CFD & Coupled CFD Simulations @ Zeus Numerix

1Build-to-Specifications | Product Approval | Engineering Services | Software Development
CFD & Coupled CFD Capabilities
@ Zeus Numerix
One slide presentation on most of the projects with
deliberate attempt to avoid repeat
V3
Abhishek Jain

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©ZeusNumerixPvtLtd:ConfidentialDocument
Presentation Overview
16 June 2019 CFD Capabilities @ Zeus Numerix
 Zeus Numerix – an Introduction
 Journey started from India’s first commercial CFD software
 No 1 Know-Why company with build-to-spec and design optimization offerings
 Non-confidential Case studies
 Compressible flow examples
 Incompressible flow examples
 Non-conventional and coupled problems
 Team and Closure
 The presentation is non-confidential and some data may be masked
 Legends in the presentation are not shown purposefully
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2004
1st Project Completed
Large Defense Project
2005 2006
1st Software Export
System design software: Korea
2007
2008
CEM Software
UAV RCS Reduced
2009
1st Built-to-Spec project
Supersonic ground
vehicle developed
2010
Fire Safety & Comfort
Building fire and HVAC
2011
Control Software
In-house development
2012
2013
Parallel GPU code Devp
Visualize big data – 4 billion points
2015
Floating Panel Design
Solar Panels in Lake
2017
1st foreign missile project
Integration & Certification
2018
1st MSME TDF Winner
D&D of Composite Sea Water Pump
2019
Incubated at IIT Bombay
Journey Begins with India’s 1st
Commercial CFD software!
400th project completed
Lockheed Innovation
Medal & India Govt
R&D Certificate
CEM Software
CEMILAC Certification
1st Store Separation
project complete
www.zeusnumerix.com/portfolio
The Journey

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Customers List: Partial

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Accolades
R&D Recognition Innovation Medal
DST-FICCI-Lockheed Martin
India Innovation Growth
Medal 2007 for
“Numerical Simulations”
Recognition as an R&D Unit by
the Department of Scientific
and Industrial Research
“Design Approval” by Centre
for Military Airworthiness
and Certification certified
CEMILAC Certificate

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Core Offerings
Product
Development
Initial sizing from first
principles
Detailed analysis
based design
Prototype
development
Testing and validation
Product
Approval
Performance
estimate by analysis
Detailed Report
Generation
Review with approval
agency
Final submission and
product approval
Engineering
Services
Design calculation
reports
Analysis – CFD, FEM,
CEM
Failure analysis and
design suggestions
Multi-disciplinary
design optimization
Software
Development
Pre-processing
Automation
Solver development
from Literature
survey
Visualization, parallel
code CPU/GPU & GUI
System simulation
tools

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CFD Capabilities
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Compressible
• Aerothermal for hypersonic/space vehicles
• Aerodynamics – Spinning projectiles
• Aeroacoustics, unsteady flows
In-
Compressible
• CFD of vehicles, power plants, ducts, piping
• Vehicle aerodynamics, HVAC, Building fire
• Ship hydrodynamics, Nuclear flows
Specialized,
Coupled
• Coupled CFD+Dynamics – Store Separation
• Particle simulations, free surface flows
• CFD software development & validation
Unsteady flow from barrel
Muzzle blast
Ship propeller unsteady simulation

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Compressible Flows
Examples of CFD for high speed flows for aerospace and
projectile geometries
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Panel Separation
 Freestream flow at 6.5 Mach
 Initial 1-DoF: panel rotates about hinge; 6DoF after hinge breaking
 Panel with nose separates slowly; Thin strakes inside panels modeled
 Large stagnation region behind panels
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Mach Number

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Vibration Load on Spacecraft
 Estimation of vibration loads on Spacecraft surface due to jet noise
 Unsteady simulation to estimate noise
 Transfer of acoustic load to various parts for vibration assessment
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Aerodynamic MBRL Rocket
 Multi-Barrel Rocket Launcher fires spinning rockets
 Aerodynamic simulation done using structured mesh and RANS solver
 Spinning motion incorporated in solver to predict Coriolis forces (drift)
 Data matches well with limited wind tunnel studies
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Optimized Acoustics in Landing Configuration
 Unsteady CFD calculation for pressure variation for near & far field noise prediction
 Convert CFD data to noise sources; Linear propagation theory (FWH solver) to farfield noise
 Genetic algorithm based optimization for low noise high lift wing shape
 800 shapes made automatically on 2048 core HPC
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Noise Amplitude vs. Frequency Directivity Plot (X) of SPL (dB)FWH Surface around Wing

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Dynamic Roll Damping Derivatives for UAV
 Estimate static & dynamic derivative of UAV using frequency domain method
 Dynamic derivatives Clp, Clq, Cmq, CLq, Cnp, Cnq, CYq estimated
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Development of CFD Software for Gas Turbine
 Customized solver for multi-stage compressor of gas turbine
 Mesh generation and parallel solver developed to estimate surge and stall
 Parallel solver installed on CDAC and DRDO HPC
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Surge and Stall
Gas turbine

