- •TABLE OF CONTENTS
- •Chapter 1 INTRODUCTION
- •The es-ice Environment
- •es-ice Meshing Capabilities
- •Tutorial Structure
- •Trimming Tutorial Overview
- •Required Files
- •Trimming Tutorial files
- •Automatic 2D Tutorial files
- •Wall Temperature Tutorial files
- •Mesh Replacement Tutorial files
- •Multiple Cylinder Tutorial files
- •Closed-Cycle Tutorial files
- •Sector Tutorial files
- •Two-Stroke Tutorial files
- •Mapping Tutorial files
- •ELSA Tutorial files
- •Chapter 2 SURFACE PREPARATION IN STAR-CCM+
- •Importing and Scaling the Geometry
- •Creating Features
- •Defining Surfaces
- •Remeshing and Exporting the Geometry
- •Chapter 3 GEOMETRY IMPORT AND VALVE WORK
- •Importing the Surfaces
- •Modelling the Valves
- •Saving the Model
- •Chapter 4 MESHING WITH THE TRIMMING METHOD
- •Modifying Special Cell Sets in the Geometry
- •Defining Flow Boundaries
- •Creating the 2D Base Template
- •Creating the 3D Template
- •Trimming the 3D Template to the Geometry
- •Improving cell connectivity
- •Assembling the Trimmed Template
- •Running Star Setup
- •Saving the Model
- •Chapter 5 CREATING AND CHECKING THE MESH
- •Chapter 6 STAR SET-UP in es-ice
- •Load Model
- •Analysis Set-up
- •Valve Lifts
- •Assembly
- •Combustion
- •Initialization
- •Cylinder
- •Port 1 and Port 2
- •Boundary Conditions
- •Cylinder
- •Port and Valve 1
- •Port and Valve 2
- •Global settings
- •Post Set-up
- •Cylinder
- •Port 1 and Port 2
- •Global settings
- •Time Step Control
- •Write Data
- •Saving the Model
- •Chapter 7 STAR SET-UP in pro-STAR
- •Using the es-ice Panel
- •Setting Solution and Output Controls
- •File Writing
- •Chapter 8 RUNNING THE STAR SOLVER
- •Running in Serial Mode
- •Running in Parallel Mode
- •Running in Parallel on Multiple Nodes
- •Running in Batch
- •Restarting the Analysis
- •Chapter 9 POST-PROCESSING: GENERAL TECHNIQUES
- •Creating Plots with the es-ice Graph Tool
- •Calculating Apparent Heat Release
- •Plotting an Indicator Diagram
- •Calculating Global Engine Quantities
- •Creating a Velocity Vector Display
- •Creating an Animation of Fuel Concentration
- •Creating an Animation of Temperature Isosurfaces
- •Chapter 10 USING THE AUTOMATIC 2D TEMPLATE
- •Importing the Geometry Surface
- •Defining Special Cell Sets in the Geometry
- •Modelling the Valves
- •Creating the Automatic 2D Template
- •Refining the 2D Template Around the Injector
- •Adding Features to the Automatic 2D Template
- •Using Detailed Automatic 2D Template Parameters
- •Saving the es-ice Model File
- •Chapter 11 MULTIPLE-CYCLE ANALYSIS
- •Setting Up Multiple Cycles in es-ice
- •Setting Up Multiple Cycles in pro-STAR
- •Chapter 12 HEAT TRANSFER ANALYSIS
- •Resuming the es-ice Model File
- •Mapping Wall Temperature
- •Exporting Wall Heat Transfer Data
- •Saving the es-ice Model File
- •Cycle-averaging Wall Heat Transfer Data
- •Post-processing Wall Heat Transfer Data in pro-STAR
- •Plotting average wall boundary temperatures
- •Plotting average heat transfer coefficients
- •Plotting average near-wall gas temperature at Y-plus=100
- •Mapping Heat Transfer Data to an Abaqus Model via STAR-CCM+
- •Chapter 13 MESH REPLACEMENT
- •Preparing the File Structure
- •Rebuilding the Dense Mesh
- •Creating Ahead Files for the Dense Mesh
- •Defining Mesh Replacements
- •Setting Up Mesh Replacement in pro-STAR
- •Setting up the coarse model
- •Setting up the dense model
- •Chapter 14 MULTIPLE CYLINDERS
- •Resuming the es-ice Model File
- •Making, Cutting and Assembling the Template
- •Setting Up Multiple Cylinders
- •Checking the Computational Mesh
- •STAR Set-Up in es-ice
- •Analysis set-up
- •Assembly
- •Combustion
- •Initialization
- •Boundary Conditions
- •Post Setup
- •Time Step Control
- •Write Data
- •Saving the es-ice Model File
- •Importing the Geometry
- •Generating the Closed-Cycle Polyhedral Mesh
- •Assigning shells to geometry cell sets
