Complete CFD Simulation in STAR-CCM+ – Advanced

Simulate multiphase oil and air flow around a gearbox using the mixture model/VOF in StarCCM Plus; generate a 2D mesh, define oil and air phases, and run the simulation.

Generate a 2d polygonal mesh with prismatic near-wall layers in StarCCM Plus and configure a mixture multi-phase, gravity-driven flow with k-epsilon turbulence for an oil and air system.

Set up and model multiphase interaction between oil and air in Star CCM+, defining the phase interaction, interaction length scale, and initial volume fractions with field functions.

Set up overset mesh regions for background, large gear, and small gear; enable drag-based slip velocity for oil–air and visualize initial oil volume fraction in scenes.

Configure a two-phase transient run by setting time step, adjust under-relaxation and smoothing, and define stopping criteria; then run the solver, observe oil fraction evolution with smooth contours and frames.

Explore how oil is picked up, recirculated, and wetted between rotating gears while visualizing lubrication patterns in StarCCM Plus, using frame sequences and solid body rotation settings.

Explore external aerodynamics by simulating flow around a concept Airbus A320 in StarCCM Plus. Import a surface mesh STL, set units to meters, and prepare the computational domain and mesh.

Create a far-field domain around the aircraft with a domain and refinement block, and use the surface wrapper to obtain a watertight geometry with optimized base size.

Create the aircraft domain with surface wrapper, assign a region, generate a polyhedral mesh with prismatic layers, and define velocity inlet, pressure outlet, and symmetry plane for steady laminar flow.

Examine the velocity and pressure fields around the aircraft on the z=0 plane, using velocity vectors and magnitude scalars with LIC visualization and animations to reveal wake patterns.

Apply volumetric controls to refine the mesh and adjust prism layers. Use cylinder refinements around winglets to sharpen local resolution for aerodynamic studies.

Analyze advanced flow field and vortex structure in star-ccm+ with a refined mesh around winglets. Visualize vorticity via thresholding and assess residuals to prepare for turbulence modeling.

Implement Reynolds stress model with elliptic blending in StarCCM Plus to capture boundary layer turbulence using a wall distance model and prism layers, then examine wake and near-wall resolution.

Apply surface controls and wake refinement to refine the airplane mesh using a target surface size of 5, and adjust the wake spread angle to capture downstream wake structures.

Explore conjugate heat transfer in a manifold, modeling heat exchange between gas and solid domains. Learn a multi-physics, multi-timescale approach with fluid steady-state and solid transient conduction using StarCCM Plus.

Define two regions, the gas region and the manifold region, and create an automatic fluid-solid interface to enable conjugate heat transfer across the common surface.

Create a conformal mesh by meshing both regions together to avoid interpolation at the interface, using surface remesher and polyhedral volume meshing for robust default controls.

Set up two custom controls to disable prism layers on the solid region and on gas inlet/outlet surfaces, and disable the thin mesher in the gas part.

Define gas-phase physics with an ideal-gas, compressible flow and turbulence in a steady gas region, and couple it to transient solid conduction in a ductile iron manifold using two continua.

Set up a solid manifold physics continuum for transient heat conduction with Segregated Solid Energy, implicit unsteady time, and 300 K initial temperature, using ductile iron from the material database.

Map the gas–manifold interface for multi-time scale CFD by setting the interface type to mapped contact interface and enabling explicit energy coupling, transferring data across the conformal interface efficiently.

Configure inlet and outlet boundary conditions for gas region, with 500 K and 10 m/s at inlet and 360 K backflow at outlet, enabling conjugate heat transfer mappings.

Configure steady gas and implicit unsteady solid solvers with 250 iterations, 50-second unsteady blocks, up to 4 inner iterations, and a 500-second time horizon with gas-solid mapping after each cycle.

Create threshold-based post-processing in StarCCM Plus to display subsets of gas and manifold cells by position; use position Z and X thresholds, combine them, and save simulation for next steps.

Post-process STAR-CCM+ results by creating reports for volume average temperature and min/max solid temperatures in the manifold, then visualize with a scalar scene and plots.

Automate a multi-time scale CFD workflow in StarCCM Plus with simulation operations, cycling between steady gas solver (250 iterations) and unsteady solid solver (50 s) until 500 s.

Create and link reports and monitors in Star-CCM+ to track loop iterations and physics continuum iterations, then plot energy residuals against iterations for thermal analysis.

Execute a full conjugate heat transfer simulation in star-ccm+ using a multi-time scale workflow, stepping through fluid and solid solves and coupling cycles to observe heat transfer.

Review the final results of a CFD simulation in STAR-CCM+, fix the unsteady solid solver time step to 0.2 seconds, and explore conjugate heat transfer, fluid-solid interfaces, and conformal meshing.