Cement production is one of the most energy-intensive and emission-intensive industrial activities, accounting for approximately 5% to 8% of global CO₂ emissions. In the modern dry manufacturing process, the pre-calciner plays a central and critical role, being the equipment where most of the limestone calcination occurs (decomposition of CaCO₃ into CaO and CO₂) and where between 55% and 65% of the system's total fuel is consumed. The efficiency of this equipment depends on a delicate thermodynamic balance between two main reactions: fuel combustion (exothermic process) and raw material decomposition (endothermic process). Due to the complexity of multiphase flow, where solid and gaseous phases interact at high speeds and temperatures, physical experimentation on an industrial scale is extremely costly and often impractical for detailed internal measurements. In this context, Computational Fluid Dynamics (CFD), with STAR-CCM+ , emerges as an essential tool for the optimization and design of these reactors. Through numerical modeling, it is possible to predict the hydrodynamics of the flow, heat transfer, chemical kinetics, and emissions, critical factors that act in the pre-calciner. Challenges and Solutions in Pre-calciner Simulation CFD simulation of pre-calciners presents challenges associated with the multiphase, thermal, and reactive complexity of the process. The cohesion and agglomeration of fine raw meal particles significantly alter the flow and calcination efficiency, requiring advanced particulate phase models. On a larger scale, the formation of gas-solid clusters introduces heterogeneities that render homogeneous drag models inadequate. Heat transfer constitutes another critical point, due to the very thin thermal boundary layers along the walls, whose correct mesh refinement is unfeasible in complete industrial geometries. As a solution, coupling CFD with simplified mechanistic models allows for realistic thermal estimates with reduced computational cost. Furthermore, the strong coupling between exothermic and endothermic reactions imposes high nonlinearity on the system. In the context of emissions reduction, oxy-fuel combustion presents additional challenges, such as ignition delay and high CO₂ concentrations, which can be mitigated by multi-stage combustion and pre-gasification strategies, ensuring operational stability and low NOx levels. CFD Simulation of the Pre-calciner This numerical simulation study, developed in STAR-CCM+ , focuses on the detailed analysis of combustion in a large-scale cement pre-calciner, emphasizing the evaluation of the characteristics of the oxy-fuel process and its impacts on the thermal efficiency and operational stability of the equipment. The modeling was conducted using a non-premixed combustion model, incorporating the chemical kinetics of coal, devolatilization phenomena, NOx formation, and thermal radiation effects. The kinetic mechanism employed is presented in Table 1. It should be noted that, in this study, the particulate model of calcium carbonate (CaCO₃) was not considered, focusing the analysis exclusively on the combustion of the solid fuel. Reaction Equation R1 2CO+O2->2CO2 R2 C + 1.5 O2 -> 0.5 CO +0.5 CO2 R3 C + CO2 -> 2CO R4 CaCO3 -> CaO + CO2 R5 Devolatilization Table 1. Chemical Reactions The numerical model adopted the following simulation assumptions: steady-state regime, ideal gases, Eddy Break-Up (EBU) combustion model, k-ε Realizable turbulence model, thermal NOx model, and coal particles modeled in a Lagrangian fashion, with an average diameter of 50 μm. The computational mesh was strategically refined in regions of higher thermal and chemical gradients, such as the primary and tertiary air intake zones and coal injection zones. Boundary conditions were defined to reproduce real operational scenarios, including prescribed air and fuel flow rates, ensuring greater physical representativeness of the model. Figure 1. Geometry and computational mesh Figure 2 shows the temperature field inside the pre-calciner. It can be observed that the regions near the central axis of the flow reach temperatures above 2100 K, evidencing intense combustion activity. In contrast, a low-temperature zone is identified near the inlet nozzles, associated with the high concentration of air in these regions, which promotes dilution of the fuel mixture and locally reduces thermal efficiency. The analysis of the thermal field allows us to assess whether the regions of interest operate within the appropriate temperature range for the process. Figure 2. Temperature profile Complementing this analysis, Figure 3 presents the axial temperature profile along the pre-calciner. A thermal peak is observed in the first 10 meters, resulting from the initial combustion reactions of the coal, followed by a gradual reduction in temperature along the flow, as the fuel is consumed and the gases are diluted. Figure 3. Temperature plot Figure 4 illustrates the concentration profiles of CO, CO₂, and O₂ along the height of the pre-calciner. The CO₂ concentration progressively decreases as the gases rise, reflecting chemical interactions and flow dilution. CO shows peaks near the burner region, associated with centralized coal injection and incomplete combustion. Due to the low local availability of oxygen, some of the CO is not oxidized to CO₂, resulting in a lower CO₂ concentration at the equipment outlet. Figure 4. Concentration profiles: (a) CO; (b) CO2; (c) O2 Figure 5 shows the evolution of the molar fraction of the main components along the vertical axis of the pre-calciner. A significant consumption of O₂ and CO₂ is observed, concomitant with the generation of species such as volatiles, CO and H₂O, characterizing the dominant stages of the coal combustion process. Figure 5. Molar fraction plot Finally, Figure 6 presents the velocity field and streamlines, highlighting the direct influence of the pre-calciner geometry on the flow. Recirculation zones near the tertiary air inlet are prominent, as are regions of low turbulence ("dead zones"), which represent potential areas for the accumulation of unreacted material. Although these regions are associated with flow separation, they also play a relevant role in the conduction and mixing of gases. These results indicate the need for geometric adjustments to optimize the flow, reduce energy losses, and improve the overall efficiency of the equipment. Figure 6. Velocity Profile Conclusion The results presented demonstrate that the use of STAR-CCM+ as a Computational Fluid Dynamics (CFD) platform for the integrated analysis of fluid dynamic, thermal, and reactive phenomena governing the performance of cement pre-calciners is effective. The robustness of the software allowed for consistent modeling of non-premix combustion, species transport, thermal radiation, and particulate behavior, enabling a faithful representation of industrial operating conditions. The adopted approach proved particularly relevant in the context of Oxy-Fuel combustion, where the coupling between chemical reactions, heat transfer, and particulate dynamics imposes additional challenges. The use of appropriate models makes it possible to evaluate operating and design strategies, such as the optimization of air and fuel injection, geometric adjustments, and burner configurations, aiming at reducing emissions, increasing energy efficiency, and greater operational robustness. In this way, CFD simulation is consolidating itself as a strategic tool for decision-making, retrofitting, and developing new technologies in cement plants, reducing dependence on empirical testing and accelerating the transition to more efficient and environmentally sustainable processes.   References ZHENG, Qiang et al. CFD simulation of a cement precalciner with agglomerate-based drag modeling. Powder Technology, v. 436, p. 119508, 2024. ZHANG, Leyu et al. Numerical simulation of oxy-fuel combustion with different O2/CO2 fractions in a large cement precalciner.  Energy & Fuels , v. 34, n. 4, p. 4949-4957, 2020. KANELLIS, Georgios et al. CFD modelling of an indirectly heated calciner reactor, utilized for CO2 capture, in an Eulerian framework.  Fuel , v. 346, p. 128251, 2023. HAIJIAN, Dou; ZUOBING, Chen; JIQUAN, Huang. Numerical Study of the Coupled Flow Field in a Double-spray Calciner. In:  2009 International Conference on Computer Modeling and Simulation . SHU, Yixiang et al. Numerical study on oxy-fuel combustion of coal pre-gasification products in cement calciner.  Applied Thermal Engineering , p. 126901, 2025. MIKULČIĆ, Hrvoje et al. Numerical analysis of cement calciner fuel efficiency and pollutant emissions.  Clean technologies and environmental policy , v. 15, n. 3, p. 489-499, 2013. If you are looking to increase the thermal efficiency of your pre-calciner, reduce emissions, and make more informed engineering decisions, CAEXPERTS can help with advanced CFD solutions using STAR-CCM+ . Schedule a meeting with us and discover how to apply numerical simulation to optimize your cement production process and accelerate results with lower costs and greater reliability. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

