tutorials on 3-D
solid elements, plane stress/strain, shell elements, vibration
(natural frequencies and mode shapes) and steady-state
heat transfer. More advanced concepts, such as contact,
assemblies and fatigue loading, are not considered. Overall,
the focus is on understanding the fundamentals through
solving canonical problems.
There are a few exercises at the end of each chapter that
provide opportunities for further exploration and practice.
These would work well as homework problems. The book
comes with a CD containing videos of each tutorial in AVI
Simulation-Driven
Teaching and Research
Academic products from ANSYS at release 11.0
are helping train future engineers.
By Paul Lethbridge, Academic Product Strategy and Planning, ANSYS, Inc.
Today’s undergraduate students are The differences in these terms of In use, the academic products have
tomorrow’s engineers and researchers. use allow ANSYS to provide academic exactly the same look and feel as the
Deploying software from ANSYS, Inc. as licenses at significantly reduced cost commercial products. For example, a
an integral part of the engineering compared to the commercial licenses, user accessing the ANSYS Multiphysics
curriculum allows academia to train which in turn helps to meet academic capability bundled with an academic
the future work force with world-class budget requirements (Figure 1). product will have the same GUI, work-
simulation tools and technology and Academic products from ANSYS flow, pre-processing, post-processing
familiarize them with Simulation Driven are also packaged differently from and solver as the commercial product.
Product Development processes. It commercial products, with product This helps ensure an easy transition
is also critical in that it ensures that names and license files that differ for the user from academia to the work-
academic research continues to push from the commercial product portfolio. place. In most cases, the academic
the technology envelope. Academic products are bundles of user will actually have access to
ANSYS offers two broad product analysis technology, often incorpo- many more features than the average
license categories — commercial and rating many commercial products and commercial user.
academic — the primary difference add-on modules, with some containing
between the two being the terms of more than 10 commercial products in Product Name
use. Commercial product licenses are a bundle. A single academic product ACADEMIC ASSOCIATE
intended for use by for-profit companies license may contain multiple tasks ANSYS Academic Associate
and organizations in which the analysis (such as five, 25 or 50 tasks) in which ANSYS Academic Associate AUTODYN
work performed is often proprietary each task maps to a separate user.
ACADEMIC RESEARCH
in nature. Academic product licenses, With a few exceptions, the aca-
on the other hand, are intended for demic products are derived directly from ANSYS Academic Research
use by academic organizations, such the commercial products. For a release ANSYS Academic Research CFD
as universities, for nonproprietary such as ANSYS 11.0, both commercial ANSYS Academic Research LS-DYNA
teaching and research. and academic products are included. ANSYS Academic Research AUTODYN
ACADEMIC TEACHING
Commercial ANSYS Academic Teaching Advanced
Academic Use Use
ANSYS Academic Teaching Introductory
Undergrad & Grad
Teaching Postgraduate Research ANSYS Academic Teaching Mechanical
ANSYS Academic Teaching CFD
Classroom University Funded Commercially
Environment Research Funded Research ANSYS Academic Teaching AUTODYN
ACADEMIC TOOLBOX
DesignSpace
specialized pre-processing concerns.
AUTODYN
FLOTRAN
HF Emag
LF Emag
Each academic product can be
CFX
TAS
purchased in defined task increments,
Academic Teaching Advanced 256K 256K 512K 1024K 1024K ∞ 512K ∞ with a task defined as a single user. For
Academic Teaching Introductory 32K 32K 64K 512K 512K ∞ 512K ∞
example, a 25-task license will allow a
maximum of 25 simultaneous users.
Academic Teaching CFD 512K Any combination of these tasks is
Academic Teaching Mechanical 256K 256K ∞ allowed, and volume discount is built
Academic Teaching AUTODYN 50K in. The academic product licenses are
floating local area network (LAN)
Figure 3. Numerical problem size limits for the academic teaching level products (Note that the limits vary by physics,
with higher limits assigned to external field physics such as electromagnetics and fluid dynamics.) licenses, utilizing a single designated
server. Since the majority of the
The ANSYS 11.0 academic product are organized into four product subfam- academic products are multiple task
portfolio includes ANSYS Multiphysics, ilies — Teaching, Research, Associate licenses, this means that all of the
ANSYS CFX, ANSYS ICEM CFD, and Toolbox — with each subfamily tasks are floated on the server’s LAN.
