A Case Study : An Ideal CFD Training Course with OpenFOAM / Ansys (part-2)

As we have mentioned in the last post, we are writing about our drafting of Ideal CFD Training Course with OpenFOAM / Ansys Fluent and other related softwares. In our training wing, we are specifically focusing on OpenFOAM. Anyways, whatever may be the CFD tool, we know the knowledge of CFD is important to properly use any software tool.

You Can’t Force somebody to learn anything (whether it is CFD, OpenFOAM  or merely alphabets 😀 )

You can't force somebody to learn anything including OpenFOAM, CFD, Ansys Fluent or any other thing

Image Source: Internet

And we know, it is very difficult to learn when the things are not linked properly. Hence, our idea for an Ideal CFD Training Course with OpenFOAM is to seamlessly include the the essentials and make a perfect recipe. Putting forward this strategy, we have designed the ideal course and the highlights are mentioned below.


Course Overview


  1. It should be a balanced course for a beginner in CFD Field
  2. The important prospect of this course, it allows the participant to built up their understanding in all the aspect to OpenFOAM as a general-purpose CFD Solver.
  3. More than half of the time will be devoted on hands-on sessions

We feel that this could be the perfect recipe for an Ideal CFD Training Course with OpenFOAM


Physics Involved and Code development Aspect


  1. Participants will solve some pre-defined cases as well as some of the newly developed cases like (physics involved):
    • Potential Flow, Simple Flow cases, Heat Transfer including natural convection
    • Turbulence Flows (RANS and LES Modeling)
    • Moving Frame of reference (MRF), Volume of Fluid (VOF), Dynamic Mesh Movements (sliding Mesh)
    • Fluid Structure Interaction (FSI) and Magnetohydrodynamics (MHD)
  2. Code Development aspect allow the students to walk through various pre-defined solvers like icoFoam, simpleFoam etc. It will also make through boundary conditions, utilities, and libraries.
    • Hands-on experience on platform to the participant for implementing various boundary conditions, incorporating solar transport in existing solvers and library development for new physics

      CFD Training Rules

      CFD Training Rules


Course Options


You can’t throw the same recipe for every one. Similarly, we have divided the overall course-concept into three parts. Hence, in total there are three options in this course:

  1. Inherit CFD Theory
  2. OpenFOAM
  3. Comparative study of Fluent

 


This course is for the ones who are:


  1. New to OpenFOAM
  2. Have partial training in OpenFOAM
  3. Want to develop proficiency in CFD / OpenFOAM
  4. Want to simplify the use of OpenFOAM
  5. PG Student, Research Scholar, starting career in CFD, R&D person either in industry / lab etc.

Prerequisite for the course


One’s interest is the perquisite for learning any thing in the world. If you ignore this urge of taking interest, then the image below is you. 😀 😀

OpenFOAM, the necessary steps

If you won’t, it can’t


Duration


We designed this course for completion in 6 weeks

Conclusion:

We tried to make the course structure as per the students feedback, there is always a scope of improvement. All the CFD training centers in the world have a long way to go.

the most important conclusion point from this blog is:

your interest is necessary for learning anything, any organization can only provide facilities and seamless learning platform.

 

in next blog, we will be writing about the fluctuating terms in turbulence modeling.

A Case Study : An Ideal CFD Training Course with OpenFOAM / Ansys (part-1)

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Our Background for this case study on CFD Training institutes in Pune, Bengaluru, Mumbai etc., with OpenFOAM / Ansys

Various companies and Institutes provide CFD Training on various software platforms like Ansys Fluent, Ansys CFX, OpenFOAM etc.. The number of CFD Training institutes in Pune, Bengaluru, Mumbai, Indore are growing rapidly like an epidemic. 


BUT the course quality is getting worsen every passing day. the final results are like:

  1. Incomplete Traning on software aspects (unable to handle the software)
  2. NO knowledge about the inherent theory (resulting in hilarious results ; see our blog adressing this issue)
  3. No Placements offered / No placements on the records
Best CFD Training with Ansys / OpenFOAM

Image Source : Internet

We are writing this blog to share the conclusions of our market analysis & research on CFD Training Provided by various institutes. 

please note that ‘CFD Training Course with OpenFOAM / Ansys’ is a case study, not a marketing blog. we are sharing the results obatined by our market analysis

Let’s start with the local market analysis

CFD Training institutes in Pune, Mumbai, Bangalore, Nagpur and Indore

It is not worth to take any names, but almost all the CFD Training institutes in the cities like Pune, Mumbai, Bangalore etc. are unable to deliver what was expected. With our survey (by seminars, online interaction and direct talks) on students, we come to know about the expectations of (Indian) students.

