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Physical correlation to FloWorks for air ducting |
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July 8, 2008, 19:35 |
Physical correlation to FloWorks for air ducting
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My primary interest has been using FloWorks to improve the flow rate of air through automotive intake systems (filter housing, filter, intake tubes.) While my goal of having the simulation show whether or not a design iteration would be superior relative to the last seemed modest, it has not been so easy.
I prefer to use FloWorks to simulate the design prior to making a rapid prototype. While using FloWorks for the past year or so I have had cases where the simulation indicated that CAD model A was surely better (less pressure drop for a given flow rate) than model B, but in making rapid prototypes of each this was not true. Sometimes the opposite is actually true, B noticeably better than A in the physical test, which means our simulation tool actually sent us in the wrong direction and lengthed development time! In exploring the cause for this, I am focusing on the knowledge that often the situation exists where the flow outlet has non-uniform pressure and velocity. Also, each design iteration will affect these pressure and velocity profiles. Therefore, the boundary conditions are never the same at the outlet. Suspecting that the boundary conditions must be identical to compare iterations, I am setting out to build geometry in the model to baffle and then diffuse the air at the outlet, so that the pressure is uniform (.1% delta between min and max value.) So my question is do others add geometry to their outlets to affect the boundary conditions in this way? What considerations or pitfalls are there in this technique? |
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