ANSYS TAS and ANSYS AUTODYN having specified terms of use and capa- The products can be installed on an
products, plus a broad selection of bilities. The Teaching subfamily is the unlim-ited number of machines con-
computer-aided design (CAD) geometry lowest priced and includes entry-level nected to the LAN, but the number of
interfaces (Figure 2). The Fluent aca- products intended for undergraduate users who can simultaneously access
demic products are not part of the and graduate class demonstrations and the software is limited by the number
release 11.0 academic portfolio, but hands-on instruction. Teaching-level of tasks purchased (one, five, 25,
some will be integrated in the ANSYS products have numerical problem size 50, etc.).
12.0 release, creating an academic limits, which vary by physics, with ANSYS is at the forefront of
product portfolio that includes all major higher limits assigned to external field providing simulation software world-
technologies from ANSYS. The guiding physics such as electromagnetics and wide for academic users — for both
philosophy is to provide academia with fluid dynamics (Figure 3). The Research teaching and research applications.
very high value bundles of analysis and Associate subfamilies have broader Academic products from ANSYS are
technology, negating the need to pur- terms of use and can be used for used by thousands of universities and
chase multiple products while reducing both research and teaching. They have colleges in more than 60 countries, with
complexity and improving scalability. no problem size limits, providing unlim- hundreds of thousands of users. ■
Academic products from ANSYS ited numerical headroom for doctoral
The classes and projects taught to compare analytical and experimental test rig. The students optimized and
by Professor Huber at the University results with FEA solutions. Students designed the components of the
of Applied Science in Germany focus also use the products to design several testing device using academic
on structural physics. Professor Huber devices. A typical project for under- products from ANSYS. Professor
has created his own tutorial to graduate students is to test the Huber estimates that approximately
introduce the students to the princi- endurance strength of pallet carriers. To 100 second- to fourth-year under-
ples of finite element analysis. For enable realistic experiments, it was graduate students have been trained
practical coursework, the students necessary for students to create a new since these classes were made
use academic products from ANSYS testing device for the servo-hydraulic available.
Reverse Engineering
“The demonstrated depth and breadth of fundamental finite element modeling technologies together with the tight
integration and ease of use makes the ANSYS Workbench platform ideal for use in an academic classroom/research setting.”
Professor Kent Lawrence, Mechanical and Aerospace Engineering, University of Texas at Arlington, U.S.A.
Professor Bhaskaran provides his bucket’s design for increased load and sharing of curriculum materials
Cornell students with a basic (2-D, capacity, maintaining bucket volume with a focus on simulation technology.
linear behavior) introduction to finite and a safety factor. Professor Bhaskaran More information is available at
element analysis (FEA) using an has developed a suite of tutorials using www.mae.cornell.edu/swanson/
in-house toolbox built on MATLAB®. ANSYS products, which can be found on workshop2008.
The classes then build on this foun- the web: http://courses.cit.cornell.edu/
dation using academic products from ansys. Cornell has also integrated Fluent
ANSYS for real-world FEA. Professor academic products into their curriculum.
Bhaskaran focuses his classes on Professor Bhaskaran estimates that 600
structural and thermal physics, both students have been trained since these
separately and as coupled field classes were made available.
effects. Student projects have
included analyzing a bicycle crank Workshop
and comparing the numerical analysis Cornell University will host an
results with those from physical educational workshop titled “Inte-
testing. Another project has involved gration of Simulation Technology
modeling a bucket used on a into the Engineering Curriculum:
Caterpillar ® hydraulic excavator A University-Industry Workshop”
(Figure 6). In this project, students on July 25 to 26, 2008. The
analyzed the stresses under normal primary objective of this workshop Stress and deformation of a bucket on a Caterpillar hydraulic
loading conditions and optimized the is to promote the advancement excavator used in the modeling project
As solvers become faster and computers more powerful, The ANSYS Workbench platform can generate meshes
the solution portion of finite element analysis shortens and a for structural, thermal, electromagnetics, explicit dynamics
larger portion of overall simulation time is spent on or computational fluid dynamics (CFD) analyses, but the
pre-processing, including generating the mesh — the funda- meshing considerations vary for each. For example, lower-
mental element-based representation of parts to be order elements with a finer mesh density tend to be used
analyzed. Recognizing this trend, ANSYS, Inc. has addressed in CFD analyses, whereas higher-order elements with a
the need for faster and more reliable structural meshing with coarser mesh density may be preferred in structural analyses.
