TABLE OF CONTENTS

1 INTRODUCTION

The es-ice Environment ............................................................................................

1-1

es-ice Meshing Capabilities ......................................................................................

1-3

Tutorial Structure ......................................................................................................

1-3

Trimming Tutorial Overview ....................................................................................

1-4

Required Files ...........................................................................................................

1-5

Trimming Tutorial files ...................................................................................

1-5

Automatic 2D Tutorial files .............................................................................

1-6

Wall Temperature Tutorial files ......................................................................

1-6

Mesh Replacement Tutorial files .....................................................................

1-6

Multiple Cylinder Tutorial files .......................................................................

1-7

Closed-Cycle Tutorial files ..............................................................................

1-7

Sector Tutorial files .........................................................................................

1-7

Two-Stroke Tutorial files ................................................................................

1-8

Mapping Tutorial files .....................................................................................

1-8

ELSA Tutorial files .........................................................................................

1-9

2 SURFACE PREPARATION IN STAR-CCM+

Importing and Scaling the Geometry ........................................................................

2-1

Creating Features ......................................................................................................

2-2

Defining Surfaces ......................................................................................................

2-6

Remeshing and Exporting the Geometry ..................................................................

2-8

3 GEOMETRY IMPORT AND VALVE WORK

Importing the Surfaces ..............................................................................................

3-1

Modelling the Valves ................................................................................................

3-3

Saving the Model ......................................................................................................

3-5

4 MESHING WITH THE TRIMMING METHOD

Modifying Special Cell Sets in the Geometry ..........................................................

4-1

Defining Flow Boundaries ........................................................................................

4-3

Creating the 2D Base Template ................................................................................

4-4

Creating the 3D Template .......................................................................................

4-19

Trimming the 3D Template to the Geometry .........................................................

4-24

Improving cell connectivity ...........................................................................

4-25

Assembling the Trimmed Template ........................................................................

4-25

Running Star Setup .................................................................................................

4-27

Saving the Model ....................................................................................................

4-27

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5 CREATING AND CHECKING THE MESH

6 STAR SET-UP in es-ice

Load Model ...............................................................................................................

6-2

Analysis Set-up ..........................................................................................................

6-2

Valve Lifts .................................................................................................................

6-3

Assembly ...................................................................................................................

6-4

Combustion ...............................................................................................................

6-7

Initialization ...............................................................................................................

6-8

Cylinder ............................................................................................................

6-8

Port 1 and Port 2 ..............................................................................................

6-9

Boundary Conditions ...............................................................................................

6-11

Cylinder ..........................................................................................................

6-11

Port and Valve 1 .............................................................................................

6-12

Port and Valve 2 .............................................................................................

6-15

Global settings ...............................................................................................

6-16

Post Set-up ...............................................................................................................

6-17

Cylinder ..........................................................................................................

6-18

Port 1 and Port 2 ............................................................................................

6-18

Global settings ...............................................................................................

6-19

Time Step Control ...................................................................................................

6-19

Write Data ...............................................................................................................

6-20

Saving the Model .....................................................................................................

6-21

7 STAR SET-UP in pro-STAR

Using the es-ice Panel ...............................................................................................

7-1

Setting Solution and Output Controls .......................................................................

7-2

File Writing ...............................................................................................................

7-4

8 RUNNING THE STAR SOLVER

Running in Serial Mode ............................................................................................

8-1

Running in Parallel Mode ..........................................................................................

8-1

Running in Parallel on Multiple Nodes .....................................................................

8-2

Running in Batch .......................................................................................................

8-2

Restarting the Analysis ..............................................................................................

8-2

9 POST-PROCESSING: GENERAL TECHNIQUES

Creating Plots with the es-ice Graph Tool ................................................................

9-1

Calculating Apparent Heat Release ...........................................................................

9-5

Plotting an Indicator Diagram ...................................................................................

9-6

Calculating Global Engine Quantities .......................................................................

9-8

Creating a Velocity Vector Display ..........................................................................

9-9

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Creating an Animation of Fuel Concentration ........................................................

9-12

Creating an Animation of Temperature Isosurfaces ...............................................

