Virtual testing has been demanded for many IE machines, especially noise assessment that is a quite challenging with full physical prototypes in a huge anechoic test chamber and it is being replaced more and more with numerical solver technologies providing accurate airflow and noise prediction in a digital test environment. The process helps a lot to accelerate a product development time and cost. However, many process steps are still manual and simulation process experts are needed to use all tools required for the existing workflows.
An automated process on SIMULIA Cloud is one of breakthrough solutions and it is an easy-to-use design concept for non-experts to provide a quick turnaround without any limitations of simulation knowledge. Underhood Cooling IE Process (See UHC e-Seminar Post) is a SIMULIA automated process that has been deployed to many customers successfully. Now it is extended to cover UHC fan noise for IE machines and IE Fan Noise Process has been deployed to IE customers:
- Quick Turnaround Time
- 1 hour labor time instead of 2 days using manual process done by experts
- Consistent Step and Use
- Same experience for all users
- No acoustic expertise required
- Compatible Process Inputs
- Extended from deployed UHC IE Process
- Identical geometry and input data format
In the process, the latest fan noise methodologies have been integrated to the case template to accurately capture the noise generation mechanisms. The well-validated and widely used IE fan noise Best Practice (BP) for noise correlation is used for the validation of the IE fan noise process. However, the BP validation resolution is costly and often not feasible to achieve noise reduction via design iterations, wherein many design iterations or DOE (Design of Experiments) follow a validation of the baseline design, and is validated by a final design verification and validation of the model.
Hence, a new simulation process strategy is required to accelerate the entire design process, supported by a design practice methodology associated to a fast turnaround time analysis. The finest voxel size (cell size) plays a key role in determining the cost and accuracy of the solution and is determined by the simulation resolution (cells along char length). The fast turnaround analysis utilizes the IE fan noise output database to decide the required simulation resolution for the design iterations:
In this new design process, the Design Practice (DP) resolution is used for design iterations to achieve a desired noise reduction, and the final design is verified with the BP resolution. This process was validated with 3DS Bee Excavator and the cost reduction and accuracy have been checked as documented in the graphs below.
For more information, please feel free to reach out to @MK, @AM.
