FLUID Simulation Software for Complex Fluids

FLUID is our extremely robust flow solver that correctly calculates especially complex rheologies (deformation and flow behaviour of substances) of multiphase flows (miscible and immiscible) in and around porous media. Thus, the software is used to simulate and optimise manufacturing and processing processes of polymers, particle and fibre suspensions, foams, concrete and much more.

To be able to provide simulation solutions for such a wide range of materials and physical effects, we have developed FLUID to ensure the rapid implementation of new rheological models and their robust and efficient solution of any multi-physics systems for industrial applications.

With FLUID, you can model and simulate the following flow dynamic phenomena, among others:

Single-phase and multi-phase flows (mixing models or non-mixing fluids with surface tension, Navier-Stokes equations) for mixtures and suspensions
Incompressible and compressible flows (fluids, gases)
Complex rheology models (shear rate, temperature and pressure dependent, thixotropy), e.g. for foams, concrete, casting compounds, etc.
Fiber orientation dynamics and fiber concentration for fiber-reinforced suspensions
Foaming and deflation through coupling with FOAM
Single- and multi-phase flow through porous media (Darcy, Brinkman, Richards equations)
Bulk material flows through coupling with GRAIN
Thermal coupling with respect to all physical quantities
Reactive concentration equations (e.g. hardening reaction, also filtration models)
Reactive mass transfer by coupling with PoreChem
Turbulence models (algebraic models, two-equation models)
Filtration by coupling with FilTEST

Our Software FLUID:

enables easy and fast implementation of individual rheological models
robust coupling of additional physical effects such as temperature, concentration equations, reactions, fibre orientation, etc.
includes a user-friendly graphical interface
offers an integrated pre-processing tool for CAD-3D data
allows interactive post-processing
uses multi-core computer technology and runs on Windows and Linux operating systems

Flow Simulation of the Electrolyte Filling of Battery Cells

Time course of local and global electrolyte saturation during the wetting process in a lithium-ion cell – simulated with our FLUID simulation software.

A time-consuming production step in cell manufacturing is the wetting process that follows the introduction of the liquid electrolyte into the cell housing. The electrolyte – driven by capillary forces and external pressures – must penetrate the pore structure of the electrodes and the separator as homogeneously as possible and displace the air. The two-phase flow in porous media can be calculated effectively with FLUID in order to calculate the filling time required for this process, the influence of external conditions and the homogeneity of the electrolyte distribution.

Simulation of Injection Molding Processes for Fiber Reinforced Materials

The fiber reinforcement of polymer materials is a very important technique in the production of lightweight construction materials. The potential of these materials can only be exhausted if the fiber direction during the production process can be predicted with high precision.

The software FLUID implements a highly developed, physically based modeling method that takes account not only of the influence of the flow on the fiber concentration and orientation, but also the return of the fiber concentration and orientation to the rheological behavior of the suspension.

Injection molding simulation of polymeric material with 30% glass fiber content.

Simulation Example: Injection Molding Simulation of an Airbag Housing

Spatially resolved information about locally existing:

pressure
velocity
fiber orientation
fiber concentration
Spread of the flow front
fluid temperature

Anwendungsbeispiele mit unserer Software FLUID

EU-Project ALMA

ALMA’s ambition is to develop a new type of battery-electric vehicle structure for passenger cars. The aim is to reduce the weight of the vehicle structure by up to 45 percent.

Potting Process Simulation of Electronic Devices

In the project SOVEB we simulate this process with FLUID so that companies can optimize their production steps.

Characterization and Modelling of Thermoplastics

We contribute our simulation expertise to the AiF project.

Simulation of the Production of Batteries

We simulate battery production processes to make them as efficient as possible without negatively affecting the product properties.

FLUID – Simulation Software for Complex Fluids

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