Computational Fluid Dynamics (CFD)

Introduction

Computational Fluid Dynamics (FEA) is a technique allowing virtual prediction of the fluid flow and thermal behaviors of a design.


The examples presented below represent a non-exhaustive list of simulations I've created for public-facing content or publications. For additional information on commercial projects I've worked on, please contact me directly.

Thermal Analysis & Electronics Cooling

Optimizing the thermal performance of air and liquid-cooled electronics and other devices, including EVs and alternative energy products up to 10+ Megawatts.

  • Passive and actively-cooled devices
  • Large assemblies (5,000+ component)
  • Heatsink, waterblock, and fan placement optimization
  • Component specification & sourcing
  • Thermal radiation & solar loadings
  • Compliance with MIL-STD-910 thermal requirements
Thermal analysis of a compact fan-cooled mini PC using SOLIDWORKS Flow Simulation.
Thermal analysis of a dual CPU 1-U Rackmount Server using SOLIDWORKS Flow Simulation. Both air-cooled and liquid-cooled configurations were assessed.

Lift & Drag Prediction

Simulating external aerodynamics and hydrodynamics to assess the performance of vehicles or the forces acting on static structures.

  • Simulation of automobiles, motorcycles, drones, and submersible UUVs
  • Estimation of lift & drag polars
  • Prediction of aerodynamic or hydrodynamic stability
  • Calculation of Drag coefficient (Cd) and Effective Projected Area (EPA)
  • Wind load estimation on static structures
Assessing the aerodynamic performance of a fixed-wing drone at various angles of attack in SOLIDWORKS Flow Simulation.

Rotating Machinery

Optimizing pumps, fans, propellers, and turbines using advanced techniques to calculate flow rates, pressure heads, and efficiency.

  • Pump curve characterization (Head vs Flow Rate, Efficiency)
  • Cavitation and acoustic prediction
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  • Multi-stage pumps and compressors
  • Moving Reference Frame (MRF), Sliding Mesh, and 6DOF
  • Steam turbines and Real Gas models
Analysis of a centripetal-style impeller water pump and volute in SOLIDWORKS Flow Simulation utilizing sliding mesh approach. Pump head and efficiency curves were calculated virtually.
Simulation of a multi-fluid mixing problem with free surface ineractions (tank headspace) in SIMULIA XFlow. A passive scalar was utilized to visualize mixing of some second fluid.

Open Channel Flows

Simulating free-surface flows where liquid interacts with a gas phase, utilizing methods such as Volume of Fluids (VoF)

  • Spillway, weir, and dam flow prediction
  • Partially-filled pipe flow
  • Boat hull resistance calculation for small and large craft
  • Tank sloshing and baffle effectiveness
  • Hydraulic jump and energy dissipation
  • Immiscible mixtures with two or more liquids (e.g. water & oil)
Open-channel water flow past a river dam simulated in SIMULIA Fluid Dynamics Engineer utilizing the Volume of Fluids (VoF) treatment for free surface interactions.

Multi-Fluid Mixing Problems

Analyzing the mixing efficiency of different fluids, species transport, and concentration distribution.

  • Static mixer design and optimization
  • Species transport and pollutant dispersion
  • HVAC air quality and circulation analysis
  • Residence time distribution studies
A variety of HVAC-style problems monitoring indoor air quality and trace contaminent disbursement created for a CFD training course.
The mixing performance of a venturi for a Propane gas burner is assessed using SOLIDWORKS Flow Simulation.

Particle Studies

Simulating discrete phase interactions to predict erosion, accumulation, and separation efficiency.

  • Erosion rate prediction on pipe bends and valves
  • Dust accretion and surface fouling analysis
  • Cyclone separator and filter efficiency
  • Lagrangian particle tracking (DPM)
A simple demonstration of Lagrangian particle injection atop an existing flow field with particle-wall collisions.

Transient & Unsteady Flows

Capturing time-dependent phenomena such as vortex shedding and flow-induced vibration that steady-state approximations miss.

  • Vortex shedding frequency (Strouhal number) analysis
  • Pulsatile flow in biomedical or hydraulic systems
  • Tank filling, draining, and startup sequences
  • Water hammer and surge pressure prediction
Transient thermal analysis for a passively cooled electronic device intended to determine the time required to reach peak temperature / steady-state equilibrium. Various solver techniques were utilized to decrease solve time.

Design Optimization

Using parametric studies to automatically iterate geometry and achieve optimal flow characteristics.

  • Manifold balancing for equal flow distribution
  • Valve flow coefficient (Cv) maximization
  • Pressure drop minimization in ducting
  • Goal-driven optimization studies
Before and after optimization efforts for a liquid-cooling CPU waterblock.
Design of Experiments (DoE) response surface for a particular optimization effort.

Verification & Validation

Ensuring solution reliability through rigorous mesh independence studies and comparison with analytical or experimental data.

  • Grid Convergence Index (GCI) calculations
  • Y+ wall spacing validation for turbulence models
  • Residual monitoring and mass balance checks
  • Correlation with wind tunnel or flow bench data
A simple case study of mesh convergence / grid independence created for a CFD training course.
Solution-adaptive mesh refinement utilized for an external aerodynamics problem. The solver dynamically subdivides the grid in areas of high pressure gradients.

Plastics Moldflow Analysis

Simulating the injection molding process to predict manufacturing defects, optimize cycle times, and validate tool design.

  • Fill time, pressure drop, and temperature distribution
  • Sink mark, air trap, and weld line prediction
  • Warpage and shrinkage analysis
  • Fiber orientation in reinforced composites
Mold filling analysis for an injection mold 'family mold' using two dissimilar parts, performed in SOLIDWORKS Platsics.

Additional Capabilities

  • Compressible Flow (High Mach)
  • Non-Newtonian Fluids
  • Multiphase Flow (VOF, Eulerian)
  • Moving Mesh & Overset Grid
  • HVAC & Comfort Parameters
  • Acoustic / Noise Prediction (dB, FFT)
  • Humidity & Condensation
  • Cavitation Prediction

Analysis Methodology

Over the course of 10+ years, I've utilized computational fluid dynamics to assess the performance of parts, products, and assemblies from hundreds of customers and clients- guiding them through the entire process from forming an analysis plan, preparing CAD models and other geometry, solving, reporting, and interpreting results.

I work closely with stakeholders to ensure that every simulation provides actionable data focused on their needs by verifying that we are solving the correct problem in a level of fidelity appropriate for the current phase of their product development cycle.

If you'd like to learn more about my capabilities or professional experience, or would like to review a sample analysis report, please reach out.

Contact me for more Info

Software Used

SOLIDWORKS Flow Simulation

ANSYS Fluent

SimScale

SIMULIA XFlow

OpenFOAM

ParaView

SIMULIA Fluid Dynamics Engineer

SOLIDWORKS Plastics

Python (NumPy/Pandas)