Version 5.

1D - 3D Coupling

January 2008

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BOOST v5.1

AVL LIST GmbH Hans-List-Platz 1, A-8020 Graz, Austria http://www.avl.com AST Local Support Contact: www.avl.com/ast_support

Revision A B C D E

Date 18-Jul-2003 23-Jun-2004 29-Jul-2005 13-Oct-2006 31-Jan-2008

Description BOOST v4.0.3 - 1D - 3D Coupling BOOST v4.0.4 - 1D - 3D Coupling BOOST v4.1 - 1D - 3D Coupling BOOST v5.0 - 1D - 3D Coupling BOOST v5.1 - 1D - 3D Coupling

Document No. 01.0108.0445 01.0108.0456 01.0108.0472 01.0108.0500 01.0108.0510

Copyright 2008, AVL All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language, or computer language in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without prior written consent of AVL. This document describes how to run the BOOST software. It does not attempt to discuss all the concepts of 1D gas dynamics required to obtain successful solutions. It is the users responsibility to determine if he/she has sufficient knowledge and understanding of gas dynamics to apply this software appropriately. This software and document are distributed solely on an "as is" basis. The entire risk as to their quality and performance is with the user. Should either the software or this document prove defective, the user assumes the entire cost of all necessary servicing, repair or correction. AVL and its distributors will not be liable for direct, indirect, incidental or consequential damages resulting from any defect in the software or this document, even if they have been advised of the possibility of such damage. All mentioned trademarks and registered trademarks are owned by the corresponding owners.

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Table of Contents
1. Introduction _____________________________________________________1-1
1.1. Scope _______________________________________________________________________1-1 1.2. User Qualifications ___________________________________________________________1-1 1.3. Symbols _____________________________________________________________________1-1 1.4. Configurations _______________________________________________________________1-2 1.5. Documentation ______________________________________________________________1-2

2. General Overview________________________________________________2-1 3. Theoretical Background _________________________________________3-1

3.1. FIRE-BOOST Interaction _____________________________________________________3-3 3.2. 1D-Coupling Software Implementation _________________________________________3-5

4. BOOST Input Data_______________________________________________4-1

4.1. Global Data__________________________________________________________________4-2 4.2. FIRE Link___________________________________________________________________4-3

5. FIRE Input Data _________________________________________________5-1

5.1. Mesh Generation _____________________________________________________________5-1 5.2. BOOST Link Data____________________________________________________________5-3 5.3. Setup Calculation ____________________________________________________________5-5 5.3.1. Boundary Conditions______________________________________________________5-5 5.3.2. Initialization ____________________________________________________________5-10 5.4. Simulation _________________________________________________________________5-12 5.4.1. Check List for Calculation ________________________________________________5-12 5.4.2. Start Calculation ________________________________________________________5-13 5.4.3. Starting from Command Line _____________________________________________5-14 5.4.4. 1D-Coupling under MPI __________________________________________________5-15

6. Result Analysis __________________________________________________6-1 7. Model-1D Variables ______________________________________________7-1

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List of Figures
Figure 3-1: Classic Species in BOOST Compared to Standard Species in FIRE................................................3-2 Figure 3-2: Start of Hybrid Calculation ...............................................................................................................3-3 Figure 3-3: Data Transfer FIRE to BOOST.........................................................................................................3-3 Figure 3-4: Data Transfer BOOST to FIRE.........................................................................................................3-4 Figure 3-5: Flow Patterns at 1D - 3D Interfaces .................................................................................................3-5 Figure 3-6: 1D-Coupling Software Implementation ............................................................................................3-5 Figure 4-1: FIRE Link Elements in a BOOST Model..........................................................................................4-1 Figure 4-2: Simulation Control FIRE Link Control Window ...........................................................................4-2 Figure 4-3: FIRE Link Dialog ...............................................................................................................................4-3 Figure 4-4: Convergence Control in BOOST........................................................................................................4-4 Figure 5-1: Mesh Generation FIRE Domain .....................................................................................................5-1 Figure 5-2: Mesh Generation CAD Surface.......................................................................................................5-2 Figure 5-3: Mesh Generation Enlarge FIRE Domain .......................................................................................5-2 Figure 5-4: Mesh Generation Connecting Edge Topology................................................................................5-3 Figure 5-5: FIRE Link Correct Connectivity Boundary ...................................................................................5-3 Figure 5-6: FIRE Link Example of Incorrect Connectivity Boundary.............................................................5-4 Figure 5-8: Data Transfer FIRE to BOOST.........................................................................................................5-4 Figure 5-9: Data Transfer BOOST to FIRE.........................................................................................................5-5 Figure 5-10: Boundary Conditions Window .........................................................................................................5-5 Figure 5-11: Boundary Type Recommendation for Intake Manifold..................................................................5-7 Figure 5-12: Convergence Problems Caused by Boundary Type ........................................................................5-8 Figure 5-13: Boundary Type Recommendation for Intake Manifold with Change in Cross-Section................5-8 Figure 5-14: BOOST: Fluid Link ID.....................................................................................................................5-9 Figure 5-15: Initialization in FIRE Domain.......................................................................................................5-10 Figure 5-16: Initialization for Intake Manifold..................................................................................................5-11 Figure 5-17: Pressure Trace at FIRE - BOOST Connectivity (1st cycle, FIRE only) .......................................5-11 Figure 5-18: Calculation Wizard 1D-Coupling Server-host Selection............................................................5-13 Figure 5-19: 1D Model Selection Window ..........................................................................................................5-14 Figure 6-1: Structure of 1D-Coupling Monitoring File using FIRE Species ......................................................6-1 Figure 6-2: Structure of 1D-Coupling Monitoring File using BOOST Species ..................................................6-2 Figure 6-3: BOOST result .....................................................................................................................................6-3

ii

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1. INTRODUCTION
This manual describes how to use the FIRE-BOOST Interface (FBI).

