In some simulation problems, not only the heat transfer within the fluid plays a role, but also that in the adjacent solid. In such cases, a coupled simulation of heat propagation between the solid and fluid (CHT – Conjugate Heat Transfer) must be performed.
We master such simulations with our open-source tools, e.g. OpenFOAM. For rapid optimization of heating and cooling performance using numerical simulation, we have created additional tools to accelerate the preparation of such simulations.
Stationary and transient 3D simulation of heat propagation in complex components made of different materials. Cooling and heating of components to determine critical heat flows, required cooling loads or e.g. avoidance of thermal stresses. Optimization of component geometries through automated geometry creation and simulation processes.
For industrial plants, chemical facilities, energy supply infrastructures, and safety-critical installations, the uncontrolled release of gases in the event of a malfunction poses a significant risk to people, the environment, and assets. The precise prediction of gas dispersion is therefore an essential component of modern safety analyses, risk assessments, and emergency planning.
Using CFD (Computational Fluid Dynamics) simulations, escaping gases in fault scenarios – both light gases (e.g., hydrogen, methane, ammonia) and heavy gases (e.g., chlorine, propane, CO₂) – are precisely captured in their spatial and temporal dispersion. The simulation takes into account the immediate surroundings (building contours, obstacles, terrain structure) as well as the distant surroundings (building density, topography, open areas) to model realistic dispersion scenarios.
The calculation of both steady-state and transient concentration fields allows for a differentiated assessment of the dispersion dynamics:
Wind direction, wind speed, and atmospheric stability classes (according to Pasquill-Gifford or Monin-Obukhov) have a significant influence on the range, concentration, and hazard zone of a gas cloud. By systematically varying these parameters, all safety-relevant scenarios are covered – from calm weather conditions with low mixing to turbulent flow with rapid dilution.
An essential quality feature of the simulation is the use of custom-developed transient inflow boundary conditions for atmospheric boundary layers. In contrast to simplified wind profiles, realistic, time-varying flow profiles with turbulent boundary layer structure are used. This ensures a high degree of agreement with real meteorological conditions and significantly increases the reliability and validity of the simulation results – a crucial advantage over classic Gaussian dispersion models.
CFD-based gas dispersion simulation is used in:
In modern development processes, thermal management is a central challenge – especially for high-performance components such as electronic assemblies, power electronics, and LED light sources. Using 3D CFD (Computational Fluid Dynamics) simulations and FEM (Finite Element Method)-based thermal analysis, precise thermal analysis is performed for the cooling of various components, including electronics, light sources, and embedded systems.
A realistic simulation considers all relevant heat transfer mechanisms:
Various cooling strategies – from passive air cooling and active forced cooling to liquid cooling and heat pipes – are virtually evaluated before a physical prototype is created. Key performance indicators such as maximum component temperatures, temperature gradients, thermal resistances, and compliance with limit values according to IEC, JEDEC, or UL standards are crucial evaluation criteria.
By integrating thermal simulation early in the development phases – from conceptual design through detailed design to series production readiness – costly redesigns and thermally induced failures can be avoided. The simulation provides reliable statements on service life, reliability, and compliance with temperature limits (e.g., Tjunction for semiconductors or Tc values for LED modules), which are directly incorporated into the design.
This ensures the product's functionality is reliably guaranteed during the development process – long before the first prototype.
The analysis of the flow with heat transfer at various operating points of technical components is the most important step in design and optimization. We have mastered the simulation tools required for this. Improved inflow and outflow and better flow control with minimal pressure losses reduce component and operating costs. Predictions about local thermal stresses can be derived from the 3D simulations.
A reduction in air conditioning energy consumption is possible through efficient and controlled ventilation. Coupled simulations (thermal radiation, conduction, convection) calculate temperatures within the vehicle and on its surfaces due to solar radiation. Optimized software (InsightCAE) for solving transient thermal radiation using CFD, taking into account thermal capacities, enables fast and efficient simulations for the client.
Lakes and other surface waters represent an enormous natural energy reserve that can be utilized both ecologically and economically efficiently. By using lake water heat pumps, this stored thermal energy can be harnessed for the heating and cooling supply of buildings, thereby contributing significantly to the decarbonization of municipal heat supply. Thermal flow simulations form an indispensable basis for spatial energy planning and enable a well-founded assessment of the framework conditions and requirements for sustainable thermal utilization of lake water.
A significant advantage of thermal flow simulations lies in their communicative function: they make the expected thermal and fluid mechanical conditions in bodies of water clearly and understandably visible to all stakeholders – authorities, planners, and energy suppliers. This considerably simplifies water law approval processes and creates a shared planning basis on which well-founded decisions can be made regarding locations, performance classes, and operating concepts for the use of lake water.
The basis of any thermal flow simulation is a precise digital terrain model of the water body. For this purpose, existing depth maps are digitized and transferred into a three-dimensional computational model that accurately depicts the real basin geometry with its depths and shorelines. The more accurately this 3D model reflects the actual bathymetric conditions, the more reliable and meaningful the results of the CFD simulation will be.
The flow simulation realistically depicts the temperature stratification in the body of water, considering both intake and discharge pipelines for heating and cooling operations. In natural waters, solar radiation, wind mixing, and seasonal influences create a characteristic thermal stratification – the so-called thermocline – which significantly influences temperature availability and flow behavior. The simulation quantifies these complex interactions between heat input/output and natural stratification, thus providing reliable planning data for the design of seawater heat pump systems.
