Headlight Multiphysics Simcenter 3D analytics tutorial

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Part 1: Preparing CAD parts for meshing: Easy geometry modifications in Simcenter 3D multiphysics

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Simplify & Streamline Multiphysics Digital Twins: Preparing the Geometry of a CAD Headlight Assembly for Meshing and Multiphysics Analysis in Simcenter 3D. Today we'll delve into Simcenter 3D's powerful and efficient multiphysics simulation and analysis. Using the example of a car headlight assembly, we'll take a close look at how to simplify and prepare parts of a CAD model for meshing using the advanced geometry cleanup capabilities of Simcenter 3D.

 

In this video, you'll learn:

  • How to select a part for modification, open it in a new window and isolate it from the rest of the assembly.
  • Three easy-to-use commands for simplifying the geometry:
  • Replace face command to delete raised faces
  • Delete face command to remove slots
  • Pocket or boss sensing options

Ready for the next step? With the changes automatically updated in the part assembly, the part is ready to prepare for meshing. Join us for our next video to learn how to prepare the headlight assembly for meshing.

 

Maya HTT
US & Canada: +1-800-343-6292 | UK: +44 (0) 330 024 1029
info@mayahtt.com | https://www.mayahtt.com
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Part 2: CAD Assemblies, FEMs and 3D Mesh in Simcenter 3D Multiphysics Analysis

 

Assembly FEMs and 3D Mesh Properties in Simcenter 3D: Preparing a CAD Headlight for Multiphysics Analysis
In part 2 of this series, we look at using Simcenter 3D's Pre/Post environment to work with an assembly FEM and create a 3D mesh of a component.

 

Continuing with the example of a car headlight assembly, we'll take a close look at creating and mapping an assembly FEM, and applying a customized mesh in preparation for coupled thermal-flow-structural analysis in Simcenter 3D Multiphysics.


In this video, you'll learn how to:

 

  • Create an assembly FEM from a CAD assembly and mesh an individual part.
  • Define the solver type as Simcenter 3D Multiphysics.
  • Map a FEM to an assembly FEM.
  • Specify the mesh type and element size.
  • Edit Mesh Collector Display options to customize the look of the model.
  • Define material properties, including radiation behavior.
  • Update the mesh into the assembly FEM with all the other components.

 

Ready for the next step?

 

With the changes automatically updated, the next step is to create a surface wrap mesh of 3D elements for air volume.


Join us for our next video to learn how to create a hybrid 3D surface wrap mesh for air volume.

 

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Part 3: Multiphysics Simulation Prep: Creating Hybrid 3D Mesh for Air Volume


Surface Wrap Recipes and Hybrid 3D Tet & Hex Mesh for Air Volume: Using Simcenter 3D Multiphysics


Welcome back! In this third video, we create a surface wrap mesh for air volume within the headlamp. We then apply a hybrid 3D mesh of tetrahedral and hexahedral elements in preparation for coupled thermal-flow-structural analysis in Simcenter 3D Multiphysics.

 

1. Find out how to:

  • Work with surface wrap recipes.
  • Define the surface wrap boundaries.
  • Detect any cavities within the assembly.
  • Select the cavity where you will apply the surface wrap mesh for air volume.
  • Define element type and size and other meshing options for the air volume surface.

 

2. Mesh the air volume with 3D elements

  • Apply a tetrahedron mesh in areas where geometries are more complex.
  • Apply a hexahedral mesh on the interior to obtain more robust calculations.
  • Trim a number of elements from the hex mesh, depending on the element size and the complexity of its geometry.
  • Inspect the mesh using Clip Sections to ensure the transition from tet to hex mesh and mesh size are adequate.

 

This wraps up the preparation steps. Ready to see the simulation?

 

Join us for our next video to explore the simulation environment of Simcenter 3D and see how to apply boundary conditions to the model.

 

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Part 4: Simple Simulation Setup with Simcenter 3D’s Automatic Face Detection

 

Digital Twin Setup for Multiphysics Simulation with Boundary Conditions, Constraints and Automatic Face Detection


In part 4 of this headlight assembly series, we take a quick look at how Simcenter 3D makes it easy to set up a full model for multiphysics simulation. Working from our dispartized model, we add the relevant physics to the simulation and unleash the magic of the Automatic Face Detection tool.


In this video, you'll learn how to


• Create a new simulation and solution for a structural-flow simulation.
• Define contacts for structural and thermal analysis
• Include boundary conditions and constraints.
• Use the Automatic Face Detection Tool.
• Detect all coincident faces in a complex assembly.
• Apply surface-to-surface gluing conditions and thermal contacts.
• Define the thermal contact magnitude.
• Prepare the contact files so they can easily be included in future solutions.


Coming up next…


Stay tuned as we continue to define our boundary conditions and constraints for our combined structural, thermal, flow analysis.

 

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Part 5: Quick & Efficient Setup of Three Breakout Models: Structural, Thermal and Flow

How to test model boundary conditions with separate structural, thermal and flow breakout models

Welcome back! In this video, we create three separate breakout models for testing in different scenarios. Working in the same environment and on the same model makes the process simple and efficient. See how to easily create separate structural, thermal and flow models in Simcenter 3D Multiphysics.


