Behr US Sculptor

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3D Shape Optimization Of Evaporator Diffuser
using Sculptor
Requested by Michael Schrumpf
Performed by Mohsen Battoei
December 05, 2005
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Objective

• The aim of this study is to optimize the shape
  of the evaporator
• diffuser to maximize flow uniformity across
  the S-section of the
• evaporator utilizing Sculptor.
• The baseline evaporator flow model was provided
  by Behr.
• The baseline is set up in Star-CD.
• The flow uniformity is defined as following

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Sculptor set up procedure
X1
X0
X2

• The model is imported into Sculptor.
• ASD (arbitrary shape deformation) volume is
  defined around the objective.
• Some control points are grouped together.
• 6 individual Design Variables (DV) are defined
  as X0, X1 , X2 , X3, X4 and X5.
• The DVs are fixed in Y and Z directions.

X3
X4
X5
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Sculptor set up procedurecontd.

• The grouped control points are selected
• as DVs in Analysis Variables menu.
• Sculptor reads in the baseline analysis results
  into the Analysis Function Dialog.
• The uniformity index is selected to be
• maximized.
• The number of optimization iteration is set to
  2.

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Results in Sculptor

• Totally 16 analysis are computed for 2
• optimization iteration in Star-CD.
• The flow uniformity index increased by
• 5.15 in 96 compared with baseline 91.13.
• The pressure drop decreased by 1.2 in 744 pas
  compared with baseline, 753 pas.

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Velocity contour on the S-section
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Velocity contour on the S-section
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Velocity contour
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The baseline and optimized shapes
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Animation
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Summary

• The model is set up for optimization in
  Sculptor.
• For the first optimization study several design
  variables are considered.
• Star-CD CFD commercial software is used as the
  solver.
• The preliminary results of flow uniformity shows
  a 5.15 increase when
• compared with the baseline case. (Baseline
  91.13 , optimized 96)
• The pressure drop shows a 1.2 decrease when
  compared with the baseline
• case. (Baseline 753 pas, optimized 744 pas)
• It is expected that further optimization is
  achievable by defining additional
• control points around the objective.
• The total 16 analysis are done in 5 hours.