AUTOSIM Workshop Lisbon. ANSYS Workbench Environment a new platform for complex simulation tasks

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AUTOSIM Workshop Lisbon ANSYS Workbench Environment – a new platform for complex simulation tasks 24.11.2006 R. Rauch CADFEM GmbH

www.cadfem.de

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AUTOSIM

Lisbon 2006

Topics:

1. Engineering simulation trends 2. ANSYS Workbench 3. The ITER - Challenge 4. Summary / Discussion

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AUTOSIM

Lisbon 2006

Engineering simulation trends

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AUTOSIM

Lisbon 2006

4 factors are impacting the CAE community: n To include all the relevant physics. — Coupled field simulation (e.g FSI, system level simulation) n To reduce the upup-front engineering time — FE Toolset for designer and analyst n To integrate CAE into the entire product development process — BiBi-directional CAD and PDM integration

n Simulating complete assemblies — Large problems

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AUTOSIM

Lisbon 2006

New Generation of CAE ANSYS Workbench

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AUTOSIM

Lisbon 2006

Mesh Mesh Generation Generation Post Post Processing Processing

Structural Structural ,, Thermal, Thermal, Electromagnetics, Electromagnetics, MBS MBS

Computational Computational Fluid Fluid DynamiX DynamiX

ANSYS Workbench Environment

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AUTOSIM

Lisbon 2006

CAD / PDM ANSYS Workbench Structural

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Fluid

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Heat

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MBS

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Electromagnetic

An adaptable multi-physics design and analysis system that integrates and coordinates different simulation tasks

Robust Design

Durability

Optimization

Customization

Legacy Data

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AUTOSIM

Lisbon 2006

Geometry Model CHT Solid Mesh

Integrated CFD and FEA

Advanced CFD with CHT

AN

SY

S

Thermal Stress Set-up

W

ork

Thermal Loads from CFX

be

nc

h

Thermal Stress Simulation

Design & Simulation Workflow

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AUTOSIM

Lisbon 2006

CAD Associativity + Project Documentation

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AUTOSIM

Lisbon 2006 Large Problems

Complex Physics

Ease of Use: Take advantage of bidirectional associativity

Define parameters to be modified in the CAECAEEnvironment

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AUTOSIM

Lisbon 2006 Large Problems

Complex Physics

Ease of Use: Modifiy geometry parameters without returning to CADCAD-system

Company – Software – Hardware – Service – DYNA – Consulting – Industry – TechNet – FEM - Gallery

AUTOSIM

Lisbon 2006 Large Problems

Complex Physics

Ease of Use: Derive sensitivties to improve system performance

Company – Software – Hardware – Service – DYNA – Consulting – Industry – TechNet – FEM - Gallery

AUTOSIM

Lisbon 2006 Large Problems

Complex Physics

Ease of Use: Summarize project information with automatic report generator

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AUTOSIM

Lisbon 2006

The ITER - Challenge

What is ITER? Ø The ITER project is an unprecedented international collaboration in which scientist and engineers from Europe, Japan, Russia, USA, China, South Korea and India are working together on the next step for the development of fusion. Ø ITER is an experimental fusion reactor based on the tokamak concept, in which superconducting coils operating at 4K, are positioned around a toroidal vessel. These coils provide a magnetic configuration in which the conditions are created and maintained for controlled fusion reactions.

Objectives of ITER Programmatic

Ø Demonstrate the scientific and technological feasibility of fusion energy for peaceful purposes.

Technical

Ø Demonstrate extended burn of DT plasmas, with steady state as the ultimate goal. Ø Integrate and test all essential fusion power reactor technologies and components. Ø Demonstrate safety and environmental acceptability of fusion.

ITER Parameters Total Fusion Power Q = Fusion power/auxiliary power Plasma inductive burn time Plasma major radius ≥ Plasma minor radius Plasma current Plasma Volume Plasma Surface Toroidal field @ 6.2 m radius

500 MW (700 MW) ≥ 10 (inductive) ≥ 300 s 6.2 m 2.0 m 15 MA (17.4 MA) 837 m3 678 m2 5.3 T

ITER Design Central Solenoid

Toroidal Field Coil

Vacuum Vessel

Poloidal Field Coil

Outer Intercoil Structure

Divertor

Machine Gravity Support

Structural Analyses Ø The ANSYS finite element program is used throughout the project by all parties (within the ITER organization and support teams) in order to support the engineering design activities. The types of finite element analyses are very diverse and range over: Mechanical Analyses (linear and nonnon-linear) Heat Analyses (linear and nonnon-linear) Dynamic Analyses (e.g. Seismic Response) ElectroElectro-Magnetic Analyses ThermoThermo-hydraulic Analyses

3D Fault Condition FE-Model The models shown so far are suitable for symmetric situations. In case of fault conditions, the current distribution becomes nonuniform and as a result, the electromagnetic force distribution is not symmetric. The analyses of such faults (like a TF-short or TFquench) require large and detailed FE-models including non-linear effects such as contact (+ gaps) and friction forces. The approach of ‘sub-modelling’ was chosen starting with a large global model to determine the loads and displacements which can be used on smaller detailed model. Ø This 3D global model describes a 180 degree section of the magnet system and includes all the important non-linearity's and components.

Courtesy by: M. Verrecchia

Results – Fatigue Assessment

0 50 100 150 200 250 300 350 400 450

Min. = 1 mm 2

A fatigue assessment is carried out is such that the maximum allowable allowable subsurface defect is calculated to sustain 60,000 cycles (safety factor of 2 on cycles). cycles). In the fatigue analysis assumptions are made such as different residual stresses in base metal and welds, safety factors, different plate thicknesses, etc.

Company – Software – Hardware – Service – DYNA – Consulting – Industry – TechNet – FEM - Gallery

AUTOSIM

Lisbon 2006

Summary

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the traditional simulation process will hardly survive

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simulation specialists have to focus on the spreading their knowledge into the development process

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coupled field analysis moves from expert level toward standard application

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development of simulation tools is more and more influenced by biomedical and future power generation industry

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