CFD Engineer Master's Certification Program

CFD Engineer Master's Certification Program

  • 0% EMI Option Available
  • Domain : CFD
  • Pre-requisites : For Mechanical, Aerospace & Automotive Engineers
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Introduction

About this program
 
The Masters in CFD program is a 12 month long, intensive program. The program comprises of 10 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 CFD using MATLAB and OpenFOAM 
2. Introduction to OpenFOAM Development 
3.Introduction to GUI based CFD using ANSYS FLUENT 
4. Introduction to Aero-Thermal simulation using Ansys Fluent 
5. Advanced CFD for IC Engine Applications using Converge 
6. Advanced Aerodynamic Simulations using Converge 
7. Advanced Turbomachinery Simulations using Converge 
8. IC Engine Calibration using GT-POWER and GT-SUITE 
9. Hybrid Electric Vehicle Simulation Using GT-SUITE 
10. Advanced CFD Meshing using ANSA

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CFD Engineer Master's Certication Program

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

1What is Computational Fluid Dynamics?

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

2Mathematics and Fluid Dynamics Essentials

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

3Introduction to MATLAB and Basic CFD Concepts

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

4Exploring CFD by Solving Standard CFD Problems using FDM

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

5Introduction to FVM and OpenFOAM

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

6Solving standard CFD Problems in OpenFOAM

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 Simulation

Highlights

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

     


     

MacCormack Method

Highlights

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

     



Laminar Flow

Highlights

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



BlockMesh Generation

Highlights

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: Introduction to OPENFOAM Development

1Introduction and Setting Up

The first week of the course introduces you to what exactly OpenFOAM is. OpenFOAM is developed primarily for the LINUX operating system. We will also cover the basics of the Linux operating system for anybody who is not acquainted with Linux. We will be covering in detail on the following topics: 

  • Introduction to OpenFOAM 
  • Users, Future opportunities
  • OS and Version Selection
  • Windows Subsystem for Linux
  • Basics of Linux
  • Test case
  • Installing opt and debug modes

2Basics of C++

The course is targeted towards the development of a CFD solver using OpenFOAM. OpenFOAM is primarily a C++ library. Hence, a good understanding of the basics of C++ is quintessential. In this week, we will cover in detail the following topics:

  • Setting up environment: Visual Studio Code
  • Namespaces
  • Data Structures
  • Pointers
  • Static and dynamic arrays
  • STL - std::array and std::vector
  • Declarations and definitions
  • Passing by reference/value 
  • Function Parameters and overloading

3Basics of C++

Object Oriented Programming brings a plethora of features to improve usability of any C++ code that you generate. In this week, we will cover:

  • OOP – Classes and objects
  • Inheritance 
  • Smart Pointers – auto, unique, and shared  
  • Template programming
  • Polymorphism
  • Operator overloading
  • Abstract classes, Virtual functions

4High Level Programming 1

C++ is a high level language that let’s users create independent programs that are easier to interpret than assembly level codes. Here we will delve into the building blocks of it’s code organization by covering the following topics :

  • Introduction to parallel programming MPI 
  • Make files and Cmake 
  • Library and class organization
  • Compiling a solver

5High Level Programming 2

In this week, we further explore the various dictionaries available in OpenFOAM and try to understand the different C++ concepts used to achieve a particular task. We will be looking into : 

  • 5 OpenFOAM Classes : Constructor/Destructor,Overloading,Inheritance & Polymorphism 
  • Time dictionary 
  • IOObject and objectRegistry
  • Fields dictionary 
  • Scalars, Vectors, and Tensors
  • Implicit & Explicit namespaces (FVM & FVC)

6FVM for OpenFOAM 1

Finite Volume Method (FVM) is one of the most commonly used methods of converting PDE’s to ALE’s. In this week, Upon introducing the basic principles of FVM, we dive deep into the way in which openFOAM handles individual terms of the governing equations. The following concepts are covered in this week:

  • General conservation equation
  • Navier-Stokes equations 
  • Gauss Divergence Theorem 
  • Discretization of the source term
  • Discretization of the convective term 
    • Upwind
    • Linear Upwind
    • Flux Limiter (TVD)
  • Stability criterion – CFL condition 

7FVM for OpenFOAM 2

FVM in openFOAM is implemented in 3 parts. 1) Surface interpolation 2) fvc and 3) fvm using the mentioned finite volume techniques covered in the previous week. In this week, we will look into the multiple algorithmic choices of gradient operators and discretization schemes that can be employed by covering the following topics :

  • Gradient schemes
    • Green-Gauss Cell Based
    • Green- Gauss Node Based
  • Discretization of the diffusion term 
  • Laplacian schemes
  • Non orthogonal meshes and solution
  • N-S Equations revisited
  • Collocated vs Staggered grids
  • SIMPLE algorithm 

8FVM for OpenFOAM 3

If we consider the discretized form of the Navier-Stokes system, the form of the equations shows linear dependence of velocity on pressure and vice-versa. This inter-equation coupling is called velocity pressure coupling and often calls for a special treatment in order to decouple the terms. This week, we will look at some of the standard techniques used in CFD to achieve the same. Topics include :

  • SIMPLE algorithm - Need for Under Relaxation 
  • SIMPLEC algorithm - Consistent SIMPLE
  • PISO algorithm 
  • PIMPLE algorithm

9Linear Solvers

Linear systems in numerical methods often reduce to a sparse system (matrix having many zero elements) which can be computationally expensive to solve using standard algebraic methods. This week we will look into the working of some of the linear solvers used in openFOAM. Topics include : 

 

  • Non-orthogonal correctors
  • From mesh to matrix 
  • Linear solvers 
  • Jacobi
  • Gauss Seidel
  • Newton-Kyrlov family 
  • Preconditioners 
  • Smoothers 
  • Solver tolerances

 



10Turbulence 1

The concept of turbulence is something that has not been understood vividly till date although turbulent flows are commonplace in most real life scenarios. Considered as the cornerstone of fluid dynamics, Turbulence modeling is the construction and use of a mathematical model to predict the effects of turbulence. This week, we will look into the basic types of turbulence models used in CFD.  

