Breakout Session

Thanks to their compactness and efficiency, swashplate axial piston pumps are widely used as fluid power sources in fixed and mobile applications that require high pressure and variable flow rates. In order to guarantee high performances, reliability and reduced time-to-market, their development process requires more and more the use of advanced simulation tools. With specific reference to fluid dynamic simulation, different approaches are available; nowadays, the most common one is still represented by the lumped parameter method (0D-1D models). The advantages of this approach are the fast computational time and the easiness to reach convergence, but some physical phenomena are inevitably simplified or even neglected at all. In this sense a three-dimensional approach is the most advanced and accurate method; nevertheless there are still considerable challenges to overcome before reach a comparable level of usability: CPU time and convergence issues, in order to solve complex transient analyses characterized by small clearances and high pressure drops.
In this work, a CFD model of fluid flow in an axial piston pump, working at high pressure, is presented. The presentation will show the workflow for the construction of the model in Ansys CFX and the model validation through quantitative comparison of predicted chamber pressures and fluid flows with those obtained with a validated 0-D model. Finally, an overview of phenomena related to spatial trajectory of oil jets inside the pump will be shown.

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Bosch Thermotechnology | Yiğit Gürler
Modelling and Simulation of Environment Friendly Packaging Concept for Combi Boiler

The combi boiler is a heating appliance that is used for providing a heat power for central and domestic hot water lines. These type of devices are exposed to loads such as drop, vibration, temperature, and stack that may cause damage starting from production to end user. Drop is more pronounced when considering other damage factors in terms of the effect of damage and probability of occurrence. EPS is one of the commonly used packaging material to protect white goods and combi-type appliances from such damage mechanisms. However, with the environmental regulations that have come into effect in the European market, especially in the UK in recent years, restrictions are being made on disposable plastic-based materials. Therefore, environmentally friendly packaging material alternatives that can be used instead of EPS come to the fore.
In this study, a packaging concept with paper-based honeycomb material was designed for the combi boiler and numerical analysis of the drop test was performed using LS-DYNA software. The findings obtained from numerical analysis were compared for packaging concept designs realized with EPS and environmentally friendly packaging material. The energy absorbed by the packaging elements and the deformation levels transferred to the appliance were determined.In this context, by guiding the packaging system development process, design improvement suggestions were made. As a result, the appliance cost and time used for experimental testing are saved.

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Castel | Lorenzo Resmini
Multi-phase fluid-dynamic simulation in electric expansion valves for refrigeration and air conditioning applications

Electric expansion valve (EEV) is one of the most important devices in refrigeration and air conditioning applications and it has the purpose of taking the refrigerant fluid from the condensing pressure to the evaporating pressure. The aim of the present activity is the calculation of refrigerant capacity in order to populate Castel's EEV manual which allows the refrigeration equipment manufacturers to select the most suitable component for their applications.
An in-depth numerical investigation has been carried out with the suite ANSYS CFD and this led to geometrical modifications that allowed to reach the desired refrigerant capacity values and a better internal design of critical geometries. The main challenge of this numerical study was modelling the transition of the fluid phase from liquid to gas.
The low capacity values obtained with CAE technology have been experimentally verified by a refrigeration testing system owned by Castel’s laboratory.

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Eaton India Innovation Centre LLP | Shashank Mishra
Modified Lumped Modelling Approach for Simulation of Electrical Components in Switchgears

