MTE 201
LECTURE NOTES ON COMPUTER AIDED ENGINEERING (CAE) LINUX
1. What is CAE?
Computer aided engineering (CAE) can be defined as broad usage of computer software in
performing engineering tasks. It includes, but not limited to:
a. Computer aided design (CAD)
b. Computer aided analysis (CAA)
c. Computer integrated manufacturing (CIM)
d. Computer aided manufacturing (CAM)
e. Materials requirement planning (MRP)
f. Computer aided planning (CAP)
2. What is CAELINUX?
Computer aided engineering (CAELINUX) can be defined as the discipline of applying LINUX
operating system (either installed on a sole computer or booted from bios) in order to analyze and
process engineering systems.
3. CAELINUX applications
Several applications are embedded in CAELINUX 2013 open source software, some of which
are:
a. Salome meca
b. openFOAM
c. code saturne
d. code aster
e. elmer
f. Impact
g. Calculix
h. GMSH
i. enGrid
4. Short notes on some CAELINUX applications: definitions, fuctions and applications
4.1 SALOMEMeca: SALOME is an open-source software that provides a generic platform for Pre-
and post-Processing for numerical simulation. It is based on an open and flexible architecture
made of reusable components. SALOME is a cross-platform solution. It is distributed as open-
source software under the terms of the GNU LGPL license. SALOME can be used as standalone
application for generation of CAD model, its preparation for numerical calculations and post-
processing of the calculation results. SALOME can also be used as a platform for integration
ofthe external third-party numerical codes to produce a new application for the full life-cycle
management of CAD models.
4.1.1 SALOME key features
1. Supports interoperability between CAD modeling and computation software (CAD-CAE link).
2. Makes easier the integration of new components into heterogeneous systems for numerical
computation.
3. Sets the priority to multi-physics coupling between computation software.
4. Provides a generic user-friendly and efficient user interface, which helps to reduce the costs and
delays of carrying out the studies.
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5. Reduces training time to the specific time for learning the software solution based on this
platform
6. Provides access to all functionalities via the integrated Python console.
4.1.2 Uses of SALOME
1. Create/modify, import/export (IGES, STEP, BREP), repair/clean CAD models
2. Mesh CAD models, edit mesh, check mesh quality, import/export mesh
3. Handle physical properties and quantities attached to geometrical items
4. Perform computation using one or more external solvers (coupling)
5. Display computation results (scalar, vectorial)
6. Manage studies (create, save, reload)
IGES = Initial Graphics Exchange Specification
STEP= STandard for the Exchange of Product model data
BREP= Boundary REPresentation
4.2 OpenFOAM:OpenFOAM (for "Open source Field Operation And Manipulation") is a C+
+ toolbox for the development of customized numerical solvers, and pre-/post-processing utilities
for the solution of continuum mechanics problems, including computational fluid
dynamics (CFD). The code is released as free and open-source software under the GNU General
Public License. The OpenFOAM name was registered by OpenCFD Ltd in 2007 and non-
exclusively licensed to the OpenFOAM Foundation Ltd in 2011.
The capabilities provided by the library are then used to develop applications. Applications are written
using the high-level syntax introduced by OpenFOAM, which aims at reproducing the conventional
mathematical notation.
Two categories of applications exist:
4.2.1 Solvers: they perform the actual calculation to solve a specific continuum mechanics
problem.
4.2.2 Utilities: they are used to prepare the mesh, set-up the simulation case, process the results,
and to perform operations other than solving the problem under examination.
4.3 Code_Saturne is a general-purpose computational fluid dynamics free computer software
package. Developed since 1997 at Électricité de France R&D, Code_Saturne is distributed under
the GNU GPL licence. It is based on a co-located finite-volume approach that accepts meshes with
any type of cell (tetrahedral, hexahedral, prismatic, pyramidal, polyhedral...) and any type of grid
structure (unstructured, block structured, hybrid, conforming or with hanging nodes...).
Its basic capabilities enable the handling of either incompressible or expandable flows with or without
heat transfer and turbulence (mixing length, 2-equation models, v2f, Reynolds stress models, Large
eddy simulation...). Dedicated modules are available for specific physics such as radiative heat
transfer, combustion (gas, coal, heavy fuel oil, ...), magneto-hydro dynamics, compressible
flows, two-phase flows (Euler-Lagrange approach with two-way coupling), extensions to specific
applications (e.g. for atmospheric environment)
4.4 Code_Aster is an Open Source software package for Civil and Structural Engineering finite element
analysis and numeric simulation in structural mechanics originally developed as an in-house
application by the French company EDF. It was released as free software under the terms of the GNU
General Public License, in October 2001.