  • Basics of turbulence 
  • RANS averaging 
  • The k-epsilon model
  • The k-omega model 

11Turbulence 2

This week is an extension of the concepts covered in the previous week where different turbulence models are weighed in against each other for specific applications. This week we further our understanding of the boundary layer theory by introducing ‘Wall functions’ which  are used to bridge the inner region between the wall and the fully developed turbulent layer to customizing a user defined turbulence model. Topics include :

  • The k-omega SST model 
  • Wall modelling and wall functions
  • Creating a turbulence model

12Temporal Discretization

Time discretization is a mathematical technique applied to transient problems which require solutions in which position varies as a function of time. Temporal discretization involves the integration of every term in different equations over a time step (Δt). Topics include :

  • Discretization of the time term 
  • Forward and backward Euler 
  • Crank-Nicholson 
  • Function Objects 
  • Latex for Report Writing 


Projects Overview

Project 1

Highlights

This project is meant to be an introduction to implementing your own solver in OpenFOAM. The points below are meant to be rough guiding points to what you should be looking at in the process. You are required to write a report (1000 words) about the steps you took to create the solver as well as results from the case you run with it.

Project Description: Use the icoFoam solver in the applications/solvers/incompressible/icoFoam directory to create your own solver - scalarFoam


The scalar transport equation is defined as:
∂s
∂s + ∇ • (us) = 0,
Where s is the scalar quantity being transported by the velocity u.


Changes in the solver:
• Replace the main working equation with
• What change will you make in the createFields.H file (Hint: the p field is originally created here)
• What change will you make in the UEqn.H file? (Hint: replace the solve function)
• Compile scalarFoam using wmake. How are the Make/files modified?


Changes in the case:
• Use the $FOAM_TUTORIALS/incompressible/icoFoam/cavity case to test out your solver. Rename it scalarCavity.
• The scalar transport equation has no pressure p to solve, instead a scalar s. What changes will you make in the 0 folder?
• You will have to change the interpolation scheme in fvSchemes to account for the ∇ • (us) term. How will you do this?
• In fvSolutions, a solver has to be specified for the quantity s. Can you just replace this with the solver used for p?
• Run this case by making the appropriate change in controlDict.

 

Project 2

Highlights

The total pressure ptotal is the contribution of the static pressure p and the dynamic pressure. To calculate this, we decide to write a coded function object called p_total which:

  • reads in the fields p and U
  • creates a field p_total (using IOobject)
  • computes the expression ptotal = p +1/2U2
  • writes the file p_total to the disk

Place this in the controlDict file of the pitzDaily tutorial and plot your results. Write a short report including the code you used in LATEX.

Project 3

Highlights

The icoFoam solver solves the incompressible flow equations for mass and momentum. Our goal is to now add an equation for temperature

Changes in the solver:

  • Create a new solver based on icoFoam called icoTempFoam
  • Replace file names and mentions of icoFoam with icoTempFoam
  • Change the solver target directory to FOAM_USER_APPBIN
  • Change createFields.H to include a dictionary reader for kappa (κ) and a field read and write IOObject for temperature T
  • Add a fvScalarMatrix in the main .C file that stores the scalar matrix value of TEqn
  • Run the solve() function on this matrix object
  • Compile the solver 

Changes in the case:

  • Copy the FOAM_TUTORIALS/incompressible/icoFoam/cavity/cavity tutorial and rename it to cavityTemp
  • Add a dictionary entry for kappa in transportProperties

kappa [ 0 2 -1 0 0 0 0 ] 0.001;

  • Add a file in the 0 folder for temperature T. Remember to set the correct dimensions for it! Set the movingWall to be 400K and the other walls and internal field to be 300K
  • Add a div(phi,T) in divSchemes and laplacian(kappa,T) in laplacianSchemes
  • Add a smoothSolver linear solver for temperature in fvSolution. Use a tolerance of 1e-07 and a relTol of 0
  • Run the solver and plot the results of temperature in Paraview
  • Write a short report including the code you used in LATEX

Project 4

Highlights

These cases should be simulated for t = 5 seconds with the same blockMesh settings as in the original sonicFoam tutorial
Diffusion
• Set velocity to 0 ( U = (0, 0, 0) ) and vary diffusion coefficient via the transportProperties file, like so:
DT DT [ 0 2 -1 0 0 0 0] 0;

• Use these diffusion coefficients and compare the contour plots of temperature for this case of pure diffusion:

  1. 0
  2. 0.0001
  3. 0.01
  4. 1

Convection
• Set x-velocity to 1 ( U = (1, 0, 0) ) and set diffusion coefficient via the transportProperties file to 0:
DT DT [ 0 2 -1 0 0 0 0] 0;
• Use the following divSchemes and compare the results for this case of pure advection