By combining well-established Simcenter modelers and solvers under a unified SaaS entitlement including Teamcenter X data management with embedded AI assistance, Siemens is expanding access to multidisciplinary simulation while enhancing its digital-thread and SaaS leadership across engineering fields. CIMdata, Industry consulting and analyst firm Introducing Simcenter X Advanced The need for efficient engineering simulation software utilization Engineering simulation offers an efficient way to streamline product development and bring product to markets faster and more cost efficient. However, numerous challenges may prevent you to make the most out of your simulation software investments: Underutilization of licenses The underutilization or wasted IT spending for desktop software is a significant cost factor. This means you need deployment methods that ensure always-on accessibility and licensing models for flexible usage. Source: Flexera, 2023 Simulation business case shift Today, faster-time-to market is the key value driver of simulation. This means you need to maximize the simulation throughput by speeding up every element of the simulation process chain. Source: McKinsey, 2023 Explosion of complexity You therefore must maximize the effectiveness of how you deploy and use your engineering simulation tools. To stay competitive, you specifically must address the following challenges: How do you reduce the complexity of deployment, license, and user management? How do you ensure optimal use of engineering simulation software? How do you equip your engineers with simulation tools to maximize productivity? How do you break down engineering silos to address complex products and unlock the power of digital threads? Simcenter X – your flexible Software as a Service (SaaS) multi-domain engineering simulation Simcenter X Advanced has been released – a flexible, Software as a Service (SaaS) multi-domain engineering simulation suite. This cloud-powered solution will address all the beforementioned challenges and enable you to unlock the power of performance engineering. With Simcenter X Advanced… …as an IT representative you will reduce your IT cost of ownership and make the most of your software licenses with a simple, flexible and easily manageable licensing model you will quickly and easily onboard simulation software users through a unified cloud entitlement, leveraging a centralized administration console that will streamline and simplify the deployment of our software …as simulation engineers and CAE team leaders you will boost productivity with AI technology and cross-domain collaboration and built-in data management you will have access to on-demand capabilities across all major engineering simulations domains (i.e. Computational Fluid Dynamics, Mechanical, Systems simulation and Multidisciplinary Design Analysis and Optimization), simple, anytime, anywhere. Accelerate digital transformation with secure, scalable solutions Simcenter X – integral part of Siemens Xcelerator and a holistic digital thread vision Simcenter X does not come in isolation. Embedded into a large ecosystem of industry software, it is an inherent part of Siemens Xcelerator, Siemens’s open digital business platform that serves as a catalyst for accelerating your digitalization journey. At the same time, Siemens has long understood that the cloud and SaaS are the way of the future. And Software for industry is no exception. Therefore, Siemens is moving the Siemens Xclelerator portfolio to the cloud at a very high pace. From design software to operations and manufacturing, a growing portfolio of cloud-based products is offered under the "X" brand. Simcenter X will be an integral part of the Siemens Xcelerator SaaS ecosystem, coexisting with various other DISW products like NX X , Teamcenter X, and many more. This strategic alignment aims to achieve a comprehensive vision of digital integration, ensuring a seamless and cohesive user experience, as well as simplified licensing management for your IT teams across all our products. One place for all: Simcenter X and Siemens Xcelerator offer centralized cloud-licensing Managing licenses for a large and diverse set of engineering software poses significant challenges and efforts to IT teams. License server configuration becomes complex, deployment of on-premises licenses takes long and user management is difficult with an “anonymous” user profile. All this poses risks to reach the goal of maximizing engineering simulation software ROI by minimizing IT burdens and optimizing license utilization. The good news is: Simcenter X makes license management simple. With cloud-based entitlement and license management, hosted and owned by Siemens, Simcenter X will To significantly simplify the use and implementation of the products, both for the IT administrator and the end user. make waiting for a new license a thing of the past: The cumbersome process of waiting for the license administrator to generate, verify and send the license file, along with the customer installing and setting up the license server, will now be an old school story, enable the IT administrator to manage all products across Siemens Xcelerator through a single unified system known as the Siemens Xcelerator Admin Console allow for the allocation of resources across a global pool of users. But the simplification isn't limited to license implementation and user management… taking advantage of the opportunity, it was decided to significantly simplify the engineering simulation pricing table… Multidisciplinary engineering simulation and design exploration made simple From Computational Fluid Dynamics, through Mechanical and Systems simulation to MDAO, Simcenter X Advanced allows your engineers and engineering teams to seamlessly set-up and run multidiscipline simulation and MDAO. Your company will transform engineering simulation thanks to Unbeaten simplicity Use one license covering flagship Simcenter applications across engineering simulation domains (CFD, Mechanical, Systems and MDAO) Universal access Unlimited guaranteed access to pre-/postprocessing for all flagship applications across all solution domains through a named-user entitlement Ultimate flexibility Run any simulation and MDAO and explore any advanced capability with a single flexible token type Results you can trust through established industry-grade simulation technology To ensure you can gather trustworthy results, Simcenter X gives you access to proven, validated Simcenter simulation technology across domains. As such Simcenter X is based on established and best-rated flagship Simcenter products. Specifically, in the Mechanical domain Simcenter X Advanced gives you access to Simcenter Femap and Simcenter 3D . For CFD, your Simcenter X Advanced entitlement enables the usage of Simcenter STAR-CCM+ , for Systems simulation you get access to Simcenter Amesim and for MDAO to Simcenter HEEDS . While you will install these engineering simulation applications on your local hardware, all licensing is enabled through the cloud. On G2 , a trusted platform for software reviews, Simcenter’s suite of products, Simcenter HEEDS , Simcenter STAR-CCM+ , Simcenter 3D , Simcenter Amesim , and Simcenter Femap , have garnered significant praise in the simulation and CAE category, all taking leader and high-performer positions on the G2 performance grid. Building Simcenter X on these industry-leading established products guarantees a seamless transition for existing users with reliable simulation results for anyone while giving additional value stemming from cloud-powered technologies. Collaborate and keep simulations consistent, up-to-date, verifiable and available across domains At this point another foundational aspect of Simcenter X Advanced comes in handy: That is the provision of integrated data-management through Teamcenter X Essentials. This additional capability comes free of charge with every Simcenter X Advanced seat. Built in data-management will allow individual engineers, engineering teams and entire organizations to organize and store their simulation data in a secure manner communicate and collaborate across different departments right where the data is keep track of simulation data changes leverage a ready-to-use environment that is intuitive and simulation engineer centric embed the data-management into a wholistic digital thread with a ready-to-scale PLM solution Make better decisions, faster with AI Whether it’s choosing the most suitable modeling approach and applying respective best practices or finding better designs in a multidisciplinary optimization study, Simcenter X Advanced will equip you with AI capabilities to speed up your engineering decisions. Better modeling decision faster with an integrated AI chat Simcenter X Advanced will introduce another foundational technology that will be available across all domains: the integration of an AI chat that will assist you in easily exploring and accessing our extensive documentation and knowledge base articles database in their natural language. The AI chat will help you to quickly extract the necessary information for efficient onboarding or expanding your knowledge, as well as exploring simulation options and enhancing your model choices. Find better designs faster, with AI-augmented optimization Simcenter X Advanced paired with Simcenter X Tokens will grant you access to Simcenter HEEDS’s AI simulation predictor. This accuracy-aware AI learns from past simulations to guide future ones and replace physics-based simulations with AI predictions where appropriate during an optimization study. With no expertise and optimization or AI technology you can easily accelerate design exploration, significantly reducing optimization times. Maximize accessibility and global license utilization Simcenter X Advanced combines named-user licensing with tokens Simcenter X is designed to enhance license utilization on a global scale, ensuring that engineering teams can access the software, solvers and advanced capabilities whenever they need it. This capability is crucial for maintaining productivity, especially in environments where model setup and analysis are time-sensitive. By implementing a named-user entitlement, users have guaranteed 24/7 access to do model setup and results analysis in the tools they are entitled to. This prevents issues like license hogging – commonly observed with shared flexible license pools, which often leads to frustrating denials for users who require immediate access. On the other hand, for compute intense tasks like meshing, solving or to access advanced modeling capabilities you don’t want to tie a license investment to a specific named-user as it would lead to costly idle-times. Therefore, Simcenter X Advanced combines the named-user license with a flexible, universal, and globally shared token pool, to grant users access to advanced capabilities and solver technology. This flexibility of a shared global token pool is combined with a controlled token allocation to individuals or groups. The approach not only optimizes access but also supports collaboration across different regions, making it easier for teams to work together seamlessly. At the same time, it allows for a more controlled distribution of license access across teams, ensuring that resources are used efficiently. Enabling users to immediately access advanced modeling capabilities through universal Simcenter X Tokens means no waiting time for a dedicated (evaluation) license, fostering the exploration of novel simulation methodologies. This enables engineering innovation at zero financial risk and without any time delays. Simcenter X – HPC & remote desktop offers cloud-hosted single-click HPC for CFD While the new Simcenter X Advanced and Simcenter X Tokens enable you to run CFD simulations on your on-premises hardware with a local installation of Simcenter STAR-CCM+ , the already established Simcenter X HPC & remote desktop solution augments this simulation deployment with a complete cloud-hosted solution. Simcenter X HPC & remote desktop means instant zero-install access to Simcenter STAR-CCM+ in your browser and single-click simulation job execution straight form