1.1. Scope
This document is for users of 1D 3D Coupling and anyone interested in theory and modeling. It does not attempt to discuss all the concepts of gas dynamics required to obtain successful solutions. It is the users responsibility to determine if he/she has sufficient knowledge and understanding of fluid dynamics to apply this software appropriately.

1.2. User Qualifications

This document is a basic qualification for using BOOST and users are recommended to continue with basic and advanced training courses.

1.3. Symbols
The following symbols are used throughout this manual. Safety warnings must be strictly observed during operation and service of the system or its components.

Caution: Cautions describe conditions, practices or procedures which

could result in damage to, or destruction of data if not strictly observed or remedied.

Convention Italics

Note: Notes provide important supplementary information.

Meaning For emphasis, to introduce a new term or for manual titles. To indicate a command, a program or a file name, messages, input / output on a screen, file contents or object names.

monospace

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SCREEN-KEYS

A SCREEN font is used for the names of windows and keyboard keys, e.g. to indicate that you should type a command and press the ENTER key. A MenuOpt font is used for the names of menu options, submenus and screen buttons.

MenuOpt

1.4. Configurations
Software configurations described in this manual were in effect on the publication date. It is the users responsibility to verify the configuration of the equipment before applying procedures.

1.5. Documentation
BOOST documentation is available in PDF format and consists of the following: Release Notes Users Guide Theory Primer Examples Aftertreatment Aftertreatment Primer Linear Acoustics 1D-3D Coupling Interfaces Validation GUI Users Guide Installation Guide (Windows & UNIX) Licensing Users Guide Python Scripting Optimization of Multi-body System using AVL Workspace & iSIGHTTM Thermal Network Generator (TNG) Users Guide Thermal Network Generator (TNG) Primer

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2. GENERAL OVERVIEW
This manual describes how to perform coupled 1D-3D gas dynamics calculations with the FIRE v8 - BOOST interface (FBI). The concept of coupling allows BOOST and FIRE to be run as independent executables. The data exchange is performed via UNIX sockets using network communication (TCP/PP).

Note: FIRE v8.6 and BOOST v5.1 are required for the 1D/3D Interface.

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3. THEORETICAL BACKGROUND
The numerical solution of the governing transport equations in the 3D domain is performed by the fully implicit finite volume method of FIRE and, in the 1D domain, by the explicit finite difference method of BOOST. In each sub-domain the unsteady conservation equations of mass, momentum and thermal energy will be solved by each program separately using the results of the attached program as boundary conditions. The boundary conditions are derived from space/time averaging of flow variables in selected regions of the domain surfaces. These regions are called fluid links. The exchange of physical quantities takes place at the beginning of each time step, whereby the geometrical definition of fluid links must be performed prior to the calculation in the CFD Workflow Manager pre-processing, using the method of SELECTIONS. Due to the mixture of fully implicit and explicit discretization schemes the flow solvers must agree upon the time step size. Since the step size of FIRE can be very large, the stability criterion for explicit schemes (Courant no. < 1) could be violated significantly, which would end up with unstable solutions in the BOOST calculation. To prevent such instabilities, BOOST is able to perform a number of sub-cycle steps until the above stability criterion becomes satisfied. There are three conditions to initiate a sub-cycle process: The FIRE crank angle (CA) increment is larger than the CA increment resulting from the CFL stability criterion. The CA increments of FIRE and BOOST do not coincide exactly. The accumulated FIRE and BOOST crank angles do not fit exactly at characteristic (pre-scribed) values, e.g. BDC or TDC.

At the end the sub-cycling process BOOST v4 provides FIRE v8 with the time integral mean values over the sub-cycles as boundary conditions. BOOST computes the one-dimensional flow of a gas mixture. Separate mass balances are solved for the individual species that make up the mixture, but only one momentum balance is solved. The BOOST species are automatically mapped to active scalars in FIRE, so that the treatment (one momentum balance for the entire mixture, separate mass balances for the species) conforms to that in BOOST. The local values (i.e. FIRE cell values) of the gas constant and the specific heat depend on the local species concentrations. FIRE does not know the species properties. It sends the species concentrations and temperatures of all cells to BOOST, BOOST computes the gas constants and specific heats and sends it back to FIRE. This is done once for each time step. In FIRE the Standard species model has to be activated to allow for species-dependent values of the gas constant and specific heat. But the FIRE species do not correspond to the BOOST species. Instead, active scalars are generated automatically in FIRE and these correspond to the BOOST species.

Note: The FIRE species do NOT correspond to the BOOST species

(unless the feature described below is active). Instead, separate active scalars are generated automatically in FIRE which correspond to the BOOST species.

