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Don’t try this at home – unless you’re simulating it! Thermal Runaway: a recap Thermal runaway of batteries is a dangerous phenomenon where the battery cell overheats uncontrollably. A self-sustaining feedback loop occurs where the battery receives a certain amount of heating, and if left unaddressed, this in turn triggers a series of chemical reactions inside the battery cell. These reactions release even more heat and gases, which can result in huge pressure build up inside the battery. Extremely hot (over 1000oC!) and combustible venting gases are then emitted from the battery cell. When these gases ignite, fire spreads to other battery cells and catastrophic damage can occur to an electric vehicle, property and of course presents a high risk to life. Look at this short video which shows the violent nature of a thermal runaway event: It should be clear that these scenarios should be avoided, and battery systems designed to ensure safe operation if a thermal runaway event occurs. Indeed there are now various national and international regulations that cell makers and electric vehicle manufacturers must adhere to. Time to test? – Accelerated rate calorimetry (ARC) The most intuitive way to understand the behavior of batteries as they undergo a thermal runaway event is to replicate the causes of thermal runaway and see how the battery behaves. In the case of overheating, a common methodology to understand the heat release of the battery is an accelerated rate calorimetry (“ARC”) test. These tests provide clear insights but come with some issues: primarily that the tests themselves are expensive, require access to test facilities and require a physical prototype of the battery cell! Of course, this is where simulation can fit in and allow for rapid design iterations early in the design cycle, with safety in mind. Simcenter STAR-CCM+ already has a wide range of models and functionalities for battery modelling and battery safety, from the 3D cell design right through to the full battery pack and thermal propagation during a runaway event: In version 2502, another layer of functionality will be added – most notably the ability to model detailed thermal runaway at the cellular level with the Homogeneous Multiphase Complex Chemistry (HMMC) model. Thermal runaway chemistry When we consider the inside of a battery cell then there are multiple solids (anode, cathode and separators), as well as liquid electrolyte. When thermal runaway reactions occur, these components can react and decompose to release flammable gases such as hydrogen and methane. This results in multiple phases all reacting with each other e.g multiphase. To capture this complexity, a framework has been developed in which the early stages of a thermal runaway event can be modeled with detailed chemical modeling. This allows designers to explicitly model the fundamental reactions that are triggered during a thermal runaway event. The reactions are considered as a homogeneous mixture, allowing for simple and easy setup in conjunction with our multiphase mixing model. Furthermore, this is all built on top of a proven complex chemistry solver, allowing reactions to be easily defined using standard chemkin file import and accounting for intra- and interphase reactions. This provides unique modeling functionality to deeply understand battery behavior. For example, one can directly configure reactions for SEI decomposition/production, conductive salt decomposition, hydrogen fluoride production, and cathode decomposition; see the example of imported reactions for thermal runaway testing above. Let’s get cookin’ – Heat-Wait-Seek Armed with a new modelling tool, let’s apply it to the simulation of an ARC test and see how it performs. The ARC test involves an initial period of heating the battery called Heat-Wait-Seek (HWS) where the battery is gradually heated before waiting to see if exothermic reactions begin. When those reactions begin, no more heat is applied to the battery, and it is left to continue reacting / self-heating until the onset of thermal runaway. Unveiling the interaction of reactions and phase transition during thermal abuse of Li-ion batteries https://doi.org/10.1016/j.jpowsour.2021.230881 One great thing about having this physics functionality inside Simcenter STAR-CCM+ is that it can leverage the automation capabilities. The ARC testing process can be easily implemented using Simulation Operations and Stages without any scripting. And the results are excellent: As can be seen, the new HMMC model can accurately capture the onset of both the exothermic reaction and thermal runaway. Being able to accurately capture this behavior allows for effective countermeasures or mitigation strategies such as heat shields to be implemented by engineers much earlier in the design process in a safe and cost-effective manner. For example, the predicted heat generation from this simulation can be used as an accurately calculated heat source directly in a larger pack level model, or the predicted vent gas compositions used for a further combustion analysis. An excellent example of how simulation is vital in the battery design cycle. Schedule a meeting with CAEXPERTS and find out how we can help your team design safer, more efficient battery systems using advanced simulation to predict and mitigate thermal runaway events. Contact us now and take your innovation to the next level! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