The time-resolved observation of temperature fluctuations in the body of water allows for a realistic assessment of the seasonal performance availability of the seawater system over a complete annual cycle. Temperature profiles and their dependence on weather influences, usage intensity, and operating regimes can thus be analyzed in detail and used for system design.
By systematically varying the supply and return geometries—that is, the number, arrangement, and orientation of the intake and outfall structures—the respective thermal influence zones in the water body are determined. In this way, hydraulic and thermal short-circuit flows can be reliably avoided, the efficiency of seawater utilization can be maximized, and potential ecological impacts on the water body can be reduced to a minimum.
As part of an innovative energy concept, a harbor basin is being used as a natural heat source and sink for the cooling and heating operations of surrounding office buildings. Surface waters such as harbor basins, lakes, or rivers are ideally suited as the basis for water-based heat pump systems due to their thermal storage capacity and can achieve significant energy savings compared to conventional air conditioning systems.
Thermal simulations were carried out to assess the thermal impacts on the water body, quantifying the temperature influence of heat withdrawal and heat input on the harbor basin. Such simulations are essential to ensure that the water temperature remains within ecologically and legally permissible limits and that no undesired thermal stratification occurs.
Particular attention was paid to the hydraulic design of the supply and discharge lines at the quay wall. Thermal or hydraulic short circuits—that is, the direct return of already tempered water to the intake point—would significantly reduce the efficiency of the system. Through careful positioning and flow engineering of the inlet and outlet structures, this effect can be reliably prevented.
To avoid excessively high flow velocities in the harbor basin, the number of inlets and outlets was varied and optimized. High local flow velocities can cause sediment resuspension, negatively impact aquatic life, and lead to increased wear on technical equipment. Distributing the volumetric flow rate across multiple discharge points reduces these risks and ensures more uniform flow through the basin.
The intake boxes were specifically sized to prevent the entry of fish and other aquatic organisms into the pipeline system. In practice, fine-mesh grates, screens, or special protective grids are used, with flow velocities kept so low that fish are not sucked in. Corresponding limit values for inflow velocity are enshrined in water law regulations and environmental requirements.
Finally, the biological compatibility of the entire system was investigated. Possible impacts on the harbor basin ecosystem were assessed, particularly with regard to temperature changes, altered oxygen levels, and the introduction of non-native organisms. Environmentally compatible planning ensures that the operation of the facility is in accordance with water law approval requirements and the objectives of the European Water Framework Directive.
Adhesive bonding is playing an increasingly important role in modern constructions – from aerospace and automotive engineering to wind turbines and general mechanical engineering. In contrast to form-fitting connections such as screws or rivets, adhesive bonds transmit loads over an area, reduce notch effects, and enable the joining of diverse materials. This makes reliable computational assessment all the more important – especially with the Finite Element Method (FEM).
Similar to bolted connections, adhesive bonds can also be precisely considered in FEM models. We use a modeling technique that not only correctly maps global load transfer but also enables a sufficiently detailed assessment of stresses within the adhesive layer itself. This reliably identifies and evaluates critical areas such as adhesive layer edges, overlap zones, and peel stress peaks.
The adhesive layer is the mechanically critical element of the bond, despite its often small thickness. Simplified or neglected modeling frequently leads to:
Depending on the requirements and available computing power, we use different, coordinated modeling approaches:
Based on the FEM results, we perform a structural mechanics assessment according to recognized codes and internal methods:
Our FEM-based adhesive joint analysis is used in many industries and components:
Do you want to computationally verify the load-bearing capacity of an adhesive bond or expand an existing FEM model with a realistic adhesive layer modeling? Contact us.
Code_Aster is one of the most powerful yet demanding open-source finite element codes worldwide, developed and continuously maintained by the French energy company EDF. With a feature set that surpasses many commercial FEM programs, Code_Aster is particularly well-suited for complex structural, thermal, and coupled analyses in industrial and scientific environments.
We have more than 10 years of practical experience in the professional use of Code_Aster and use this FEM code for a wide spectrum of demanding calculation tasks – from simple static analysis to highly complex transient simulations with nonlinear material behavior and contact.
Whether it's operating load, impact, or time-varying loads – we calculate the mechanical behavior of components and structures under realistic load conditions. We utilize the full range of element types offered by Code_Aster:
Contact problems are among the numerically most challenging tasks in FEM. Code_Aster offers robust algorithms for this purpose, which we specifically employ for issues such as press fits, bonded joints, sealing surfaces, or the lifting of components under operational loads. Geometric and physical nonlinearities – such as large deformations or elastoplastic material behavior – are also accurately represented.
The realistic modeling of bolted connections in FEM models requires both methodological know-how and experience with the peculiarities of the respective solver. We simulate pretension forces and the elastic behavior of bolted connections using proven methods – for reliable validations according to common standards such as VDI 2230.
Knowledge of the natural frequencies and mode shapes of a structure is a prerequisite for assessing resonance risks and designing vibration-damped constructions. With Code_Aster, we perform modal analyses and, if necessary, combine them with harmonic or transient vibration response calculations – for example, for rotating machinery, piping systems, or seismically stressed installations.
Our Code_Aster projects span numerous industrial and engineering fields:
Are you looking for an experienced partner for structural mechanics calculations with Code_Aster? Contact us – we will discuss your task and jointly develop an efficient and robust simulation strategy.
