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Simcenter STAR-CCM+ 2406 Released! What's New?

What's new in STAR-CCM+

Accurate and affordable multiphase simulation, including mixtures

Hybrid multiphase is a smart approach for the affordable simulation of multiphase liquids such as jets, films, droplets and mist. However, the current state-of-the-art VOF-Lagrangian Multiphase – Fluid Film approach could not adequately cover applications with mixtures (mist) as it required everything to be resolved or accounted for discretely – which would mean significant computational cost.

To address this, the new Simcenter STAR-CCM+ 2406 release introduces several features to put Multiphase Mixing with Large-Scale Interfaces MMP-LSI at the heart of hybrid multiphase modeling. First, the new release supports the transition of small Lagrangian droplets to MMP. This enables more efficient treatment of very small droplets—typically 10s of microns in size, transported in continuous flow—where LMP is not an efficient model. Additionally, S-Gamma for MMP-LSI enables accurate transport and prediction of droplet or bubble size distributions in MMP phases from LMP (and other sources). Finally, MMP-LSI’s Impact of LMP on Free Surfaces enables simulation of scenarios where LMP droplets transition into high volume fraction regions of the corresponding continuous phase.

Together, these new capabilities allow you to cover applications including mixtures, always leveraging the most efficient multiphase model to be used locally, while transitions between the best-fit models are handled automatically. This innovation allows you to efficiently simulate resolved free surfaces, ballistic droplets, films and mixtures in a single simulation. The result is accurate predictions of droplet sizes and phase transport, making it efficient for a wide range of applications such as electric motor cooling.

Improved fidelity for battery cell aging risk assessment

 Battery Cells

Degradation of a battery cell's internal active materials leads to decreased cell performance in the long term, posing a challenge for battery designers in identifying mitigation methods.

With the new release of Simcenter STAR-CCM+ 2406, the Sub-grid Particle Surface Film model for cell degradation captures two key aging mechanisms: Solid-Electrolyte Interphase (SEI) film growth and lithium plating film growth. Designed to be used in conjunction with the 3D Cell Designer in Simcenter STAR-CCM+, this model allows you to pinpoint the cellular areas most impacted by aging, with all models validated against experimental results from the European Commission-funded MODALIS project.

This innovative approach helps you model the complexity of aging processes in batteries. It complements long-term time-domain focused system simulations by providing valuable spatial insights into cell degradation mechanisms and thus contributes to more effective mitigation strategies.

Improved particle agglomeration modeling of granular (wet) flows

Particle granulation is an important part of the process industry and pharmaceutical manufacturing and plays a crucial role in the final quality of the pharmaceutical product. Simulation of such industrial processes with agglomeration or deposition of solid particles is challenging and requires accurate modeling of the cohesive forces.

With the new release of Simcenter STAR-CCM+ 2406 , the particle agglomeration model, which replaces the parallel bond model, facilitates the formation of bonds based on user-defined local and temporal conditions. This model allows bonds between particles and boundaries and includes bond stiffness independent of mechanical properties. These improvements enable more realistic simulation of particle agglomeration processes in various industrial applications, significantly improving realism and reducing computational cost.

Compromise-free contact modeling for complex fluid-structure interaction (FSI) contacts

The standard penalty method for mechanical contacts requires user input for the penalty parameter, which describes the stiffness of the contact. This can be challenging, especially in complex contact situations.

The new version of Simcenter STAR-CCM+ 2406 includes the Augmented Lagrangian Multiplier (ALM) method, based on the Uzawa algorithm, which mitigates this by enforcing precise contact regardless of the penalty parameter. It is robust even to sudden contact changes, with an optional automatic update of the penalty parameter for faster convergence. Now you can achieve high accuracy and robustness in complex contacts without compromise.

Faster design exploration studies through intelligent simulation initialization

Exhaust manifold optimization study

Extensive design exploration studies benefit most from the acceleration possibilities of the underlying individual design simulations.

The new version of Simcenter STAR-CCM+ 2406 introduces a solution that automatically initializes simulations of a new design that is closest to the expected results by leveraging existing results from the nearest neighbor previously simulated in the design space. In other words, the solution takes the calculation result of the solution that is assumed to be the closest. This approach speeds up individual design simulations and, consequently, reduces the overall turnaround time of the design exploration study. It should be noted that in cases where the design space and the solution space are non-linearly correlated, the time saved may be negligible. For monitoring and understanding purposes, you can easily identify reused designs and designs reusing results with specific Design Sets. The workflow is simplified without the need for manual operation, and this feature is available for Scan, Design of Experiment, and Optimization studies, even if you are not saving all Designs.

This simple method allows you to conduct more efficient and faster design exploration processes, significantly increasing productivity.