The latest update to Simcenter STAR-CCM+ 2502 brings pivotal enhancements across various domains, focusing on boosting simulation speed, enhancing model accuracy, and improving integration across different engineering disciplines. Key advancements include an efficient mesh motion technology for moving objects, faster vehicle thermal management and aerodynamics simulations, streamlined data exchange for E-Machines, and sophisticated methods for accurately modeling battery thermal runaway onset, corrosion and complex non-Newtonian fluid behavior. These developments are designed to help you accelerate development cycles, optimize product performance, and facilitate cross-team collaboration, ultimately driving innovation and efficiency in your projects. Improved battery safety simulations Battery manufacturers face the critical challenge of ensuring safety, particularly the risk of thermal runaway during short circuits or other failures. Traditional modeling tools have struggled to accurately predict these complex chemical and electrochemical reactions. To address this, the latest release of Simcenter STAR-CCM+ 2502 features the “Homogeneous Multiphase Complex Chemistry Model,” designed to provide a detailed simulation of battery cell behaviors under adverse conditions. Although a general model, the homogenous multiphase complex chemistry model can allow designers to explicitly model the fundamental reactions that are triggered during a thermal runaway event, providing detailed insight into the electrochemical and thermal response to a short circuit or nail penetration incident in a battery. This allows engineers to gain deeper insight and design batteries with high degrees of safety without the cost of physical testing. This improved capability ultimately helps in preventing accidents, enhancing consumer trust, and complying with stringent safety regulations. Advanced corrosion analysis Corrosion is a pervasive issue across many industries, leading to significant maintenance costs and equipment downtime. Traditional analysis tools often fail to predict the onset and progression of corrosion effectively, leading to unexpected failures. Simcenter STAR-CCM+ 2502 integrates Corrdesa’s Corrosion Djinn Database for advanced corrosion analysis. High-quality polarization data describes the relationship between the potential drop at the material interface and the specific electric current and are important inputs to the Electrodynamic Potential solver of Simcenter STAR-CCM+ . The Corrdesa Corrosion Djinn material database hosts collection of data, including surface polarization, derived through rigorous experimental quantification. This feature offers engineers robust tools to simulate and predict corrosion under various environmental conditions, using high-fidelity data. As a result, industries can proactively design out potential corrosion issues, extend equipment lifespan, and significantly reduce maintenance costs. Accurate modeling of complex fluids In the food processing industry, accurately predicting the behavior of complex fluids, such as mayonnaise, which exhibit non-Newtonian characteristics, presents significant challenges. These fluids can behave like a solid at lower shear stress levels before moving like a fluid at elevated stress levels. This behavior is complicating production processes and quality control. In response, Simcenter STAR-CCM+ 2502 introduces Generalized Non-Newtonian Fluid Models, namely the Yield Stress Threshold and Yielding Viscosity for Non-Newtonian Cross and Carreau-Yasuda laws. These advanced viscosity models capture the intricate behaviors of such complex Bingham fluids under stress more accurately than ever before. By simulating these fluids’ behaviors, engineers can precisely predict how they will act in the real world, thereby optimizing manufacturing and filling processes. Uniform spray coverage for various applications Achieving uniform spray coverage is imperative in industries ranging from agriculture to automotive manufacturing, where it impacts everything from crop yields to paint finishes. Variability in this process can lead to inefficiency and wastage, posing a substantial logistical challenge. In many such cases the flat fan nozzle Injector provides a uniform, flat spray pattern of a thin, fan-shaped sheet of liquid. In agriculture, flat-fan nozzles are e.g. essential for providing uniform spray coverage in aerial pesticide applications. Similarly, these types of injectors are used for cleaning and degreasing, coating and painting, cooling and humidifying, lubrication, surface Treatment and dust control. The Flat Fan Nozzle Injector model in Simcenter STAR-CCM+ 2502 makes it easy to set-up such injectors quickly and