within Simcenter STAR-CCM+ on Siemens managed HPC infrastructure. Simcenter X HPC & remote desktop capabilities are enabled through Credits. In contrast to tokens for Simcenter X Advanced, which are checked out from a pool and checked back in when the job is finished, credits are time-based and get consumed when used. Therefore, credits offer the ultimate pay–as-you-go option, incorporating all cost into an hourly rate. As such, Simcenter X HPC & Remote Desktop perfectly augments Simcenter X Advanced for CFD users. With its high flexibility it enables quick responses to changes in demand for HPC resources. Transform engineering with Simcenter X Let‘s summarize this exiting milestone for the engineering simulation community and look at Simcenter X at a glance. Simcenter X: fosters seamless multidiscipline simulation with a single license makes license management simple through centrally managed cloud-licensing increases accessibility with named-user license for pre-and postprocessing maximizes flexibility with a managed pool of tokens to access solvers and advanced capabilities is based on trusted flagship Simcenter simulation technology enabling existing Simcenter users a seamless transition, and create reliable simulation results for everyone fosters collaboration across teams with integrated scalable data-management helps to make smart modeling decisions faster with an integrated AI chat lets you find better designs faster through AI-augmented design exploration and optimization maximizes flexibility with pay-as-you-go credits for Siemens-hosted HPC to address peak loads and minimize CAPEX investments for CFD The time is now to transform your engineering simulation and minimize IT burdens – with Simcenter X Advanced. Want to understand how Simcenter X Advanced can reduce IT complexity, increase your engineers' productivity, and maximize the ROI of simulation in your company? Schedule a meeting with CAEXPERTS and discover how to implement this SaaS solution strategically, quickly, and in line with your engineering challenges. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

If you haven't yet checked out Part 1 of our retrospective, we recommend starting there to catch up on the content ranked 10th to 6th and get a complete picture of how computational simulation was present throughout 2025. Continuing the retrospective, this Part 2 brings together the posts that stood out most for their technical impact, depth of analysis, and direct relevance to critical industrial applications. These are articles that show how different simulation methods support safer, more efficient, and physics-based engineering decisions. 5️⃣ DEM simulation applied to boilers Discrete Element Method (DEM) allows for a highly detailed analysis of the behavior of solid particles in boilers, considering collisions, friction, deposition, and wear. In this post, we show how this approach helps to understand complex phenomena that are difficult to measure experimentally, contributing to more robust designs, reduced failures, and increased operational availability. 4️⃣ Case: Bronswerk Heat Transfer uses Simcenter FLOEFD to locate pressure losses This case study practically demonstrates the value of simulation applied to real-world engineering problems. Bronswerk Heat Transfer used Simcenter FLOEFD to identify bottlenecks and pressure losses in its equipment, enabling performance improvements with less need for physical prototyping, cost reduction, and increased efficiency. 3️⃣ How CFD Simulation Can Improve and Maximize Heat Exchanger Design and Performance Heat exchangers are present in numerous industrial processes and play a central role in energy efficiency. In this content, we detail how CFD simulation can be used to optimize geometries, increase thermal efficiency, and reduce pressure drops, supporting design decisions in both new developments and improvements to existing equipment. 2️⃣ Smoother gear operation with SPH fluid injection The application of the SPH (Smoothed Particle Hydrodynamics) method allows for a more realistic simulation of fluid injection lubrication in gears. This post shows how this approach contributes to the reduction of vibration, noise, and wear, as well as providing a more precise understanding of the loads acting on high-performance mechanical systems. 🥇 FEA Analysis of Pressure Vessels with Simcenter 3D At the top of the 2025 ranking is a classic and highly critical topic in engineering: the structural analysis of pressure vessels. This post shows how the use of FEA in Simcenter 3D allows for the evaluation of structural integrity, compliance with applicable standards and codes, and increased operational safety. A clear example of how simulation is indispensable for responsible decision-making in high-risk projects. As this is the first post of the year, the CAEXPERTS team takes this opportunity to wish everyone an excellent New Year. May 2026 be marked by new challenges, successful projects, and increasingly innovative and reliable engineering solutions. Count on CAEXPERTS throughout 2026. If you are looking to improve your projects, reduce uncertainties, and make more informed engineering decisions throughout the entire development cycle, talk to CAEXPERTS . Our work in computational simulation supports companies and engineers in transforming complex challenges into efficient, safe, and intelligent solutions. We are ready to continue this journey with you in 2026 and beyond. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Throughout 2025, CAEXPERTS published a series of technical articles reflecting an increasingly clear scenario: computational simulation has ceased to be merely a support tool and has taken on a central role in modern engineering. Whether to increase the reliability of critical systems, reduce development costs, meet regulatory requirements, or explore innovative solutions, simulation was present in virtually every challenge addressed throughout the year. This retrospective brings together the posts that stood out most in 2025, considering technical relevance, industrial applicability, and reader interest. More than a ranking, it offers a consolidated view of how different numerical methods—such as CFD, FEA, FSI, DEM, and SPH—were applied to solve real-world problems in diverse sectors. This Part 1 presents the articles ranked from 10th to 6th place. They demonstrate the breadth of simulation applications, ranging from electric mobility and medical devices to industrial processes and high-performance products. 🔟 Is your EV battery going to fail? With the advancement of electric mobility, concern about the safety, reliability, and lifespan of batteries is also growing. This post explores how multiphysics simulation allows for the anticipation of failures, evaluating phenomena such as heat generation, aging, degradation, and extreme operating conditions. By predicting problems during the design phase, engineers can reduce risks, increase safety, and make more informed decisions throughout the product lifecycle. 9️⃣ Peristaltic pump FSI simulation for safer dialysis In biomedical applications, small uncertainties can have large consequences. In this content, we show how Fluid-Structure Interaction (FSI) simulation is used to analyze peristaltic pumps employed in dialysis processes. By simultaneously considering fluid flow and component deformation, it is possible to reduce the risk of hemolysis, increase performance predictability, and raise the safety level of the device. 8️⃣ Clearances in gas turbines: the remarkable difference 1mm can make In gas turbine engineering, seemingly small geometric tolerances can have a significant impact on performance and efficiency. This post shows how simulation helps to understand the effect of clearances on losses, aerodynamic efficiency, and component lifespan, supporting more robust design decisions and avoiding surprises during testing or operation. 7️⃣ Designing the perfect bicycle race bottle: Engineering in hydration Simulation also finds its place outside the traditional industrial environment. In this article, CFD techniques are applied to the design of hydration bottles for cycling, evaluating aspects such as flow, ergonomics, and aerodynamics. A clear example of how engineering fundamentals can be used to optimize everyday products, where performance and user experience go hand in hand. 6️⃣ Virtual Body: An efficient approach to painting and filling processes with STAR-CCM+ Processes such as painting and bottling involve multiple physical and operational interactions. The Virtual Body concept allows for the integrated simulation of these processes, anticipating problems, reducing rework, and optimizing material consumption. This content reinforces how simulation can increase efficiency, quality, and competitiveness in complex industrial environments. In Part 2 of the retrospective, we will present the content ranked 5th to 1st – posts that stood out for their high technical impact and direct application in critical energy systems, thermal processes, and structural engineering. Don't miss the continuation of this retrospective! The CAEXPERTS team wishes everyone an excellent end to 2025 and a Happy New Year. May 2026 be marked by new projects, technical achievements, and increasingly innovative solutions. Thank you for following us throughout this year and for trusting in our content and expertise. Let's build the next challenges together. If you're looking to make safer engineering decisions, optimize designs, and reduce uncertainty throughout product and process development, talk to CAEXPERTS . Our expertise in computational simulation can help transform complex challenges into intelligent, efficient, and reliable solutions. We're ready to support your engineering in 2026 and beyond. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Christmas is a time marked by gatherings, celebrations, and, of course, the preparation of traditional dishes. Among them, roast turkey occupies a prominent place. But what happens inside the oven while the roast is being prepared? To answer this question in a technical and accessible way, a simulation was performed using Simcenter FLOEFD , a Computational Fluid Dynamics (CFD) software, with the aim of analyzing air circulation and heat distribution in a convection oven during the preparation of a turkey. Model of a turkey in a convection oven in Simcenter FLOEFD The simulation scenario The turkey did not have exactly the correct dimensions, being just a solid block. There was no cavity for stuffing or for the neck, therefore the measurements were estimated visually and some cuts were made. As one of the most relevant issues was the amount of airflow through different spaces (in the cavities and under the turkey), some objects were created to collect this data. The oven was configured in convection mode, with a fan located at the rear, responsible for propelling air horizontally over the roasting area. For this model, the height of the rack is set at just over 1mm above the bottom of the roasting pan. Turkey cavity This model was run as a snapshot, meaning the turkey temperature was set at a point where it was not yet fully cooked (120°F). The oven temperature was set to 375°F, with the heating elements positioned at the bottom of the oven operating at a slightly higher temperature of 400°F. Boundary Conditions for Turkey Roaster Analysis Initially, the flow lines are observed, which are analogous to the smoke lines shown in wind tunnel tests used in car commercials. These lines indicate the direction of airflow. The fan was defined as the starting point of the flow lines. Although the flow lines exhibit quite chaotic behavior, it is possible to extract relevant information from them. By sectioning the model, the interior of the roaster and the turkey cavity become visible. Compared to the flow lines outside the turkey, it is observed that little air enters the roaster and passes under the turkey, and an even smaller amount passes through the interior of the turkey. This result was expected, especially regarding the airflow in the cavity. The fan propels the air transversely to the width of the turkey, not along its length. For the air to enter the cavity, it would be necessary to go around the turkey and then make a 180-degree turn, which is not physically plausible. Furthermore, due to the large size of the turkeys, it is not possible to orient them in the same direction as the airflow generated by the fan. The airflow from the oven fan surrounds the turkey, whose color varies according to the temperature The oven fan's airflow is directed towards the roasting pan and the turkey cavity Observing a contour plot of air velocity passing through the central plane of the turkey and the oven, it can be seen that the air velocity through and under the turkey is very low, while higher values ​​are observed above the turkey and below the roasting pan. Low-velocity air is considered to be air whose magnitude is comparable to that of a natural convection oven, where the typical air velocity is on the order of 0.2 m/s. Therefore, there is no significant gain in heat transfer provided by the fan, since most of the turkey's surface is subjected to air velocities below 0.2 m/s. Air Velocity Contour Graph For a more precise understanding of this behavior, a graph of the air velocity near the surface of the turkey is observed. The image has been divided into two parts: one representing the surface of the turkey facing the fan and the other showing the opposite side. The difference between the two regions is evident. As a consequence, one side of the turkey tends to cook or dry out more quickly than the other if the food is not rotated periodically. Higher air velocities result in more intense convection, a principle illustrated by the act of blowing on soup to accelerate its cooling. Speed ​​close to the surface of the turkey, near the fan Air velocity near the surface of the turkey, opposite to that of the fan. Returning to the contour plot, when analyzing the temperature distribution, it is clearly observed that the air inside the turkey has significantly lower temperatures. This occurs due to air stagnation, since there is no effective circulation of hot air inside the turkey. It is also observed that, below the turkey, in the space of approximately 1 cm (0.4 inches) provided by the grill, the air temperature is lower than that of the rest of the oven. Again, this behavior is explained by the limited circulation of renewed hot air in this region. Air temperature contour graph along the centerline of the turkey The question arises as to why air has difficulty penetrating the space between the turkey and the bottom of the roasting pan. Observation of the flow lines indicates that the cause is essentially the same as that which prevents air from entering the inside of the turkey. The air from the fan tends to follow the path of least resistance. To flow under the turkey, the air would need to go around the wall of the roasting pan, descend through the space between the turkey and that wall, and then make a 90-degree turn to flow under the turkey. Along this path, there is a reduction in speed and a loss of temperature. Both factors are relevant, since colder air tends to descend. Furthermore, since the flow velocity is lower than that of a natural convection current, the warm, renewed air cannot displace the air already present in that region. For this reason, it is observed that the air reaches the roasting pan, but cannot advance under the turkey, instead recirculating near the wall of the roasting pan. Contour graph of air velocity and streamlines along the width of the turkey The images provide a good qualitative understanding of the phenomenon; however, in many cases, a quantitative analysis is necessary. Data evaluation indicates that the oven fan moves approximately 22.8 CFM of air. The airflow that effectively enters and exits the roaster is about 0.35 CFM, which corresponds to approximately 1.5% of the total fan flow. Regarding the air entering the turkey cavities, the inflow and outflow were analyzed in both the neck cavity and the larger rear cavity. The measured flow rates were 0.08 CFM and 0.146 CFM, respectively. From these results, it is concluded that the stuffing is not responsible for preventing air circulation inside the turkey, since this circulation is already intrinsically very limited. This does not exclude the effect of the additional thermal mass of the stuffing, which can result in longer cooking times and drier meat—a topic that deserves specific analysis. Nor should one expect significant air circulation under the turkey capable of producing a completely crispy skin. A higher rack or a roasting pan with lower sides might offer some improvement, although this effect is questionable. In practice, using a rack or vegetables like carrots, celery, or potatoes serves a similar function, elevating the turkey and keeping it away from the accumulated fat. Want to understand how simulation can bring that same level of technical analysis to the real-world challenges of your engineering? Schedule a meeting with CAEXPERTS and discover how CFD and advanced simulation solutions can optimize your projects and processes. We also take this opportunity to wish you a Merry Christmas and a Happy New Year! 🎄✨ WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

The new release of Simcenter Culgi 2511 brings significant advancements to empower your computational chemistry simulation workflows. With enhanced viscosity prediction, you can now achieve reliable results more quickly, with greater accuracy and even the most complex fluids, thereby reducing the need for extensive laboratory testing. The support for realistic crystalline structure modeling unlocks new possibilities for simulating complex materials, while auto-completion for Python scripting and a built-in library of physical constants streamline your workflow and minimize errors. These features collectively enable you to explore more complex systems, accelerate your material development process, and ensure higher precision in your results. Achieve dependable viscosity predictions validated against industry standards Measuring viscosity is a complex and time-consuming task, yet it is a critical property across many industries. Traditionally, obtaining accurate viscosity values for different formulations has required extensive lab work and sophisticated experimental setups, often leading to project delays. With the new release of Simcenter Culgi 2511 , you can now leverage state-of-the-art viscosity prediction methodologies, including the impact of shear, at both atomistic and coarse-grained levels. Simcenter Culgi 2511 integrates the SLLOD equation methodology, enabling you to predict viscosity under various conditions with ease. Additionally, the Stop-on-Met precision feature automatically halts measurements once a specified accuracy (such as 0.5%) is achieved, further optimizing your formulation development process. This comprehensive toolkit enables rapid candidate screening and significantly reduces the need for laboratory tests. As a result, you benefit from reliable, industry-standard, validated results, ensuring your predictions are both accurate and dependable. Ultimately, this empowers you to make informed decisions faster and with greater confidence, driving innovation in your projects. Model realistic crystalline structures with atomic precision As simulation techniques advance, the demand for modeling increasingly complex systems, such as crystalline structures, continues to grow. The limitations of traditional simulation geometries, often restricted to cubic or rectangular boxes, have made it challenging to accurately represent real-world crystalline forms. With Simcenter Culgi 2511 , you can now import and simulate non-rectangular simulation boxes, overcoming the previous constraints. This new capability allows you to import your unit cell and expand your crystalline structure for simulation, both at the atomistic and coarse-grained levels. By enabling realistic modeling of crystalline structures, you can reduce the need for physical testing and identify potential limitations before moving to experimental phases. This enhancement not only streamlines your workflow but also ensures that your simulations are more representative of actual materials, ultimately leading to better-informed decisions and more successful outcomes. Accelerate your scripting with 90% reduced command lookup time Engineers often appreciate the flexibility of exporting and integrating Simcenter Culgi scripts into advanced Python workflows. Remembering the multitude of Simcenter Culgi-specific commands and their functionalities can be a significant hurdle, especially when developing or modifying scripts from scratch. With the latest Simcenter Culgi 2511 release, you now have access to auto-completion and command help directly within your preferred Python IDE. As you write scripts, you can quickly look up native commands, access help by hovering, and autocomplete commands as needed. This accelerates the development of complex multiscale workflows, reduces the time spent searching for the right commands, and lowers the barrier to entry for new users. The result is a 90% reduction in command lookup time, enabling you to focus on innovation rather than routine tasks. Faster onboarding and improved user experience mean your team can deliver results more efficiently. Ensure improved calculation precision Coarse-grained simulations, such as Dissipative Particle Dynamics (DPD), are a hallmark of Simcenter Culgi, but they traditionally lack real units, requiring manual conversion to physical units. This process often involves manually entering physical constants, such as the Boltzmann constant or Avogadro number, which is both tedious and prone to error. With Simcenter Culgi 2511 , you benefit from a built-in library of the most common physical constants used in computational chemistry. Now, you can simply select the required constant and continue building your equations without worrying about transcription errors or loss of precision. This enhancement not only streamlines your workflow but also ensures that your results maintain the highest level of accuracy. By removing a common source of error and saving valuable time, you can develop multiscale workflows with greater confidence and efficiency. If you want to accelerate your projects, reduce lab testing, and increase the accuracy of your chemical simulations with the latest advancements in Simcenter Culgi 2511 , schedule a meeting with CAEXPERTS now and discover how we can support your team in getting the most out of these new features. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Believe it or not, the Smoothed-Particle Hydrodynamics (SPH) technology, which has significant applications today, was actually developed for astrophysical purposes. It was originally used to simulate the dynamics of galaxies and the behavior of stars and planets: Smoothed Particle Hydrodynamics | Annual Reviews Monaghan, J. J. 1992. “Smoothed Particle Hydrodynamics.”, Annual Review of Astronomy and Astrophysics 30:543-74. doi: 10.1146/annurev.aa.30.090192.002551. Just like cosmic formation, where countless particles coalesce into refined structures to form stars and planets, the SPH solver in Simcenter STAR-CCM+ 2510 now offers local particle refinement. But you don’t have to go to outer space to make use of this capability: it can actually be used for any down-to-earth application, like, for example, to better capture the oil around planetary gears. And no, planetary gears are not an astrophysical application, even though this thing is pretty close to one: Enhance simulation precision with SPH particle refinement technique In previous versions of SPH in Simcenter STAR-CCM+ , achieving higher fidelity required refining the particle size, which inevitably increased simulation time. Conversely, opting for faster simulations meant coarsening particle size, sacrificing accuracy. This is the classic CFD dilemma with no easy solution. Now, with version 2510, Simcenter STAR-CCM+ introduces local particle refinement for the SPH solver, allowing you to enhance flow accuracy precisely where it’s needed without necessitating a fine particle size across the entire fluid domain. This new capability enhances precision in critical areas while maintaining efficient simulation time, offering a balance between local high-fidelity results and computational performance. The performance improvement largely depends on the application and the size of the refinement area. In the SPH solver’s adaptive time-stepping, the chosen time step is still determined by the finest particle size. Consequently, the performance boost is not driven by the time step but achieved by reducing the total number of particles compared to a fully refined particle simulation. As a result, the more localized and specific the refinement areas are, the greater the performance gains you will experience. As illustrated in the animation, you now have the ability to locally create geometry particle refinement criteria using block, cylinder or/ and sphere shapes. In the example, cylinder refinement criteria have been defined around each gear to accurately capture the oil distribution close to the teeth. Your simulation can incorporate one or multiple refinement shapes, and they can even overlap as needed, especially when dealing with complex geometries such as gear teeth. You can define up to 10 levels of refinement, allowing particle size specifications to go below one micrometer, starting from a base particle size of 1 mm. Also noteworthy is the ability to assign a coordinate system to the refinement shapes. This is particularly useful if you need the refinement to follow a moving solid, ensuring it maintains an accurate resolution while moving along a trajectory in space. To demonstrate the higher fidelity benefit for this planetary gear application, this chart depicts the average wetted surface over time. As shown, the simulation using particle refinement (particle base size of 1 mm using two levels of refinement) achieves accuracy that closely matches the finest simulation (0.25 mm). In contrast, it outperforms the coarse simulation (1 mm), highlighting the effectiveness of particle refinement in balancing precision and computational efficiency. Another key advantage of particle refinement is its significant reduction in memory consumption. As illustrated above, using particle refinement results in a fourfold decrease in memory usage compared to the finest simulation, enabling you to efficiently handle more complex cases. Simplify planetary gearbox simulation with just a few clicks Just as effortlessly as planets revolve around the sun in our solar system, setting up a planetary gearbox in Simcenter STAR-CCM+ has never been easier. Starting with version 2506, the new kinematics solver allows for the use of Planetary Gear and Revolute Joint Body Couplings, enabling you to configure motions with just a few clicks. Additionally, version 2506 introduced enhanced data analysis capabilities. You can now measure mass flow or various other quantities across section planes, thanks to the compatibility of the SPH solver with constrained plane and arbitrary section-derived parts. Furthermore, visualization of the free surface is now possible using the SPH solver’s compatibility with the iso-surface derived part of the liquid volume fraction. Those enhancements in the motion and data analysis contribute to a faster setup and getting more insights into the quantitative solution. Accelerate SPH simulations with lightning-fast GPU workflows In Simcenter STAR-CCM+ 2510 , SPH simulation feels akin to traveling at the speed of light, thanks to seamless GPU acceleration compatibility throughout the entire workflow. The solver supports native GPU acceleration since version 2410 for single GPU and expanded to multiple GPUs in version 2502. With the latest version 2510, data analysis capabilities are now also ported to GPU hardware. As a result, you can now utilize and visualize point probes, free surfaces, constrained plane sections, and arbitrary sections derived parts up to five times faster compared to before. This allows for rapid solution analysis, maintaining your workflow at a lightning-fast pace. In this specific example, running the planetary gear lubrication simulation on an NVIDIA RTX6000 GPU achieves a speedup of nearly five times faster compared to using 56 CPU cores. This demonstrates that the entire workflow for this application, including particle refinement, is fully optimized and compatible with GPU acceleration. Explore new simulation frontiers with enhanced SPH capabilities Simcenter STAR-CCM+ continues to advance its SPH solver with significant enhancements, including local particle refinement, a streamlined workflow for planetary gears, and additional data analysis capabilities, as well as robust GPU acceleration. With more accuracy, faster setup, and runtime, the SPH solver may help you reconnect with your inner child by looking at all new types of planets and stars in planetary and sun gears. And ultimately, we want to enable you “to boldly go where no (wo)man has gone before.” Perhaps even for your SPH simulation, one day space will become the final frontier. Schedule a meeting with CAEXPERTS and discover how to leverage the full potential of SPH in Simcenter STAR-CCM+ to increase the accuracy of your simulations, reduce computational costs, and accelerate your GPU workflows—all with the expert technical support of those who deeply understand these technologies. Let's take your analyses to the next level? WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

In today’s competitive engineering landscape—defined by tight development timelines, limited budgets, and no tolerance for design failures—teams must quickly explore more design alternatives while optimizing increasingly complex systems to balance objectives such as performance and cost. Modern engineering solutions must bridge web and desktop environments to support distributed teams working from anywhere, while intelligently leveraging AI to automate routine tasks and accelerate decision-making. This combination of flexible access and intelligent automation enables engineers to focus on high-value creative work. This release delivers just that - Simcenter HEEDS 2510 for simulation-based design optimization and Simcenter HEEDS Connect 2510 for workflow integration address these needs with enhancements that make advanced optimization accessible and productive for teams of all sizes, accelerating innovation through simulation-driven design. SHERPA’s enhanced multi-objective capabilities: better trade-offs, faster results At the heart of this release is a major update to SHERPA's multi-objective search strategy, the HEEDS optimization strategy used to efficiently explore project spaces and find optimal engineering solutions. For teams tackling multi-objective trade-off studies with constraints, you’ll benefit from improved search strategies that help you discover more robust Pareto frontiers faster. Regardless of your use case or industry, the improved multi-objective SHERPA enables you to make informed decisions more quickly and with greater confidence. Benchmarking SHERPA’s enhanced multi-objective capabilities with an XLR UAV (analysis tool: Simcenter STAR-CCM+). Performance and speed comparisons are based on median values, represented by dotted lines, while the shaded areas indicate the 95% confidence intervals. AI-powered acceleration with more iterations, less waiting Simcenter HEEDS 2510 features an updated AI Simulation Predictor, leveraging artificial intelligence to accelerate optimization studies. By intelligently predicting simulation outcomes, this capability reduces optimization time by up to 30% without compromising solution quality. The intuitive interface democratizes AI-powered optimization, eliminating the need