CFD Engineer Master's Certification Program : Skill-Lync

Introduction

About this program

The Masters in CFD program is a 12 month long, intensive program. The program comprises of 6 courses that train you on all the essential engineering concepts and tools that are essential to get into top OEMs. as a CFD Engineer.

Courses:

1. Introduction to Computational Fluid Dynamics using MATLAB and OpenFOAM

2. Advanced CFD Using ANSYS Fluent

3. Computational Combustion using Python and Cantera

4. Advanced IC Engine Simulation

5. IC Engine Calibration using GT-POWER

6. Electronic Cooling Simulations using ANSYS ICEPAK

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Course One: Introduction to Computational Fluid Dynamics using MATLAB and OpenFOAM

In this module, you will understand what CFD is and its significance. You’ll also learn what the Navier-Stokes equations are and how they’re derived.

CFD - An introduction, necessity, advantages, CFD modeling process
Deriving and understanding the Navier Stokes equations

Substantial derivative
Continuity equation
Momentum equation
Energy equation

Significance of Reynold’s number in the NS equations

In this course, you will be writing solvers and getting your hands dirty with different numerical methods. Before we do this, it is very important to understand the essential mathematical and fluid dynamics concepts that you will encounter.

Basic vector calculus

Divergence, gradient, and curl

Taylor’s series
Initial and boundary conditions
Classification of PDEs and their characteristics
Learning essential Fluid Dynamics quantities and their dimensional analysis

It is essential to establish a rigid foundation before plunging into the farther depths of CFD. This is where you get introduced to MATLAB and learn the basic concepts of CFD by writing MATLAB scripts. Here are some topics that we would cover:

Getting acclimated to the MATLAB interface
Numerical discretization and its types
FDM - understanding different schemes with worked examples in MATLAB
Deriving own FD schemes using Taylor’s table
Solving ODEs in MATLAB using the ‘ode45’ solver

In this section, you would venture into the Finite Difference Approach to discretization and solving various benchmark CFD problems in MATLAB. You’ll also be working on two major and two minor projects here. The list of projects are as follows;

Solving the 1D linear convection equation and performing stability analysis
Major Project: Simulating 2D unsteady/steady heat conduction equation and studying implicit vs explicit approaches
Solving coupled linear systems using iterative solvers

Jacobi
Gauss-Seidel
SOR

Major Project: Simulating Quasi 1D subsonic-supersonic nozzle in FDM and studying conservation vs non-conservation forms of governing equations

OpenFOAM is an open-source toolbox with an in-built numerical solver and pre/post processors for solving CFD Problems. It is based on the Finite Volume Method of discretization. In this section, you will learn how to run a simulation on OpenFOAM and the significance of using an FVM approach. These are the topics you would learn:

Finite Volume Method and Gauss divergence theorem
Understanding the Linux environment
OpenFOAM code organization and case setup
Detailed blockMeshDict tutorial

It is important to get a real feel of problem-solving using the OpenFOAM software so that you can explore and simulate a wide variety of problems. In this module, we will create a platform that will enable you to start any simulation from scratch.

You will be working on the following major projects.

Flow over Backward Facing Step

Code the geometric mesh information inside the C file ‘blockMeshDict’
Implement mesh grading factor

Laminar flow through the pipe and Validate results

Automate the ‘blockMeshDict’ generation on MATLAB
Characterization of fully developed flow
Explore different boundary conditions

Projects Overview

2D Heat Conduction Simulation

In this project, you will learn how to discretize and solve an unsteady and steady diffusion phenomenon using a Finite Difference Method in MATLAB/Octave. Also, you will learn to use both implicit and explicit time integration approaches to solving an unsteady problem. We will work on how to use 3 different iterative methods to solve implicit equations and compare their effectiveness. Finally, you will perform a stability study and understand the criteria to obtain a stable and reliable solution.