Any (Indian) Student expects only two things from CFD Training Institutes (either online or in Pune, Mumbai or Bangalore)

Any (Indian) Student expect only two things from CFD Training Institutes (either online or in Pune, Mumbai or Bangalore)

  1. Detail knowledge to independently handle general CFD projects (not so complicated cases)
  2. Placements Opportunities after the completion of the courses
  3. Appropriate duration for the course

OpenFOAM, Ansys and CFD Training Institutes in Pune

Sample Image: Screen shot of OpenFOAM Training Sessions in Pune Branch

We addressed the problems of the students

With our detailed analysis, we have formulated an ideal course structure. and you know what, it works fantastic with complete knowledge on CFD and 100% placements. The duration of the course was just 6 weeks (about one and a half month).

The Second part of this blog

The second part of this blog will be published tomorrow on 09-Sep-2016. In the second part we will be writing about how we drafted the course structure and how we addressed the problems

Conclusion

  1. CFD Training institutes in Pune, Mumbai, Bangalore etc. have a long way to go.
  2. Only quality of your education can give you better job opportunities and a sustainable development

 

We figured out why recent Engineering graduates are not able to get the jobs??

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Primarily for Mechanical graduates…

Around 1.5 Million Engineers are graduated in every year in India with a mammoth 4000 Institutes. Over Last 10 years there is more than 200% increment in the intake and pass outs (So called) Engineers.

In last 3 Months we have interviewed 300 students / Engineers for 3 various post in our firm, we were very shocked after seing the results because,70% Engineers failed in aptitude and almost no-One knows the physical meaning of the values obtained by the calculations There are some problems in the mindset and in learning process, also we have focused on Remedies of it.

CAD, CREO, CFD, EMPLOYABILITY, EMPLOYMENT

Pic Source : Internet ||  Workshopwale is the platform to achieve it..

In that interview series we digged out and got following results as follows-

A. Why are we pursuing the Engineering?

  1. A straight forward answer is , In India a normal students (Not Everyone) is pursuing Engineering because everybody doing so and the worst thing is parents also feeling the same.

B. Knowledge Approach??

  1. Absolutely no idea about the physics behind the Projects/Machines & No idea about the results of the calculations.
  2. Blindly trusting the available information available on the internet i.e GOOGLE & WIKI. &
  3. Take it easy Approach.

We would like you to take towards the positive aspect of the concept and list out the things which may be useful to get rid of a dilemma

Here we go..

Remedies

  1. Come out from your comfort zone and start learning some advance courses like CAD, Cre-o & CFD etc. For more details you can visit www.workshopwale.com.

  2. You must have clear idea about what are you doing, build the positive attitude towards knowledge, break your own barriers. For all youngsters you must go for YES +/ Happiness programme of Art Of Living, there you will come to know, how to get read of your negative approach and worries.

  3. Gets hands on training on Open Sources Like free CAD / OpenFoam etc.

  4. Always build the curiosity about your projects, works & scenarios.

Conclusion:-

Intention behind this blog is very simple and clear that one must be aware about the current advance techniques because if you want to be a part of change , you must know what is change. Because Unemployment is not our main problem, the problem is Unemployability .

2 Proven Cases In CFD

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In my previous blogs, we had put special emphasis on saying that learning some software is not CFD. You need to have a sound knowledge about the basics of the subject then only you can validate the results.

Today, let’s see an example where the two different cases of same geometry and condition will give two different meaning to CFD. But, let me first warn you, this could be little more technical for first few lines afterwards, you can enjoy the meaning.

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Case 1: Colorful Fluid Dynamics

The first one obviously abbreviate CFD as Colorful Fluid Dynamics.

Let us take a case of Exhaust Gas Recirculation (EGR) valve of a single cylinder naturally aspirated engine. In this case, we are considering the spring-loaded valve.

The physics of the valve says that it should deliver some fraction of exhaust gases with fresh air during the suction stroke of the engine. The geometry and boundary conditions are such that the temperature and velocity should be in the range of 487K to 298K and 60m/s to 0 m/s respectively. Let’s not go much into technical, we assume that the walls are at 298K and with no-slip conditions.