1. Set up the structural breakout model:

  • Define solver parameters.
  • Check the results outputs are appropriate for the analysis.
  • Reuse surface-to-surface gluing conditions.
  • Add fixed constraints and a load force.
  • Ensure structural contacts and materials are behaving properly before running the full analysis.

 

2. Set up the thermal breakout model:

  • Clone the structural model.
  • Toggle the solver from thermal to flow.
  • Verify parameters and results outputs.
  • Reuse surface-to-surface contacts as thermal contacts.
  • Ensure the right heat transfer coefficient.
  • Add thermal constraints to test conduction through the contacts and materials before adding complexities to the model.
  • Remove the structural constraints and structural load.

 

3. Add the flow analysis breakout model:

  • Clone the thermal solution.
  • Add the flow solver to turn on CFD calculation for the model.
  • Instruct the solver to compute buoyancy forces.
  • Verify parameters and results outputs.


In our next video, we will complete the analysis setup by defining radiation boundary conditions and then combine the three breakout models.

 

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Part 6: The Big Picture: A Whole Model View for Multiphysics Analysis


How to reduce computation time by explicitly defining radiation enclosures


In this video we bring it all together in one model. We add radiation enclosures to the model and then combine all the previous solutions into one final structural thermal flow multiphysics analysis.


The view factor calculation is the most computationally expensive part of solving thermal radiation models. One way to tackle this is to explicitly define the radiation enclosures.


We demonstrate how to quickly set up radiation enclosures for this complex headlight assembly:

  • Separate radiation enclosures for each bulb, selecting the filament and the glass bulb surrounding it.
  • Use deterministic method for calculating view factors.
  • Look at the element normals to ensure the correct optical properties for both the top and bottom surfaces.

Next, we create a streamlined solution that includes simulation objects, loads, and constraints for the thermal flow and structural solvers:

  • Include new flow surfaces for the structural-to-flow interaction.
  • Reuse surface-to-surface contacts from structural analysis and thermal analysis.
  • Add convection to exterior and interior boundary conditions.
  • Reuse two fixed conditions from structure and add a gravity load.
  • Add the four tungsten filament thermal loads.

Voilà, it's ready to be solved!


Stay tuned as we verify that our lighting system performs as intended and we prepare to visualize our results in a full structural-thermal-flow multiphysics simulation.

 

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Part 7: Visualizing Results with Simcenter 3D's Powerful Post-Processing Tools

How to visualize results and ensure constraints and boundary conditions are correctly defined.

Before running the full multiphysics solution results, we want to be sure we have everything well defined. To do that, we evaluate the results from intermediate solutions.


Simcenter 3D's powerful post-processing tools let us visualize the results to ensure each constraint and boundary condition is correctly defined.

  • Structural: Was the surface-to-surface gluing correctly defined for bonding conditions?
  • Thermal: Is the thermal coupling correctly defined? Are the temperature grades smooth or disjointed? Are there areas of the design that need further investigation? Are there hotspots that could indicate stagnation zones?

We take the flow visualization a step further with specific velocity cut planes:

  • Create layer states with multiple post views overlaid.
  • See how fluid is moving in specific planes and identify potential problems.
  • Visualize the fluid temperatures on the same cut planes.

Thermal-structural model solution:

  • Animate the solid temperature overlaid on the deformation plot.
  • See the scale of deformation more clearly on the complex geometry inside the lighting system.
  • Reveal the structural deformation process caused by the thermal stresses.

In the next video, we’ll see how to use overlaid plots.

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Part 8: Simplify and Streamline the Creation of Your Multiphysics Models

 

How overlaid plots and deformation animation deliver comprehensive visualization of complex physical phenomena.

 

Simcenter 3D's powerful post-processing features make it possible to include all the physics in one structural-thermal-flow model.


See how to efficiently obtain comprehensive, informative and instructive visualizations of a full multiphysics solution.
In this second-to-last video of our headlight series, we use layout states and:

 

  • Get a side-by-side view of the thermal flow results and the structural deformation.
  • Obtain a view of the lighting system while retaining a protion of the lens and bezel.
  • Modify the position of the plot elements using the edit graphics feature.
  • Animate the structural displacement plot to clearly show the deformation of the housing and other components due to thermal stressas and fluid pressures.
  • Use overlaid plots to represent multiple variables simultaneously and help interpret and understand the reults.


The next video concludes our series on the full multiphysics headlight assembly model.

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Part 9: Adding Complex Physics to a Structural-Thermal-Flow Model

How Simcenter 3D delivers sophisticated treatment of solar radiation, condensation and evaporation.


In this last video of the series, we include advanced physics into our headlight assembly model.


See how to incorporate complex physics such as solar heating, humidity, condensation and evaporation with just a few clicks.


Add solar heating effects and define parameters:

  • Calculate heat loss with parameters for the sun's position, the model's orientation and shadowing elements.  
  • Precisely model atmospheric attenuation and scattering, as well as ground reflection.
  • Easily model changing humidity levels and account for humidity transport and evolution over the course of the simulation.
  • Toggle on condensation analysis to account for condensation on surfaces inside the lighting system.

 

This concludes our video series on building a comprehensive multiphysics model of a headlight assembly. Thanks for watching!