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The BOOST species transport model Classic conforms to the FIRE species model Standard. If this model is activated in BOOST, FIRE will directly map the BOOST species to its standard species, without creating active scalars. In this case, the gas constants and specific heats for all cells are directly computed in FIRE. Combustion or other processes working on the standard species concentrations will affect also the BOOST species. The old species-coupling-mechanism with separate active scalars can still be enforced also in this case by setting the environment variable FORCE_1D_PROPS to 1 (i.e. with the additional solver argument -env=FORCE_1D_PROPS=1 in the Calculation Wizard or cfdwm_solver script). A comparison of the species mechanism is shown in Figure 3-1.

Figure 3-1: Classic Species in BOOST Compared to Standard Species in FIRE mfFb mfFv mfCP mfm mfEGR mass fraction fuel burned mass fraction fuel vapor mass fraction combustion products mass fraction fuel mixture mass fraction Exhaust gas return

When the old species coupling mechanism is used (using BOOST species) in FIRE the fluid properties are taken also from the BOOST database. The update of the properties is done at the beginning of each time-step (see message in .fla file: %fire-I-CPL1D_UPDATE_RGAS_CP, cp, Rgas updated from 1D code). With the species coupling mechanism FIRE uses it's own standard species. The update of the properties is done for each iteration.

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Note: Small differences may result from the frequency of the update
between the two coupling mechanisms. Differences are expected only in cases with high temperature or species gradient.

3.1. FIRE-BOOST Interaction

When the BOOST model is initialized, an additional pipe containing one cell is created automatically. The overlapping length of the pipe in the following figure is input in the BOOST pre-processor. In the FIRE preprocessor a cell selection (with a specific name) has to be created for each overlapping region, corresponding to the shaded cells in the figure below. (If no selection is defined, only the first cell layer at the interface is used as overlapping region in FIRE).

Figure 3-2: Start of Hybrid Calculation At the start of the calculation of a time step, the density, momentum and temperature are averaged over the part of 3D domain in the corresponding cell selection. This data is transferred to the additional BOOST pipe as shown in the following figure.

Figure 3-3: Data Transfer FIRE to BOOST

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As BOOST uses an explicit scheme for solving the pipe flow, the time step can then be calculated. As a result, the average mass flow and the flows of momentum and energy over the interface between BOOST and FIRE are obtained. These flow rates are specified as boundary conditions for FIRE at the interface and the calculation of the conditions at the end of the time step are done by FIRE as shown in the following figure:

Figure 3-4: Data Transfer BOOST to FIRE The FIRE 3D code uses an implicit scheme for the solution of the governing equations. It therefore allows Courant numbers larger than 1. BOOST uses an explicit scheme and therefore requires Courant numbers smaller than 1. This is usually not a severe restriction as the modeling of critical parts in the engine with the 3D code requires a fine mesh, whereas the 1D code is able to resolve pressure waves with satisfactory quality using a coarser grid. This gives the desired ratio of the Courant numbers in the two calculation domains with the same absolute value for the time step. The user must ensure that the transition between the BOOST and FIRE calculation domains is located in a straight pipe section where a one dimensional flow field can be assumed. The length of the pipe section should be sufficient to avoid recirculation zones crossing the boundary, shown in the following figure.

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Figure 3-5: Flow Patterns at 1D - 3D Interfaces

3.2. 1D-Coupling Software Implementation

A client-server architecture is now used for all 1D couplings. Both solver and a 1D coupling server run as separate programs on the same and different platforms. The communication is performed over network, using TCP/IP and sockets. A coupling server has been implemented to couple with BOOST. The software architecture is depicted below.

1D-Coupling Server (Platform A)

Solver (Client) (Platform B)

Interface Functions 1D-Code Library

NetworkCommuni cationLibrary

Network (TCP-IP)

NetworkCommuni cationLibrary

Figure 3-6: 1D-Coupling Software Implementation This architecture decouples BOOST from the FIRE solver so that both can be compiled independently with different compilers and compiler options. The architecture also allows the client (FIRE solver) and coupled server (BOOST) to run on different platforms.

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The hostname for the coupling server (i.e. the name of the computer running the server), the input-dataset name for BOOST and a port number for the network connection has to be specified when starting FIRE from the GUI or from command line. The coupling server is started automatically together with FIRE. The FIRE solver operates according to the procedure below (given in pseudo code).

Start: Init 1D coupling for all time steps { for all 1D-interfaces { set interface flow values for 1D code } advance 1D simulation one FIRE-timestep for all interfaces { get interface flow values from 1D code } advance FIRE 3D simulation one time step } exit 1D simulation end Algorithm 1: Basic Solver Algorithm for 1D-Coupled Simulations

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4. BOOST INPUT DATA

Please refer to Chapter 5 of the BOOST Examples manual for a description of FIRE BOOST examples (pipe and intake manifold). For a time and cost effective simulation of three dimensional (3D) flow patterns, BOOST enables a 1D/3D hybrid calculation using FIRE. In this calculation mode, BOOST is used as a subroutine of FIRE. The user must design a one dimensional (1D) BOOST model using the BOOST preprocessor and a 3D FIRE model using the FIRE pre-processor for the engine geometry between the 3D-sides of the FIRE Link elements. The user must ensure that the interface between the 1D and 3D domains is located in a pipe section, where essentially one dimensional flow occurs. The FIRE Link elements located in the BOOST model represent interfaces between the 1D BOOST domain and the 3D FIRE domain. The FIRE Link element is similar to a flow restriction with two attached pipes, but with one explicit 1D-side and one explicit 3D-side. The BOOST sub-model between the 3D-sides (shadow network) should be a 1Dapproximation of the 3D FIRE domain. Pipes are attached to the FIRE Link element in a similar way as is done for a restriction.