In electrical switchgears, heat generation due to electrical resistivity, eddy currents and contact resistance results in temperature rise. This temperature rise exceeding the allowable limits as prescribed in standards may lead to potential damage to electrical devices within the switchgear reducing its life and efficiency. In the recent times, there has been a tremendous impetus towards modelling of switchgears to reduce the design & development cycle time as the requirement of reduced footprint poses increased challenges to meet the thermal requirements.
A typical Low voltage switchgear consists of many electrical components such as busbars, ACBs, MCCBs, relays, contactors etc. Detailed modelling of switchgear systems along with these electrical components becomes difficult due to geometrical complexities and meshing constraints. Hence, general practice followed in industry is to model electrical components in full system modelling as lumped heat sources as per catalogues power loss data. This approach though computationally faster, jeopardizes the accuracy of temperature rise predictions as it doesn’t closely simulate the actual physics of heat interaction of the component with the neighboring environment in 3D simulations/modelling. Present work aims to develop a Modified Lumped Modelling approach that captures the distribution of heat dissipation from/within the component closer to reality without altering its interaction with the neighboring environment in 3D thermal simulations of full assembly. Experimental temperature rise test results of individual components is used to determine the distribution of heat loss from/within the component. Similar approach is then further extended to two or more components (e.g. MCCB and contactor), which are coupled in series in drawers of switchgear. This Modified Lumped Modelling approach when utilized in 3D modelling and simulation of complete switchgear system, results in improved accuracy without compromising computational time for different variations of switchgears based on Ingress protection, ambient conditions, ventilation systems for same combination of components inside a drawer. Simulation results for individual component, components coupled in series and switchgear system are validated with temperature rise tests. For individual component, the correlation coefficient is 0.98 and Absolute Average Deviation (AAD) is 5.1%; whereas for coupled systems, the correlation coefficient and AAD is found to be 0.96 and 10.79% respectively. For complete switchgear system the correlation coefficient and ADD are 0.93 and 5.84% respectively.

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PETROLVALVES SPA | Simone Bosotti
Swing check valve seat-clapper dynamic structural impact simulation using Ansys Autodyn explicit solver

Swing check valve seat-clapper dynamic structural impact simulation due to pipe rupture of the upstream pipeline, by means of Ansys Autodyn explicit solver (free for mechanical enterprise license) instead of classical LS-Dyna explicit one (not in mechanical enterprise license pool): a CFD analysis of the clapper shut off due to emergency condition was carried out in order to calculate the clapper impact velocity. At CFD simulation end, the swing is still open with a minimum gap. The clapper velocity in this position and the fluid dynamic torque (end condition of CFD analysis) are the initial condition of the dynamic structural impact finite element analyses. Normally the dynamic structural impact FE analyses were performed using Ls Dyna which is not in the Ansys mechanical license pool. The goal is to perform the analysis by Ansys explicit solver thus being in the Ansys mechanical enterprise license till 2018 for free.

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It is sometime quite complicated to make a choice when a company is looking for a 1D piping tool. A lot are present on the market...they are all different, each of them has its own advantages. The author was involved with 3 of them (some since 1994), in Europe and North America, and also wrote a few papers. He worked with Flowmaster from 1994 to 2008 and from 2015 to 2017, with Flownex from 2017 to 2020 and with Hydrosystem since 2019. He will present below the three products and the best one for a few usages. After a brief history of the tools, you will see a description of the capabilities of each of them in the following area: User Interface, Ease of Use, Incompressible isothermal flows, Compressible and multiphase flows, Transient flows, Interface with CAD, CFD and FEA products, Main applications, Validation and Pricing.
This presentation is done considering our actual knowledge of the various tools and the original document was sent to representative of all products in the case where they would add any comments namely as far as recent of future capabilities would be concerned.
Each situation is different, the needs of your company are not necessarily the same as another society, they may also have changed with years. Do the right choice for your digital transformation.

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SIMUNE Atomistics | Anna Kimmel
Multi-physics approach for materials modelling

The increase in consumer demand pushes the industry to produce more advanced and cheaper products at a shorter time. Batteries must last longer, cars travel longer and emit less, consumer electronics must be lightweight, more powerful and desirably flexible. To synchronise the demand with the production capabilities, the industry reorganises its manufacturing cycle by employing modern technologies for product creation and materials screening. The industry needs a robust tool for understanding how their products would work to achieve the production goal.
CAE built a strong reputation as a verification, troubleshooting and analysis tool. However, modern products become ever more complex and this leads to an increased need for multi-physics analysis. Advanced atomistic modelling offers a way to explore the multi-physics of complex systems providing an insight into fundamental interactions at molecular and atomic level.
Here we present several case studies how modelling at quantum mechanical and/or atomistic levels makes possible to design novel materials and composites, predict their properties, understand multi-physics of processes happening in them.

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