- •Specifying General, Events and Cylinder parameters
- •Creating a spray-optimised mesh zone
- •Importing a user intermediate surface
- •Checking the spray-optimised zone
- •Creating the closed-cycle polyhedral mesh
- •Running Star Setup
- •Creating and checking the computational mesh
- •Saving the Model File
- •Chapter 16 DIESEL ENGINE: SECTOR MODEL
- •Importing the Bowl Geometry
- •Defining the Bowl Shape
- •Defining the Fuel Injector
- •Creating the 2D Template
- •Creating the Sector Mesh
- •Creating and Checking the Mesh
- •Saving the Model
- •Chapter 17 DIESEL ENGINE: STAR SET-UP IN es-ice and pro-STAR
- •STAR Set-up in es-ice
- •Load model
- •Analysis setup
- •Assembly
- •Combustion
- •Initialization
- •Boundary conditions
- •Post setup
- •Time step control
- •Write data
- •Saving the Model File
- •STAR Set-up in pro-STAR
- •Using the es-ice Panel
- •Selecting Lagrangian and Liquid Film Modelling
- •Setting up the Fuel Injection Model
- •Setting up the Liquid Film Model
- •Setting up Analysis Controls
- •Writing the Geometry and Problem Files and Saving the Model
- •Chapter 18 DIESEL ENGINE: POST-PROCESSING
- •Creating a Scatter Plot
- •Creating a Spray Droplet Animation
- •Chapter 19 TWO-STROKE ENGINES
- •Importing the Geometry
- •Meshing with the Trimming Method
- •Assigning shells to geometry cell sets
- •Creating the 2D template
- •Creating the 3D template
- •Trimming the 3D template to the geometry
- •Assembling the trimmed template
- •Running Star Setup
- •Checking the mesh
- •STAR Set-up in es-ice
- •Analysis setup
- •Assembly
- •Combustion
- •Initialization
- •Boundary conditions
- •Post setup
- •Time step control
- •Write data
- •Saving the es-ice Model File
- •Chapter 20 MESHING WITH THE MAPPING METHOD
- •Creating the Stub Surface in the Geometry
- •Creating the 2D Base Template
- •Creating the 3D Template
- •General Notes About Edges and Splines
- •Creating Edges and Splines Near the Valve Seat
- •Creating the Remaining Edges and Splines
- •Creating Patches
- •The Mapping Process
- •Chapter 21 IMPROVING THE MAPPED MESH QUALITY
- •Creating Plastered Cells
- •Chapter 22 PISTON MODELING
- •Meshing the Piston with the Shape Piston Method
- •Chapter 23 ELSA SPRAY MODELLING
- •Importing the Bowl Geometry
- •Defining the Bowl Shape
- •Setting the Events and Cylinder Parameters
- •Creating the Spray Zone
- •Creating the Sector Mesh
- •STAR Set-up in es-ice
- •Load model
- •Analysis setup
- •Assembly
- •Combustion
- •Initialization
- •Boundary Conditions
- •Time step control
- •Write data
- •Saving the Model File
- •STAR Set-up in pro-STAR
- •Using the es-ice panel
- •Activating the Lagrangian model
- •Defining the ELSA scalars
- •Setting up the Lagrangian droplets
- •Defining boundary regions and boundary conditions
- •Setting up analysis controls
- •Adding extended data for the ELSA model
- •Writing the Geometry and Problem Files and Saving the Model
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•Set the domain to Port 4 of Cylinder 1
•Check that Use data of is set to Port 1 of Cylinder 1 as it is an intake port
•Check that the remaining cylinder components are correct by referring to the following table:
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Cylinder of Cylinder 2 |
Cylinder of Cylinder 1 |
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Port 1 of Cylinder 2 |
Port 1 of Cylinder 1 |
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Port 2 of Cylinder 2 |
Port 2 of Cylinder 1 |
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Port 3 of Cylinder 2 |
Port 2 of Cylinder 1 |
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Port 4 of Cylinder 2 |
Port 1 of Cylinder 1 |
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Boundary Conditions
In the Boundary conditions view of the Star controls panel, specify boundary conditions for all engine components.