PIPE 2 = Shadow Network

Figure 4-1: FIRE Link Elements in a BOOST Model

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4.1. Global Data

When performing a BOOST-FIRE simulation specify the required data in the Simulation Globals section as shown in the following figure:

Figure 4-2: Simulation Control FIRE Link Control Window Number of BOOST-only cycles The BOOST simulation is performed using the shadow network as 1Dapproximation of the 3D FIRE domain. Number of FIRE/CFD-only cycles The FIRE simulation is performed applying fixed boundary conditions generated during the last cycle of the BOOST-only simulation. This allows the coupled BOOST-FIRE simulation to be performed in three steps: 1. Simulation of BOOST only During the Number of BOOST-only cycles the BOOST simulation is performed using the shadow network as 1D-approximation of the 3D FIRE domain. During the last of these cycles the conditions at the 3D-side of all FIRE-link elements are stored for use as boundary conditions during the FIRE-only simulation. 2. Simulation of FIRE only During the Number of FIRE-only cycles the FIRE simulation is performed until the end of the FIRE-only cycles is reached using the boundary conditions generated during the last BOOST-only cycle.

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The third step is the coupled simulation, where the BOOST and FIRE calculations are performed simultaneously and full data exchange FIRE BOOST and BOOST FIRE appears. The calculation in the BOOST shadow network also is performed. A data exchange from the coupled BOOST-FIRE-simulation to the shadow network appears, but does not appear in the other direction. Splitting the simulation procedure into three steps will yield a better convergence of the results and therefore a decrease of calculation time.

4.2. FIRE Link

This improved link allows to perform BOOST only calculations until it is converged, after this a single cycle with the existing BOOST results is calculated to initialize the FIRE domain and the last few cycles are calculated as a combined FIREBOOST calculation.

Figure 4-3: FIRE Link Dialog

Note: When restarting a co-simulation run, all data written for time levels bigger than the actual restart time will be automatically deleted from the monitoring file.

A convergence control can be performed with FIRE, where the calculation stops if a prescribed convergence criterion is fulfilled. The convergence criterion is that the variation of the cycle-averaged values ("transients") of some parameters in BOOST elements over the last three consecutive cycles is less than a prescribed threshold. When the convergence criterion has been fulfilled, FIRE stops the coupling calculation. A message will be found in the .fla file.
%fire-I-cpl1d_advance, % 1d program indicates cycle-convergence stopping

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Select Convergence Control in the Time Step Control window, then select the Convergence Control sub-group in the tree to open the following window.

Figure 4-4: Convergence Control in BOOST

Note: The convergence control flag has to be set to FLAG. The option FINISH is not active in the case of the 1D-3D coupling.

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5. FIRE INPUT DATA

5.1. Mesh Generation
To get a suitable volume mesh (calculation grid) the FAME Advanced Hybrid meshing technique is used. This includes a fully automatic mesh generator, where all settings for the refinement are done before starting the mesh generator. The following steps give an overview of the meshing procedure: Import surface mesh. Create edge mesh. Perform meshing process to get a volume mesh. Check newly created volume mesh. Smooth newly created volume mesh if required. Apply necessary selections to specify regions for boundary conditions.

Figure 5-1: Mesh Generation FIRE Domain This document does not explain the meshing process in detail, please refer to the FIRE Primer manual for details. The user must ensure that the transition between the BOOST and FIRE calculation domains is located in a straight pipe section where a one dimensional flow field can be assumed. As this requirement might be difficult to fulfill with the highly complex and compact manifold shapes, the following recommendations are given to avoid problems during the calculation. It is very important that the connectivity to the FIRE domain is perpendicular to the pipe, as shown in Figure 5-2. The length of the pipe section should be sufficient to avoid re-circulation zones crossing the boundary. This might cause solver instability and will probably increase calculation time. In the worst case the calculation can diverge.

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NO

YES

Connectivity at inlet not perpendicular to pipe, inlet too close to separation plate Connectivity at inlet almost perpendicular to pipe, cylindrical pipe at inlet considered

Figure 5-2: Mesh Generation CAD Surface If possible a pipe section with the length of at least 1x the diameter of the corresponding pipe should be considered at the transition between BOOST and FIRE. As it is not always possible to provide the perfect pipe shape at the inlet and outlet it is recommended to add at least a small cylindrical pipe to the FIRE domain (refer to Figure 5-3). The best way to do this is to enlarge the connectivity areas in the direction of the pipes for at least few cell layers (i.e. 5mm to 10mm).

Figure 5-3: Mesh Generation Enlarge FIRE Domain

Note: The position of the 1D 3D interface must match between FIRE

and BOOST and the pipe length has to be consistent.

At all inlet/outlet boundaries it is strongly recommended to use a connecting edge topology as the solver may have problems in terms of convergence behavior. In the automatic meshing process (FAME Advanced Hybrid) the connecting edge will be created on the boundary of a face selection.

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Without connecting edge, cut through volume mesh

With connecting edge, cut through volume mesh

Figure 5-4: Mesh Generation Connecting Edge Topology

Note: A connecting edge has to be created always, when fluid is entering

or leaving the simulation domain.

