Reliable Heat Dissipation Concepts and Flow Designs Using CFD Simulation
We’d be happy to advise you.
Contact us now
The Physical Foundations of Computational Fluid Dynamics
The term Computational Fluid Dynamics describes the solution of the Navier-Stokes equations as well as the conservation laws for mass, momentum, and energy to predict fluid flows. As an interdisciplinary field between physics and numerical mathematics, this methodology uses powerful algorithms to model the laws of fluid flow and heat transfer. In doing so, we apply theoretical principles of fluid dynamics to complex, real-world geometries.
How We Implement a CFD Flow Simulation Methodically
A CFD flow simulation involves the practical application of numerical calculations to your specific digital model. The simulation examines the interaction of fluids (gases or liquids) with solid surfaces, but it can also model mixing processes, multiphase flows, or chemical reactions within the fluid.
Industrial Applications of Computational Fluid Dynamics (CFD)
The wide-ranging applications of Computational Fluid Dynamics (CFD) span nearly every sector of modern industry. Wherever fluid flow occurs, this technology provides valuable insights into heat dissipation and potential flow optimization:
-
Plant Engineering: Analysis of fluid flow in piping, valves, and reactors to improve efficiency and operational safety.
-
Electronic Cooling: Conducting conjugate heat transfer analyses to accurately predict temperatures in dense assemblies and designs, thereby reliably preventing thermal failures.
-
Air conditioning technology: Optimizing air circulation in a building or control cabinet to ensure specified operating conditions.
-
Fluid machinery: Improving the efficiency of pumps and fans by analyzing and preventing unwanted flow separation at the blades.
In all these areas, predictive analytics leads to a significant increase in the safety of your products and systems, as well as a measurable reduction in development cycles.
CAD Models and Fluid Domain Extraction for CFD Calculations
The quality of a CFD calculation depends directly on the quality of the input data. The minimum information required includes geometric data in the form of 3D CAD models. The CFD software requires a volumetric model of the fluid domain for meshing. If only sketches or physical prototypes are available in the early project phases, these can first be converted into usable CAD data (for example, through 3D scanning or re-engineering).
Furthermore, the object of investigation must be clearly defined—that is, whether we are examining a single part, a specific component, or an entire system.
System Components: Boundary Conditions and Material Properties
To accurately model the system behavior of fluid flow, we systematically record the properties and boundary conditions of your components. Defining the transitions at the system boundaries—such as mass flow inlets, pressure outlets, or the application of appropriate wall functions—is essential for the quality of the calculation.
-
Fans: Unless specified by the customer, we recommend a suitable fan. The type, the performance curves (P-Q curves), and the exact position are documented.
-
Active components: For these, the power dissipation, geometric data, and manufacturer specifications regarding thermal resistance are required.
-
Printed circuit boards (PCBs): Depending on the appropriate and desired level of detail, we take into account the respective basic structure, the number of layers, the copper content, and additional details in the simulation. By homogenizing the microscopic copper-FR4 structure, the effective orthotropic thermal conductivity in the in-plane and cross-plane directions is derived for the computational model.
-
Heat sinks: The geometric data, the material used, and the thermal resistance are incorporated into the models.
-
Air inlets and filters: Fan inlets can be modeled in detail or, like filters, as porous media with defined viscous and inertial resistance coefficients. This allows us to optimize the computational effort required for an accurate physical representation.
If specific thermal data is unavailable, our engineers initially rely on proven experience values. To ensure validity, we use sensitivity analyses or worst-case scenarios in such cases.
From Discretization to Current Status Analysis
After discretizing the flow domain and defining all boundary conditions, the initial calculation is performed. This serves as the basis for the current status analysis. The evaluation quantitatively illustrates the current behavior of flows and temperatures in the design. Building on this initial analysis, we develop well-founded optimization recommendations for your thermal management or flow control.
Targeted Optimization and Variant Analysis for Efficient Systems
The primary goal of our service is functional optimization. As part of variant analyses, we calculate different geometries or modified boundary conditions and evaluate their effects. The resulting discussion of the results and the systematic comparison of solutions enable targeted improvements to the thermal or fluid dynamics design.