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Incompressible Flows
CFD for low speed flows for industrial domains in energy,
transport, water and construction
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Blockages in Nuclear Pin Bundles
 Sodium cooled pool type reactor with heat generation in the fuel subassemblies
 217 tightly packed pins
 Parametric studies to understand the effect of size, shape & location of blockages
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Fabric Filter: Flow Optimization
 Pulse jet type fabric filter (6 bag nests - 558 bags each) for flow uniformity
 Particle tracking for dust settlement regions
 Guide vanes & Damper cut-out size change recommended to achieve optimum flow
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CFD of Cooling Tower Fan & Drift Eliminator
 Cooling towers of power plants not performing needing design change
 FanZ software used for initial design; CFD used to establish 20% increase in efficiency
 Validation of CFD results with wind tunnel at IIT Kanpur (1:10 model); final design delivered
 Determine loss of pressure across the drift eliminator for different spacing & speed
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Pressure

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CFD Analysis of Vertical Turbine Pump Sump
 Approx. 10 pumps installed with few as redundant
 CFD analysis to find vortex formations, swirls, flow concentrated zones etc.
 Swirl plots show the eddies; input has swirl angles that are mitigated
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Pressure Drop Estimation: Valves
 Pressure drop estimation for various values of valve opening
 Estimation of Cv of different types of valves; coupled structural analysis
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Cv CFD within 2.49% of
experiment for DBBD Valve
Non-ReturnValvemeshandpressure
Pressure250bar,Temp300C,CFD+FEM

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Smoke in High Rise
 India’s tallest building (320m) with world’s tallest atrium (225m)
 Time-Space history of smoke evaluated
 Mechanical ventilation strategies designed
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ExternalView
Smoke on building section; Time history

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CFD of Air Vent's Aeraulics for Optimal Throw
 CFD with domain starting from AC unit to air vent and car interior
 To estimate the pressure drop in the AC duct and air vents
 To understand the flow pattern with different air vent deflections
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Power Supply Heat Exchanger Study
 Compact heat exchanger to cool the electronics of airborne system
 Heat dissipation to ethylene glycol and water mixture; FEM with thermal effects
 Complex geometry with large no of narrow channels
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Unconventional and Coupled Flows
CFD analysis coupled with dynamics, FEM and unconventional
simulations
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Advanced Light Bomb: Store Separation
 Asymmetric configuration and light weight separation (CFD+Dynamics) simulation
 Flatness at bomb windward side was a matter of concern due to high ‘lift’
 Results match with wind tunnel data
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Accurate Geometry Not Shown

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Multi-disciplinary Simulation for Parachute
 Multidisciplinary software for parachute design developed ab-initio
 Dynamics of opening with Coupled CFD & FEM for membranes (parachute cloth)
 Multiple types of parachute – Ring tail, ram air, unicross with & without hole etc.
 Validation with wind tunnel experiment
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ADRDEwindtunneltestInflationinParaZ
Software GUI
Animation: Parachute Opening

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Customized Software: Shock Absorber
 Performance analysis of hydraulic damping devices
 Damping characteristics, Oil Leakage Analysis, Flow & Turbulence estimation
 Customized parametric software developed and delivered
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UnsteadyCFDAnimation

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Ship Seakeeping & Maneuvering Performance
 Seakeeping simulations using CFD and SPH codes
 Calculation of resistance due to waves
 Shapes of waves predicted for sea state 1 – 5 (including green sea)
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Movie – rough sea

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Blast Welding Containment Chamber Design
 CFD simulations to study pressure range acting on pipe due to variable charge mass
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Schematic
Unsteady pressure after blast: Movie

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Design of In-Pipe Hydro Turbine
 Design of in-pipe hydro turbine for municipal applications
 Design for hydrodynamic efficiency and structural (static and torsional load)
 Generation of production drawings
 Turbine manufactured and being tested
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Team and Closure
Details of the team and consultants and summary of
presentation
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Core Team
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 Prof Gopal Shevare (Chairman) – PhD IIT Bombay with 40+ years research exp
 Expert in MDO, fluid dynamics, numerical methods and simulation product development
 Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience
 Expert in preliminary design, project management,
 Irshad Khan (COO) – Bachelor Mechanical with 22 years experience
 Expert in mesh generation, drawings, product development and vendor management
 Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp
 Expert in parallel solver development for CFD, Electromagnetics and free surface flows
 Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer
 Expert in new software development, visualization, parallelization and GUI
 Ten engineers certified by CEMILAC including above

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Consultants and Collaborations
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 MOUs and Collaborations
 Centre for development of advanced computing – HPC usage in Teraflops
 NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM)
 IIITDM – Joint projects of analysis adding to product development
 Expert Panel (partial)
 Mr. SG Joshi – 40+ years experience in pump design and manufacturing
 Prof S C Lakkad – 45+ years experience in composite design and manufacturing process
 Prof K Sinhamahapatra – 20+ years experience in acoustic prediction
 Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects
 Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance
 Mr A Patki – 40+ years experience in space systems for reliability and weight reduction

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Closure
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 Experience of 400+ high tech projects in both strategic and industrial sectors
 Engineers trained in Aerospace grade quality and confidentiality
 Robust engineering software development experience
 Modular code development with high reusability
 Experience of parallelization and cloud computing
 Domain expertise in aforementioned sectors
 Contribution by the engineering team enhanced to design suggestions
 Flexible engagement model
 Fixed cost, Time and Material, Cost plus or models as per problem statement
 Unafraid to take R&D projects – Test Us

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www.zeusnumerix.com
+91 98190 09836
Abhishek Jain
abhishek@zeusnumerix.com
Thank You !

CFD & Coupled CFD Simulations @ Zeus Numerix

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