Thermal Analysis: CFD and FEA Based Simulation

ESimLab’s Engineering team with efficient utilizing real world transient simulation with FEA – CFD coupling if needed, with FEA Solvers such as AbaqusAnsysLS-dynaNastran and MSc Marc and computational fluid dynamics (CFD) solver like Siemens Star-ccm+ and Ansy Fluent for advanced Thermal simulation and have clear knowledge about the assumptions and simplifications that must be made to get results with required accuracy.

The effects of heat and thermal management of structures is more and more critical as performance limits are pushed further by the need to have lighter, smaller and more efficient designs. Convection, radiation and conduction loads are obvious, but the need to include the effect of power losses and thermal energy from friction and external sources such as pipe flows means that analysts need to have more tools at their disposal to simulate thermal models accurately. We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort and covers a wide range of Industries like Automotive, Aerospace, Oil and gas, marine, medical devices, heavy engineering and Industrial and consumer appliances.

With using CFD based design optimization solutions serve as an important link for our clients to realize their product promise right from concept to realization. Our team of CFD engineers in conjunction with experienced FEA Engineers for FSI and complicated industrial multiphysics problem is delivering solutions to major engineering verticals globally.

• Conduction, convection and radiative heat transfer
• Conjugate heat transfer
• Electronic component cooling design and analysis
• Turbo machines
Combustion and multiphase flows.
• IC Engine flows
• PCB thermal analysis
• Thermal analysis of radiator with heat pipe

Why we use Coupled FEA-CFD?

Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).

Reduced Costs
Easier, earlier, quicker analysis enables design simplification, especially on unusual hull designs. Early design correction avoids costly rework in production.
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Quicker Delivery
Reduce project delays caused by late-emerging design changes and rework. Reduce contingency planning.
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Better Design Quality
Easier analysis workflow promotes more thorough design development.
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Reduce Project Risk
Begin construction work with increased confidence. Reduce the risks and contingencies in tackling unconventional designs.
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Underbody/hood Modeling

An underbody and exhaust system modeling effort is a complex thermal management challenge, but ESimLab engineering team uses Ansys Fluent, Ansys CFX and Siemens Star CCM plus+ in coupled with Structural Solvers to solve this issue daily. Our team establishes an efficient process for modeling the exhaust system in a realistic, time-dependent environment. CFD and FEA simulation of the systems, allows our team to make design changes to protect unwanted thermal load on critical components.  This could reduce overall vehicle development costs, reduce your testing expenses.

Exhaust Thermal Modeling

Vehicle exhaust systems are subject to intense thermal loading. It requires both careful methodology and engineering experience to accurately predict their shielding, underhood, and underbody temperatures. Whether your goal is mass reduction, improved manifold shielding, or developing diesel particulate filters, the fastest, most cost-effective way to a reliable solution is working with Advanced CFD  and FEA tools combining with ESimLab engineers experience and innovative simulation procedure. ESimLab engineering team includes experts from within the automotive industry that have many years of experience developing solutions to multiphysics and heat transfer problems. From optimized heat shield design to full-vehicle simulations of hot soak driving cycles, our engineers provide you with the most cost-effective and comprehensive simulations.

Brake Thermal Modeling

our engineers are well-prepared to employ FEA and CFD tools to capture all modes of heat transfer from the system: radiation, conduction and convection. Our simulation methods include all transient braking events whether that is a high-speed track test or any transient customer driving profile. Our engineers can help you identify ways to reduce the mass of your system while improving thermal performance or exploring highly wear-resistant materials. Using FEA and CFD softwares, ESimLab engineers quickly produce accurate models of brakes, clutches, or other friction devices. We deliver comprehensive engineering reports, and in-depth aero-thermal analysis for the entire brake system.

HVAC/Climate Control Analysis

Climate control systems are often subjected to different thermal loads and require a conjugate heat transfer analysis. Most of systems have both environmental loads and electric dissipation loads and the purpose of many climate control systems is human thermal comfort. With using advanced Thermal analysis tools we can test the efficacy of passive thermal designs and energy-saving devices, without sacrificing human comfort. ESimLab provides both system-level and building-level analysis. From study of a window design to a full system analysis of HVAC loading requirements, our experience and efficiency are leveraged to a cost-effective solution.

Climate Control System Design

ESimLab engineers place virtual buildings, vehicles, and human models into simulated natural environments with specific global positions, real weather data, and, in some cases, virtual human thermal models. Simulating the total energy balance of the building or vehicle over time, including the performance of the climate control system, we predict the temperatures of the exterior and interior spaces.The temperatures of the human body segments and body core are simulated in response to the building or vehicle environment, including solar transmission through windows onto the human model. The results of such analyses allow improvements to thermal performance of engineered systems with lower energy consumption by HVAC systems.

Battery Thermal Management

We offer consulting to simulation plan that will achieve customer objectives. Our staff can rapidly mesh vehicle or battery geometry for optimal simulation time and carry out the model setup, analysis, and validation/verification. Using the advanced methods, we can simulate battery operating scenarios using 3D Advanced simulation tools.