Now, suppose we have our first simulation, done by someone who is very good in operating software, but very poor in basics. For him, the colorful picture is CFD result. Let’s see what has he got as a result of 1-wwek of computing.

img2

The key points of the result are:

  • The velocity ranges up to 660 m/s which is nearly equal to M=2. i.e., Mach 2. Now, let me disclose, the engine was single cylinder 400cc naturally aspirated, at no point of time this velocity of M=2 is possible. In other words, you are riding a bike with the speed of a missile. God bless.
  • The temperature range is from 487K to 169K i.e., from about 200degC to -100degC. In other words, you have 3 in one system, generating power from the engine, heating requirements fulfilled and the biggest one, throw-out refrigerators from your home. -100degC, there is no refrigerator at your home which can cool even closer to this temperature.
  • Pressure variations are drastically higher to give enough shock to break the engine body.

In simple words, this results shows that you can not generate enough power with a good quality of heating and start a home production of dry ice. Millionaire in a week!!!

But, unfortunately (or fortunately) this results doesn’t have any physical sense. Hence, this simulation abbreviates CFD as ‘Colorful Fluid Dynamics’.

Case 2: Computational Fluid Dynamics

Now, let’s take another guy, who knows the governing theories and also knows how to apply it using software tools. The result shown by him are:

img3

The key points of the result are:

  • The velocity ranges up to 60 m/s as well as the temperature is well in range 487K to 298K.
  • Results closely approximate the practical conditions, hence are acceptable.
  • It can be further taken for experimental validation.
  • But unfortunately, this can’t make you a millionaire because you can do readymade co-generation of dry-ice, process heat, and power.

This result will abbreviate CFD in its proper sense, i.e., Computational Fluid Dynamics.

Conclusion

Friends, the point I am trying to make here is: the software whether it is Ansys, OpenFOAM, StarCCM or any other, is just a tool. The software is made by us, like any other tool. Hence, it is of prime importance to learn the proper theories before using these tools. In Bangalore and Pune, there are a lot of institutes which train you in CFD, but believe me, they are not training you in CFD. They are just making you end user of some software.

Want to know more about the background working of Softwares, Discretization Techniques, Errors and Error Propagation, Stability Analysis, stay tuned to Workshop Technologies.

So what say, Guys, have something in mind? Share it and we can discuss together.

3 Approaches To Fluid Mechanics

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In my previous blog Simulation Science And Computational Fluid Dynamics, I had talked about the interpretation of CFD concepts and my discussion was limited to the nature of solution obtained from CFD simulations. As we look into the classical approach of fluid mechanics, we will see that there were three approaches for the determination of fluid phenomenon. 

In this blog, I will talk about the nature of solutions and its interpretations in real-world applications. Let’s look at the three approaches in detail.

The 1st and 2nd Approach To Fluid Mechanics

The 1st approach in fluid mechanics is mostly theoretical. In order to validate the 1st approach, 2nd approach (i.e. experiment) is used. We can’t completely rely on theory because of assumed values and simplifications. Similarly, it is not very economical to conduct experiments and to articulate the real life conditions.

For example, if we want to test an aircraft at the speed of say M=5, i.e., Mach 5. In this case, most of our theoretical calculations fail because of unusual curved geometries and complex structures. The experiments at ground testing facilities require wind-tunnels of such capacities. We are lacking the wind tunnels that can simultaneously maintain the higher Mach number and higher flow field temperatures. Also, there is a big question about the accuracy of the results. Hence, it is always better to start with a better estimate of the values. This ‘better estimate’ is provided by Computational Fluid Dynamics (CFD), the 3rd Approach.

Let’s dig a little deeper into this.

3rd Approach To Fluid Mechanics

As we discussed the two approaches, we can consider CFD as the 3rd approach in fluid mechanics. I am not saying that CFD will completely replace the theory or it will completely replace the experiments. The only thing I am saying here is that the ‘3rd approach’ will assist both the approaches in reducing the overall effort and cost. Hence, we can more confidently say that CFD is just an engineering tool. A good computer programmer can write a CFD code and solve some problems, but the results he/she will get may not make any physical sense.

The point I am trying to make here is, learning some software is not CFD. For using a complete potential of CFD, you need to learn the governing principles and ideas driving CFD. Once you are familiar with the theory and algorithms in CFD, you can use any of the software with a little practice. It doesn’t matter whether you are using Ansys Fluent, CFX, StarCCM or OpenFOAM, of you are familiar with the concepts any software can be used effectively. focus on OpenFOAM

Workshop Technologies focus on OpenFOAM because it is free in all respect. It is easy to program, fast and reliable. All the software, if used intellectually will give similar, but not exactly same results. This is because of the inherent mathematical approximation in algorithms.

