Why flow simulation?
In a world without flow simulation, the development of new products relies on experience and the construction of prototypes. Depending on the size of the product or the materials required, this step can be very time-consuming and expensive. Operating conditions also cannot always be easily reproduced (e.g., very high temperatures, sloshing effects, supersonic or hypersonic speeds). The analysis of a prototype is carried out through measurements, which can also be highly challenging. Moreover, measurements only provide values for a limited number of flow quantities (typically velocity, pressure, and temperature) and only at a small number of measurement points. Other important parameters, such as turbulence, are very difficult to measure. Sensors provide only point-based data, which means that complex interactions or local effects often cannot be captured.
In contrast, a numerical model makes ALL flow quantities visible at EVERY location in your product. Areas that are inaccessible in a physical prototype can be examined closely. Even the flow of media that are not visible (e.g., air) can be visualized without difficulty. The influence of geometric parameters or different operating conditions can be investigated. Flow simulation provides you with a better understanding of your processes in less time. This allows you to eliminate design concepts and implement optimizations early in the development phase. The “real” prototype is replaced by a numerical prototype, enabling you to bring your product to market faster, more efficiently, and therefore more cost-effectively.
Where is flow simulation used?
The short answer is: everywhere!
In general, flow simulation is applied across all technical and scientific fields to analyze or optimize the behavior of one or more flowing media. Wherever flows, heat transfer, or aerodynamic effects play an important role, numerical models can be used.
In mechanical and plant engineering, pumps, turbines, and heat exchangers are made more efficient through CFD by minimizing pressure loss and optimizing the flow path.
Flow simulations are also used throughout the automotive industry. On the one hand, the aerodynamics of a vehicle or component can be improved. On the other hand, internal flows for engine cooling or vehicle air conditioning can be optimized.
In the aerospace industry, flow simulation is a central tool for optimizing lift and drag of wings, as well as engine components and fuselages. CFD calculations are also highly beneficial for analyzing cabin airflow or kerosene and cooling-air flows inside the engine.
Beyond that, CFD is widely used in construction and civil engineering to study wind loads, smoke extraction systems, and building ventilation. In process and environmental engineering, it helps to understand flows in pipelines, wastewater treatment plants, or the dispersion of pollutants. Even in medicine, CFD is used—for example, to simulate blood flow in vessels or to support the development of ventilators.
Overall, flow simulation enables the analysis and optimization of flows involving gases, gas mixtures, liquids, liquid mixtures, or multiphase media (free surfaces, particle flows, evaporation/condensation) in virtually all application areas.
Application Examples
KELLER: Your experienced partner for reliable flow simulation
Are you currently developing a new product and want to validate your concept? Or is there a need for improvement or optimization of an existing product or system?
Get in touch with us!
At KELLER, we have been successfully relying on flow simulation for 18 years. Within our simulation department, you benefit from nearly 40 years of combined CFD experience.
Already during the proposal phase, we discuss your questions and expectations in detail to ensure that you gain as many insights as possible from the simulation—within a fair budget. You provide us with the geometry of your system or product in CAD format as well as the boundary and operating conditions, and we integrate everything into the flow simulation. The results and potential measures are then discussed with you.