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4.5 Elmer is an open source multiphysical simulation software mainly developed by CSC - IT Center for
Science (CSC). Elmer development was started 1995 in collaboration with Finnish Universities,
research institutes and industry. After its open source publication in 2005, the use and development of
Elmer has become international.Elmer includes physical models of fluid dynamics, structural
mechanics, electromagnetics, heat transfer and acoustics, for example. These are described by partial
differential equations which Elmer solves by the Finite Element Method (FEM).
5. Approach To Simulation/Modelling In Computer Aided Engineering
5.1 Introduction
Engineering system design involving complex physical systems require the use of physical models and
simulation. CAE provides the means for developing a representation of a physical system that includes
the equations and variables needed to describe behaviour of the system. Such equations, mainly due to
non-linearity associated with them, are complex, and to date, their analytical solutions were only achieved
in a simplified manner. To develop a discrete approximation of the original equations, CAE simulation
uses numerical methods to solve them. This representation can then be stored and shared with others, and
presented to various simulation platforms, which in turn will then perform a simulation of the physical
system as well as enable design optimization, sensitivity analysis, and other such dynamic systems
synthesis and analysis tasks.
Physical models are useful in several ways. First, they can help designers understand how systems from
different domains interact with each other and enable engineers to optimize the overall system design.
Physical models are also useful in helping estimate overall system performance metrics and can also
reduce physical prototyping, thus speeding up the design cycle. Consequently, major agricultural
machinery manufacturers are using virtual prototyping, and hardware-in-the loop simulation and testing,
all of which rely on high fidelity physical models.
CAE is used in all stages of the engineering process:
• Conceptual studies of new designs
• Detailed product development
• Optimization
• Troubleshooting
• Redesign
Analysis in CAE complements testing and experimentation by reducing total effort and cost required for
experimentation and data acquisition
All CAE simulations (in all mainstream CAE software products) are approached using the following 3
phases as described below:
1. Remember to first think about what the aims of the simulation are prior to creating the geometry
and mesh (Pre processing
2. Make sure the appropriate physical models are applied in the solver, and that the simulation is
fully converged (Analysis Solver)
3. Scrutinize the results, you may need to rework some of the earlier steps in light of the flow field
obtained (Post Processing)
4.
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5.2 Steps involved in CAE simulations
5.2.1 Step 1. Define Your Modeling Goals
a. What results are you looking for (i.e. pressure drop, mass flow rate, deformation,), and how will they
be used?
b. What are your modeling options?
c. What simplifying assumptions can you make (i.e. symmetry, periodicity)?
d. What simplifying assumptions do you have to make?
e. What physical models will need to be included in your analysis
f. What degree of accuracy is required?
g. How quickly do you need the results?
h. Which is the most appropriate tool? (e.g is it CFD)
5.2.2 Step 2. Identify the Domain You Will Model
a. How will you isolate a piece of the complete physical system?
b. Where will the computational domain begin and end?
c. Do you have boundary condition information at these boundaries?
d. Can the boundary condition types accommodate that information?
e. Can you extend the domain to a point where reasonable data exists?
f. Can it be simplified or approximated as a 2D or axisymmetric problem?
5.2.3 Step 3. Create a Solid Model of the Domain
a. How will you obtain a model of the fluid region?
b. Make use of existing CAD models?
c. Extract the fluid region from a solid part?
d. Create from scratch?
e. Can you simplify the geometry?
f. Remove unnecessary features that would complicate meshing (fillets, bolts…)?
g. Make use of symmetry or periodicity? – Are both the flow and boundary conditions symmetric /
periodic?
h. Do you need to split the model so that boundary conditions or domains can be created?
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5.2.4 Step 4. Design and Create the Mesh
a. Meshing
Meshing is the automated process of creating computer models for computational fluid dynamics (CFD)
and finite element analysis (FEA). Although a wide range of mesh generation techniques are currently
available, these were usually developed to generate models from computer-aided design (CAD).
Purpose of the Mesh
• Equations are solved at cell/nodal locations
– Domain is required to be divided into discrete cells (meshed)
b. Discretization Methods in CAE
In order to solve the equations describing the behaviour of the system in question, first their numerical
analogue must be generated. This is done by a process referred to as discretization. In the discretization
process, each term within the equation describing the behaviour of the system is written in such a manner
that the computer can be programmed to calculate. Special care must also be taken to ensure that the
discretization handles discontinuous solutions gracefully. Three of the most commonly used techniques,
namely: (1) the finite difference method, (2) the finite element method and (3) the finite volume method
are described as follows:
Finite difference method (FDM)
The finite difference method (FDM) has historical importance and is simple to program. It is currently
only used in few specialized codes, which handle complex geometry with high accuracy and efficiency by
using embedded boundaries or overlapping grids (with the solution interpolated across each grid). Due to
difficulties in the handling of complex geometry, finite difference techniques are rarely used in
engineering flows.
Finite element method
Finite Element Analysis (FEA) is a computerized method for predicting how a real-world object will react
to forces, vibration, heat, and etc. in terms of whether it will function as planned.