easily. Accurate results are achieved by the Linear Instability Sheet Atomization (LISA) method. This technology ensures uniform application across varied operations, improving resource utilization and process efficiency. Ultimately, this leads to reductions in waste and costs, contributing to more sustainable and eco-friendly production practices. Faster adjoint-based optimization Adjoint optimization methods rely on a series of multiple simulations, in which the adjoint solver is executed at each step. Considering that the adjoint solver is very expensive in terms of computational resources, these optimization studies easily reach the limit of feasibility. The algorithmic improvements made in Simcenter STAR-CCM+ 2502 to the adjoint solver with second order discretization drastically improve the convergence rate, thus lowering significantly the total turnaround time. Furthermore, this improvement reduces the need for falling back to first order adjoint discretization for a robust convergence, hence improving the accuracy of the computed adjoint sensitivities. The reduced simulation time and higher-quality results, enables engineers to explore and realize optimal designs much more efficiently and effectively. Fast and scalable simulations of moving objects Many applications, such as paint dipping and bottle filling, involve the movement of a solid body that affects the motion of a fluid. To capture the motion the overset meshing approach offers both flexibility and accuracy by utilizing a background mesh combined with a body-fitted moving mesh. This configuration ensures high mesh quality near the boundaries of moving objects, leading to precise results. However, this accuracy comes at the cost of increased complexity, which results in higher computational expense and suboptimal scaling. The new Virtual Body approach that is available in the new version of Simcenter STAR-CCM+ 2502 eliminates the need for two separate meshes and provides a more cost-effective, scalable, and easier-to-setup alternative to overset for various validated application. Furthermore, it also offers a more stable solution in scenarios involving tight gaps. Faster sliding mesh simulations on GPUs and CPUs Many applications like external vehicle aerodynamics with rotating wheels, require rigid body motion (RBM) to capture transient, unsteady flow phenomena. This employs the sliding mesh interfaces, also known as non-conformal interfaces. Traditionally, in such scenarios the interface intersection is performed at every time step. Because of the complexity of the intersector algorithm and its high interface data requirement, the performance of the sliding meshes when deployed on large core counts or used with GPUs, has been restricted. Case (cell count) Total sim time (min) No Caching Total sim time (min) Caching Number of CPU/GPUs Speed up Case 1 (120 M) 165.6 149.8 8 x A100 GPUs 10% Case 2 (150 M) 223 187.4 8 x A100 GPUs 16% Case 3 (38 M) 862 470 8 x A100 GPUs 45% Case 4 (140 M) 13 hrs 10.5 hrs 16 x V100 GPUs 19% Case 5 (136 M) 50.7 hrs 44.9 hrs 1600 Cores 12% The new Boundary Interface Caching strategy that is available in the new version of Simcenter STAR-CCM+ 2502 allows for the interface data to be calculated only once and reused for the subsequent time steps, thereby significantly reducing sliding mesh simulation time on both CPUs and GPUs. Faster Vehicle Thermal Management simulations on GPUs The automotive industry is constantly pushed to enhance energy efficiency while managing the heat generated during operation, a demanding aspect of vehicle design. At the same time the benefits of GPUs to solve CFD simulations faster and in a more energy efficient way are without a doubt. With Simcenter STAR-CCM+ 2502 we are further expanding the range of thermal management applications you can tackle on CPUs and GPUs through the porting of more GPU-native solvers: The new GPU-native Actual Flow Dual Stream Heat Exchanger method leverages GPU acceleration to perform complex VTM simulations. Further applications covered include faster CHT simulations of headlamps with the GPU-native segregated and coupled energy solvers for solid shell regions as well as faster Batteries CHT and Electronics cooling analyses thanks to GPU-native Orthotropic, Anisotropic and Transverse Isotropic material property methods. This will increase your throughput and hardware options while a unified solver architecture for CPU and GPU ensures consistent results. As a result, you can perform more thermal management simulations in less time, enhancing productivity and accelerating the development cycles. Native automation of advanced aerodynamics and turbomachinery workflows Complex simulations involving multiple physical phenomena or varied operational stages can be cumbersome to set up, often requiring intricate scripting and setup. The Stages feature within Simcenter STAR-CCM+ streamlines this process. It provides a user-friendly interface for defining and managing simulation stages, cutting down setup time and allowing engineers to focus more on analysis and less on setup. With Simcenter STAR-CCM+ 2502 