Front-loading CFD in the Design Process

Terms like UpFront CFD, Engineering Fluid Dynamics and Simulation Driven Product Development have become associated with the areas of rapid growth in Computational Fluid Dynamics (CFD) implementation in recent years. The basic message behind each of these phrases is that there are major benefits in introducing CFD tools early on in the engineering design process, as this is when the biggest changes in the design are practical. 

The more traditional approach of using CFD as a troubleshooting tool late in the design process, or even after the device has gone into production, means that any changes suggested by the simulation are far more expensive to implement.  The effort involved with the simulation at this stage may well, as a consequence, turn out to be worthless. Simulation early in the Design Cycle can also save on the time and costs involved with multiple prototypes.

To encourage this up-front approach to simulation, many software packages are now targeted at multi-tasking design and development engineers. This is possible by either integrating the software closely with the CAD tools commonly used by these engineers, or by providing application specific graphical user interfaces (GUI’s). Of course, in some larger organisations, the same effect can be achieved by calling in existing CFD expertise at the design stage and allowing these engineers to influence the design process, but in small and medium (SME) companies these experts often do not exist.

The idea of giving access to CFD tools to design engineers has been frowned upon by some, And due to the complex non-linear nature of the physics and mathematics involved there is some basis to their reluctance, but many companies who have invested in such technology are reaping major benefits. 

This NAFEMS seminar addressed all of these issues, and answered some of the relevant questions, such as: 

• How have companies successfully implemented design based CFD? 
• How have they avoided falling into the pitfalls associated with the complex physics involved? 
• Have the CFD vendors provided the tools necessary to give reliable answers? 
• What skill sets and training are needed to Front Load CFD in the design process?

The seminar provided an insight into the CFD processes within industries such as Formula 1, IndyCar racing, telecommunications, and motion & control, with top-class presentations made from each of these areas.

Presentations 

Welcome & Introduction to NAFEMS
Michael Clapp, UpFront Engineering Simulation Ltd & Althea de Souza, dezineforce

Front Loading CFD in the Design Process: An Inpendent 
Introduction   
John Verdicchio, Rolls Royce

CFD and Return on Investment at Parker Hannifin
Bruno Fairy, Parker Hannifin

Case Study Examples from a Consultant’s Perspective:From 
IndyCar to Product Design
Koen Beyers, Voxdale

Integrated CFD simulation in F1 (this presentation is not available for publishing)
Kris Midgley, Renault Formula 1 Team

Is Your UpFront CFD Simulation Correct? Verification, Validation
and Training for Design Focused CFD
Michael Clapp, UpFront Engineering Simulation Limited

Expert Systems Deliver Bespoke Upfront CFD Capability
Richard Bell, Prospect

OneBTS Base Station Thermal Simulation Vs Thermal Test Results:
Electronics Cooling Design Example
Lucius Akalanne, Alcatel Lucent

Supporting Design Engineers to Simulate Hydraulic Assemblies
Althea de Souza, dezineforce