Transparent Presentation of Results and Delivery of Documentation
The transparent results of the calculations will be presented to you during a results presentation. This presentation includes a detailed description of the underlying computational model as well as a list of the boundary conditions used. To illustrate the complex physical processes, we use high-resolution images and contour plots of the calculated velocity and temperature fields. After the official project completion, you will receive a comprehensive results report.
Talk to us about your fluid dynamics concept
Every application has its own specific requirements regarding flow behavior and thermal conditions. We would be happy to evaluate your CAD data and project goals during a technical consultation. To give you further insight into our methodology, we have summarized the key points in the following questions.
The Project Workflow of a Structured CFD Simulation
To generate reliable results, the simulation requires a standardized project workflow. As a professional service, our approach is based on close collaboration and transparency.
The process begins with your inquiry, which includes initial information, requirements, and basic boundary conditions. This is followed by a feasibility study. Based on this, a detailed proposal is prepared, which includes a project plan with clear estimates of time, effort, and design options. Once the formal order is placed, structured modeling begins.
FAQ: Frequently Asked Questions About Our Services (CFD Analyses)
1. What is the difference between general fluid mechanics and CFD?
Fluid mechanics is the broader field that deals with the physical behavior of fluids (gases and liquids). CFD (Computational Fluid Dynamics) is the specific numerical method used to solve these fluid mechanics conservation equations virtually, using computer-based models.
2. At what stage of development does it make sense to perform a flow simulation?
It is already recommended in an early design phase. As soon as the first digital 3D CAD models are available, initial investigations can begin. Early CFD analyses help identify fundamental design flaws in flow behavior before prototypes are manufactured at high cost. We also successfully apply our methods to existing products. This allows us to identify opportunities for optimization and enhance the reliability of both function and design.
3. How are unknown parameters in preliminary stages handled?
When specific data is not available, our calculation engineers rely on proven estimates or industry-specific empirical values. To ensure the validity of the calculation, we also perform sensitivity analyses. This ensures that we methodically assess the extent to which uncertain assumptions affect the overall result.
4. Which physical results does a CFD calculation provide?
The output provides comprehensive flow and thermodynamic relationships. These include pressure and velocity fields, total pressure losses, static pressure drops, or pressure loss coefficients (ζ-values), as well as detailed volume and mass flow rates. In addition, there are 3D temperature fields and vector representations of flow patterns.
5. Do we always have to simulate the entire system?
No. It is perfectly possible to analyze just a single component or an isolated subsystem. In doing so, we pay particular attention to defining realistic boundary conditions at the interfaces (such as mass flow inlets), since the subsystem must be correctly delimited in terms of fluid dynamics.
6. How are filters and perforated plates accounted for in the simulation?
Such components are modeled as porous media with defined viscous and inertial resistance coefficients (according to the Darcy-Forchheimer approach). This allows us to optimize computational effort while maintaining a precise physical representation, without overloading the computational mesh by fully resolving the geometry of every single hole.
If grids, fins, or perforated plates are the primary focus of the investigation, we also fully discretize these geometries. This approach enables the precise identification of resistance coefficients as well as pressure loss and device characteristic curves, which subsequently serve as valid input parameters for more complex system models.
7. Can the results of a CFD simulation be used for certification?
CFD simulation significantly accelerates the development and certification process and provides sound evidence of functional safety. However, as part of official approval procedures, methodological validation of the computational model through experimental measurements (for example, in a wind tunnel or a thermal measurement chamber) on a real prototype is generally required.
In contrast, when dealing with existing systems, well-founded model assumptions and simulated predictions of system behavior are considered standard and accepted practice.
8. How long does a typical flow analysis take?
The duration depends on the complexity of the geometries and the level of detail required. As early as the proposal drafting stage, we develop a project plan that includes a well-founded time estimate for the fluid domain extraction, the discretization, and any required variant analyses.
Products
Air conditioning components and more