for machine learning expertise. This allows more design iterations, faster turnaround, and improved productivity, enabling teams to focus on innovation rather than waiting for results. Native HyperMesh integration: from mesh to results in one workflow Simcenter HEEDS 2510 enables seamless tool integration with specialized connectors for Altair HyperMesh and HyperView/HyperGraph . These connectors automate the entire optimization workflow: parameterized mesh morphing in HyperMesh , automated simulation execution, and consolidated results visualization in HyperView/HyperGraph . By eliminating manual file transfers and standardizing post-processing procedures, engineering teams can concentrate on design insights rather than data management, thereby reducing the time spent on each design iteration. Smarter optimization setup with intelligent guidance Setting up optimization studies can be challenging, particularly when deciding the appropriate number of evaluations. The new Optimization Intelligence feature offers automated settings for minimum evaluation counts, tailored to specific problem characteristics, including the number of design variables, response objectives, variable types, and workflow complexity. Optimization Intelligence analyzes your setup and recommends the minimum number of evaluations required for meaningful results. Visual alerts guide users toward best practices, reducing guesswork and helping both novice and experienced engineers in developing robust studies that deliver reliable results. This helps set realistic expectations and encourages the selection of evaluation budgets that reflect the available engineering budget. SHERPA’s adaptive algorithms continue to enhance solution quality with additional evaluations, allowing the discovery of superior design alternatives while requiring careful resource management. Simcenter HEEDS Connect: Seamless web-to-desktop workflow transitions Simcenter HEEDS Connect 2510 enables teams to collaborate and iterate efficiently, regardless of location. The new “Open in Desktop” feature bridges HEEDS Connect’s web environment with the full power of HEEDS MDO on the desktop. With project locking and automated data sync, users transition workflows between environments without losing context or data integrity. Teams can use the cloud for fast collaboration and the desktop for in-depth editing and analysis. Seamlessly move between Simcenter HEEDS Connect and Simcenter HEEDS desktop Workflow editing with real-time adjustments Building on previous workflow visualization capabilities, Simcenter HEEDS Connect 2510 now allows direct editing of key analysis parameters for Simcenter STAR-CCM+ , NX CAD , and Microsoft® Excel® integrations— directly within the browser. Engineers can make real-time adjustments to simulation setups, validate changes instantly, and collaborate on parameter modifications without needing to switch environments. This results in a more agile, accessible, and collaborative design exploration process. Edit analysis properties directly in Simcenter HEEDS Connect web interface Immersive 3D visualization for collaborative reviews With the addition of VCollab 3D Visualization, HEEDS Connect 2510 delivers an immersive, browser-based experience for reviewing CAD and CAE results. Teams can interactively explore complex geometries, annotate models, and measure features in real time to accelerate decision-making and foster more engaging design reviews. This capability enhances cross-team communication and streamlines the review cycle, helping organizations bring better products to market faster. Interactive 3D navigation, annotation, and measurement tools for detailed model exploration Designed for the engineering community Simcenter HEEDS 2510 and HEEDS Connect 2510 demonstrate our commitment to supporting the engineering community with integrated, intelligent, user-friendly solutions. Whether optimizing complex systems, collaborating across teams, or accelerating innovation, these releases provide the tools needed to succeed. If you want to leverage the full potential of Simcenter HEEDS' new features to accelerate your optimizations and integrate teams more intelligently, schedule a meeting with CAEXPERTS . We can show you how to apply these solutions directly to your workflow and transform your engineering efficiency. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Autonomous urban air mobility vehicles will revolutionize the urban mobility market. A digital twin is invaluable as part of an efficient development process that ensures a safe product. Safe operations are key when it comes to flying autonomous urban air mobility vehicles. Validating the flight management system for as many flight scenarios and operational conditions as possible is crucial. This is why the digital twin of the flight management system must include simulation models of both : aircraft and environment. A simulation framework for autonomous urban air mobility vehicles This study evaluated whether a simulation framework with a proven track record in the development of Automated Driving Systems for ground vehicles is able to support the development of automated flight management systems in an integrated manner. The framework includes 3 coupled software packages performing time-domain simulations. Simcenter Amesim models the flight dynamics, the propulsion systems and the navigation control loops. Simcenter Prescan models an urban environment and exteroceptive sensors that detect features in the environment (e.g. camera, lidar) Simulink® connects both, Simcenter Amesim and Simcenter Prescan . The figure below displays the simulation framework. The states of the drone are passed from Simcenter Amesim to Simcenter Prescan to position the aircraft geometry and sensors with respect to the environment. Next, Simcenter Prescan computes the sensor data and provides the reference trajectory information. The object detection and safe trajectory planning algorithms uses this input to compute a safe trajectory. This is then passed to Simcenter Amesim . Figure 1 - Simulation framework Modeling the urban air mobility vehicle and the environment To demonstrate this approach, the study makes use of an all-electric, four-seater, octocopter with realistic design parameters. The urban air mobility vehicle has 4 sets of 2 ducted counter-rotating propellers. Each propeller is coupled with an electric motor of 200kW that is based on the former Siemens SP-200D motor. A battery with a capacity of 110kWh powers the aircraft. As a result, the vehicle has an autonomy of 15min with a cruise speed of 120km/h. The Simcenter Amesim model contains 8 propeller models coupled with subsequently 8 models of phase modulated synchronous motors. Together with a 6 degree of freedom model and simplified aerodynamic model, it provides the flight dynamics behavior. The system model also includes a battery, ground contract elements and PID control loops. The PID control loops make the aircraft follow the safe trajectory. A high-fidelity model of the Siemens Perlach campus, near Munich, was implemented as an urban environment in Simcenter Prescan . The Simcenter Prescan lidar sensor model represents a high-performance commercial lidar system, providing point cloud information of the environment. Finally, a simplified obstacle detection and avoidance algorithm in Simulink was implemented. Simulating multiple collision scenarios The study simulated multiple collision scenarios to evaluate obstacle detection and avoidance functions using a simulation framework. The scenarios included a tower crane with different orientations along the planned flight path. Different trajectories were calculated depending on the crane's orientation. When the crane is positioned perpendicular to the flight path, it is detected well in advance. A gentle deflection over the crane ensured safe operations. However, when the crane is aligned with the flight path, it is detected too late. An aggressive lateral maneuver could avoid the obstacle. In this case, the system simulation revealed that the propulsion systems had to operate close to their limits. The results also show the aircraft's acceleration levels for structural evaluation and passenger comfort assessment during evasive maneuvers. Figure 2 - System simulation results of obstacle evasion maneuver This study concludes that Simcenter Amesim together with Simcenter Prescan includes all required capabilities to support the development and validation of automated flight functions of autonomous urban air mobility vehicles. This study can be expanded with: human body motion simulations of passengers modeled with Simcenter Madymo . the coupling with aircraft dynamics simulated with Simcenter 3D Motion . the prediction of fly-over noise using Simcenter 3D Acoustics . Jan Verheyen performed the above study as part of his internship at Siemens Digital Industries Software in Leuven, Belgium. Jan is a master student aerospace engineering from the control and simulation department of the Delft University of Technology. CAEXPERTS can help your company accelerate the development of autonomous air mobility vehicles with advanced simulation and digital twin solutions, ensuring safety and efficiency at every stage of the project. Schedule a meeting with us and discover how to transform your aerospace development process with Simcenter Amesim . WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Breaking barriers with a simplified electric motor design process. In the world of electric machine design and development, time is always the enemy. As the sun rises on another day at an electric mobility company, three engineers from different departments gather around a conference table, their expressions tense. The prototype deadline is just weeks away, but a critical design change has brought complexity and risk to the schedule. The team needs to modify the axial flux design to solve thermal problems, but recreating the electromagnetic (emag) model in the simulation tool would take weeks—time that is not available. This scenario is repeated daily throughout the industry. While the world rushes toward electrification, the tools and processes used to design these critical components often remain fragmented across disciplines, creating invisible barriers between the teams that most need to collaborate. The Hidden Cost of a Disconnected Project When an electrical engineer spends weeks perfecting an electric motor design in a dedicated tool like Simcenter E-Machine Design , their work represents only the beginning of a much longer journey. For that design to become a reality, it needs to undergo detailed validation, as well as thermal, structural, and