Easily evaluate the impact of CAD parameters on a cost function

Pressure assessment

Designing a product often requires analyzing how changes in geometric parameters affect performance, a task that can be daunting without extensive parametric design exploration studies.

In the latest release of Simcenter STAR-CCM+ 2406, you can now compute adjoint sensitivities of a cost function with respect to global parameters used in 3D-CAD, extending the Compute Parameter Sensitivity functionality introduced in release 2306. This enhancement enables you to efficiently evaluate the impact of CAD parameters on global cost functions, such as pressure drop, without the need for complex setups. This means you can now quickly understand the effects of design changes on key performance metrics, streamlining the design optimization process. This capability enables you to make informed decisions faster, reducing the time and effort required for design iterations.

Improved ease of use of gradient-based optimization (Adjoint)

Surface sensitivity

Gradient-based adjoint is a powerful optimization method. But it is not always beneficial to compute and evaluate the adjoint over the entire geometry. Restricting the computation of sensitivities to specific areas of interest required laborious assignment to specific thresholds.

The new version of Simcenter STAR-CCM+ 2406 introduces per-surface subgroups for calculating adjoint sensitivities, allowing you to optimize design components more effectively by calculating surface sensitivity only when needed. This configuration avoids unnecessary adjoint evaluations outside the region of interest, making the gradient-based optimization workflow more efficient and easier to use.

Immersive exploration of results from scratch Install Virtual Reality on the web

Using Virtual Reality for CFD simulations previously required an on-premises installation of Simcenter STAR-CCM+ Virtual Reality. This can be challenging in highly restrictive IT environments, which may be a reason not to incorporate the technology into new workflows.

Now, with the new release of Simcenter STAR-CCM+ 2406, Virtual Reality exploration can be triggered from the Simcenter STAR-CCM+ Web Viewer with a single click. This allows you to better understand your results anytime, anywhere, without installation. You can easily enter the Scene directly from the browser and seamlessly transition to Virtual Reality, enhancing understanding and sharing insights more effectively.

Greater efficiency in manipulating and nullifying instanced bodies

Explicitly manipulating instanced bodies in the Simcenter STAR-CCM+ embedded 3D-CAD modeler can force you to perform repetitive and inefficient geometry preparation steps, and it also risks becoming a memory bottleneck.

The challenge of efficiently handling instanced bodies is addressed with the new Simcenter STAR-CCM+ 2406 release by using pre-existing CAD instance information to create instances of the original body. This approach ensures that modifications applied to any instance can be propagated to all instances, including repair features, sketch commands, and body operations. This results in reduced memory consumption proportional to the number of instances within the geometry, making the process more efficient for you.

More efficient boundary layer capture with Adaptive Mesh Refinement (AMR)

Adaptive Mesh Refinement

Adaptive mesh refinement (AMR) offers several benefits, including increased accuracy, improved efficiency and scalability, and reduced memory usage. However, with isotropic refinement of the prismatic layer, AMR can result in unnecessarily large numbers of cells within the prismatic layer and the inner domain. This represents an unnecessary penalty in runtime without adding any benefits in terms of increased accuracy or stability.

To address this, the new version of Simcenter STAR-CCM+ 2406 now supports anisotropic prismatic layer refinement during AMR. This refinement strategy reduces the overall number of cells, resulting in faster simulation times. You benefit from high flexibility with support for isotropic, tangential, normal, and criteria-based refinement strategies, ensuring more efficient boundary layer capture without compromising accuracy.

Tackle complex helicopter simulations more easily

The design of rotary aircraft presents significant challenges due to the complexity of analyzing and predicting flow fields under unsteady trim conditions.

The new blade element method cutting option in Simcenter STAR-CCM+ 2406 provides a fast, mid-fidelity solution for analyzing these unsteady flow fields during cutting operations. By incorporating this method, you can streamline your workflow by eliminating the need for manual adjustments after each run, which shortens the overall simulation process. The result is faster response times compared to the traditional rigid body motion (RBM) approach, allowing you to quickly obtain reliable results. The new version makes it easier to tackle complex rotorcraft simulations.

Benefit from scalable and faster rigid body motion simulation

Rigid body motion graph

Applications involving rigid body motion (RBM), such as unsteady vehicle aerodynamics and electric motor cooling, often rely on sliding mesh interfaces, which can be computationally demanding and limit performance at large core counts.

The new metric-based intersection in Simcenter STAR-CCM+ 2406 offers a solution to this challenge by providing faster and more scalable interface intersection calculation.

By employing this innovative approach to interface intersection computation, you can achieve improved performance and faster response times for complex simulations involving large interfaces.