  1. upwind
  2. linearUpwind
  3. quadratic
  4. cubic
  5. vanLeer
  6. QUICK

The comparison of convection schemes should be done via a plot that captures the
change of the temperature profile along the length of the tube, as shown in the lecture
(and on the next slides )

Plot of temperature profile at t = 0



Plot of temperature profile at t = 5



• Write about the difference in results because of different diffusion coefficients and what it
could mean physically. Additionally, explain how this could be controlled by the user in
fvSchemes
• Why do different convection schemes cause changes in the original temperature profile
when convected?
• What is the most accurate convection scheme from the list and why?
• Summarize the case, your changes, your results, and answers to the above questions in a
LATEX report


Course Three: Introduction to GUI based CFD Using ANSYS Fluent

1Introduction to CFD

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

2Simulating Laminar and Turbulent Flows in ANSYS Fluent

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

3Performing Steady State Simulations

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

4Exploring Meshing Strategies

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

 


5External Aerodynamics

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

6Conjugate Heat Transfer

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

 


 

 

7Discrete Phase Modelling

Discrete Phase Modelling (DPM) is used to model particles, fuel drops, coal and any other type of suspended phases. You will work on problems like Cyclone Separator, where you will incorporate the DPM approach to simulate how suspended impurities travel through a Cyclone Separator. You will be getting hands-on experience in

  • Different types of Discrete Phase Boundary conditions and its effects

  • Methods of tracking the Discrete Phase Particles

  • Turbulence Intensity and Vortex Core Visualisation

8Introduction to User Defined Functions

You will learn how to write a customized program and create different monitor points and take the relevant information you need to form a simulation.

9Basic Reacting Flows

In this module, you will learn how to simulate reacting flows using ANSYS Fluent. This includes combustion applications.


Projects Overview

Heat Transfer

Highlights

In this project, you will be analysing the heat transfer coefficient and the high-temperature concentration zones through which effective cooling can be achieved. You will implement local sizing methods to improve the meshing and to balance the cell count. 


Concepts learnt:

  1. The Importance of sharing the topology

  2. Need for the Interface

  3. Effective meshing

  4. Volume rendering in CFD post

Oil Sloshing

Highlights

In this project, You will be analysing the sloshing effect of different lubricants in the gearbox through a dynamic mesh approach. You will be introduced to User-defined functions and its compiling procedure with ANSYS Fluent for providing motion to the gears. Also, You will gain knowledge of the various dynamic mesh settings like smoothing and re-meshing.


Concepts learnt:

  1. Extracting the required 2D geometry from a complex component

  2. Dynamic mesh settings

  3. Methods to overcome floating point exception

  4. Defining motion to gears by user-defined functions


Course Four: Introduction to Aero-Thermal Simulations using ANSYS FLUENT

1Introduction to FLUID FLows

This week will take you through the basic theory on Fluid Mechanics and FLUID dynamics. We will cover the basic fundamental properties that are used to describe a fluid flow along with general CFD methods

  • Types of fluid properties
  • Newtonian and Non Newtonian fluids
  • Description of fluid flows
  • Overview of CFD methods

2Introduction to Aerodynamics

Aerodynamics plays a very important role while designing a particular product which is exposed to environments that will affect its purpose. In this video, you will learn

  • Role of aerodynamics in design
  • Parameters of focus
  • Instruments used in aircraft
  • Similarity parameters
  • Aerodynamic forces and moments

3International Standard Atmosphere

The properties of the atmosphere vary from one place to another. This resulted in the comparison of aircraft performance in different parts of the world to not be realistic. Hence, a common decision was made to create an “International Standard Atmosphere” for comparison purposes. In this video, you will learn

  • What exactly ISA is
  • How to calculate the properties according to height.

4Tetra/Prism generation in ICEM CFD

The quality of the mesh and the elements you use determines the accuracy of the result that you obtain. Using ICEM CFD, you will be introduced to steps to create a suitable domain for a helicopter fuselage. The domain will be meshed with tetrahedral and prism elements. Quality parameters to assess your mesh will also be introduced to you. In this video, you will 

  • Be introduced to ICEM CFD
  • Understand the steps to setup your domain in ICEM CFD
  • Generate a mesh for your geometry
  • Assess the quality of the mesh

5Introduction to flow over airfoil

You can find airfoils in many aerodynamic applications. If you can’t find it, then you would probably have to take a cross sectional view to properly visualize it. For example, the cross section of an airplane wing is in the shape of an airfoil. The airfoil shape helps in generating the necessary forces to help the airplane fly. In this video, you will

  • Be introduced to what an airfoil is
  • Understand the forces acting on an airfoil
  • Use ICEM CFD to generate the domain required to analyse the flow over an airfoil
  • Generate the mesh for two cases
    • Incompressible flow over airfoil
    • Compressible flow over airfoil
    • Assess the quality of the mesh

6Introduction to Turbulence modelling

You would have visually experienced turbulent flow of a fluid by simply opening the tap in your kitchen. The fluid flow will follow an unruly nature once you increase the flow. This is a simple example. Turbulent flows can have negative effects on your product when it flows through air. If you take the example of your car, having highly turbulent flow in certain regions can lead to sources of noise generation and can also affect the performance of your car. Through CFD simulations, it has been made possible to capture this turbulent phenomena to better design your product. In this video, you will

  • Be introduced to what exactly turbulence is
  • Learn why it is important
  • Understand how to model turbulent flows
  • Understand the turbulence models available in commercial CFD packages.