vibration (NVH) analyses—each requiring the model to be manually recreated in different simulation environments. In some cases, it can take three months just to recreate a 3D axial flux machine template for more detailed analysis. This represents lost innovation time in what boils down to digital paperwork. This disconnect not only consumes time but also limits collaboration between teams. When each model recreation takes weeks, the rapid iteration and innovation cycle becomes unfeasible. Engineers end up making more conservative decisions simply because they cannot afford to explore alternatives with the necessary agility. Weaving the Digital Thread Now, imagine a scenario where the electric motor design, carefully developed in the design tool, can flow effortlessly between different tools and teams—where a single click sends the complete model, with all its complexity, directly to the next simulation environment. This is precisely the proposition of the new model transfer capability in the Simcenter portfolio. It's not just a feature—it's the digital thread that connects previously isolated tools and disciplines. After optimizing the axial flux machine design in Simcenter E-Machine Design —exploring hundreds of variants in a few hours, thanks to the equivalent circuit approach—the engineer can now transfer the complete model directly to Simcenter 3D or Simcenter STAR-CCM+ . The thermal team, in turn, receives not just data or specifications, but a three-dimensional model ready for the solver, with the appropriate mesh and complete simulation configuration. What used to take weeks now happens in minutes. Geometry, materials, and electromagnetic properties are transferred in their entirety—even complex features such as skew and end windings, which would be particularly time-consuming to recreate manually. From Concept to Validation in One Day This integrated approach completely transforms the development of electric motors. In a typical scenario, the team might identify a new axial flux machine concept in the morning, by midday the team uses Simcenter E-Machine Design to explore 500 potential configurations, optimizing efficiency and performance, and can transfer the most promising design to Simcenter 3D in the afternoon. Before the end of the day, structural validation can begin using the exact same model—without recreation, simplification, or delays. Meanwhile, the thermal team works on the same model within Simcenter STAR-CCM+ , coupling electromagnetic and cooling simulations to validate performance under real operating conditions. Identified issues can be addressed quickly, as everyone uses the same digital representation of the motor. The Human Impact More than just technical gains, this integration redefines how engineering teams collaborate. When a thermal problem arises that requires design modifications, teams can work together and validate changes in a matter of hours, instead of weeks. For engineering managers responsible for coordinating multidisciplinary teams, the impact is profound. Projects that previously needed to be carried out sequentially, with long intervals between phases, can now advance in parallel and synchronized. Rapid and continuous iterations become routine, increasing the quality and efficiency of the final products. Connecting Today's Innovation to Tomorrow's Success This functionality—now available in the latest version of Simcenter E-Machine Design 2506 —represents more than just time savings. It embodies a fundamental shift in how electric drive systems are developed, connecting the digital workflow from initial concept to detailed validation across all disciplines. For companies competing to launch the next generation of electric vehicles to market, this connected approach not only accelerates development but also enables entirely new levels of productivity and innovation that were not possible when teams worked in isolation. In the enterprise setting, as engineers leave the meeting with a new plan, there is a palpable sense of relief. Design changes can be implemented, validated across disciplines, and ready for prototype manufacturing—all on schedule. What once seemed impossible becomes simply another workday in the connected world of Simcenter tools. Eliminate the barriers between your engineering teams and accelerate the development of electric motors with a truly integrated digital workflow. Speak with CAEXPERTS and discover how to simplify your processes and drastically reduce the time between concept and validation — schedule a meeting today! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Turbomachines are made of assemblies of different bladed disks An interesting exploitation of the periodicity of the structure is to consider cyclic symmetry sectors, instead of the whole 3D structure. When the industrial application requires the machine to be made of different stages, each with a different number of sectors, special care is required when connecting those sectors to ensure a smooth junction between the two stages. When the periodic structure deviates from its regular axisymmetry shape like at the propellers with few blades, a simulation in a rotating frame can no longer be avoided. The limitations on the non-rotating parts apply for such calculations: indeed, the non-rotating parts (stator and bearings) must be isotropic, which can be a rough assumption for industrial applications. For such cases, the Simcenter Nastran solver for Rotor Dynamics proposes a method of avoiding model limitations with the use of Coleman transformation. Indeed, with this method, bladed rotors assembled to an anisotropic stator and bearings can be computed! While this is a challenge to complete, it allows you to model the complexities and explore more possibilities when simulating and modeling rotating structures. For industrial applications like turbochargers, steam turbines, or jet engines, the assembly is made of multiple stages of bladed disks, and the assumption that the rotor has axisymmetry is not always true. Therefore, Simcenter 3D 2506 for Rotor Dynamics has expanded the use of the Coleman transformation to assemblies of multiple stages of cyclic symmetry rotors.ontagens de múltiplos estágios de rotores com simetria cíclica.   Coleman transformation for multiple stages of cyclic symmetry rotors The Coleman transformation is a solution for producing time invariant matrices in the fixed structure for cyclic symmetric rotors, as described by Kirchgassner 2016 . Campbell diagrams and stability analysis are then used to calculate the critical speeds at which resonance occurs. This method is equivalent to the Floquet method when the structure is strictly cyclic symmetric, as described by Skjoldan 2009 . . Simcenter 3D advanced capabilities for bladed rotors Simcenter 3D has taken a step further in the simulation of advanced bladed rotors applications, allowing an assembly to be computed satisfying the hypothesis of rotor dynamics calculations based on the axisymmetry or unsymmetry of the different parts of the system. It allows easy postprocessing including the production of Campbell diagrams and presents modes as output in a fixed reference frame for easy interpretation Top right, model preparation of different cyclic symmetry sectors connected at the junction; bottom right: the Campbell diagram output in fixed reference frame; left: complex mode; 57Hz at 600rpm, backward whirl. Complex modal analysis in 5 steps Step one In Simcenter 3D , prepare an associative model, where the different stages can be linked to the geometry. It will allow any changes in the geometry to be communicated to the finite element model and adapted in such a way that only the simulation has to be computed again, to account for the changes. This method is called the master model concept. Step two Prepare the finite element model of the cyclic symmetry sector of each stage, by identifying the sector as a portion of the structure that can be repeated about the rotor axis. It can contain a single blade or multiple blades. Step three Assemble the different stages at the junction Identify each junction between two connected stages. The solver will take care of the continuity of results at this junction by automatically adding the higher order harmonics. Step four Prepare the simulation Set up a complex modal analysis in the rotating frame and activate the Coleman transformation. The rotating parts modeled in cyclic symmetry will be calculated in multi blade coordinates for different cyclic waves (harmonic index). The Coleman transformation will compute time-invariant matrices that will allow results to be output in a fixed reference frame. The bearings and the stator can be anisotropic and are calculated in the fixed reference frame, allowing for the simulation of the whole assembly. Step five Post-process results in Simcenter 3D The Campbell diagram shows the evolution of the eigenfrequencies with the rotation speed, highlighting the gyroscopic effects for the relevant modes. The advantage of the Coleman transformation is the simultaneous consideration of multiple harmonic indices, which is usually not the case with simulations using cyclic symmetry. Modes at 0-diameter, or 1-diameter are output in our example. What else can cyclic symmetry do? For all these applications that show a periodic structure, cyclic symmetry is an interesting alternative to full 3D models, since it enables the use of model reduction and makes the simulation time more reasonable. But what else? let’s review what Simcenter 3D Rotor Dynamics can do with cyclic symmetry models: Consider hybrid models, that is, a model that consists of sections that are 1D, 2D, and/or 3D, it is now possible to model a rotor made of a cyclic symmetry sector, in one or multiple stages, with a connection to a 2D Fourier portion of the rotor, a 1D shaft, as well as a 3D portion of the structure. Bearings, springs, dampers, etc can be used to connect the rotor to the ground with stiffness and damping properties or to a casing. If you want to go further in the model reduction, you can create a super-element of the cyclic symmetry sectors, for one or multiple stages, using Component Mode Synthesis methods. This super-element can then be used in an assembly with bearings, in rotor dynamics solutions. The postprocessing enables you to recover the results for the original cyclic symmetry sectors and for the whole recombined structure. For bladed rotors that can have large deformations due to centrifugal loads or other types of solicitations, which might occur when the blades are long and thin, it is possible to compute a modal basis of the structure with a preliminary nonlinear prestress. The nonlinear prestress of the structure computes the equilibrium state due to large deformations, and the modal basis is computed around this equilibrium state. Afterwards, you can use that tangent modal basis in a modal frequency response to compute the vibrations of the system due to external loading. For Campbell diagram, stability study and complex mode calculations, this blog shows that Simcenter 3D Rotor Dynamics can now be used to solve multi-stage rotors modeled in cyclic symmetry, with anisotropic bearings and output results in a fixed reference frame. Want to know more about simulating rotors in Simcenter 3D ? Schedule a meeting with CAEXPERTS and see how to apply these cutting-edge technologies to gain performance, reduce simulation time and deal with real geometries and conditions much more efficiently. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Accelerate surface wrapping. Refine SPH accuracy. Assess transient passenger thermal comfort. Plus, many more. New enhancements in Simcenter STAR-CCM+ are aimed at helping you: Model the complexity Explore the possibilities Go faster Stay integrated The Simcenter STAR-CCM+ 2510 release introduces a suite of powerful new features designed to elevate your simulation workflows. You can now model greater complexity with enhanced transient thermal comfort analysis, enabling more realistic vehicle thermal management simulations. The latest capabilities empower you to explore engineering possibilities faster and more reliably, thanks to dynamic penalty update for topology optimization. Workflow speed is dramatically improved with parallelized surface wrapping, more GPU-accelerated applications, and local particle refinement for SPH, all designed to help you achieve results in less time without sacrificing accuracy. Together, these new features enable you to drive productivity, accelerate development, and make better engineering decisions with confidence. Model the complexity Capture all aspects of HVAC systems and human comfort over time Modern electric vehicles face the challenge of maximizing energy efficiency across all driving scenarios, especially during extreme temperatures, where heating or cooling the cabin and battery can significantly reduce range. Traditionally, simulating passenger comfort during transient cabin cycles has required cumbersome co-simulation with third-party tools, which limits automation and fidelity. With the new release of Simcenter STAR-CCM+ 2510 , you can now use advanced thermal comfort models, including Fiala and Berkeley models, directly in transient analyses. This means you can simulate any unsteady cabin cycle, capturing the full dynamics of HVAC systems and human comfort over time, all within a single, seamless workflow. The solution integrates natively into existing Vehicle Thermal Management (VTM) processes, eliminating the need for external coupling and enabling full automation. As a result, you gain the ability to assess trade-offs between HVAC energy use and passenger comfort duration, leading to more informed design decisions. The primary benefit is a significant improvement in user experience, enhanced automation capabilities, and increased simulation fidelity, enabling you to deliver vehicles that are both comfortable and energy-efficient. Explore the possibilities Run up to 3x faster and stable Topology Optimization with reduced user intervention Achieving optimal performance in adjoint topology optimization is often hampered by the difficulty of selecting the right penalty strategy, which can lead to overshooting constraints, optimizer instability, and increased simulation time. Manual fine-tuning of penalty factors is tedious and detracts from the usability of the optimization tool. With Simcenter STAR-CCM+ 2510 , you benefit from a Dynamic Penalty update that automatically adjusts penalties during the optimization process, leveraging the augmented Lagrangian method for each constraint. This enhancement ensures smooth convergence without overshoots, even in constraint-heavy problems, and eliminates the need for manual adjustments. You can now focus on critical design aspects rather than penalty tuning, achieving up to three times faster and more stable optimization runs. You benefit from a streamlined workflow that accelerates innovation and improves the overall user experience. Enable quick and lean analysis of Transient 3D data Large transient simulations generate massive data sets, making it impractical to interactively analyze results or capture unexpected phenomena unless analysis bodies are pre-placed. Previously, storing and analyzing full-resolution 3D results required significant storage and memory, limiting flexibility. With the latest Simcenter STAR-CCM+ 2510 release, you can now store resampled volumes in Solution History files, drastically reducing data and memory footprint while retaining all relevant qualitative information at every time step. This allows you to interactively analyze 3D transient data, leverage results in screenplays for insightful animations, and investigate any plane in the full domain after the simulation is complete. The solution combines the benefits of Solution Histories and resampled volumes, allowing for qualitative analysis without the need for the original mesh. Perform quick, lean, and comprehensive analysis of large-scale transient simulations, supporting deeper insights and faster decision-making. Go faster Leverage faster surface mesh preparation Preparing a closed, manifold surface from complex or “dirty” CAD geometry is essential, often time-consuming, especially for large models. Even with previous parallelization efforts, runtime remained a bottleneck for many users. With Simcenter STAR-CCM+ 2510 , you can now take advantage of Phase 2 of the MPI Surface Wrapper, which brings further speedup compared to earlier versions. The process is parallelized across multiple processors, reducing wrapping time by up to ~50% compared with previous releases. The performance gain enables you to increase simulation throughput or create a more refined wrapped surface for improved mesh quality. The solution delivers consistent results regardless of processor count and can prepare complex surfaces in minutes. You can move from CAD to simulation much more quickly thanks to streamlined surface mesh preparation. Speedup rotorcraft simulation with GPU power Simulating complex rotating machinery, such as rotorcraft, is computationally intensive and often constrained by project timelines. Traditional CPU-based approaches, while accurate, can occupy a lot of resources and extend turnaround time. With the 2510 release of Simcenter STAR-CCM+ , you can now leverage GPU acceleration for Virtual Disk simulations, achieving drastically shorter runtimes while maintaining equivalent accuracy. This enables you to execute multiple simulation variants or entire design exploration studies much faster, reducing energy consumption per simulation. The solution empowers you to evaluate hundreds of geometry variants or apply finer resolutions within standard project timelines, transforming design-space exploration and providing robust insights early in the design process. By speeding up rotorcraft and rotating machinery simulations, this approach helps unlock resources and boost innovation. Enable faster and easier setup of DEM multiphase interactions Setting up complex particle flow simulations with multiple DEM phases and boundary types traditionally required repetitive and error-prone configuration of interaction pairs. This process became increasingly cumbersome as the number of phases grew. With Simcenter STAR-CCM+ 2510 , you can now use user-defined templates for contact models, applying them to multiple interaction pairs simultaneously. This enhancement increases productivity and improves the user experience by allowing multiple default interaction settings, each associated with distinct sets of interaction pairs. The solution streamlines the setup process, reduces errors, and provides greater flexibility for customizing interactions. Faster and easier setup of DEM multiphase interactions allows you to focus on simulation objectives rather than configuration details. Boost simulation accuracy and efficiency with SPH particle refinement Ensuring high accuracy in Smoothed Particle Hydrodynamics (SPH) simulations previously required refining the entire domain, leading to high runtimes. This was especially challenging for applications such as gearbox lubrication or tire water splashing, where only specific regions required high resolution. With Simcenter STAR-CCM+ 2510 , you can now enable local particle refinement for fluid particles in targeted areas of your domain. You define adaptive refinement shapes, such as blocks, cylinders, or spheres, and particles are refined only when inside these shapes, then coarsened outside. This approach delivers higher accuracy where needed, with a negligible runtime penalty compared to globally fine simulations. This enables faster turnaround times without compromising accuracy, making high-fidelity SPH simulations more practical and efficient. Stay integrated Unlock more design possibilities with expanded e-machine type support Radial flux machines (RFMs) account for more than 95% of the e-machine market, and previously, simulation workflows for these machines were complex and fragmented. The lack of a uniform file format across Simcenter EMAG and e-machines solutions made it difficult to ensure seamless workflow and numerical continuity between teams. With Simcenter STAR-CCM+ 2510 , you can now import radial flux machine designs through the SimCenter Data eXchange (SCDX) file format, which is compatible across all e-machine and EMAG Simcenter tools. This solution allows you to carry both CAD and physics data in a single file, ensuring a seamless workflow and consistent results across teams. This advancement brings more design options and a smoother simulation experience, with particular relevance to the automotive sector thanks to expanded e-machine support. These are just a few highlights in Simcenter STAR-CCM+ 2510 . These features will enable you to design better products faster than ever, turning today’s engineering complexity into a competitive advantage. Discover how Simcenter STAR-CCM+ can revolutionize your simulation workflows, accelerating innovation and increasing the accuracy of your designs. CAEXPERTS can help you explore the full potential of this new version and strategically integrate it into your engineering processes. Schedule a meeting with us and see how to transform complexity into competitive advantage. WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br