stages become available for a further extended range of applications: With the support of harmonic balance and harmonic balance turbulence models you can tackle turbomachinery simulation workflows with ease. Stages support for Moving Reference Frame and Rigid Body Motion simplifies workflows with a change from steady state to transient, such as external aerodynamics with rotating parts. The Stages method not only accelerates the simulation workflow but also significantly boosts productivity and mitigates potential setup errors. Streamlined data exchange for E-Machine design Collaboration between electric machine designers and computational fluid dynamics engineers is often hindered by incompatible data formats and systems. The “Simcenter Data Exchange (SCDX)” format, newly implemented in Simcenter STAR-CCM+ 2502 , resolves these issues by ensuring smooth and efficient data transfer across different software tools and teams. This integration capability facilitates a more cohesive workflow, reducing errors, and enabling faster project completion through improved collaboration. These are just a few highlights in Simcenter STAR-CCM+ 2502 . These features will enable you to design better products faster than ever, turning today’s engineering complexity into a competitive advantage. Multiversion support for Simcenter X HPC Facing an urgent CFD project that requires immediate HPC capacity? Questioning massive CAPEX investments for on-premise HPC clusters? Tired the complex IT setup associated with running CFD software on 3rd party cloud-providers? Just not interested in waiting in the queue? Simcenter X HPC enables you to unlock productivity gains with the power of turn-key cloud simulation. Run your Simcenter STAR-CCM+ simulations anytime in the cloud, straight out of Simcenter STAR-CCM+ in 3 clicks. No queuing involved, no IT overhead, no on-premise HPC hardware investments. To make the most out of Simcenter X HPC, with the release of Simcenter STAR-CCM+ 2502 you will have immediate access to the most recent version. Alongside 2502, multiple versions of Simcenter STAR-CCM+ are now available on Simcenter X HPC, including previous versions 2410, 2406, 2306. Use clusters of sizes from 100s to 1000s of cores, instantaneously from a few clicks. Schedule a meeting with CAEXPERTS now and find out how Simcenter STAR-CCM+ can transform your simulation processes, reducing development time and increasing the accuracy of your projects. Talk to our experts and take your engineering to the next level! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Safety at work should be a priority in any operation, but in emergencies, quick and assertive decision-making can be the difference between life and death. To increase operator safety during activities carried out at height, it is essential to determine the maximum wind speed for safe operation. This is a classic example of an operation using rappelling. In these conditions, the operator faces high-speed winds, which can cause oscillations during work and can result in collisions with other equipment or objects. But how can you anticipate and plan responses to these events? This is where CAE simulation makes all the difference. CAE Simulation The acronym CAE (Computer-Aided Engineering) refers to Computer-Aided Engineering, a technology that uses software to simulate and analyze engineering projects. This tool allows you to predict the behavior of a product before its physical construction, assisting in the development and improvement of projects. CAE simulation is applied in several areas, including structural, fluid, thermal and electromagnetic analysis. The best-known and most widely used techniques are Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) . The benefits of CAE simulation for companies are: Greater efficiency, reliability and quality Cost reduction Reduced developer time in product development Elimination or reduction in the number of test prototypes to be built Increased competitiveness CAE simulation allows for the digital recreation of several scenarios, for example, by analyzing factors such as fall conditions, interaction with the environment, performance of safety equipment and emergency evacuation strategies. With this information, it is possible to improve equipment, enhance protocols and develop more effective training to increase the safety of workers and rescue teams. The Importance of Emergency Planning Emergencies such as falls, leaks or fires can occur even with rigorous preventive measures. The difference lies in how well the team and systems are prepared to deal with these situations. CAE simulation transforms the unpredictable into something controllable, allowing: Faster responses: Equipping teams with elaborate information and ready action plans. Damage reduction: Minimizing impacts on the worker and the operation. Tragedy prevention: Developing strategies to prevent similar situations from occurring again. Simulation The operator, weighing 90 kg, is suspended by a rope, simulating a rappel down a 50-meter tower. The analysis considers the acting forces, such as weight, wind force