7Simulate the flow over a NACA0012 Airfoil

Using the mesh created in the previous week, you will be taken through how to setup a simulation to analyse the aerodynamic forces on a NACA0012 airfoil. In this video, you will ,

  • Learn how to setup your simulation for analysing aerodynamic forces on an airfoil
  • Analyse the results for various angles of attack

8Introduction to moving zones

There can be two types of motion in fluid flow problems. One is rectilinear and the other one is rotary. Till now, we spoke about rectilinear motion. In order to simulate rotary motion, you need a different approach. In this video, you will 

  • Learn about moving zones
  • Approaches to model moving zones
    • Moving reference frame
    • Moving mesh

Types of mesh encountered at interfaces

Run a simulation to understand moving zones

9Comparison of Moving Reference and Moving mesh approach

From the two approaches discussed in the previous video, we will use a turbomachinery model to compare the application of both methods and compare the results. In this video, you will

  • Use a turbomachinery component to compare MRF and MM approach
  • Setup the simulation with appropriate parameters
  • Analyse the results

10Transient flow over air compressor

An air compressor is a common turbomachinery component with a large number of moving parts. It is quite difficult to model the entire component. Hence, we will take a sector of the component and apply a periodic boundary condition to the geometry. We will use the FLUENT Console to employ periodic zones in the simulation. In this video, you will

  • Work on a sector a large air compressor
  • Setup periodic zones in FLUENT console
  • Setup the simulation to analyse the turbomachinery component
  • Analyse the results

11Introduction to Computational Aeroacoustics

Noise is generated by an aerodynamic body when it is moving through air. The shape of the body determines the sources that generate this noise. For a car, the mirrors, gaps between the wheels etc are regions of noise generation. Manufacturers use CAA( Computational Aero-Acoustics) to study such sources and minimise the discomfort caused by it to the customer. In this video, you will

  • Learn about acoustics
  • Learn about acoustic analogy methods
  • CAA methodologies

12Broadband Noise modelling

The broadband acoustic solver is one of the CAA methodologies mentioned in the previous section. In this video, we will use the broadband solver to analyse the noise sources over an Ahmed Body. An Ahmed body is a simplified car body that was developed in 1984. This model is used for validation purposes. In this video, you will

  • Use ANSYS Mesher to generate the mesh for your domain
  • Setup a symmetric model in FLUENT
  • Run the acoustic solver to analyse noise sources


Projects Overview

Project 1

Highlights

In this project, the student will have to setup the domain for analysis of flow over an airfoil at subsonic and supersonic regime. The airfoil will be analysed at 3 different angles of attack and the lift and drag coefficient will be compared in all cases

  • Create domain for flow analysis
  • Setup simulation for subsonic and supersonic regimes at
    • 50, 100, 150 angle of attack

Project 2

Highlights

In this project, using the CAA methodologies learned in the course, the student will have to perform an acoustic analysis of an automotive ORVM. 

  • Create the domain for analysis
  • Setup the simulation
  • Obtain high noise generating regions

Course Four: Advanced IC Engine Simulation

1CONVERGE Studio Module

In this module you will learn how to set up a CFD simulation using CONVERGE CFD. You will be provided with step-by-step instructions on the following:

  • CAD import and cleanup

  • Decomposing the model into boundaries and volumetric regions

  • Inputting valve timing

  • Choosing turbulence and combustion models

  • Running the case in parallel environment

  • Post processing



2Surface Preparation

In this module, you will learn surface preparation in complete detail.


Specifically,


  • Setting up the piston motion profile

  • Boundary flagging

  • Setting up the intake and exhaust valves

3Region Initialization and Valve Motion Setup

In this module, you will learn the following concepts:


  • Initializing pressure, temperature and species concentration in the intake, Exhaust and fire deck regions

  • Disconnect triangles

  • Valve timing and the concept of minimum lift

  • Valve profile input

4Turbulence Modeling

In this module, you will learn how turbulence is modeled and simulated in a state-of-the-art CFD solver. You will learn about the different classes of turbulence models and understand their merits and demerits.


  • Learn about RANS approach to model turbulence

  • Comprehend the math involved behind RANS and its derivations


Learn theory on different types of turbulence models available (RNG k-ε, k-ω SST, etc.) and appreciate which model is suitable for which type of application.

5Combustion Modeling

In this module, you will learn how the SAGE detailed chemical kinetics solver works. In addition to this, you will also learn how to use the Shell CTC combustion model.

6Emissions Modeling

To design efficient engines, one needs to have a firm grasp of emissions modeling. You will learn about the Hiroyasu Soot Model and the Zeldovich Nox model and apply them in engine simulations.


Projects Overview

Throttle Body

Highlights

The objective here is to simulate flow past a throttle body under steady state and transient conditions. Your task is to study the effect of the valve dynamics on key flow quantities.

 

Diesel Engine

Highlights

In this project, you will run closed cycle simulations of the CAT3410 engine using two different piston bowls. You will be looking at the effect of piston bowl shape on the final solution.

