CFD Engineering Consultancy in Research and Development and Product Development

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Few Challenges and Issues for Managing Global R&D

Working in a R&D company developing engineering products to global markets can be overwhelming sometimes. Challenges are the same than in this Research Study back to 2004:

  • Use of internal/external and distributed research centers
  • Worldwide communications and meetings, virtual organizations
  • Optimal resource allocation
  • Network and tools to connect
  • Long project duration, regulatory environment
  • State-of-the-art virtual product development tools
  • Structure vs Process in R&D
  • Creating real international partnership

Many of these issues and challenges are tackled by outsourcing engineering work for the consultant. This is most likely to happen when there is a peak load or special skills needed for.

Typically R&D is decentralized or research facilities and centers are segregated. In addition to this, the company’s internal process to purchase extra in-house resources may be truly cumbersome and in fact, more expensive.

Design Engineers will cope with the environment, where a lot of changes are happening. Project managers get the pressure from stakeholders and constant specification changes in the discussion with potential customers. Managers are between the lack of engineering resources and upcoming timeline issues. Sometimes the product is just too late or not anymore matching to customer expectations.

Time, Quality, Cost — you can have any two.

Building several product prototypes are always needed for but when problems with the performance is found, costs and time to market are increased. On the other hand, allocating resources tightly internally and minimizing information exchange with similar engineering teams can quickly result in isolated information silos. This reduced communication and collaboration decreases efficiency, while same wheel is re-invented again inside your company.

The higher amount of communication is substantial time thieve of designers weekly hours. Endless meetings between organization members, own team, etc will keep you informed, but having enough your own time for successful product development may diminish.

So, what is the typical solution for overcoming product development challenges?

Depending on the company size and strategy, resource solutions are often found from:

  • Acquiring capabilities and workforce In-House by recruitment
  • Hiring external consultants now and then
  • Getting external consultants in-house for fixed contracts

Several Reasons You Should Consider Hiring an Engineering Consulting Firm, Hiring consultants is actually outsourcing the need of extra employees by virtualization

Typically in R&D a problem will arise unexpectedly. And usually, if your team has an expert to solve it, he can’t be allocated to the task. New hires, recruiting and training may be impossible or project resources limited and having a risk to prolong.

To Access to Specialized Skills and Experience and getting A Different, Outside Perspective to Your Problem, you need to hire an external consultant. This consultant can:

  • Solve your problem and give precise solutions
  • Improve efficiency, save costs
  • You can focus on core business activities and
  • access to experience and get an intelligent advice

A consultant is an available on-demand resource and a process of firing a consultant is a lot easier than firing a new employee.

Later in this Article:

Chapter 2 shows an example of CFD simulation in engineering consultancy and how it succeeded.

Chapter 3 will open up “Virtualization of the real world, developing a digital prototype” And give insight…

But, also a lot of product development is at the same time made more virtualized. Virtualization of engineering products is developing a digital prototypes using CAD models and investing in simulation.

Chapter 4 reveals examples of CFD software licenses and costs.

Chapter 5 gives an insight of Protacon Descal consultancy services, such as CFD, FEM, Laser scanning and Vibration Measuring Service.

Chapter 6 summarizes typical customer cases, where CFD is used.

From Chapter 7 you can find a specialist finnish engineering team that continuously solves customer challenges globally and internationally.

What is a CFD (Computational Fluid Dynamics) simulation and FEA & CFD consulting?

Using CFD will allow quick virtualized product testing and accurate results without unnecessary prototyping and measuring of a physical sample. But beside of reducing precious and time-consuming methods, CFD can be used to evaluate fluid flows where no measurements are possible.

Flow Analysis of moving fluid, gas or liquid is more than studying pressure drops or fluid forces. CFD allows the fluid mass flow, velocity, pressure, density, temperature, concentration or any other fluid flow property to be analyzed throughout the CAD model. In the example video below, the aerodynamic noise is estimated by the CFD-simulation.

What is a typical CFD analysis and consultation workflow?

There are several steps in a typical CFD workflow:

  1. Understanding the assignment and customer’s real need.
  2. Simplifying the problem.
  3. CAD preparation and modification.
  4. Meshing or grid generation.
  5. Model generation and selection, different simulation scenarios, possible data analytics for boundary conditions.
  6. Solving the 3D CFD computer simulation.
  7. Results, analysis and presentation, reporting.
  8. Customer feedback, reasonable size backups of large size simulation data.