Conclusion

CFD is a developing science. The current state of CFD is such that we can easily solve the laminar flow problems, but due to extensive computational cost and time required, we need turbulent models for calculating the turbulent flows. Direct Numerical Simulation (DNS) is limited to Reynolds value of few tens of thousands. If nothing new came up recently, then we are correct in mentioning that the achieved DNS till date is for Re=30,000. Still, DNS is not practically useful for most of the engineering problems due to computational limitations. Grid independence and governing equations are key players in the estimation of the correctness of results. Next blog will be dedicated to these topics.

Have any questions about CFD? I’d be more than happy to discuss them in the comments below.

Simulation Science And Computational Fluid Dynamics

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The wheel invented centuries ago has now taken speed. World today is fast moving with new product extensively coming in to replace the existing product. Experimentation is always necessary to introduce a product. Only experiments can validate the theory and purpose of a product. However, experimentation is not very easy and cheaper. The increasing cutting throat competition in the world is driving the business leaders to find a new and cheaper way to assist, if not replace, the need of experimentation.

We humans have invented mathematics as a solution to the problems of the physical world. And we are struggling to solve various equations to get the proper solutions to the real life problems. This same is applied everywhere in engineering product design and development. As I mentioned earlier mathematics will closely approximate the real-life problem and hence we are solving the corresponding equations. But these equations are complicated and we do further approximations to simplify our efforts. We all know life is not simple, so is the equations. Hence, it is least possible for any human to solve the equations for the complicated situations like a fluid flow say blood in our bodies, water in a steam-power plant pipelines, equations for conversion of water to steam and what not.

We are surrounded with fluids everywhere, from the air we breathe to the blood flow in our body, from water in domestic pipelines to the steam in the thermal power station. The estimate of fluid flow and flow parameters are very important to develop an upgraded product. For example, just take the first aircraft of modern days, made by Wright brother and compare it with the latest available aircraft. Present day aircraft are much faster, efficient and way better than the first built.

But was the first one unimportant?

Absolutely not. Actually, it was our first step to the better and efficient air crafts. Our aerofoil structures are designed mush better these days. But have you ever imagined the cost of experimentation for these newly designed aerofoil?

Depending upon the experiments the cost may range from few lacs to several crores. What if these experiments fail? Absolutely the first thing is a direct loss to that amount. Secondly, there is an advantage to the competitor because he had already saved that money.

So the question is, Is there something which we can do to save this money?

The answer is yes and this lies in the description above. As mentioned above, we are closely approximating the physical phenomenon using mathematical equations but we are facing difficulties in solving them. So, it would be better if we generate the equations and let some machine compute it. This is the mother thought of invention and development of simulation science. This science is still under development phase but the progress is really astonishing. Now we can simulate from the stresses to the complicated flow using computers.

One of the simulation science deals extensively with the fluid flow and is named as ‘Computational Fluid Dynamics’ globally adopted as an abbreviation of CFD. By seeing the beautiful pictures obtained in the results, some people also call it as Colourful Fluid Dynamics:):).

For me, it is a combination of both art and science. I can surely justify it for you. Most of the people reading this blog are comfortable with MS Word, but how many of us are a good writer?

There is a mechanic in a garage who knows how to use a drill and an engineer is also there. Both know how to drill but does the mechanic knows where to drill? Similarly, one may say a mathematician and a computer graduate can together solve an equation using computer. The mathematician will write the algorithm to solve while the computer science fellow will write the program for the same. But can we say confidently that they understood the physics of the problem? The results they obtained using CFD tools are correct? Do the results make sense?

In fact, if there is improper boundary conditions, or improper grid or even improper method to solve the equations, the results obtained will be erroneous. I will be similar to using a drill for tightening a screw.:):)

There are a lot of solvers commercially available like Ansys Fluent, CFX, OpenFOAM StarCCM etc. But we need a proper understanding of the subject before proceeding toward the subject. Here in Pune, I have seen a lot of training institutes claiming to train in CFD. Personally, I have tested few of them and fortunately or unfortunately, Workshop Technologies is the only training institute which gives proper knowledge and guidance in CFD. It is not like I am doing advertising for them, but seriously the way Workshop Technologies (workshopwale.com) handles the concepts and apply it the software tools is really astonishing and interesting. They said they are having two branches in Pune and Bangalore. They also do online training.

In further blogs, we will talk about some interesting cases and results of CFD.

Note: I am a working professional doing training at workshop technologies. as a request they allowed me to publish a blog on their behalf.  😀 😀