Fuel Injection

Highlights

  • Clean up complex CAD model using CONVERGE STUDIO

  • Assign proper boundary and initial conditions

  • Setup appropriate physical models (spray, turbulence, combustion and emissions)

  • Running simulations in parallel

  • Runtime results visualization

  • Post processing results

  • Cerating cut views, iso-surfaces, images and animations

 

You will also focus on analyzing the data obtained from your simulation using line plots. You can find an example below.Last but not least, there is a reason why CFD is called colorful fluid dynamics. Here are some visualizations that beautifully convey the complexities of the various physical phenomena that you can expect in an I.C Engine.

 


 


Course six: Advanced Aerodynamic Simulation using Converge

1Preparing the Surface for Flow Simulation

In this module, you will learn how to import your CAD designs into CONVERGE Studio for performing flow analyses. The CAD geometry contains information on what the model is supposed to look like. You will work on fixing any errors, if present, and then split the geometry into boundaries so as to set up the simulation. This involves, but is not limited to:

  • CAD import and cleanup
  • Splitting the model into boundaries and flagging these boundaries

2Setting up the Simulation

In this module, you will learn about

  • Creating Virtual Wind Tunnel
  • Setting the boundary conditions effectively
  • How to choose the right turbulence model? K-Epsilon Vs. K-Omega SST
  • Understanding Y+ and choosing suitable grid sizes for our simulation

3Physics Modelling

A student of Aerodynamics needs to familiarize themselves with how different concepts in physics are captured by mathematical models. Without this understanding, an engineer will not be capable of setting up an external flow simulation with accuracy. We will cover the following modules under physical modelling:

  • Turbulence Modelling
  • Conjugate Heat Transfer
  • Shock Capturing

 

4Extracting Aerodynamic Quantities

    The main reason for performing an aerodynamic simulation is to extract vital information from the solution like the drag and lift on specific boundaries.

    • Understanding the wake and the effect this will have on the aerodynamic parameters
    • Extracting information such as drag and lift force from Converge CFD


    Projects Overview

    Airfoil

    Highlights

    In this project, you will be simulating the flow over an airfoil for different angles of attack and make drag and lift calculations for each of these cases. A comparison of how the lift is being produced in each case, stall predictions and separation can be studied. Additionally, another comparison of turbulence modelling on the prediction of separation can be studied.

    • Lift and Drag predictions for different angles of attack
    • Effect of turbulence model on flow separation

    Ahmed Body

    Highlights

    In this project, you will be simulating the flow over an Ahmed body and can alternatively study how separation occurs at the rear over different slant angles and compare your results with experimental data to validate the results. 
     
    • Drag predictions for different slant angles
    • Effect of turbulence model on flow separation
    • Effect of slant angle on flow separation

    FSAE Car

    Highlights

    In this project, you have the opportunity to perform as many simulations as you want to understand the aerodynamics of an FSAE car. We encourage students to work on open-ended problems and you can choose to solve as many problems as you want. Here are a few different project ideas that you can work on. 
     
    NOTE: Each of the following topics is a project and requires a fair amount of work. You can work on more than one topic at a time if you are hard-working and motivated.
    • Lift and drag predictions for different Yaw angles
    • Grid dependence test

    Course Seven: Advanced Turbomachinery Simulations using Converge 

    1CONVERGE Studio Module

    In this module, you will learn how to set up a CFD simulation using CONVERGE CFD. We will provide step-by-step instructions on the following:
    • CAD import and cleanup
    • Decomposing the model into boundaries and volumetric regions
    • Inputting valve timing
    • Choosing turbulence and combustion models
    • Running the case in a parallel environment
    • Post-processing

    2Surface Preparation

    In this module, we will elaborate on surface preparation in complete detail. Here you will learn the following:


    • Setting up the moving boundaries
    • Geometry cleanup

    3Regions and Initialization

    In this module, you will learn the following concepts:
    • Initializing pressure, temperature and species concentration in different flow regions
    • Disconnect triangles
    • While setting up the case, one will come across complex problems where there will be different zones where the value for any thermodynamic properties like Pressure or temperature will be different and set up the case accordingly, CONVERGE provides a very good feature of creating a region (volumetric region) in which there will be particular value for the pressure, a temperature that user will provide according to his needs.
    • A very good example of the application of regions and initialization is a SHOCK TUBE problem in which there are 2 chambers filled with fluid, one at high pressure and other at low pressure and these 2 regions are separated with the help of the diaphragm. Now to set up such cases, a feature of Regions and Initialization seems to be really important and useful.
    • After creating 2 regions, we need to provide initial values to both regions accordingly and this is how students will learn to create volumetric regions.


    4Turbulence Modelling

    In this module, students will learn how turbulence is modelled and simulated in a state-of-the-art CFD solver. You will learn about the different classes of turbulence models and understand their merits and demerits.

    • Here, students will learn about the RANS approach to model turbulence.
    • You will get to appreciate the mathematics involved behind RANS and will learn the derivation part as well.
    • You will learn various turbulence models available like (RNG k-ε, k-ω SST etc) and understand which model is suitable for which application.
    • Mostly, RNG k-ε suits best for Internal flows and k-ω SST suits best for external flows.


    5Cavitation Modelling

    In this module, you will learn how Cavitation can be simulated. We will be focussing on the Volume of Fluid Method (VOF). You will also learn about VOID FRACTION which is the basis of the VOF method.