So as seen above, there are several steps, where the consultation can go wrong in a way or another

Estimating the project duration is something that will come from the experience. Right combination to fulfill consultation requirements is a lot of being smart about:

  1. Quoting and Scheduling
  2. Communicate with your clients right
  3. Keeping right amount of Follow Ups
  4. Make and maintain Connections with Clients people related to the project

Points 2–4 might be the most complicated part in long-lasting customer relationship succeeding and takes time to achieve. These points are naturally demanding for introvert consultants while exciting for extroverts.

Why use CFD

This chapter will answer to the next questions:

  1. What will be the Key Usage and Results of CFD project?
  2. Benefits Of Availing CFD Analysis Services
  3. CFD Analysis Capabilities, CFD Solution for Industries
  4. Why to invest in Simulation and outsource these services?

Clients Benefit from CFD Consulting Services

CFD offers unrivaled benefits to across the diverse spectrum of industrial applications

The accuracy of Computational Fluid Dynamics methods is, without exception, enough to increase the level of design insight.

Using of external consultation releases internal resources available to design engineers throughout the design process.

This will greatly reduce customer’s exposure to technical risk when developing thermal and fluid flow based products.

The use of CFD is a key tool in the design process to minimize the amount of physical prototypes. Which are always necessary during the development process. Less prototypes and testing consequently reduce the time-to-market and cost-to-market substantially.

Here are few important aspects as well to achieve product development goals:

  • Simulation helps design troubleshooting and validating initial design performance
  • Simulation helps streamline design processes
  • Simulation helps avoiding modification or redesign
  • Cost and energy savings through more efficient design
  • Better product performance, less field failures
  • Test multiple case studies, what-if-analysis
  • Less measurements and testing, helps set-up experimental testing
  • Helps right sizing, decision making, mitigate risks and eliminates design errors
  • Giving more valuable time and technical understanding for design engineers

Despite of using simulation and analysis in cutting the number of prototypes, CFD shows its value:

  • Feasibility studies
  • Testing new innovations
  • Conceptual designs
  • IP portfolio development
CFD simulation can used early in concepts and innovations.

Modeling is used more and more when developing new products in industrial design, startups, kick-starts, crowdsourced designs and even in reverse engineering while investigating of competitor products.

This CFD modeling example shows a gas dispersion of poll evaporation hazard. Via simulation and safety structure sizing optimization customer saved more than 400 000 Eur, when the analysis cost was <<10kEur.

CFD Gas Dispersion Analysis.
  • Lesson learned: Enhance product performance, reducing the design to market time, avoid unexpected field failure, reduce physical test expense, derive optimized design from multiple concepts, increased efficiency, reduce design cycle time significantly by eliminating errors.

CFD softwares, Which commercial CFD package is best for your organization?

Not much have happened in commercial fluid dynamics software business in last ten years, if you think about license costs. Typically it is impossible to have the best tools without 30–60k$ early investment,+15kEur-25kEur annual costs (annual updates, TECS, maintenance) and very often you need more than one type of license. In the beginning it is better to prepare for the +80kEur starting investment and 30kEur annual fees.

Read more about Best available CFD package comparison on LinkedIn.

Two major CFD software houses are ANSYS and Siemens.

ANSYS and Siemens are having a tough fight about the future in simulation software business. Siemens did huge investments in Mentor Graphics ($4.5 billion deal) and CD-Adapco ($970 million) and ANSYS bought SpaceClaim ($85 million).These two companies have basically the monopoly in simulation driven CFD software business and competitors are far behind.

Mentor Graphic’s CFD tools are FloTHERM, FloTHERM XT and FloEFD. CD-Adapco’s Star CCM+ is a direct competitor to ANSYS Fluent and CFX. ICEPAK is having competition against FloTHERM product’s, in electronics (thermal engineering). There are lots of other CFD tools available in the market, such as Autodesk CFD (former CFdesign), Comsol, Cradle…

Choosing right CFD software is not an easy task.

For companies to invest in own CFD driven engineering design, have to make big investment in software. Selection of the software can be challenging and it’s nearly impossible to compare one software against another, because:

  • Prices and licenses features won’t match
  • The need of software training support (often charged separately), which differs the software and its easiness to use
  • One software can be master against other in one type of simulation problem or field (such as thermal engineering, CAD requirements, marine industry, etc)
  • The need of HPC (High Performance Computing, parallel CPUs) licenses is complicated to estimate and share
  • Most likely staff is having background and experience from one software only
  • After investing in one software, it’s very tricky to go back and select another

Even after selecting one software, it gets complicated later on when software provider change their price tags and license types. For instance ANSYS typically raises annual costs +2.5–3% per year and the lifetime of one software can be only 3 years. After the time is passed, the implementation of new features are taken away and there will come extra +10% annual additional costs to keep “old” software running”. This should be kept in mind, when considering to buy a perpetual license. The perpetual license cost is >55kEur and you need +10kEur for each and every year for these 3–5 years to keep license updated (typically 2–3 per year). Then TECS costs are forced to raise and most likely drop off from updates will likely to happen.