and turbulent interaction and the tension on the rope. The simulation allows for the inclusion of an air speed curve in relation to height, making the assessment of air flow more accurate, considering turbulence and interaction with the environment. Including the air speed curve in the simulation allows us to assess how wind currents influence the operator's oscillation during rappelling. The intensity and direction of the wind affect the operator's movement, impacting balance and stability. With this analysis, it is possible to predict these effects, helping to understand external forces and their impact on the safety and performance of the operation. In addition, the data obtained allows us to optimize the planning of activities at height and select the most appropriate equipment to reduce risks.   During the simulation, it was possible to determine the force applied to the rope, considering the environmental conditions and the characteristics of the rappelling operation. Factors such as wind speed and sudden movements directly influenced this force. In scenarios with strong winds, with a speed of 15 m/s, the force on the rope reached a peak of 3000 N, which can reach the breaking limit of the rope. This result highlights the importance of evaluating environmental and operational conditions to ensure safety, in addition to the need to carefully choose the materials and equipment used in risky activities. Commitment to life The application of numerical simulations goes beyond innovation; it is a demonstration of commitment to the safety and well-being of workers. In times of emergency, where decisions need to be made in seconds, having the confidence that every detail has been analyzed and planned can save lives. If you would like to explore how CAE simulation can transform workplace safety, optimizing prevention and response to emergencies, get in touch. Let's build safer environments together and protect what is most valuable: people. Schedule a meeting with CAEXPERTS and find out how CAE simulation can transform safety in your workplace! With advanced technology and detailed analysis, we help your company prevent risks, optimize processes and protect lives. Contact us now and take operational safety to the next level! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Find out why CAEXPERTS is the best technological partner to boost your company's competitiveness and innovative potential. Advanced Engineering; Digital Twins; Knowledge Transfer; Assertive Solutions; Cost Reduction; R&D and Innovation Contact us Find out why CAEXPERTS and the best solution for your company's engineering to go even further. Whatsapp WhatsApp: +55 (48) 98814-4798 Schedule an online meeting E-mail: contato@caexperts.com.br Name Last name Email Telephone Company Subject Write your message... To send Thank you for contacting us

CAEXPERTS brings together an experienced and multidisciplinary team of CAE experts, prepared to deliver advanced engineering and computational simulation at different scales and levels of maturity. We use high-performance hardware and software resources that are scalable in the cloud. SIMULATION SPECIALISTS We are a team prepared to deliver results , innovation and competitiveness . Resquest for Quotation Areas of expertise Advanced Engineering Digital Twins Knowledge Transfer Assertive Solutions Cost Reduction R&D and Innovation Digitization of Engineering With the advancement of globalization and technological competitiveness, products and their manufacturing processes are increasingly complex , with more restricted life cycles . In response to this, vanguard companies use computer simulation to virtually test their projects, concepts, inventions, products, equipment and processes, in the most critical scenarios, seeking to always be ahead and go even further. SIEMENS Digital Industries takes this seriously and brings the broadest range of software tools for digitization and computer-aided engineering to the market . Know the Tools Discover the Disciplines Why CAEXPERTS CAE implementation As official resellers of SIEMENS Digital Industries software, we help your company build a high-performance CAE team for your engineering, combined with the ideal simulation tools in conjunction with our technical team, so that your production generates assertive results in an intelligent and fast way. We are simulation experts and know how industries can obtain a high return on their CAE investments. Engineering Services We help industries increase their competitiveness and raise their level of innovation. We work with projects and consultancy for the development of products and equipment, as well as conduct studies aimed at reducing Capital Costs and Operating Costs of industrial enterprises, owner engineering, R&D in industrial processes, integrity analyses and increased operational reliability of production assets. In addition, we are official resellers of Siemens software, which allows us to offer the best technological solutions to our customers. Conheça os nossos serviços Discover our Services Softwares ofertados Software Licensing 3D Multiphysics