new technologies in ANSYS Workbench Simulation 11.0 (also For each physics, different criteria are used for element
known as ANSYS Workbench Meshing 11.0). These new shape checking to ensure that the elements provide accurate
capabilities result in very robust meshing and save consider- results for that particular analysis. For mechanical analysis
able amounts of time (especially for complex geometries) users, STANDARD and AGGRESSIVE shape checking are
with features that automate many routine tasks while also available. STANDARD shape checking is suitable for
providing users high levels of control of their model. linear analyses, while AGGRESSIVE checking provides more
During the past several years, meshing in ANSYS
Workbench Simulation has not only grown to encompass
typical meshing algorithms available in traditional structural
software from ANSYS but has also included many features
requested by its large base of users worldwide. This wealth
of new meshing capabilities includes:
• Physics-based meshing and element shape checking
• Higher degree of mesh sizing controls
• Patch independent surface and volume meshing
• Flexible sweep and hexahedral meshing, including Figure 1. In an analysis of 2-D contact between gears, a SPHERE OF INFLUENCE
(in red) is defined with a user-specified radius (left). This generates a fine mesh
automated generation of SOLSH190 solid-shell within this area for studying von Mises stresses at the point of tooth contact as well
elements as within the geometry of the gear body (right).
Figure 4. In modeling a part with various surfaces and fillets (left), the default mesher honors all surface boundaries, resulting in mesh size
variations (middle) in the highlighted area. The patch independent mesher tends to produce a more uniform-sized mesh (right) in this area by
not honoring all boundaries of unscoped surfaces.
generate a uniform mesh. Although the mesher can skip SOLSH190 node numbering, the generation of which can
over small features, any scoped surfaces (that is, loads sometimes be a cumbersome task in some software from
applied on certain faces) will have their boundaries respected. ANSYS. ANSYS Workbench Simulation, however, provides a
Although VIRTUAL TOPOLOGY can be used in conjunc- convenient meshing capability to automatically generate
tion with the PATCH INDEPENDENT MESHER, the author SOLSH190 elements with the proper orientation. For sweep-
recommends using either of the following procedures for meshable parts, the METHOD mesh control provides
meshing (Figure 4): automatic or manual sweep meshing. There is an additional
• Use the default patch-conforming meshing algorithm option for THIN MODELS, which generates SOLSH190
for surfaces/parts, and use virtual cells to group small elements. Besides automatic detection of source and target
surfaces to adjacent ones, if needed. This method surfaces, users can specify multiple source areas and not
provides a mesh that conforms to the geometry, be limited to a single source area (Figure 5). ■
although the user can merge together unimportant,
small surfaces to reduce the node/element count.
This technique is helpful if a lot of manual defeaturing
(via VIRTUAL TOPOLOGY) is not required. The user
can also set the DEFEATUREPERCENT variable for
global defeaturing of very tiny geometric features.
• For bulky, complex geometry whose surfaces the
user may not need to mesh in detail, add a METHOD
branch to specify the patch independent meshing
algorithm and any defeaturing or curvature/proximity
refinement that is desired. Scope (via NAMED
SELECTIONS, CONTACT REGIONS, LOADS &
SUPPORTS and RESULTS) all geometric entities
whose features should be kept. This technique is
useful if gross defeaturing is required, since manual
specification of regions is not required.
Coupling Momentum
and Continuity Increases
CFD Robustness
FLUENT technology introduces a pressure-based
coupled solver to reduce computation time for low-speed
compressible and incompressible flow applications.
By Franklyn J. Kelecy, Applications Specialist, ANSYS, Inc.