Run GPU-accelerated, workflow-supercharged vehicle thermal management simulations

Execution time comparison

The 8x reduction in execution time is evaluated by comparing a CPU solution on 128 AMD EPYC 7532s with a GPU solution on 4 and 8 NVIDIA A100 cards.

Conjugated Heat Transfer (CHT) applications, such as full Vehicle Thermal Management (VTM), are computationally intensive, particularly when radiation models are employed. In such studies, all solid parts of the vehicle (10k+ in modern configurations) must be modeled in detail to ensure that no component overheats during a wide range of operating conditions. Surface properties, such as emissivity, of each solid part play a key role in the accuracy of the simulations.

Simcenter STAR-CCM+ 2406 introduces a GPU-native Surface to Surface (S2S) radiation model, as well as a completely revised workflow for storing and inputting surface properties. The GPU-native S2S model accelerates VTM and other CHT simulations, providing CPU-equivalent solutions while maintaining a unified codebase. The new surface property workflow dramatically reduces preprocessing time for simulation files with thousands of solids through better integration with material and model databases.

By leveraging the power of GPUs and native automation capabilities, you can achieve significant reductions in the end-to-end simulation process, making it possible to perform detailed thermal analysis more efficiently. These advancements not only speed up your simulation processes, but also ensure that results are consistent and reliable regardless of the hardware used.

Take advantage of more solvers and features ported to GPUs

Solvers and resources for GPUs

Additionally, several solvers and features have been ported to GPUs to expand the range of applications that benefit from the GPU.

Simcenter STAR-CCM+ 2406 now supports GPU-native grid sequencing, which accelerates steady-state vehicle aerodynamics. Porting the partial slip and isothermal segregated fluid model to GPUs allows you to run rarefied flows more efficiently. Finally, any type of simulation will benefit from GPU-native derived part tracking.

With these improvements, you can run simulations on the hardware that best suits your business needs and projects, seamlessly transition between GPUs and CPUs, and ensure consistent results through a unified codebase.

Choose from more hardware options for native GPU acceleration

Expanding hardware options

Likewise, hardware options are being expanded. In the Simcenter STAR-CCM+ 2402 version, the first AMD GPU functionality was introduced, to accompany NVIDIA GPU functionality, with the ability to run on AMD Instinct™ MI200 series GPUs,

With the new release of Simcenter STAR-CCM+ 2406, support has been expanded to include AMD Instinct MI300X and Radeon™ Pro W7x00. This extension provides you with even more flexibility and access to native GPU acceleration, offering a cost-effective performance boost by supporting both high-end GPUs and workstation-style graphics cards.

Run an expanded range of applications with SPH

Smoothed-Particle Hydrodynamics (SPH) technology is a powerful alternative method for modeling complex transient flows with highly dynamic free-surface flows. While the introduction of SPH in Simcenter STAR-CCM+ 2402 provides integrated access to this method alongside the traditional mesh-based approach, the initial release was limited in its range of applications. To cover more applications, SPH capabilities are being continuously expanded.

With the new release of Simcenter STAR-CCM+ 2406, liquid injection applications for SPH are now enabled through the support of inlet boundary conditions for SPH particles. This expands the set of applications covered by SPH to include vehicle water runoff and powertrain lubrication with oil jet injection. This increases the versatility of SPH within Simcenter STAR-CCM+ and expands your options for modeling highly dynamic flows with the most appropriate method from within a single simulation environment.

Leverage extended simulation automation intelligence

Implementing Java scripts to automate complex CFD workflows, while powerful and flexible, can be challenging to maintain and update.

In Simcenter STAR-CCM+ 2406, native simulation automation is being expanded to support multiple physics configurations and even more complex workflows in a single simulation. Two new features support turbulence model selection in Stages and nested Simulation Operations sequences. This means you can easily automate RANS-to-DES workflows and robustly launch supersonic and hypersonic aerospace simulations using a fully automated Inviscid-to-RANS workflow, all with a single physics continuum and without the need for Java scripting. Nested Simulation Operations make it easier to manage, maintain, and troubleshoot complex simulation sequences, increasing the reliability and efficiency of your workflows. It also enables you to create a single simulation model for multiple scenarios, reducing the need for manual intervention and scripting. These new capabilities help you quickly create and execute sophisticated automated workflows, improving productivity and ensuring consistency across different simulation projects.


Discover how Simcenter STAR-CCM+ can revolutionize your projects! With innovative solutions for complex mixes and advanced industrial processes, you’ll achieve more efficient and accurate forecasts. Schedule a meeting with CAEXPERTS today to explore how we can help transform your operations, reduce costs, and increase productivity. Don’t miss the chance to take your projects to the next level!

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