9-15

10 USING THE AUTOMATIC 2D TEMPLATE

Importing the Geometry Surface ............................................................................

10-2

Defining Special Cell Sets in the Geometry ...........................................................

10-3

Modelling the Valves ..............................................................................................

10-4

Creating the Automatic 2D Template .....................................................................

10-6

Refining the 2D Template Around the Injector ......................................................

10-9

Adding Features to the Automatic 2D Template ..................................................

10-10

Using Detailed Automatic 2D Template Parameters ............................................

10-12

Saving the es-ice Model File .................................................................................

10-15

11 MULTIPLE-CYCLE ANALYSIS

Setting Up Multiple Cycles in es-ice ......................................................................

11-1

Setting Up Multiple Cycles in pro-STAR ...............................................................

11-2

12 HEAT TRANSFER ANALYSIS

Resuming the es-ice Model File .............................................................................

12-3

Mapping Wall Temperature ....................................................................................

12-4

Exporting Wall Heat Transfer Data ........................................................................

12-6

Saving the es-ice Model File ...................................................................................

12-8

Cycle-averaging Wall Heat Transfer Data ..............................................................

12-8

Post-processing Wall Heat Transfer Data in pro-STAR .........................................

12-9

Plotting average wall boundary temperatures .............................................

12-10

Plotting average heat transfer coefficients ..................................................

12-12

Plotting average near-wall gas temperature at Y-plus=100 ........................

12-13

Mapping Heat Transfer Data to an Abaqus Model via STAR-CCM+ .................

12-15

13 MESH REPLACEMENT

Preparing the File Structure ....................................................................................

13-2

Rebuilding the Dense Mesh ....................................................................................

13-2

Creating Ahead Files for the Dense Mesh ..............................................................

13-6

Defining Mesh Replacements .................................................................................

13-8

Setting Up Mesh Replacement in pro-STAR ..........................................................

13-9

Setting up the coarse model .........................................................................

13-10

Setting up the dense model ..........................................................................

13-11

14 MULTIPLE CYLINDERS

Resuming the es-ice Model File .............................................................................

14-2

Making, Cutting and Assembling the Template .....................................................

14-2

Setting Up Multiple Cylinders ................................................................................

14-3

Checking the Computational Mesh .........................................................................

14-4

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STAR Set-Up in es-ice ............................................................................................

14-7

Analysis set-up ...............................................................................................

14-8

Assembly ........................................................................................................

14-8

Combustion ..................................................................................................

14-11

Initialization .................................................................................................

14-12

Boundary Conditions ...................................................................................

14-15

Post Setup .....................................................................................................

14-21

Time Step Control ........................................................................................

14-22

Write Data ....................................................................................................

14-23

Saving the es-ice Model File .................................................................................

14-23

15 DIESEL ENGINE: FULL-CYLINDER CLOSED-CYCLE MODEL

Importing the Geometry ..........................................................................................

15-2

Generating the Closed-Cycle Polyhedral Mesh ......................................................

15-3

Assigning shells to geometry cell sets ...........................................................

15-3

Specifying General, Events and Cylinder parameters ...................................

15-4

Creating a spray-optimised mesh zone ..........................................................

15-6

Importing a user intermediate surface ..........................................................

15-10

Checking the spray-optimised zone .............................................................

15-11

Creating the closed-cycle polyhedral mesh .................................................

15-12

Running Star Setup ......................................................................................

15-13

Creating and checking the computational mesh ..........................................

15-13

Saving the Model File ...........................................................................................

15-14

16 DIESEL ENGINE: SECTOR MODEL

Importing the Bowl Geometry ................................................................................

16-2

Defining the Bowl Shape ........................................................................................

16-2

Defining the Fuel Injector .......................................................................................

16-3

Creating the 2D Template .......................................................................................

16-4

Creating the Sector Mesh ........................................................................................

16-7

Creating and Checking the Mesh ............................................................................

16-9

Saving the Model ...................................................................................................

16-10

17 DIESEL ENGINE: STAR SET-UP IN es-ice and pro-STAR

STAR Set-up in es-ice .............................................................................................