The FLUENT computational fluid The ANSYS CFX solver relies on segregated solution approach where
dynamics (CFD) solver has undergone a pressure-based coupled solver the momentum and continuity equa-
extensive development to extend its approach to achieve robust conver- tions are solved separately. While
robustness and accuracy for a wide gence rates. ANSYS now offers a these approximations do not affect
range of flow regimes. Since its similar pressure-based coupled solver solution accuracy at convergence,
initial release, the FLUENT solver has (PBCS) for the first time with version they can hamper the convergence rate
provided two basic solver algorithms: 6.3 of the FLUENT software. As its for certain classes of problems. With
The first is a density-based coupled name implies, the algorithm solves the the coupled approach, removing the
solver (DBCS) that uses the solution of continuity and momentum equations in approximations due to isolating the
the coupled system of fluid dynamics a coupled fashion, thereby eliminating equations permits the dependence of
equations (continuity, momentum and the approximations associated with a the momentum and continuity on each
energy); the second is a pressure-based
algorithm that solves the equations in a
segregated or uncoupled manner. The
segregated pressure-based algorithm Segregated
Pressure-Based
has proven to be both robust and Solver PBCS DBCS
Initialize Begin Loop Solver?
versatile, and has been utilized in Solve U-Momentum
concert with a wide range of physical
models, including multiphase flows, Solve V-Momentum
Solve Mass,
conjugate heat transfer and combus- Solve Mass & Momentum,
Solve W-Momentum Momentum Energy &
tion. However, there are applications in Species
which the convergence rate of the Exit Loop Repeat
Solve Mass Continuity;
segregated algorithm is not satisfactory, Update Velocity
generally due to the need in these
Check Convergence
scenarios for coupling between the Solve Energy
continuity and momentum equations.
Situations in which equation coupling Solve Species
can be an issue include rotating machin-
Solve Turbulence
ery flows and internal flows in complex
geometries.
Update Properties Solve Other Transport
Equations as Required
other to be felt more directly. This contain dependent variables from the It is important to note that, unlike
leads to a more rapid and monotonic other equations. In the segregated the density-based schemes, the PBCS
convergence rate and hence faster algorithm, these variables are supplied does not include the energy equation
solution times. In addition, the coupling simply by using previously computed in the coupled system. This means that
leads to improved robustness such that values, which introduces a decoupling the density-based solver may still
errors associated with initial conditions, error. The decoupling error can delay be preferable for high-speed com-
nonlinearities in the physical models, convergence in cases in which strong pressible flow cases, in which coupling
and stretched and skewed meshes do pressure–velocity coupling exists. the energy equation is important. The
not affect the stability of the iterative The pressure-based coupled PBCS can be used instead for all
solution process as much as with solver differs from the segregated cases in which one previously would
segregated algorithms. The coupled algorithm in that the continuity and have used the segregated scheme,
algorithm can also be used with a momentum equations are solved in a including low-speed compressible
wide range of physical models such as fully coupled fashion. That is, a single flows, incompressible flows or cases
reacting flows, porous media, and many matrix equation is solved in which the that require models available with only
multiphase models, including volume of dependent variable is now a solution the pressure-based solver.
fluid (VOF) models. vector containing the unknown
velocities and pressures. This is Using the Pressure-Based Coupled Solver
Algorithm Overview similar to the density-based implicit Activating the pressure-based
A flowchart illustrating the pressure- solver, except that the density-based coupled solver in FLUENT software is
based and density-based solver solver also includes the energy very straightforward. First, select
algorithms is shown in Figure 1. This equation in the coupled system and the Pressure-Based option in the
diagram depicts the process by which employs a different discretization of DefineàModelsàSolver panel as
the pressure-based, segregated algo- the flux terms, among other differ- shown in Figure 2. (Users of older
rithm solves the momentum equations, ences. The tradeoff with respect to versions of FLUENT software should
for the unknown velocity components computational resources is that the note that this manner of selecting
one at a time, as scalar equations and PBCS requires about twice the solver algorithms is new in version 6.3.)
then solves a separate equation for memory per cell as the segregated Once this option is activated, the user
mass continuity and pressure. The algorithm. This is due to the storage then can select the coupled solver
pressure solution is used to correct required for the coupled (matrix) from the Pressure-Velocity Coupling
the velocities such that continuity is equations. In general, the storage list in the SolveàControlsàSolution
satisfied. When the flow equations are requirements are comparable to, panel, as shown in Figure 3.
coupled together, the coefficients though slightly less than, the density- Activating the pressure-based
that are computed for each equation based implicit algorithm. coupled solver exposes new solver
Figure 2. Selection of solver algorithms reflected in the Figure 3. Solution controls for the pressure-based coupled solver
DefineàModelsàSolver GUI (This panel was introduced
as new in FLUENT 6.3.)