The finite element method (FEM) is used in structural analysis of solids, but is also applicable to fluids. It
one of the most successful numerical methods widely employed in solving flow problems. However, the
FEM formulation requires special care to ensure a conservative solution. The FEM formulation has been
adapted for use with fluid dynamics governing equations. Although FEM must be carefully formulated to
be conservative, it is much more stable than the finite volume approach. However, FEM can require more
memory and has slower solution times than the FVM. However, because of the difficulties involved in the
programming and implementation of this technique not many commercial finite element packages exist.
FEM is characterized by three features:
a. The domain of the problem is represented by a collection of simple subdomains called finite elements.
The collection of finite elements is called the finite element mesh.
b. Over each finite element, polynomial functions and algebraic equations relating physical quantities at
the corners of elements called nodes approximate the physical process.
c. The element equations are assembled using continuity and ‘‘balance’’ of physical quantities.
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Common finite element formulations make use of the weak form of the equations of motion, and the
incompressibility equation to solve such problems
Finite volume method (FVM)
The finite volume method (FVM) is a common approach used in CFD codes, as it has an advantage in
memory usage and solution speed, especially for large problems, high Reynolds number turbulent flows,
and source term dominated flows in that this method is sensitive to distorted elements which can prevent
convergence if such elements are in critical flow regions. In the finite volume method, the governing
partial differential are recast in a conservative form, and then solved over discrete control volumes. This
discretization guarantees the conservation of fluxes through a particular control volume. When finite
volumes methods are used, they form a physically intuitive method of achieving a systematic account of
the changes in mass, momentum, and energy as fluid crosses the boundaries of discrete spatial volumes
within the computational domain. The ease in the understanding, programming and versatility of finite
volumes has meant that they are now the most commonly used numerical techniques in CFD code
development.
Questions to ask in Meshing
a. What degree of mesh resolution is required in each region of the domain?
b. Can you predict regions of high gradients?
Note: The mesh must resolve geometric features of interest and capture, gradients of concern, e.g.
velocity, pressure, temperature gradients
c. Will you use adaption to add resolution?
d. What type of mesh is most appropriate?
e. How complex is the geometry?
f. Can you use a quad/hex mesh or is a tri/tet or hybrid mesh suitable?
g. Are non-conformal interfaces needed?
h. Do you have sufficient computer resources?
i. How many cells/nodes are required?
j. How many physical models will be used?
5.2.5 Step 5: Set Up the Solver
For a given problem, you will need to:
a. Define material properties – Fluid – Solid – Mixture
b. Select appropriate physical models – Turbulence, combustion, multiphase, etc.
c. Prescribe operating conditions
d. Prescribe boundary conditions at all boundary zones
e. Provide initial values or a previous solution
f. Set up solver controls
g. Set up convergence monitors
For complex problems solving a simplified or 2D problem will provide valuable experience with the
models and solver settings for your problem in a short amount of time
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5.2.6 Step 6: Compute the Solution
The discretized conservation equations are solved iteratively until convergence
Convergence is reached when:
a. Changes in solution variables from one iteration to the next are negligible – Residuals provide a
mechanism to help monitor this trend
b. Overall property conservation is achieved – Imbalances measure global conservation
c. Quantities of interest (e.g. drag, pressure drop) have reached steady values – Monitor points track
quantities of interest
The accuracy of a converged solution is dependent upon:
a. Appropriateness and accuracy of physical models
b. Assumptions made
c. Mesh resolution and independence
d. Numerical errors
A converged and mesh independent solution on a well posed problem will provide useful engineering
results
5.2.7 Step 7: Examine the Results
Examine the results to review solution and extract useful data
a. Visualization Tools can be used to answer such questions as: – What is the overall flow pattern? – Is
there separation? – Where do shocks, shear layers, etc. form? – Are key flow features being
resolved?
b. Numerical Reporting Tools can be used to calculate quantitative results: – Forces and Moments –
Average heat transfer coefficients – Surface and Volume integrated quantities – Flux Balances
Examine results to ensure correct physical behavior and conservation of mass energy and other conserved
quantities. High residuals may be caused by just a few poor quality cells.
5.2.8 Step 8: Consider Revisions to the Model
a. Are the physical models appropriate?
b. Is the flow turbulent? • Is the flow unsteady? • Are there compressibility effects? • Are there 3D
effects?
c. Are the boundary conditions correct?
d. Is the computational domain large enough?
e. Are boundary conditions appropriate?
f. Are boundary values reasonable?
g. Is the mesh adequate?
h. Does the solution change significantly with a refined mesh, or is the solution mesh independent?
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i. Does the mesh resolution of the geometry need to be improved?
j. Does the model contain poor quality cells?
High residuals may be caused by just a few poor quality cells