CFD software license prices are high.

Big companies avoid costly investments and generally choose to buy a CFD license per year only and be able to reduce/increase the total number of licenses. Renting of licenses is in the long run, the most expensive option, prices around +20–25 kEur per year, one license only. However, big companies can share licenses easily between continents and even globally and also get significant discounts. For instance HPC licenses can be shared globally for tens of workers.

Smaller consultancy companies may experience real difficulties to match ANSYS or Siemens price politics. Running costs and hourly consultancy prices are favoring larger teams, that have enough workers to share less licenses. Just only software license costs can surely cover over 25–30% of total hourly prices in CFD consultancy. Probably no discount is given for one small company’s single software investment.

As seen above, the investment costs and costly annual updates keep top, genuine commercial CFD softwares as tools that you can’t find from the freelancers (Upwork, Freelancer, Guru, PeoplePerHour) tool boxes.

Why Choose Us

This chapter will answer to the next questions:

  • Why choose our CFD Simulation and Modeling Services?
  • What kind of CFD (Computational Fluid Dynamics) and FEM (Finite Element Method) consulting services we provide?

CFD Consulting Services

We offer CFD analysis services and solutions in Finland and Worldwide:

  • Global solution provider, 80–90% of our company projects are outside Finland
  • We focus on longstanding client relationships with large and small companies
  • We have a good balance of the project cost, scope/accuracy and time because of extensive know-how in engineering simplicity of complex problems
  • We are fast and flexible in support with quick responses

Please check more specific CFD case studies later in this article (Chapter 6).

FEM (Finite Element Method)

FEM is Stress analysis tool that can be applied extensively in manufacturing scenarios where cost, material, weight, strength, etc., need to be optimized or where safety factors need to be determined.) We are experts in:

  • Structural Dynamics and Design Analysis.
  • Earthquake and Seismic Analysis, Stability Analysis.
  • Stress Hand and Mechanical Calculations, Dynamic Analysis (FEA).
  • Non-linear stress analysis (material plasticity, large deformation and contact).
  • Fatigue, buckling, Vibration & Modal Analysis and Dynamics.
  • Tank and pressure equipment design, steel and structure design.
Silo and tank seismic design and earthquake engineering is our key competence through the world.

About Us, Company Details, Strength Calculation and Analyzes:

Protacon Descal Ltd. with International and Global Commercial Services:

  • Design Engineering Services, Detailed Engineering
  • FEA Consulting and Analysis Consultant in CFD Fluid Flow, Thermal, Strength and Structural Analysis
  • Engineering Consulting Services Offered Such as:
  • Plant Engineering, Process Optimization Consulting, Project Supervision

Our latest customer solutions are delivered worldwide are:

  • 3D Laser Scanning, Point Cloud Modeling, CAD Conversion Services
  • Vibration testing and modelling services (measurement equipment), acoustic vibration, piping & structural vibration
  • CFD fluid flow and thermal analysis

We are ready to establish and solve new engineering challenges, please check Chapter 7 and get in touch!

Summary of this Chapter, Descal offers:

CFD consulting services to solve your fluid dynamics challenges.

Complete range of computational fluid dynamics (CFD) consulting services for diverse spectrum of industrial applications including laser scanning and vibration measurement services.

Extensive experience across industries and with FEM ANSYS simulation software.

References

Areas of our CFD Consulting Expertise since 2006 covers a huge amount of different Flow Analysis of Applications and Devices. Here are only Some CFD Project Examples and case studies where we are ready to helping you:

  • Acoustics, noise, Noise Adsorption Walls, Turbulence Generating Noise.
  • Automotive, Aerodynamic Analysis, CFD Simulation of Exhaust Infiltration, Aftertreatment devices such as Catalyzers, particle filters, SCR, Engine CFD Analysis, External Airflow Simulation Around and Through Structure, Measuring Lift & Drag Forces for a Flow, recirculating air, underhood cooling.
  • Biomedical, Healthcare Facilities, Medical cleanroom airflow analysis.
  • Blast, explosion and electronic arc destructive testing simulations.
  • Building Engineering, Building Physics, Office Buildings, CFD Simulation for Design of Building, Internal Ventilation Systems, green building design.
  • CFD Transient Flow, buoyancy-driven steady-state models, Study of incompressible fluid flows.
  • Conduction, Convection, Radiation from Heat Sinks to Heat Pipes, Thermosyphons, Outdoor Electronics Enclosure.
  • Environmental Impact, Renewable Energy, Solar (PV Photovoltaic) equipments such as inverters, ocean wave energy systems and prototypes, small scale burning devices, chimney development.
  • Electronic Cooling, Thermal Optimisation of Drives, Fan Performance and selection CFD Analysis, Data centers, telecommunication equipments, Grilles and Enclosures, Air Guide Vanes and Ducts.
  • Evaluation & Optimization, Design Optimisation.
  • Fire Engineering, Safe Design Analysis for Plant Operation, Depressurization, Pressure Relief & Process Design, Tube Rupture Analysis.
  • Fire modelling is a key tool when trying to predict the spread of smoke and heat from fires in built environments and when used correctly can be a powerful design and safety tool.
  • Fluid Structure Interaction, Particle Flows, Particle Transport, CFD simulation of wind driven rain.
  • Heat Transfer Analysis, Heat Exchangers , Thermal Management of System, Thermal equipments consulting, Thermo-Fluid Design, Thermal Calculations, Heat Sink, Enclosure, High-Power Thermal Analysis, Improving the Thermal Performance of Containers, High-Temperature Furnace, Electronics Assembly for Outdoor Environments.
  • Heavy industries, Industrial Fluid Dynamics, Manufacturing Facilities, tunnels, pulp & paper, energy production.
  • HVAC Analysis Services, Flow Vents, Air-Handler Flow Baffle Optimization, Flow Behavior in an Inlet Nozzle, CFD Flow Analysis Diffuser, Duct Flow Optimization, Design and modelling of the external ventilation system, Air conditioning CFD simulation, Indoor climate, Airflow simulations and consultancy for comfort, safety and sustainability in the built environment, Simulate air quality very early on in the design stage.
  • Hydrodynamic Analysis, Multiphase Flow Analysis, Steam-water, Waste water treatment, Sediment Pipe Flow, avoid cavitation and erosion.
  • Power Generation, Petrochemical Applications, Power Plant Buildings, Reactors, Solid Mass Bio-Fuels.
  • Pressure drop in valves, Paper machines, black liquor in recovery boiler furnaces, tube convectors, oil boilers, economizers, oil recovery equipments, electrostatic precipitators.
  • Pressure & Thermal Equipment and Piping, Airflow Inside Oil Tank, the cooling channels of boilers.
  • Process Design & Simulation, Exhaust Gas Dispersion into Atmosphere, Scrubber Flow Analysis, Separator Analysis, Pollutant dispersion.
  • Rotating equipment, Pump/Motor, impeller/stator, Flow Mixing, Design & Flow-Induced Pulsation and Vibration Analysis, Modeling Flow-Induced Vibration, mixing chambers and vessels, Pump performance.
  • Risk & Hazard Assessment, Health and Fire Safety, Fire and Smoke Modelling Studies, considering an investigation of the pollution, impact of fires on building designs.
  • Wind Engineering and Modelling, Wind Studies , Wind Load Analysis, Wind Force Analysis, Wind Flow Optimization, Urban microclimate, Wind comfort.

Leads, How to Buy

Contact Info

This article was written by Ismo Talka.

Thank you for reading my article. I and my colleagues are constantly looking new engineering consultancy projects, let us help you and don’t hesitate to ask more!

Let’s get connected on LinkedIn.

Request or get a consultation, quote or information, please select the best suitable option for you below:

Option 1: Call us now!:

Phone numbers and emails can be found from this page:

https://www.descal.fi/en/personnel

Please contact a member of our team from link above to discuss your specific requirements or for a quotation

Option 2: Online instant message, easiest outreach with Ismo:

https://virtauslaskenta.bookmark.com/

Good to know:

  • U.S. workers spend 3.2 hours checking their work email each day. Instead of subscribing to boring mailing list, Signing-up for never read e-newsletter or following any extra blog also help us to avoid spam and cold email reach, please contact via direct messaging option 2.
  • Are you tired of unanswered email messages or online quote request without replies? No worries, from here you will receive a timely response depending your local time and zone.
  • You can also follow Protacon Descal in Linkedin: https://www.linkedin.com/company/descal-engineering-oy/about/
  • Keywords: Request information, Connect, Follow on LinkedIn, Submit your CFD project, Receive more information, Web application, Instant fee quotation, Contractor request, Share on Skype

Note:

Due to the urgency of most engineering projects, all consultancy enquiries submitted through the email are typically dealt with within 2–15 hours. To receive an instant fee quotation, please call or use a direct messaging option.

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