17-1

Load model ....................................................................................................

17-1

Analysis setup ................................................................................................

17-1

Assembly ........................................................................................................

17-2

Combustion ....................................................................................................

17-3

Initialization ...................................................................................................

17-3

Boundary conditions ......................................................................................

17-4

Post setup .......................................................................................................

17-5

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Time step control ...........................................................................................

17-6

Write data ......................................................................................................

17-7

Saving the Model File .............................................................................................

17-7

STAR Set-up in pro-STAR .....................................................................................

17-7

Using the es-ice Panel ...................................................................................

17-8

Selecting Lagrangian and Liquid Film Modelling ........................................

17-8

Setting up the Fuel Injection Model ..............................................................

17-9

Setting up the Liquid Film Model ...............................................................

17-15

Setting up Analysis Controls .......................................................................

17-16

Writing the Geometry and Problem Files and Saving the Model ...............

17-19

18 DIESEL ENGINE: POST-PROCESSING

Creating a Scatter Plot ............................................................................................

18-1

Creating a Spray Droplet Animation ......................................................................

18-3

19 TWO-STROKE ENGINES

Importing the Geometry ..........................................................................................

19-2

Meshing with the Trimming Method ......................................................................

19-3

Assigning shells to geometry cell sets ...........................................................

19-3

Creating the 2D template ...............................................................................

19-5

Creating the 3D template ...............................................................................

19-8

Trimming the 3D template to the geometry ................................................

19-11

Assembling the trimmed template ...............................................................

19-12

Running Star Setup ......................................................................................

19-14

Checking the mesh ......................................................................................

19-14

STAR Set-up in es-ice ..........................................................................................

19-16

Analysis setup ..............................................................................................

19-16

Assembly .....................................................................................................

19-17

Combustion ..................................................................................................

19-18

Initialization .................................................................................................

19-19

Boundary conditions ....................................................................................

19-22

Post setup .....................................................................................................

19-28

Time step control .........................................................................................

19-28

Write data ....................................................................................................

19-29

Saving the es-ice Model File .................................................................................

19-29

20 MESHING WITH THE MAPPING METHOD

Creating the Stub Surface in the Geometry ............................................................

20-1

Creating the 2D Base Template ..............................................................................

20-8

Creating the 3D Template .....................................................................................

20-21

General Notes About Edges and Splines ..............................................................

20-28

Creating Edges and Splines Near the Valve Seat .................................................

20-29

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Creating the Remaining Edges and Splines ..........................................................

20-36

Creating Patches ....................................................................................................

20-40

The Mapping Process ............................................................................................

20-42

21 IMPROVING THE MAPPED MESH QUALITY

Creating Plastered Cells ..........................................................................................

21-1

22 PISTON MODELING

Meshing the Piston with the Shape Piston Method .................................................

22-1

23 ELSA SPRAY MODELLING

Importing the Bowl Geometry ................................................................................

23-3

Defining the Bowl Shape ........................................................................................

23-3

Setting the Events and Cylinder Parameters ...........................................................

23-4

Creating the Spray Zone ..........................................................................................

23-5

Creating the Sector Mesh ......................................................................................

23-11

STAR Set-up in es-ice ...........................................................................................

23-12

Load model ..................................................................................................

23-13

Analysis setup ..............................................................................................

23-13

Assembly ......................................................................................................

23-14

Combustion ..................................................................................................

23-16

Initialization .................................................................................................

23-17

Boundary Conditions ...................................................................................

23-18

Time step control .........................................................................................

23-22

Write data .....................................................................................................

23-23

Saving the Model File ...........................................................................................

23-24

STAR Set-up in pro-STAR ...................................................................................

23-24

Using the es-ice panel ..................................................................................

23-24

Activating the Lagrangian model .................................................................

23-25

Defining the ELSA scalars ...........................................................................

23-25

Setting up the Lagrangian droplets ..............................................................

23-31

Defining boundary regions and boundary conditions ..................................

23-34

Setting up analysis controls .........................................................................

23-36

Adding extended data for the ELSA model .................................................

23-40

Writing the Geometry and Problem Files and Saving the Model .........................

23-42

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