Experiment
Figure 7. Comparison of computer resources and solver performance for the RAE 2822 airfoil
Fluid Dynamics
on the Big Screen
Fluid simulations have come of age in the world of movie-making.
How are the requirements for simulation in motion the simulations may be run with higher resolution or over
picture animation different than for engineering more frames if the scene requires it.
simulation involving real-world problems?
The differences are enormous and primarily relate to the What fluid phenomenon is the hardest to simulate for
end goal. For motion picture effects, the goal is to create visualization in motion picture animation and why?
something that satisfies the visual expectations of the We have been able to realistically simulate liquids,
director. If the fluid behaves inaccurately, or even unphysi- gases and fires with our tools. The most difficult problem is
cally, that is not a problem if it fits within the look and story to simulate very large regions of fluid at very high resolution.
of the film. Frequently, the story is about an unusual situa- Limited computing resources ultimately limit our ability to
tion, so unusual fluid behavior fits with that theme. simulate big and small scales simultaneously, which is one
of the most difficult problems in fluid dynamics as a whole.
How do the fluid physics engines driving animation We continue to improve our tools and hardware in order to
software differ from those driving commercial simulate greater volume and detail, but we also have
engineering simulation software? evolving tools for the post-processed enhancement of
At the core of the simulation code, the differences simulations. These tools, implemented in a proprietary
between our simulation algorithms and those in commercial scripting language, are based on a combination of physical
systems are not that great. We work toward solving the reasoning and artistic inspiration.
Navier–Stokes equations through a mix of Eulerian gridded
methods, Lagrangian smooth particle hydrodynamics Can you provide an example of a challenging fluid
methods and some others that are proprietary. The two simulation from a recent movie?
codes diverge in the way the simulations are accessed or You might not expect it, but there was a hard simulation
driven. Animation artists work in specialized software pack- problem in Alvin and the Chipmunks. For a concert scene,
ages designed for their specific workflow and have the the chipmunks performed near and on top of a cauldron
ability to create imaginative methods of forcing the fluid and with dry ice vapors, which had to be simulated using our
applying boundary conditions. Also, there are a number of CFD system. Since the camera was very close in many
post-simulation tools available either to alter the simulation shots, we needed to simulate at high resolution, resulting in
results to enhance or suppress behaviors or to use the sim- about one week of simulation time. Also, the chipmunks
ulation to drive geometry, particles and volumes. We rarely danced in the vapor, inducing compromises to the simu-
use raw simulation output in final imagery. lation stability. In the end, since the effect was a minor
priority, we simulated at a lower resolution and then
How much time does it take in terms of processing, enhanced the simulation output to achieve a nice visual
person-hours, etc., to produce a challenging fluid quality for the final result. ■
simulation-based animation?
As with all visual effects elements, simulations are set
up, run and revised incrementally over an extended period,
because the goals for the simulation evolve during the
course of the work. For a single iteration, the artist sets up
the simulation conditions (initial fluid state, boundaries,
objects, forcing) and sends multiple versions of the simula-
tion conditions to the simulation farm, producing three to 20
variations on a simulation per day. Early in development,
setup may take a day to accomplish, but as the work
evolves, setup time is reduced to just a few minutes. By run-
ning multiple simulations simultaneously, the artist can vary
factors such as forcing strength, viscosity,
accuracy, etc., over a short period of
time. The goal is to have a daily
cycle of simulation results, at Jerry Tessendorf of Rhythm & Hues works on an animation sequence with fluid simulation
least for testing and develop- for Alvin and the Chipmunks.
ment. Late in the development,