Originating in the early 1960s, Computational FluidDynamics, also known as CFD(Computational Fluid Dynamics), began to be more widely used in the 1990s due to the development of computer technology in recent years.

O method method is applied by combining numerical calculations and the laws of thermofluid dynamics.

CFD therefore uses numerical simulations to analyze systems with fluid flow, heat transfer and other related phenomena.

What are the steps to do a CFD simulation?

Normally, a simulation with mathematical programs using CFD methodology has three stages: pre-processing, simulation and post-processing.

Pre-processing

In pre-processing, the parameters are defined: study region (domain), geometry and mesh of the problem (discretization of the domain), physical and numerical criteria, among others.

CFD simulation

Simulation involves solving the equations that describe fluid dynamics. In this way, it is possible to obtain the values of the variables of interest, such as velocity, pressure and temperature.

Simulation is only possible due to the discretization of the fluid, generally using the finite volume method. This allows the Navier-Stokes equations to be solved in order to obtain the desired result.

Post-processing

Finally, in post-processing, it is necessary to analyze whether the result achieved is coherent. At this stage, the relevant data is extracted, which can be converted into graphs and tables to make it easier to study the system. 

At this stage, it is essential to use the knowledge learned during the academic and professional life of the person carrying out the analysis, especially in thermofluid dynamics subjects.

CFD makes it possible to visualize the distribution of the fluid with regard to the desired variable in different ways. In the case exemplified in Figure 1, both the velocity profile of a fluid inside a combustion chamber and the flow lines were obtained. 

It is also possible to simulate flow using three-dimensional videos and observe critical points in a system's operation.

What are the main applications of CFD in industry?

Resolved Analytics conducted a survey of 624 people who use CFD programs. From this data, it was possible to see in which areas of industry Computational Fluid Dynamics is most commonly applied.

The automotive sector recorded the highest percentage of users, with 20%. Followed by the engineering services sector, with 18%. In third and fourth place came the energy and aerospace sectors, with 10%.

Figure 2: Main areas of industry in which CFD is applied - SOURCE: https://www.resolvedanalytics.com/cfd-user-survey-results.

For the areas mentioned, see possible applications of CFD:

• Vehicle design: seeking maximum performance and lowest cost for land, sea and aeronautical vehicles;
• Power plant projects: with the aim of achieving high levels of efficiency and few pollutants; 
• Reactor design and operation;
• Studies of fluid flow phenomena in pipes;
• Analysis and optimization in industries that use heating or cooling in process equipment.

It is also vale noting the increasing use of CFD in biomedical applications. Its application to the study of fluid flow in the human body is a trend and could grow considerably over the next few years.

A great example of the application of CFD in the automotive field, carried out by Kot, is the aerodynamic modeling of a racing prototype with the aim of developing a rear wing to increase downforce. With the design of the wing configuration ready, it was possible to simulate it and the result was an increase in downforce values of 75%.

Figure 3: Aerodynamic simulation on a racing prototype - SOURCE: Kot Collection.

Another interesting situation is the thermofluid dynamic study of equipment that is part of a dedusting system. Kot's study was based on an analysis of the behavior of the water flow inside the cooling pipe circuit and the distribution of temperature and pressure in the pipe. Finally, the different rates of heat transfer between the fluids and the structure were compared. 

Figure 4: Temperature distribution along the pipe - SOURCE: Kot Collection.

However, applications should not be limited to the main industries. Computational fluid dynamics can be used in projects and analysis in the most diverse sectors involving fluid handling.

Why use CFD tools?

The option of using CFD software can greatly facilitate the development of new projects that use heat and fluids in their production process, as well as helping to obtain solutions for these processes. This is because, without computer simulations, it would be necessary to build several prototypes for analysis, which would make engineering more costly and time-consuming.

Computational Fluid Dynamics allows tests to be carried out in different scenarios by changing parameters. In this way, it is possible to see which ones would perform poorly and find the ideal scenario more easily. As a result, the prototype is only built for the models in which good performance has been achieved.

In addition, the construction of prototypes can be financially unfeasible or difficult to access, depending on the system being analyzed. This is not the case with computational fluid dynamics. The use of CFD tools makes it possible to analyze phenomena that occur in internal and confined spaces, where a visualization of the phenomenon studied in a physical model would not be possible or too expensive.