For the cylinder component of Cylinder 1 (see Figure 14-20), set the following conditions:
•Select domain Cylinder of Cylinder 1 from the drop-down menus at the top
•Set the Combustion dome regions type to Fixed and the Temperature to 450 K
•Set the Piston crown regions type to Fixed and the Temperature to 550 K
•Set the Cylinder wall regions type to Fixed and the Temperature to 500 K
•Select the Extra regions toggle button to create a region for the spark plug
•Click Define to open the Boundary Tool
•In the Boundary Tool, click Display all to display all cylinder surface shells
•Click Keep picked to select the spark plug patches, as shown in Figure 14-19
Figure 14-19 Spark plug patches for Cylinder 1
•Press q on the keyboard to exit from the pick mode
•Click Define in the Boundary Tool to define the patches as a spark plug
•Set the Name to Spark Plug
•Set the Regions type to Fixed wall
•Set the Temperature to 600 K
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Figure 14-20 Multiple cylinder Star Controls > Boundary conditions panel for Cylinder
For the Port and Valve 1 of Cylinder 1 (see Figure 14-22), specify the following conditions:
•Select domain Port and Valve 1 of Cylinder 1 from the drop-down menus
•Check that the Valve stem, Valve face and Port wall regions are set to
Adiabatic
•Under Extra regions, click Define to open the Boundary Tool
•In the Boundary Tool, click Display all to display all surface shells
•Click Keep picked to select the intake flow patch, as shown in Figure 14-21. The intake flow boundary region is split between Cylinder 1 and Cylinder 2, which is why it appears to be incomplete.
Intake flow patch
Figure 14-21 Intake flow boundary patch for Cylinder 1
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•Press q on the keyboard to exit from the pick mode
•Click Define in the Boundary Tool to define the displayed patch as the intake flow region
•Set the Name to Intake Flow
•Check that the Regions type is Pressure
•Set the Absolute pressure to Constant and Environmental using the drop-down menus
•Check that the Pressure is 101325 Pa (for atmospheric pressure)
•Check that the Temperature is 293.15 K (for atmospheric temperature)
Figure 14-22 Multiple cylinder Star Controls > Boundary conditions panel for Port 1
Since the relevant flow boundary patch belongs to Cylinder 2, it will be used here to define the boundary conditions (see Figure 14-24):
•Select domain Port and Valve 2 of Cylinder 2 from the drop-down menus
•Set Use data of to Port and Valve 2 of Cylinder 2 from the drop-down menus
•Under Extra regions, click Define to open the Boundary Tool
•Click Display all to display all surface shells
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•Click Keep picked to select the exhaust flow patch, as shown in Figure 14-23
Exhaust flow patch
Figure 14-23 Exhaust flow boundary patch
•Press q on the keyboard to exit from the pick mode
•Click Define in the Boundary Tool to define the displayed patch as an exhaust
•Set the Name to Exhaust Flow
•Check that the Regions type is set to Pressure
•Set the Absolute pressure to Constant and Mean using the drop-down menus
•Check that the Pressure is 101325 Pa (for atmospheric pressure)
•Check that the Temperature is 293.15 K (for atmospheric temperature)
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Figure 14-24 Multiple cylinder Star Controls > Boundary conditions panel for Port 2
As with initialisation, the remaining ports and cylinders use the boundary conditions that were defined for their equivalent components, i.e. cylinder, intake or exhaust. However, for boundary conditions, you also need to define patches for the spark plug and the intake and exhaust boundary regions for Cylinder 2.
•Select domain Cylinder of Cylinder 2 from the drop-down menus
•Select the Extra regions toggle button and click Define
•Click Display all to display all surface shells
•Click Keep picked to select the spark plug patches, as shown in Figure 14-25
•Press q on the keyboard to exit from the pick mode
•Click Define in the Boundary Tool to define the displayed patches as the spark plug
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Figure 14-25 Spark Plug patches for Cylinder 2
•Select domain Port and Valve 1 of Cylinder 2 from the drop-down menus
•Under Extra regions, click Define to open the Boundary Tool
•Click Display all to display all surface shells
•Click Keep picked to select the intake flow patch, as shown in Figure 14-26
•Press q on the keyboard to exit from the pick mode
•Click Define in the Boundary Tool to define the displayed patch as an intake
Intake flow patch
Figure 14-26 Intake flow boundary patch for Cylinder 2
•Select domain Port and Valve 2 of Cylinder 1 from the drop-down menus
•Set Use data of to Port and Valve 2 of Cylinder 2 from the drop-down menus
As there are numerous boundaries in this case, it is advantageous to use the
Summary feature to check that all boundary regions are correctly defined.
•Select Cylinder of Cylinder 1 and click the Summary toggle button to open the Summary view of Boundary conditions, as shown in Figure 14-27.
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