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Fluid Flow Simulation

Fluid flow simulation is at the core of what our CFD consulting technical experts do at our Singapore offices in BroadTech Engineering.

Featured Fluid Flow Simulation Case Studies

Fluid Flow Simulation

Design of a Savonius-Type 3-Bladed Wind Turbine

The objective of this fluid flow simulation project was to show the influence of correctly modeling the fluid-induced motion of a generally rigid body, as well as creating an efficient design for a cheap, mass-production feasible, wind turbine model to use in urban areas.
For this CFD consultancy project, after a simple 3-bladed design was created, 2D CFD simulations were performed for both steady-state and transient models with fixed angular speed (enough imposed to generate zero torque), as well as the realistic model itself, also 2D. Initially, the steady case was used by our CFD consultants to predict a good initial mesh (particularly the inflation) and turbulence models, resulting in the selection of the Spalart-Allmaras model, a compromise between accuracy, reliability and calculation speed. A non-motion transient CFD modeling process was then carried to determine a feasible time step (even though an implicit formulation was selected, the time advancement cannot be so great as to physically distort solutions, or introduce an excessive amount of numerical dissipation).
Next, the fixed rotation motion was introduced into the computational fluid dynamics simulation, with some adjustments made to time-step in order to accommodate a dynamic remeshing process, necessary to avoid excessive mesh distortion and zero-volume elements as the body rotates.
Finally, taking on all previous results, the realistic model was carried out using the CFD simulation software, for as long as 10s (DT = 1e-4 for a small, slow turbine), with the rigid body motion driven by airflow. In all these models, a coupled pressure-velocity scheme was rather a necessity, as segregated models consistently failed to achieve a reasonable convergence or convergence rate.
Although the 3D model is still being carried out, the 2D modeling provided enough data for the computational fluid Dynamics analysis to understand the impact of correct motion prediction, particularly for lighter and faster turbines, where motion is by no means constant. On the practical side, it was possible to give an initial prediction on the power generated by a single turbine and to infer that, in an average sense, the steady-state approach is rather suitable initially, but must later be improved by either an experiment of a realistic model. This opened the question for future work and research on modeling procedures for wind turbines.

Analysis & Design of an Efficient Hydrofoil based on Zhukovsky Wing Profile

It was requested that a high lift low drag hydrofoil is designed to provide extra upwards force for a vessel to be utilized in shallow-to-medium waters, at rather slow speeds.
Based on the mathematical description of Zhukovsky for wing profiles, and the general shape of a manta ray, our team of CFD design engineers in our CFD company decided on combining those two features to solve the question, betting on 3D printer production of the difficult geometry traits associated.
To analyze the resulting body in the computational fluid analysis, initially a 2D, steady state fluid flow simulation was carried to decide on wing chord length, total extension and camber, which gave preliminary results, later compared and adjusted by a 3D, fully immersed fluid dynamics simulation.
In both cases, the trial-and-tested Spallart-Almaras turbulence model was chosen, as it is preferred for low stall wing models.
Finally, to better assess the model’s suitability to the proposal, a shallow water model (two-phase air-water model) was carried, with an introduction of numerically generated waves, as a rather qualitative tool to give proof of capability.



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Customers who engage in our CFD services will be provided with fully tailored CFD reports which outline in detail the Methodology, in-depth fluid dynamics analysis, and recommendations. These valuable insights allow our clients to optimize performance and make informed engineering decisions in a scientific, proven manner.
If you are still interested in learning more about Fluid Flow Simulation and to see what our CFD consulting services can do for you, simply call to contact us today at +6581822236 for a no obligation discussion of your needs.
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Other Featured Fluid Flow Simulation Case Studies

3D CFD Analysis of Components in IC Engine Exhaust Layout using OpenFOAM

The prime objective of the simulation project was to analyze the flow of exhaust gases and atmospheric air in the EGR valve specifically been developed for single cylinder engines.
The methodology used: The concept was discussed among the team of four peoples and finally Orifice-type of EGR valve concept was approved for the CFD analysis Engineering design and CFD flow analysis of the concept was implemented. We used Pro-E for CAD, ICEMCFD for meshing (tetra mesh) and OpenFOAM for CFD analysis.
Later, for post-processing, ParaView, Gnuplot and Libre office (open-source, default office program in Ubuntu OS) is used
Outcome and Conclusion: It was found that, during the exhaust stroke of the engine, when both inlet and exhaust valves are open, the pressure in the exhaust valve is very low compared to an inlet. Hence, the air was moving out of the EGR valves and was not able to mix with exhaust gases. That is why, instead of the air-exhaust mixture, only the fresh air was supplied to the engine.

Flow simulation in Venturi Scrubber

Objective: Evaluating performance of the current design by estimating following parameters:
 SMD(Sauter Mean Dia) of liquid droplets at mid-plane of Venturi’s throat
Liquid Jet Dia at mid-plane of venturi throat
Approach: For SMD estimation,  Discrete Phase Method with atomization and DEM models. For Jet Dia estimation, Volume of the Fluid method. (Ansys Fluent)
Conclusion: Results matched well with experimental results of the client.

Flow Simulation of Full Vehicle in idle Condition 

Objective: To estimate Air Temp in front of COND
Approach: Steady analysis, heat source and porous media in COND, RAD; Const temp on eng and transmission parts. (Star CCM+)
Outcome: Identification of gaps from where hot air recirculates to the front of heat exchanger unit, C/M proposals and checking of C/M for attaining target.

CFD Simulations and Validation from the ‘Lab Data’ for the performance of the ‘DAMA’ and the ‘Ambiator’

Simulation Objective: the entire project was to design, analyze, experimentation and validation of a fully functional HVAC lab.
Methodology: the biggest size of ‘Ambiator’ (an IDEC based air cooler) was taken into consideration. The heat load was calculated and the required size of heating, cooling and humidification apparatus was determined.
Later CAD model was created using Creo-Parametric 2.0, meshing was done partially using ‘Salome’, ‘netgen’ and later a complete mesh was created using ICEMCFD. CFD fluid flow analysis was done using OpenFOAM.
From the flow analysis, the mixing of different steam of air was analyzed at the inlet and respective performance of DAMA (a patented heat exchanger) at various inlet conditions (as determined by ISHRAE and ASHRAE) are simulated.
Results and Conclusion: CFD simulation were showing the proper mixing of various streams of air at the inlet. Based on the CFD results the lab was constructed in the new unit of ‘HMX’. The CFD results co-related closely agreeing with the lab results
Specific water consumption, heat and mass balance was balanced within error range of +/- 5%

Flow Simulation of Check-in Premises of International Airport

Objective: To estimate hot pockets in the premises
Approach: Steady analysis, compressible flow, energy equation enabled, heat sources for energy input by humans and electronic appliances. (Ansys Fluent)
Outcome: Identification of hot pockets, C/M proposals and reporting to the client.