Aerodynamics & Thermal Development
Our Approach
Fluid dynamics development can be a complex task. The development phase of any project can be split into three stages:
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02
03
Concept Development
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Analysis of the concept
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Large surface charges and concept evaluation.
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Quick simulation turnaround
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Low to medium model resolution and accuracy of results.
Detailed Engineering
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Complex simulation models to account for all engineering requirements.
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High computational resolutions.
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Design based on engineering limitations and focused on deliverables.
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Experimental testing to support and correlate simulations.
Validation
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Final prototype testing
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Tuning of components for final engineering design.
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Overall performance evaluation.
Concept development is critical for the success of the project. At this stage the concept is confirmed with a simplified geometry based on large CAD geometry modifications and low to medium accuracy computational fluid dynamic (CFD) simulations for a quicker turnaround. This stage determines the overall performance and viability of the design without going into detail. It ensures the design complies with the general scope of the project. The results from this stage will allow the company to evaluate the potential of the product, estimate a return on investment and analyze the requirements for marketing and supply chain strategies.
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Once the initial stage is completed it is necessary to undergo a detailed engineering stage where a mixture of complex high accuracy CFD simulations are used together with experimental testing to support and correlate the simulations. The design of the product is based on engineering limitations and modifications are taken to comply with the physical requirements while maintaining the performance in line with the scope of the project. This stage delivers a functional prototype for final validation.
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The final stage of the development process is validation. This part of the process is key to make sure that the product is in line with all the pre-established deliverables and that it complies with all the acceptance criteria from the project scope. As part of the validation stage, in most cases, it is necessary to perform a short loop of full-scale prototype testing while tuning the components for final engineering design depending on the complexity of the product.
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In VFluid Advanced Technologies we believe in delivering high quality products but we are flexible to the requirements and limitations of each project. Each project is different, so we are happy to adjust our tools and way of working to align with the development requirements.
Simulation & Testing
The fundamental tools for product development in fluid dynamics are CAD, CFD and experimental testing. CAD is the starting point where the initial prototype is designed in order to run CFD simulations and/or experimental tests. CFD simulations are the go-to tool for fluid dynamics development. Nowadays the existence of cloud computing has made possible the accessibility to 1000s of cores at an affordable price without large upfront costs. Nevertheless, running some of these simulations can be complex. Making sure that the results are correct and representative of the problem requires experienced engineers, otherwise what can be a simple and inexpensive task can become a lengthy costly process.
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At VFluid Advanced Technologies we offer expertise in several types of CFD simulations that can be part of an integrated and automated process depending on the requirements of each project. We can become responsible for the entire development process related to fluid dynamics but we can also assist our clients in building an automated process for their own use, be it for a purpose-built cluster or cloud migration. Our vision for a CFD process in a development environment that requires repetitive design loops (such as for transportation design companies) involves a simple easy to use process that relies on scripts which take existing CAD and turn it into the desired CFD simulation. As part of the system the results will be post-processed automatically, integrated to a database for data analysis which can then be further optimized using machine learning techniques. Implementing an automated process can provide a significant speed up in simulation turnaround times and increase development efficiency by maximizing the time spent by engineers performing data analysis and design improvements. It will also help reduce mistakes during the development process.
CAD
Input from Studio & Engineering
Simulation
Management
Software
Data Anaysis
& Storage in Common Database
Machine
Learning
Optimization
Output to Engineering
Experimental Results
Steady State
Transient
Internal or External Flow
Thermal
Aero Acoustics
Multiphase
Correlation
Nevertheless, CFD continues to be a simulation tool and therefore a lot of care needs to be taken when considering the results. In most cases the simulations serve as a reasonable prediction of the reality, to understand the potential of a product and to find a reasonable solution to a problem when considering large changes. When a more detailed result is needed then CFD simulations cannot be trusted on their own and hence why experimental testing for correlation purposes is recommended.
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On the one hand carrying real case tests is the most accurate way of obtaining results and data, but sometimes it can be too expensive and the lack of repeatable conditions can render the data unusable for analysis. This type of tests are sometimes necessary but in most cases should be reserved for final development stages and design confirmation. The use of controlled and repeatable experimental tests makes data analysis and CFD correlation analysis easier and cheaper. It allows the engineers to understand the problem and any differences that appear with respect to the CFD simulations. Nevertheless, attention to detail and experience are important because mistakes can also be made in the experiment and therefore the results may be skewed from reality.
Product Definition Engineering Input
Styling Input
Feasibility Study
Output
Correlation
Experimental Validation
Results Analysis
Product Design
Development by Simulation
VFluid Technology has many years of experience in fluid dynamics, covering CAD design, CFD simulations, wind tunnel testing, data analysis, correlation, process automation and technical project management. Our experience has taught us that a balanced method of design, simulation and testing is the best approach to product development in order to accomplish the scope of any project.
