Knowledge Base

Multi-physics Simulation for Industries

Introduction
Simulation is the process of creating a digital model of a real-world system or process and experimenting with it to gain insights, optimize performance, and make informed decisions. It involves developing mathematical models, discretizing them numerically, and solving them computationally. Simulation enables faster innovation, improved product quality, and better understanding of complex systems. By simulating different scenarios and "what-if" analyses, simulation provides a powerful tool for decision-making and problem-solving across various industries.

Multi-physics simulation takes the simulation process one step ahead. It involves the simultaneous simulation of different aspects of a physical system and the interactions between them. This is achieved by modelling and numerically solving a set of coupled equations that describe the various physical processes occurring in the system.

Key Aspects of Multi-physics Simulation

  • Identifying the relevant physics: The first step is to identify the different physical processes that need to be simulated, such as fluid flow, heat transfer, structural mechanics, electromagnetics, and chemical reactions.
  • Coupling the physics: The interactions between the different physical processes need to be properly modelled through coupling terms in the governing equations. This ensures that the simulation captures the full complexity of the system.
  • Numerical implementation: Multi-physics simulations are typically implemented using discretization methods like the finite element, finite difference, or finite volume methods. This allows the coupled partial differential equations to be solved numerically.

Multi-physics simulation offers numerous advantages that enhance product design and development. By integrating multiple physical phenomena such as fluid flow, heat transfer, and structural mechanics into a single simulation, multi-physics modelling accurately capture the intricate interactions present in real-world systems. This capability ensures more precise predictions of product performance compared to traditional single-physics simulations.Moreover, multi-physics simulation promotes collaboration across various engineering disciplines such as mechanical, electrical, and thermal engineering. It provides a unified platform for analyzing integrated system behaviour, facilitating better teamwork and enhanced decision-making throughout the design process.

Multi-physics simulation has numerous real-world applications across various industries and fields. Here are some examples:

Automotive Industry

  • Powertrain optimization: Multi-physics simulation is extensively used to optimize the design of automotive powertrains, including engines, transmissions, and electric motors. Engineers can model the complex interactions between electromagnetics, heat transfer, structural mechanics, and fluid dynamics to improve efficiency, performance, and reliability.
  • Vehicle aerodynamics: Multi-physics simulation can model the intricate interactions between airflow, structural deformation, and heat transfer to optimize the vehicle's shape and under body design. This helps reduce drag and lift forces acting on the car.
  • Crash safety: Multi-physics simulation is used to model the complex nonlinear behavior of vehicle structures, airbags, and seatbelts under impact loads.
  • Vibration and noise analysis: Simulation can predict the dynamic response of components like the suspension, steering system, and powertrain to road inputs and unbalanced forces. This helps identify and mitigate sources of vibration and noise.
  • Electromagnetic compatibility: With the increasing electrification of vehicles, managing electromagnetic interference between electronic systems is crucial. Multi-physics simulation can model the complex electromagnetic fields and their coupling to mechanical structures, enabling optimization of shielding and grounding designs

Solar Energy Applications

  • Solar Panels: Simulating the thermal and electrical behaviour of solar panels to optimize their performance and efficiency in real-world environments
  • Photovoltaic (PV) Cell Design and Optimization: Modelling of the absorption of sunlight and the generation of electron-hole pairs in the PV cell, analyzing heat generation and dissipation to ensure the PV cell operates within optimal temperature ranges, and improving efficiency and lifespan
  • Structural analysis: Assesses mechanical stresses and strains on PV panels caused by wind, snow, and other environmental factors to ensure durability and reliability

Electronics and PCB Design

  • Analyzing nonlinear behaviour: Electronic systems exhibit nonlinear behaviour that cannot be accurately modelled using linear approximations. Multi-physics simulation allows capturing the inherent nonlinearity of semiconductors, heat generation, mass transport, and mechanical stresses. This enables more realistic modeling of the system's performance
  • Coupling multiple disciplines: Electronic systems are governed by multiple interacting physical processes like electromagnetics, heat transfer, fluid dynamics, and mechanics. Multi-physics simulation accounts for these couplings by solving the governing differential equations simultaneously, providing a comprehensive understanding of the system behaviour
  • Optimizing designs: By simulating the entire system, including trade-offs between competing requirements, multi-physics enables finding the best design. For example, optimizing antenna placement for 5G phones requires balancing electromagnetics and mechanical constraints

Energy and Power Generation

  • Power Plants: Optimization of the flow of fluids in turbines, boilers, and cooling systems to improve efficiency. Modelling heat transfer processes to enhance the design and operation of power generation systems
  • Renewable Energy: Simulating aerodynamics and structural dynamics of wind turbines to optimize blade design and turbine performance
  • Hydropower: Modelling fluid flow and mechanical stresses in turbines and dams to ensure efficient and safe operation
  • Grid Systems: Electrical simulation to analyze power distribution and load balancing to improve grid reliability and efficiency. Ensuring electrical components in substations and distribution networks operate within safe temperature ranges

Aerospace and Defence

  • Aircraft and spacecraft design: Simulation of airflow around structures to optimize designs for lift, drag, and stability
  • Aerodynamics and structural mechanics: Simulating the interactions between fluid flow, structural stresses, and thermal effects in aerospace systems to improve their performance and reliability
  • Thermal management: Models heat transfer in engines and other systems to prevent overheating and ensure optimal performance
  • Propulsion systems: Analyzes fuel combustion processes in engines to improve efficiency and reduce emissions.
  • Fluid dynamics: Optimizes the flow of air and fuel in propulsion systems for better performance
  • Radar and electromagnetic Systems: Modelling of radar and communication systems to enhance signal strength and reduce interference.

Materials Science and Engineering

  • Materials development: Microstructure simulation helps in the development of material microstructures during processes like solidification and phase transformation to optimize material properties
  • Mechanical simulation: Analyzing the mechanical behaviour of materials under various loads to design stronger and more durable materials
  • Additive manufacturing (3D printing): Simulating the 3D printing process to predict and mitigate defects, ensuring high-quality production
  • Casting and forging: Modelling thermal and mechanical processes to optimize manufacturing techniques and improve material properties.
  • Fatigue and fracture analysis: Evaluating how materials perform under cyclic loading and identifying failure points to improve durability
  • Corrosion simulation: Modelling the effects of environmental factors on materials to develop more corrosion-resistant alloys and coatings

Multi-physics Software

These are only a few industries where multi-physics simulation plays an important role in product development. As a matter of fact, multi-physics systems are almost universal, and across industries. Commercialmulti-physics software packages provide a framework to define the different physics, specify the coupling, and solve the resulting system efficiently. For example, Altair offers top-tier multi-physics software like SimLab™, HyperWorks, FEKO™, EDEM™, Flux™, etc. for simulating various physical interactions such as fluid-structure interaction, flexible bodies, aero-acoustics, and thermo-mechanical scenarios. Coupled with Altair’s advanced optimization and scalable high-performance computing (HPC), it efficiently tackles real-world engineering challenges.