    Projects Overview

    Centrifugal Pump

    Highlights

    The objective of this project is to simulate flow through a centrifugal pump and obtain the pump performance curve. The performance curve is the plot of Volume flow rate Vs. Total pressure drop. It is a tool that shows how a pump is going to behave in terms of head and flow. The performance curve defines the range of possible operating conditions for the pump. With the help of this curve, we can determine the size of the impeller, NPSH and the efficiency required to pump against a particular head and at a given flow rate. You will work on transient simulations so that you can capture the flow physics.

    Supercharger Flow

    Highlights

    The objective of this project is to simulate flow through a supercharger. Superchargers are characterized by complex flow structures and tiny gaps. By applying a robust meshing methodology, the student can validate the mass flow rate and outlet temperatures accurately.

    Turbocharger Flow

    Highlights

    The objective of this project is to simulate flow through a Turbocharger and obtain the performance curve. You will be running transient simulations to capture the flow Physics.
     

    2D Cavitation

    Highlights

    The objective of this project is to look for the Cavitation zone by using the Volume of Fluid (VOF) method and plot the Cavitation zone length with respect to the pressure difference. The study of Cavitation is very important as it affects mass flow rates coming into a cylinder via fuel injectors. Cavitation occurs because of a sudden drop in pressure heads and this occurs because of abrupt change in flow area. When the flow area suddenly decreases, it creates a zone of low pressure or separation zone. When the pressure becomes lower than the vapour pressure of the fluid, fluid instantaneously vaporizes into the gas phase and this affects the injector properties in terms of delivering the required fuel flow rate and this can further affect the combustion and emission performance. And that’s why it’s very important to look at Cavitation in automotive applications. In the HVAC or Turbomachinery world, Cavitation is extremely important in rotating devices.


    Course Five: IC Engine Calibration using GT-POWER

    1Week 1: Introduction to GT-POWER and GT-SUITE

    GT-POWER is the industry's first choice when reliable results are needed for engine thermodynamics and combustion/emissions development. The intelligent integration of modules within it [GEM 3D; Cool 3D; GT - VTD; GT - TAItherm ] coupled with Simulink, Star CD, Converge, Fluent and other codes facilitates easy solutions for complex tasks early in the development phase and provides unparalleled accuracy during the detailed design phase.


    • Need of a 1D thermodynamic simulation tool
    • Overview of GT-POWER, GT valve train, GT cool, GT drive, etc.
    • Introduction to GUI
    • Templates and libraries
    • Representation of engine parts
    • Implicit vs Explicit approach
    • Navier Stoke equation relevance

    2Week 2: SI Engine Modelling Techniques

    Over the past decade, an increase in air pollution all around the globe as well as the recognition that fossil fuels will not be available forever, has inspired OEMs to develop electrified powertrains. But, this has also opened the door to investigate new technologies that could significantly improve the ‘old fashioned’ combustion engine in both efficiency and emissions. In this section, you will get an in-depth look at the functioning of SI Engine operations.


    • Challenges in SI engine modeling
    • Combustion modeling approach
    • Port injection and gasoline direct injection approach
    • Tumble modeling
    • Gas exchange modeling and analysis

    3Week 3: Case Study on SI Engine

    Virtual prototyping is an efficient and effective way to test new ideas. In this module, you will look into some aspects of SI Engine including the basics of fuel spray in the combustion chamber, spray and wall film models accounting for premixed and sooting diffusion combustion detecting knock precise heat transfer modeling.

    • Engine specifications for modeling
    • Performance and emission prediction

    4Week 4: CI Engine Modelling Techniques

    Understanding the mechanics for modeling combustion in a CI Engine. These solutions play an integral role in engine simulations to accurately predict performance, fuel consumption, and engine-out emissions. Various models are available to predict combustion and pollutant formation based on in-cylinder conditions, knock, cycle-to-cycle variation (CCV), and other related processes.  


    • Challenges in CI engine modeling
    • DI pulse Combustion modeling approach
    • Swirl modeling
    • Turbocharger modeling


    5Week 5: Case Study on CI Engine

    Further our understanding by modeling an ‘On-road’ application by calibrating critical CI Engine concepts such as ignition delay time for mixtures of air, fuel, and residual gases using detailed kinetics. This challenge enables the user to understand the correlations for ignition delay (CI) or knock (SI) that consider the effect of pressure, temperature, equivalence ratio, residual gas fraction, fuel composition, etc.


    • Engine specifications for modeling

    • Performance and emission prediction

    6Week 6: Turbocharger and Supercharger Modelling

    Turbocharging allows automakers to reduce engine size and emissions while continuing to deliver the power and performance consumers demand. Students will be taken across the turbine and compressor mechanics to understand the fluid flow and to improve overall engine performance, reduce pollutant formation, optimize NVH and ensure component durability. 

    • Fixed geometry TC modeling
    • Wastegate TC modeling
    • Variable geometry turbine modeling
    • Two-stage turbocharger modeling
    • Supercharger modeling
    • eTurbo modeling

    7Week 7: Case Study on FRM Builder

    GT-POWER engine models and the validated solution methodologies, can be used by the controls system engineer for ECU development, calibration, and testing to generate a fast running, real-time capable engine plant models. With seamless integration with Simulink and the most popular real-time software tools, controls engineers are empowered with the ability to run fully physical, crank angle resolved models, capable of predicting pressure wave dynamics and in-cylinder combustion in a real-time environment. Advanced control strategies, such as combustion control, can now be tested with a detailed physical engine model at significantly faster computation speeds with minimum effort and maximum accuracy, predictiveness, and fidelity.