Solve 2D Steady and Transient heat conduction problem
Implement Jacobi, Gauss-Seidel and Successive Over-Relaxation solvers
Implement Implicit and Explicit methods to solve the transient part
Implement Diffusion CFL number-based time step control

Supersonic Nozzle Flow Simulation using MacCormack Method

In this project, you will simulate the conditions for an inviscid flow inside a Subsonic-Supersonic Convergent-Divergent Isentropic Nozzle. You will perform a quasi-1D simulation using the FDM approach in MATLAB/Octave. The student will then investigate the conservation and non-conservation forms of the governing equations and learn their characteristics and applications.

1D supersonic nozzle flow using MacCormack Method
Implement Conservative and Non-Conservative form
Implement Courant Number based time step control
Solve Normalized Governing equations

Flow over a Backward Facing Step

In this project, you will simulate a laminar viscous flow across a sudden steep expansion in area and study the boundary layer separation phenomena. You will learn how to set up and run a case in OpenFOAM in the Linux environment. You will also learn how to customize the course code to suit this problem. And finally, implement different mesh grading factors and compare the results.

Simulate this classical CFD benchmarking problem
Run grid dependency test
Implement mesh grading
Study the boundary layer separation phenomenon

Automated BlockMesh Generation for Meshing Pipe Geometry

In this project, you will simulate the laminar viscous flow through a regular pipe using symmetry and wedge boundary conditions and compare the simulation result with the analytical one obtained using the Hagen-Poiseuille formula. You will to then write a program to automate the generation of the Mesh file. The simulation will be run in OpenFOAM and post-processed in Paraview.

Automate mesh generation process using MATLAB/Octave
Perform Wedge Vs. Symmetry BC study
Understand fully-developed flow and Hydro-dynamic entrance length
Compare the results with the analytical result from Hagen-Poiseuille formula

Course Two: Advanced CFD Using ANSYS Fluent

In this module, you will learn about CFD and its uses. You will also be introduced to the basic governing equations solved and many schemes and algorithms used to stabilize and improve the accuracy of the solution.

Governing equations of fluid motion
Numerical discretization
Fluid solver
Boundary conditions
Post-processing

In this module, the focus is to simulate basic compressible and incompressible flows using ANSYS Fluent.You will be introduced to the streamlined workflow on the Workbench tool from geometry creation to the solution post-processing procedure.

You will be getting hands-on experience in

Geometry creation
Meshing
Boundary and initial condition calculation
Setting up solution algorithms
Solving and post-processing

In this module, the focus is to simulate basic compressible and incompressible steady-state simulations. This provides you an introduction to the solution setup procedure for a steady-state simulation.

You will get hands-on experience in

Geometry creating using space claim
How to setup steady-state simulations?
Checking for convergence and understanding when the simulation converges for different Boundary Conditions?
How to create runtime animation of engineering parameters?
Project 1 - HVAC simulation inside a mixing TEE
Project 2 - Performing a parametric study on flow inside a gate valve
Project 3 - Performance characterization of a cyclone separator

Meshing is an important component in CFD analysis. Improper meshing can lead to bad results. In this module, you will learn the different meshing techniques that can improve the solution accuracy with a balanced computational cost.

Methods of providing local refinement like a sphere of influence, body sizing, etc.
Concept of Y plus and its importance
Inflation layers and controls
Mesh dependence test

You will learn the fundamentals of performing external flow analysis using ANSYS Fluent. It provides you with the knowledge on the boundary layer concept, needs of Y plus, and wall functions. Here, we will focus on the following topics.

Setting up virtual wind tunnels using the enclosure utility
Item 2
Understand Vortices, calculating downforce & drag on a vehicle
Y+ Estimation & grid refinement

In this module, you will learn how to simulate solid side heat transfer along with the fluid flow. Conjugate Heat Transfer (CHT) refers to simulating multiple modes of heat transfer. For example, in one of the projects, you will simulate the heat transfer in an exhaust manifold when hot exhaust products are flowing through it. When you complete this module, you will be able to do the following

Extracting solid and fluid volumes
Creating shared topologies for creating conformal meshes
Setting up volumetric heat sources
Visualizing heat transfer coefficient distribution