Zeus numerix CFD simulations

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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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 !

Zeus numerix CFD simulations

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