    • Introduction to FRM builder
    • Modeling of various engines using FRM builder approach
    • Crank-angle resolved, physically conservative formulation for accurate results
    • Built-in DOE and neural network trainer for MV model development

    8Week 8 : Aftertreatment Modelling Techniques

    The starting point for the development and optimization of exhaust gas after-treatment systems is 1D simulation. GT’s Quasi-steady-state AFT solver offers unmatched modeling depth, simple model setup, and extremely short simulation times – faster than real-time if desired. It solves the very demanding fluid flow, heat transfer, and chemical reactions taking place in after-treatment systems of modern IC engines by employing the most advanced set of physics and chemistry models. 

    • Introduction to chemical kinetics
    • Modeling precious metal catalysts
    • Pre-defined test cases and scenarios

    9Week 9: Case Study on 3-way Cat DOC DPF and SCR System

    For the detailed 1D & 2D design of exhaust gas after-treatment components, GT-SUITE offers outstanding capabilities modeling all relevant physics and chemistry. This makes it a crucial element in the design, development, and optimization of both diesel and gasoline after-treatment devices. Together with GEM 3D, it forms a unique and dependable 1D/3D solution that can be applied consistently throughout the layout, concept and detailed design stages in both component and system development to provide a seamless development approach with the reuse of models and results among tools assuring maximum consistency and efficiency. The after-treatment system performance data integrated in-vehicle models are used to predict drive cycle emissions.

    • Modeling 3-way cat con
    • Modeling DOC
    • Modeling DPF
    • Modeling SCR

    10Week 10: Optimization Techniques

    Every GT license includes full access to a built-in optimizer that allows optimization of any combination of model inputs (factors) to maximize, minimize, or target any single or multiple model outputs (responses). Key features include: Multiple local and global search algorithms to exploring design trade-offs among multiple competing responses and constraints with the multi-objective Pareto optimization tool and the NSGA-III [Genetic search algorithm].

    • Design of experiments
    • Single-factor optimization
    • Multi-objective optimization
    • Case study on gas exchange optimization

    11Week 11: Discretization Techniques

    GEM3D is a 3D graphical pre-processor that combines building and importing tools used to create 1D GT-SUITE models from 3D geometries. From primitive components like pipes, flowsplits, etc. it can also be used to import 3D CAD models from other applications, like GT-SPACECLAIM.

    • Introduction to SPACECLAIM
    • Overview of GEM 3D
    • Discretizing intake manifold
    • Discretizing exhaust manifold


    12Week 12: Hybrid Engine Modelling

    Build any hybrid configuration with any level of electrification, including but not limited to: 48-volt mild hybrids with an electric boost, strong power-split hybrid (HEV), parallel through-the road (TTR) plug-in hybrids (PHEV), or battery electric vehicles (BEV) using a comprehensive controls library, including finite state machines in GT-SUITE, or co-simulate with Simulink to develop and optimize control algorithms.

    • Overview of hybrid system configuration
    • Modeling of P0 and P1 configuration
    • Built-in optimization and DOE tools to evaluate architectures, components, and control strategies


    Projects Overview

    Tractor Engine

    Highlights

      • Perform calibration and simulation on a commercial application on road tractor engine to meet the performance and the emission requirements.
      • Case studies including baseline simulations that compares different variants [Naturally aspirated vs Turbocharged] for performance and [Cooled EGR configuration] for meeting NOx targets.


      AFT System

      Highlights

        • Detailed AFT circuit system integrated with the engine model to accurately model the chemistry that captures the engine out emissions using a 3 way catalytic converter
        • Modelling DOC , DPF and SCR with Urea Injection strategy to meet the stringent Euro emission norms for commercial CI engines.



        Eicher Pro

        Highlights

          Complete Engine + Aftertreatment modelling for a BS IV variant HDT [Heavy duty truck] by employing suitable in cylinder strategies and AFT techniques to convert the same into a BS VI compliant variant.



          Course Nine: Hybrid Electric Vehicle Simulation Using GT-SUITE 

          1Introduction to Hybrid Electric Vehicle

          In this video we will touch upon the topic- What is a Hybrid Electric Vehicle?. It is vital that a student have knowledge on this topic before proceeding on with the course. In this video we will be covering-

          ● Introduction to BEVs

          ● Requirement of HEVs

          ● Classification of HEVs

          ○ Classification based on powertrain

          ○ Classification based on degree of hybridisation

           

          2Introduction to Battery Electric Vehicles and Batteries.

          Once we have a fair understanding of what a HEV is, we will move on to BEVs or Battery Electric Vehicles. Since most HEVs have a battery powertrain, it is vital that a student familiarises this topic. In this video we will be covering-

          What are BEVs?

          Degree of hybridisation

          Components of BEVs

          What are batteries?

          Construction and Working of Lithium ion batteries


          3Understanding Series, Parallel and Series-Parallel HEVs.

          There are many classifications of HEVs. Since, the classification based on Powertrain is the most widely used, we will be covering it in depth.

          ● What is a powertrain?

          ● Classification of HEV based on powertrain.

          ● Explanation of Series HEV

          ● Explanation of Parallel HEV

          ● Explanation of Series-Parallel HEV

          4Objectives of Modelling and Simulation

          The course is oriented towards “Simulation” of an HEV model. Most of us know what a 3D or 2D model/ simulation is. But,  GT-SUITE is primarily a 1D modelling/simulation software suite. So, in this video, we will be having a discussion on the many types of simulation and the specifics behind it. We will be covering-

          ● What is modeling? What is the importance of modeling?