5.2. BOOST Link Data

Selections have to be defined to specify boundary conditions (inlet/outlet and wall) and to set up the connectivity between FIRE and BOOST. Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4

1D 3D Link: Boundary faces

1D 3D Link: Integration volume

Figure 5-5: FIRE Link Correct Connectivity Boundary

C1

C2 C3

C1

C2 C3

1D 3D Link: Boundary faces

1D 3D Link: Boundary faces

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NO
C1 C2

NO

NO
C2

C3

C1

C3

1D 3D Link: Definition of Integration volume not correct

1D 3D Link: Integration volume of C1 and C2 mismatched

Figure 5-6: FIRE Link Example of Incorrect Connectivity Boundary

Note: It is important that the boundary conditions and the connectivity are set
up correctly. Wrong selection definition will have a significant influence on the result.

At each 1D/3D interface the overlapping length (or more precisely the integration volume) should be defined explicitly as a cell selection. The integration volume can be added to the mesh using the Enlarge option. All 3D flow quantities sent to BOOST will be averaged over these cells.

Integration volume

Figure 5-7: Data Transfer FIRE to BOOST As a result, the average mass flow and the flows of momentum and energy over the interface between BOOST and FIRE are obtained. These flow rates are specified as boundary conditions for FIRE at the interface and the calculation of the conditions at the end of the time step are done by FIRE as shown in the following figure:

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Figure 5-8: Data Transfer BOOST to FIRE

Note: For the data exchange between BOOST and FIRE at each pipe
attachment, the overlapping length must be defined in the BOOST preprocessor. The length must be according to the length of the integration volume in FIRE.

5.3. Setup Calculation

5.3.1. Boundary Conditions
In the Solver Steering File (SSF) parameter tree, select Module activation and activate the Species Transport model. In the Species Transport menu, activate the Standard option. Select Boundary conditions in the parameter tree to open the following window:

Figure 5-9: Boundary Conditions Window

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Default Sel. for BC This pull-down menu includes the names of all the selections defined for the volume mesh. Select the appropriate Face Selection that corresponds to the desired boundary. The name selected in Sel. for BC is automatically entered here. This name will also appear in the parameter tree. Select Inlet/Outlet from the pull-down menu. Select 1D-Coupling from the pull-down menu. NoSelection

Name of BC

NoName

Type of BC Inlet/Outlet Phase 1 Coupling mode

Since a fluid link is treated as inflow/outflow boundary it can be either of Mass Flow, Pressure or Total Pressure. Mixtures of both types on the same model are possible. Basically both boundary types (pressure / total and mass-flow) can be applied. Nevertheless it has to be considered that the pressure boundary cannot ensure that mass-flow is set to 0. Since the pressure is updated in BOOST due to 3D flow effects it is not recommended to use the pressure boundary type near to closing or opening devices like vales or throttles. In this case the massflow boundary will give correct results. If only the mass-flow boundary type is used the system pressure information might not be exchanged between FIRE and BOOST sufficiently. This could lead to de-coupling of the pressure. A combination of mass-flow and pressure boundary type therefore is recommended. A further point to be considered is that the pressure boundary should be chosen only at regions where strong redirection or changes in the cross-section do not occur in the geometry. A diffuser like effect will cause unrealistic high velocities (when the pressure type (static pressure) is used at those boundaries (refer to Figure 5-11). In such configurations the mass-flow boundary is recommended.

Fluid link id

The fluid link id entered here must be the number of the corresponding 3D fluid link in the 1D model. Refer to Figure 5-13.

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Integration volume

Select the cell selection containing the cells of the overlapping region. If no selection is defined as the integration volume at the interface, the (single) cell layer adjacent to the interface is used automatically. It is strongly recommended to define the first 2-3 layers as the integration volume to avoid solver problems in terms of convergence behavior.

NoSelection

Turbulence velocity and length scale

The turbulent length scale can be prescribed either directly (Turb. length scale) or as a fraction of the hydraulic diameter of the boundary surface (% of hydraulic diameter). In the latter case, the absolute value in meters is computed and displayed in the GUI immediately. The solver only receives the value displayed under Turb. length scale. The default values should be used as long as more precise data is not available (i.e. experience). After the FIRE BOOST connectivity has been set up then the wall temperature has to be defined. The temperature must be specified according to the value used in BOOST. Enter the turbulence velocity at the boundary in % of the mean flow velocity. Enter the turbulent length scale at the boundary in % of the hydraulic diameter of the boundarycondition-face-selection. Enter the turbulent length scale in meters. 10

% of mean velocity % of hydraulic diameter

10

Turb. length scale

0.001

RED: Massflow boundary GREEN: Pressure boundary

Figure 5-10: Boundary Type Recommendation for Intake Manifold

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NO

pstat

pstat

YES

Figure 5-11: Convergence Problems Caused by Boundary Type

RED: Massflow boundary GREEN: Pressure boundary

Figure 5-12: Boundary Type Recommendation for Intake Manifold with Change in Cross-Section

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FIRE Link

Figure 5-13: BOOST: Fluid Link ID

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5.3.2. Initialization
The whole domain is initialized according to the BOOST data. When pressure and temperature values are specified the density is recalculated in the solver automatically. The whole domain should be smooth using 100 iterations for the pressure as well as for the temperature value (refer to Figure 5-14).

Figure 5-14: Initialization in FIRE Domain A key point for stability at calculation start is the correct initialization. Insufficient or even wrong initialization will have a negative effect on the convergence behavior and in the worst case it will cause divergence of the calculation. It is recommended to initialize the BOOST values of pressure and temperature in the integration volumes. The data has to be taken from measurement points connected to the 1D/3D interfaces. The data according to the coupling calculation start should be used (in BOOST activate the data reader option in the curve properties). Figure 5-14 shows an example for initialization of an intake manifold.