• Optimized simulation process for cell and pack level studies
• Cooling, insulation, and heat protection studies
• Vehicle drive cycle model: heat up and cool down
• Electrical drive cycle power profile
• Coupled thermal-electrical simulation
• Analysis of battery cells
• Design of battery pack systems
• Packaging and vehicle integration
• Battery life prediction and battery runaway

Transient Vehicle Thermal Management

Extending from steady state to transient simulation allows engineers to investigate the real conditions of vehicle driving cycles. The processes we use are efficient utilizing real world transient simulation including FEA-CFD coupling if needed. The majority of virtual vehicle thermal management utilizes the coupling of FEA Solvers like Abaqus, Ansys, LS-dyna , Nastran and MSc Marc to a computational fluid dynamics (CFD) solver like Siemens Star-ccm+ and Ansy Fluent. This technique can significantly reduce the turnaround time by creating a cost and time efficient process that utilizes the strengths of each solvers.

Human Thermal Modeling

Based on established models, the Human Thermal modelinng is a state-of-the-art segmental model that operates within our thermal analysis software to provide a comprehensive simulation of human thermo-regulation under transient and asymmetrical environmental conditions. All thermo-regulatory responses are computed locally based on environmental conditions, clothing, body percentile, and activity level.

• Blood flow
• Respiration
• Shivering/sweating
• Conductive contact

Thermal Analysis Application

Human thermal applications include architectural analysis, passenger compartment design for vehicles and trains, firefighter safety equipment, and advanced materials for clothing systems.

• Protective clothing simulation
• HVAC optimization
• Window placement studies
• Localized building design
• Heated and cooled seats
• Human effectiveness and safety

Cabin Comfort Analysis

Operating a vehicle when the temperature conditions are inaccurate is uncomfortable and unnecessary. Cabin comfort is important for the driver and passengers. ESimLab Use combination of special CAE tools to predict transient thermal comfort for humans in a variety of realistic environments. Using advanced simulation, our analysis provides data taking into account the inert surfaces, outside air and the human metabolism. We can provide you with energy-saving innovations that will provide a comfortable, climate controlled cabin in any environment and save you valuable time and resources.

Matlab, Fortran, Python CFD FEA
Abaqus , Ansys, Matab, Fortran, Python CFD, FEA
CFD FEA ABAQUS Ansys Fluent Star-ccm+ Siemens matlab
CFD FEA ABAQUS Ansys Fluent Star-ccm+ Siemens matlab

Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.

FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.

Esimlab’s engineering team use advanced methodology and procedure in programming and correct constitutive equation in solid, fluid and multiphysics environment based on our clients needs.

We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.

ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.

Together, we enable customers to reduce R&D costs and bring products to market faster, with confidence.

Do you need more information or want to discuss your project?

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A world-class consultancy for engineering, technology, innovation, our industry know-how and technical expertise is unrivalled.

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We use advanced virtual engineering tools, supported by a team of technical experts, to global partners in different industries.

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Our Software team is made up of developers, industry experts and technical consultants ensuring we can respond to each client’s individual needs

Do you need more information or want to discuss your project?

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Real world Simulation: Combination of experience and advanced analysis tools

Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming  and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies. ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.

CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling

Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.

metal forming simulation: ansys abaqus simufact forming
Metal Forming Simulation
Automotive Engineering: Powertrain Component Development, NVH, Combustion and Thermal simulation, Abaqus, Ansys, Ls-dyna, Siemens Star-ccm EsimLab
Crash Test and Crashworthiness
Finite Element and CFD Based Simulation of Casting esi procast
Casting Simulation
Additive Manufacturing: FEA Based Design and Optimization with Abaqus, ANSYS and Nastran
Additive Manufacturing
MultiObjective Design and Optimization of Turbomachinery: Ansys Fluent, Numeca fine turbo, Siemens star-ccm+, simulia abaqus, Ls-dyna, Matlab
Design of Turbomachinery
CFD Heat Thermal simulation: Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab
CFD Heat Transfer
Fluid Structure Interaction FSI with Ansys Abaqus, Fluent Star-ccm Comsol
Hydrodynamics
Fluid Structure Interaction FEA CFD FSI Abaqus Ansys Comsol LS-dyna Wind Turbine EsimLab
Fluid Strucure Interaction
Exhaust Acoustics and vibration: ESI va one, msc actran, abaqus, ansys, fluent, star-ccm , nastran
Acoustics & Vibration
Aerodynamic Simulation CFD Ansys Fluent Siemens Star-ccm+ Numeca xflow cradle
Aerodynamic Simulation
Ansys Fluent, Siemens Star-ccm+ Numeca fine , Avl Fire, Matlab
Combustion Simulation
Multiphase Flow Simulation Abaqus, Ansys, Fluent, Siemens Star-ccm+, Matlab
MultiPhase Flow Simulation
Fatigue Simulation Abaqus Ansys FE-Safe NCode Design Life FEA Finite Element ESimLab
Creep & Fatigue
Multibody dynamics MBD Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab, fortran , C++, Python
Multi-Body Dynamics (MBD)
composite impact simulation , Comsol Abaqus, Ansys, Fluent, Siemens Star-ccm+, Aerospace and defenceMatlab, Fortran, Python CFD FEA
Composite Design
welding FEA Simulation Simufact Welding ESI Sysweld Abaqus Ansys ESIMLAB
Welding Simulation
Optimization of Wind Turbine Composite Fracture Mechanic Damage Design Abaqus Ansys Finite Element CFD ESIMLAB
Multi-Objective Optimization
CFD and FEA based Fortran, C++, Matlab and Python Programming
Advanced Fortran, C++, Matlab & Python Programming