All of this makes it possible to reduce the time spent on the project, thanks to identifying faults early on. It also reduces costs because, as explained above, making changes to the simulation is cheaper than building a new prototype.

Not just for projects, CFD is also essential for checking the operation of existing systems. Clogging, high temperatures, high pressures and low yields are common problems in industry, and the cause can be identified through simulations. Finding solutions in these cases is essential to avoid system breakdowns or production stoppages.

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FAQ

1. O que é a tecnologia CFD e em quais princípios físicos ela se fundamenta?

CFD (Computational Fluid Dynamics, ou Fluidodinâmica Computacional) é uma ferramenta computacional voltada para a solução numérica de problemas que envolvem a movimentação de fluidos (líquidos e gases) e trocas térmicas. Sua base teórica fundamenta-se nas leis da termofluidodinâmica, aplicando o Método dos Volumes Finitos (FVM) para resolver as Equações de Navier-Stokes (que regem a conservação de massa, quantidade de movimento e energia no domínio estudado).

2. Quais são as três etapas fundamentais para a realização de uma simulação CFD?

Toda análise em CFD é estruturada em uma sequência rigorosa de três fases:

1. Pré-processamento: Definição do domínio geométrico de estudo, geração e refinamento da malha de volumes de controle (discretização do espaço), além da atribuição das propriedades do fluido e das condições de contorno (como pressões de entrada, velocidades e temperaturas);

2. Simulação (Processamento): Solução iterativa das equações diferenciais pelos algoritmos do software para determinar variáveis de interesse como velocidade, pressão, turbulência e temperatura em cada volume de controle;

3. Pós-processamento: Análise crítica dos resultados por engenheiros especialistas, com extração de gráficos, vetores de escoamento, mapas de gradiente e vídeos tridimensionais para validação do sistema físico.

3. Quais setores da indústria mais utilizam a Fluidodinâmica Computacional?

De acordo com dados de mercado da Resolved Analytics citados no artigo, a distribuição de usuários por setor industrial destaca-se da seguinte forma:

• Setor Automotivo: 20% dos usuários;

• Serviços de Engenharia Consultiva: 18% dos usuários;

• Setor de Energia e Usinas: 10% dos usuários;

• Aeroespacial: 10% dos usuários.

Há também uma expansão crescente na aplicação em tecnologias biomédicas, como o estudo do escoamento sanguíneo e dinâmicas respiratórias no corpo humano.

4. Como a Kot Engenharia aplicou CFD para otimizar o desempenho de um protótipo de corrida?

A equipe de engenharia utilizou a modelagem aerodinâmica em CFD para desenvolver e posicionar uma nova asa traseira em um protótipo de competição. Por meio de testes virtuais da geometria e do comportamento das correntes de ar, atingiu-se um incremento de 75% no valor de downforce (força descendente que aumenta a aderência dos pneus nas curvas), otimizando a estabilidade e a velocidade do veículo sem a necessidade de múltiplos testes em pistas reais.

5. De que forma o CFD foi aplicado no diagnóstico de um sistema de despoeiramento?

Em um estudo termofluidodinâmico voltado para a indústria pesada, o CFD foi utilizado para avaliar o circuito de tubulações de resfriamento de água em um sistema de despoeiramento. A simulação permitiu:

• Mapear o perfil de velocidade e pressão do fluxo d’água no circuito interno de tubos;

• Identificar os gradientes e a distribuição de temperatura ao longo da tubulação;

• Determinar e comparar as taxas de transferência de calor entre a estrutura metálica e o fluido refrigerante.

6. Quais são as principais vantagens econômicas e operacionais de adotar o CFD na indústria?

• Redução Drástica do Time-to-Market e Custos: Evita a construção de múltiplos protótipos físicos caros e demorados, permitindo simular dezenas de geometrias e cenários operacionais no ambiente virtual antes da fabricação;

• Acesso a Regiões Confinadas: Permite visualizar fenômenos térmicos e de escoamento em espaços internos ou ambientes agressivos onde a instalação de sensores físicos é inviável;

• Diagnóstico e Troubleshooting de Plantas Existentes: Identifica com precisão a causa raiz de problemas como entupimentos, altas perdas de carga, sobreaquecimentos localizados e baixos rendimentos operacionais em equipamentos já em produção.