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Figure 5-15: Initialization for Intake Manifold Since several 1D 3D coupling cycles are calculated the initialization at calculation start will not affect the final result. But due to a more precise initialization less coupling cycles might be necessary and calculation time could be decreased.
120000

115000

110000

C 3, w/o Initialisation in IV C 3, w Initialisation in IV C 5, w/o Initialisation in IV C 5, w Initialisation in IV

105000

Pressure [Pa]

100000

95000

90000

85000

80000

75000

70000 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Crank angle

Figure 5-16: Pressure Trace at FIRE - BOOST Connectivity (1st cycle, FIRE only)

Note: Boundary and initial conditions in FIRE must be defined according

to the BOOST data.

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5.4. Simulation
5.4.1. Check List for Calculation
Before starting the calculation the following checks should be made to reduce user errors.

BOOST:
FIRE Link positions correlate with FIRE model (i.e. air cleaner position is inside/outside FIRE domain, pipe length is correct, ...) Check FIRE Link for correct set up of connection direction (1D and 3D side) BOOST only and FIRE only cycle are defined (30 BOOST only and 1 FIRE only cycle are recommended values) The BOOST input file (.bst file) has been generated and includes the latest corrections made in the BOOST model.

Network connection to FIRE is available and online. Classic species transport is activated.

FIRE:
FIRE model correlates with the BOOST model (connectivity location is defined correct). All relevant details are considered in the 3D model and correct placed (i.e. flap position,...). The FIRE model contains no negative volumes or negative normal distances. The solver cannot accept those cells. All selections for the 1D 3D connectivity have been set up (boundary faces and integration volume). No selections are overlapping or mismatched (i.e. no boundary faces are connected to the wrong integration volume). The Fluid ID is defined correctly (check with BOOST). The correct engine speed is defined (check with BOOST). The crank-angle range covers the required range (FIRE only cycle + coupling cycles). The selected port number for TCP/IP connection is not in use (further 1D 3D coupling calculation, license server, ...). Check if the correct 1D-coupling server version is available. Standard species transport is activated. If the check list has been passed successfully the calculation can be started.

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5.4.2. Start Calculation

The 1D-program always runs its own process separately from FIRE. This program is called the 1D-server (i.e. fire_boost_server.ia32-unknown-winnt for WINDOWS platform or fire_boost_server.ia32-unknown-linux for Linux 32 bit system). It is started automatically with FIRE. The 1D-server-executable must be installed parallel to the ASTbin-directory. The 1D-server-host selection is shown in Figure 5-17. The 1D-server may be local (i.e. the same host running FIRE and the server) or remote, in which case the machine name and a user name must be specified. The port-number is necessary for the interprocess-connection and must be in the range 1025-65000.

Note: The same port-number must NOT be used for running 1D-coupling
simulations simultaneously on the same computer.

Figure 5-17: Calculation Wizard 1D-Coupling Server-host Selection The 1D model selection is shown in Figure 5-18. Select BOOST as the required 1Dprogram to couple with. The calculation wizard checks which 1D-servers are installed and only these are selectable. Additionally, the BOOST.bst-file input file must be specified. The input file must be accessible under the specified path from the server-host.

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Figure 5-18: 1D Model Selection Window If more than one FIRE BOOST coupling calculation is started different BOOST input files have to be used. The time-out for the TCP-connection (see 3.2) between FIRE and the 1D-program is 3600 seconds by default. This means, FIRE will keep on running and try to re-establish a connection to the 1D-program for one hour if the connection was lost. A shorter or longer time-out can be defined by specifying the additional solver argument env=ASTPNT_RECONNECTION_TRIES=n, where n is the number of reconnection-tries. FIRE waits three seconds after each try, so the resulting time-out is 3n seconds.

5.4.3. Starting from Command Line

Starting a 1D-coupled FIRE -simulation from command line is possible using the cfdwm_solver-script. Basically the same parameters for the 1D-coupling have to be specified as for starting from the GUI. The corresponding options are: -1dcpl_cmd <1D-program> -1dcpl_project <1D-input-file> BOOST Location of the input file for BOOST, including path Name of host to start coupling server Name of user on <1D-host> Port number under which to run coupling server, 1024 < port-number < 65000

-1dcpl_host <1D-host> -1dcpl_user <1D-user> -1dcpl_port <port-number>

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5.4.4. 1D-Coupling under MPI

1D-coupling is supported also under MPI. In this case only one coupling server will be started. Only the first MPI-sub-process will communicate with the server and distribute the data accordingly among the other sub-processes.