          ● What is simulation?

          ● Importance and examples of simulation

          ● Types of simulation

          ● What is the Navier-Stoke equation and how does  GT-SUITE solve it?

          5Introduction to GT-SUITE

          In this session, we will be showing you how to open  GT-SUITE and explain the various features of the software. We will be covering-

          What are the applications of  GT-SUITE?

          Softwares provided in  GT-SUITE

          Resources available in  GT-SUITE

          Templates. Models, and Examples in GT-SUITE,


          6Development of P0P4 HEV model.

          During this week, we will be importing an HEV model in  GT-SUITE and explain the templates used in the model. 

          ● The basic theory behind IC engines and electric motors. 

          ● How to import a P0P4 model into  GT-SUITE

          ● What are the various templates used in the P0P4 model?

          ● What are the parameters used to define the templates?

          ● Changing of the vehicle drive cycle.

          ● Case setup

           

          7Analysis of simulation results and conclusion

          This is the final chapter of the course. Here, we will take a look at the results we have obtained from the simulation.  In this chapter, we will be covering-

          ● Modifications that can be done in case setup

          ● “Maximum Simulation Duration Time” option

           GT-SUITE GUI

          ● How to access simulation graphs and results

          ● Report generation

          ● How to study and correlate simulation graphs.

          ● Vehicle state and supervisory controls.

           


           


          Course Ten: Advanced CFD Meshing using ANSA

          1Introduction to ANSA GUI and Tools

          In this module you will be introduced to the ANSA Software. You will learn the Graphical User Interface(GUI) of the ANSA tool. You will get to know about different solvers and types of analysis carried out using them. You will be introduced to basic tools that will help you with geometric cleanups and other deck setups in ANSA.
          The topics covered in this module are, 

          • Introduction to ANSA,
          • ANSA GUI,
          • Geometric Tools and Topology cleanup
          • Different Tools used in TOPO deck

          22D (Surface) meshing to Pressure valve

          In this module you will be introduced to the Pressure valve model. You will get to know how to perform Surface Meshing to a Pressure valve model. 
          The topics covered in this module are, 

          • PID creation and PID assignment,
          • Different selection techniques and visibility tools,
          • Basic Topology cleanup
          • Basic tools used in Surface mesh

          33D (Volume) meshing to Turbocharger

          In this module you will be introduced to the Turbocharger model. You will get to know how to perform Volumetric Meshing to a Turbocharger model. 
          The topics covered in this module are, 
           
          • Geometry cleanup to define volumes.

          • Various Geometry checks

          • Surface meshing as per Quality Criteria 

          • Volumetric Meshing as per requirements

          4CFD meshing to BMW M6 Model inside Wind tunnel

          In this module you will be introduced to the BMW M6 model. You will get to know how to perform CFD Meshing to a BMW M6 model. 
          The topics covered in this module are, 

          • Advanced Topology cleanup to define volumes.
          • Variable Surface meshing part by part 
          • Solving quality failed elements as per Quality criteria
          • Symmetry operation for surface and mesh elements
          • Wind Tunnel Creation 
          • CFD Meshing for Wind tunnel

          5Surface wrap to an Automotive assembly

          In this module you will be introduced to three different automotive models: Engine, Transmission, Gearbox. You will get to know how to perform Surface wrap to an automotive assembly for outer flow CFD Analysis. The topics covered in this module are, 

          • Geometry cleanups for surface wrap.
          • Merging of different models in one GUI.
          • Surface wrapping for an Assembly.


          Projects Overview

          CFD meshing to a Truck Model inside Wind tunnel

          Highlights

          You will be provided with a Truck Model. You have to perform Topology cleanup as per volume requirements and meshing the whole model by achieving all the mentioned quality criteria parameters.
           

          Flexible Course Fees

          Choose the Master’s plan that’s right for you

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          • Access Duration : 9 Months
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          FAQ

          1Who are the instructors and what is the learning process?

          Our instructors are industry experts working in Fortune 500 companies. We partner with them to deliver the lectures online. You will be given access to recorded content and assignments each week.

          2Are there any pre-requisites for this program

          You should be pursuing or have graduated with a B.E/B.Tech in Mechanical or Automotive Engineering

          3What is the support that I can expect when I have doubts?

          Our team of dedicated support engineers are available around the clock to assist you with any questions that you might have when you are studying. There are different ways to contact your support engineer, 

          • You can either raise a ticket from your study window
          • You can raise the question in the dedicated Whatsapp chat
          • You can come to the Skill-Center and have your questions answered in person. 
          We will answer your questions through either one of these means and help achieve better conceptual clarity. 

          4How are these courses different from what I have learnt in college?

          Our courses are crafted after consultation with industry experts and are designed to bridge the gap between academia and industry. The modules that you work have real-world applications and the projects that you work on as part of each module will be a project that is currently being conducted in an OEM, the only difference being the scale of the project. 

          5What is the advantage in taking this program?

          You will have an edge over your peers by working extensively on industry-relevant projects, practice on tools and software that will set you apart and help you in getting ahead of the competition. Our course will strengthen your portfolio to get better grants and scholarship opportunities for MS Admits, explore options in Research & Development, and land that much-coveted job in top core companies. 


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