Simulation Simcenter 3D Star-CCM+ FloEFD Femap CAD Design Solid Edge NX 1D Systems Simulation Flomaster Amesim Electromagnetic Simulation and Design Magnet E-machine Design Speed HEEDS Optimization Learn more Why CAEXPERTS Professional Development: Program designed for engineers and professionals who want to master the use of computer simulation tools in real industry applications. Personalized: We work side by side, from the selection of relevant topics, the study of the state of the art, the scientific technical development stages, training until the completion of the project. Real Projects: The training is developed based on real industry challenges, providing applied and practical learning that prepares you for concrete challenges. Recognition: Master computer simulation in practice and become an expert valued by the industry. Discover our specialization program Areas of expertise ACOUSTICS ELECTROMAGNETIC COMPATIBILITY DESIGN OF ELECTRONICS CIRCUI S COMPUTATIONAL FLUID DYNAMICS THERMOFLUID DYNAMIC SYSTEMS WIRING AND WIRING HARNESS ELETRIC MACHINES STRUCTURAL ANALYSIS PROJECT OPTIMIZATION MATERIALS ENGINEERING ADDITIVE MANUFACTURING AUTOMATION Âncora 1 Know more Recent Posts 2 days ago 5 min read Case study: using Femap helps NASA develop next-generation space telescope Simulating the performance of James Webb Space Telescope components Challenges Design a next-generation space telescope Coordinate... Feb 12 3 min read Rapid axial-flux motor analysis – New in Simcenter E-Machine Design 2412 The analysis of an axial-flux machine requires three dimensions because of its inherent three-dimensional magnetic flux paths. Thus, to... Feb 5 7 min read What’s new in Simcenter FLOEFD 2412? CAD-embedded CFD simulation The new Simcenter FLOEFD 2412 software release is now available in all its CAD-embedded CFD versions, and... Jan 29 8 min read CFD for clean air 3 ways to fight contamination in public buildings, transportation and production facilities Until 2020 Computational Fluid Dynamics aka.... 1 2 3 4 5 See it all Let's start Get in touch and find out why CAEXPERTS and the best solution for your company's engineering to go even further. Name Last name Email enter a message I agree to receive information and news by email To send Thank you!

Acoustic simulations help analyze noise quality in designs, Productive tools for designing, refining and validating prototypes throughout the development cycle. Aeroacoustics; Boundary Element, Ray Acoustics, FEM/BEM solvers; acoustic modeling; 3D Meshing for Acoustics; SIMCENTER 3D; SIEMENS Specialization Program in CAE At CAEXPERTS, we understand that digitalization and computational simulation are a reality for the industry and in this context, training is essential to face real engineering challenges. The CAE Specialization Program was designed for professionals who seek to deepen their knowledge by applying computational simulation tools to solve real engineering challenges, ensuring that you or your team are prepared to transform ideas into solutions. Master computational simulation in practice and become an expert valued by the industry. Join Our CAE Specialization Program Fill in the details below and we will build this chapter together. Name E-mail Phone/WhatsApp Company Submit Thanks! We will be in touch soon. Why choose our Specialization Program? What will you learn? Who should participate? Personalized: we work side by side, from the selection of relevant topics, the study of the state of the art, the scientific technical development stages, training until the completion of the project. Technology: this program provides access to the best CAE software on the market and is focused on the efficient use of software applied to practical cases. Real Projects: the training is developed based on real industry challenges, providing applied and practical learning that prepares you for concrete challenges. Articles and Procedures: the combination of theory and practice culminates in the technical scientific production of materials based on practical experiences, creating a legacy of knowledge and documentation for the industry. Our program includes: Exploring Advanced Technologies: Stay up to date with the latest in software and engineering techniques. Solving Real Problems: Learn from projects inspired by challenges faced by real companies, ensuring direct and meaningful learning. Creating Specific Procedures: Develop procedures that can be immediately applied in your organization. Our program is ideal for: Engineers who want to improve their skills in computational engineering and the use of CAE software. Companies looking to empower their teams to deal with complex problems. CAEXPERTS Differentiators With an experienced team, we are experts in combining technology and practice to generate concrete results. Our support goes beyond training, offering consultancy and monitoring to ensure that you or your team reaches their maximum potential. How to register? Contact us to schedule a personalized conversation. We are ready to adapt the program to your needs and contribute to your success. ⇐ Back to Disciplines