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6. RESULT ANALYSIS
Result analysis of volume data must be performed with the build-in post-processing tools of each program. For transient analysis of locally exchanged data 2D plot-files containing the most important flow variables will be written by FIRE. In order to distinguish the bi-directional data exchanges FIRE 1D-model and 1D-model FIRE two sets of 2D-plotting files are created for each fluid link. The corresponding data is written in ASCII format. The filenames and extensions are derived from the exchange directions and the fluid link IDs, e.g. FIRE-2-1D-program.00001 represents data transferred from FIRE to the 1D-program at fluid link number 1. 1D-program-2FIRE.00001 represents data transferred from the 1D-program to FIRE at the same fluid link. Each 2D file consists of a header and a data section (refer to Figure 6-1). The header section displays information about general interface settings and certain single-valued model parameter. In the data section the space/time averaged values of momentum, pressure, density, temperature and species concentrations, which are exchanged at the beginning of each co-simulation step, are recorded. To visualize the 2D data standard plotting tools, like XMgrace (http://plasma-gate.weizmann.ac.il/Grace) or MS-Excel, can be used.
######################################################################## # # FIRE-M1D Interface: Data Exchange History # ######################################################################## # FluidLink ID 1 # FluidLink Index 1 # BoundaryRegion Index 0 # Selection Name BOOST_Link_1 # Species Type FIRE standard species # Interface Type 1D-general # Data Exchange Direction FIRE --> 1D-general # Boundary Type MASSFLOW # Initial FIRE Crank Angle 1.00000 [deg] # Initial FIRE Time Step 4.166667E-05 [sec] # Overlap Length 6.000000E-03 [m] # Unit Normal Vector x 0.00000 [m] # Unit Normal Vector y 0.00000 [m] # Unit Normal Vector z 1.00000 [m] # Attachment Area 1.648350E-03 [m^2]
################################################################################################# ###
# # TS CA VEL PRE DEN MASSFLOW TEM EGR MixtureFrac Fuel # [deg] [m/s] [Pa] [kg/m^3] [kg/s] [K] [kg/kg] [kg/kg] [kg/kg] # ################################################################################################################# #### # 1 1.00 0.0000E+00 9.4106E+04 1.0797 0.0000E+00 302.4114 0.0000E+00 0.0000E+00 0.0000E+00 2 2.00 -3.1872 9.3263E+04 1.0728 -5.6363E-03 301.6216 0.0000E+00 4.1821E-05 4.1821E-05 3 3.00 -37.0375 8.0162E+04 0.9615 -0.0587 289.3098 0.0000E+00 2.2460E-05 2.2460E-05 4 4.00 -45.7185 7.8677E+04 0.9491 -0.0715 287.6481 0.0000E+00 1.1481E-05 1.1481E-05 5 5.00 -49.6092 7.7770E+04 0.9417 -0.0770 286.5586 0.0000E+00 5.6442E-06 5.6442E-06 6 6.00 -50.6968 7.7629E+04 0.9409 -0.0786 286.2711 0.0000E+00 2.7570E-06 2.7570E-06 7 7.00 -50.5994 7.7749E+04 0.9423 -0.0786 286.2666 0.0000E+00 1.3522E-06 1.3522E-06 8 8.00 -49.8662 7.8022E+04 0.9451 -0.0777 286.4371 0.0000E+00 6.6974E-07 6.6974E-07 9 9.00 -48.8307 7.8374E+04 0.9484 -0.0763 286.7051 0.0000E+00 3.3591E-07 3.3591E-07

Figure 6-1: Structure of 1D-Coupling Monitoring File using FIRE Species

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######################################################################## # # FIRE-M1D Interface: Data Exchange History # ######################################################################## # FluidLink ID 1 # FluidLink Index 1 # BoundaryRegion Index 0 # Selection Name BOOST_Link_1 # Species Type 1D-code species # Interface Type 1D-general # Data Exchange Direction FIRE --> 1D-general # Boundary Type MASSFLOW # Initial FIRE Crank Angle 1.00000 [deg] # Initial FIRE Time Step 4.166667E-05 [sec] # Overlap Length 6.000000E-03 [m] # Unit Normal Vector x 0.00000 [m] # Unit Normal Vector y 0.00000 [m] # Unit Normal Vector z 1.00000 [m] # Attachment Area 1.648350E-03 [m^2]
################################################################################################################# #### # # TS CA VEL PRE DEN MASSFLOW TEM BurnedFuel CombustionP FuelVapour # [deg] [m/s] [Pa] [kg/m^3] [kg/s] [K] [kg/kg] [kg/kg] [kg/kg] # ################################################################################################################# #### # 1 1.00 0.0000E+00 9.4106E+04 1.0839 0.0000E+00 302.4114 0.0000E+00 0.0000E+00 0.0000E+00 2 2.00 -3.1611 9.2265E+04 1.0771 -5.6124E-03 298.3848 0.0000E+00 0.0000E+00 4.1840E-05 3 3.00 -34.9840 8.0021E+04 0.9711 -0.0560 287.0853 0.0000E+00 0.0000E+00 2.3000E-05 4 4.00 -43.2405 7.8681E+04 0.9584 -0.0683 285.9963 0.0000E+00 0.0000E+00 1.2063E-05 5 5.00 -47.1203 7.7772E+04 0.9507 -0.0738 284.9616 0.0000E+00 0.0000E+00 6.0818E-06 6 6.00 -48.2060 7.7640E+04 0.9499 -0.0755 284.7308 0.0000E+00 0.0000E+00 3.0467E-06 7 7.00 -48.1333 7.7757E+04 0.9512 -0.0755 284.7376 0.0000E+00 0.0000E+00 1.5323E-06 8 8.00 -47.4218 7.8026E+04 0.9540 -0.0746 284.9082 0.0000E+00 0.0000E+00 7.7835E-07 9 9.00 -46.4027 7.8374E+04 0.9573 -0.0732 285.1674 0.0000E+00 0.0000E+00 4.0043E-07

Figure 6-2: Structure of 1D-Coupling Monitoring File using BOOST Species

Note: When restarting a co-simulation run, all data written for time levels bigger than the actual restart time will be automatically deleted from the monitoring file.

CYLINDERS: Average Values ------------------------Total Engine Firing TDC [deg] Bore [mm] Stroke [mm] Conrodl. [mm] .. .. IMEP Exh. [bar] IMEP Int. [bar] IMEP Gasex. [bar] IMEP HP [bar] FMEP [bar] BMEP [bar] -1.1938 0.5240 -0.6698 4.3559 0.9300 2.7262 Cyl. 1 0.00 87.00 90.00 149.00 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6

120.00 87.00 90.00 149.00

240.00 87.00 90.00 149.00

360.00 87.00 90.00 149.00

480.00 87.00 90.00 149.00

600.00 87.00 90.00 149.00

-1.2262 0.8252 -0.4009 9.4861 0.9300 8.1351

-1.1622 0.2124 -0.9498 1.9576 0.9300 0.0479

-1.2071 0.8392 -0.3678 6.2764 0.9300 4.9000

-1.1159 0.2180 -0.8979 1.1272 0.9300 -0.7007

-1.2530 0.8264 -0.4266 6.1235 0.9300 4.7370

-1.1987 0.2229 -0.9758 1.1649 0.9300 -0.7000

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ISFC (tr.f.) [g/kWh] .. .. Gas Exchange: A/F-Ratio (Cmb.) [-] Excess Air Ratio [-] Pressure at SHP[bar] Total Mass at SHP[g] Av.Airmass at SHP[g] Airpurity [-] Res.gas content [-] Air Delivered [g] Air Delivered [g/s] Delivery Ratio [-] Airdeliveryratio [-] Rel. to Ave. [-] Rel. To PL 1 [-] Mass Delivered [g] Mass Delivered [g/s] Airmass Trapped [g] Airmass Trapped [g/s] Trapp. Eff. Air [-]

365.5883

119.1628 1949.6969

185.6863 6927.7773

190.6682 6697.1391

19.96 1.3764 0.7260 2.3746 2.0595 0.8673 0.0835 2.0475 68.2504 0.5268 0.5120

37.29 2.5716 1.2824 0.6825 0.6459 0.9464 0.0429 0.6362 21.2072 0.9805 0.9545 1.8644

8.70 0.6000 0.2053 0.1426 0.0748 0.5246 0.2549 0.0748 2.4940 0.0748 0.1123 0.2193 0.1135 0.0498 1.6611 0.0748 2.4940 1.0000

36.33 2.5057 1.2819 0.6817 0.6378 0.9357 0.0386 0.6378 21.2600 0.9636 0.9569 1.8690 0.9674 0.6423 21.4086 0.6378 21.2600 1.0000

8.70 0.6000 0.1557 0.0998 0.0349 0.3495 0.3958 0.0349 1.1631 0.0905 0.0523 0.1022 0.0529 0.0603 2.0105 0.0349 1.1631 1.0000

36.10 2.4899 1.2711 0.6706 0.6275 0.9357 0.0423 0.6252 20.8387 0.9640 0.9379 1.8320 0.9482 0.6425 21.4179 0.6248 20.8278 0.9995

8.70 0.6000 0.1595 0.0974 0.0386 0.3966 0.3955 0.0386 1.2874 0.0878 0.0579 0.1132 0.0586 0.0585 1.9502 0.0386 1.2874 1.0000

0.5176 2.1070 70.2326 2.0469 68.2287 0.9997

0.9650 0.6535 21.7845 0.6359 21.1965 0.9995

Figure 6-3: BOOST result In the example of Figure 6-3, the FIRE link direction has not been set up appropriately for cylinder 2, 4 and 6. They have been specified in the wrong direction (1D 3D direction). As a result the air delivery ratio is unrealistically low (0.1123, 0.0523 and 0.0579) compared to the other cylinder which have been linked correctly (0.9545, 0.9569 and 0.9379).

Note: Check the Airdeliveryratio in the BOOST file (.bst). If the

connectivity has not been set up correctly it would be visible here.

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7. MODEL-1D VARIABLES
In the tables below the most important integer and real variables belonging to the Model1D interface are described: Table 7-1: Integer Variables

Name IMOD1D NUMM1D NUMCONC NCMOD1D(2,:) NBMOD1D IM1D_TYPE

Size 2*NREG+1 NREG+1 NREG+1

Description 1D gas dynamics model activation. Number of active fluid links. Number of concentration equations solved for. Index range of attachment regions. Fluid link IDs. Model-1D type: Values: always 10 with FIRE versions >= 8.2.2

IM1D_CONC

NREG+1

Active concentration equations

Table 7-2: Real Variables

Name AVG_VEL AVG_U1 AVG_U2 AVG_U3 AVG_PRES AVG_DENS AVG_RGAS AVG_TEMP

Description Mass averaged velocity magnitude. Mass averaged Cartesian u-velocity. Mass averaged Cartesian v-velocity. Mass averaged Cartesian w-velocity. Volume averaged static pressure. Volume averaged density. Mass averaged gas constant. Mass averaged temperature.

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AVG_PS AVG_XN1 AVG_XN2 AVG_XN3 ATT_AREA XM1D_LEN

Mass averaged passive scalars. Averaged x-component of unit normal vector. Averaged y-component of unit normal vector. Averaged z-component of unit normal vector. Attachment area. Overlap length.

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