When designing new products, engineers must validate their decisions based on robust evidence. There comes a point in the design process where selecting the right concept—whether for economic, performance, or aesthetic reasons—is critical.
Before the digital age, engineers relied on assumption-based calculations and intuition. While this approach could be refined through trial and error, it was time-intensive and costly. Today, engineers have access to simulation-based tools, such as Computational Fluid Dynamics (CFD), which provide precise, efficient, and cost-effective insights.
What is Computational Fluid Dynamics?
Computational Fluid Dynamics is a powerful simulation tool that models the three-dimensional behaviour of fluids under specific conditions within complex physical volumes. These simulations allow engineers to:
- Analyse fluid flow and heat transfer
- Solve conservation equations for mass, momentum, and energy
- Understand compressible and incompressible flows
- Apply boundary conditions and observe laminar or turbulent flow behaviours
The operating environment of the component defines the conditions for the simulation, while the designer optimises the structure to ensure efficient fluid movement within the available space. Numerical methods, such as solving partial differential equations like the Navier-Stokes equations, underpin CFD simulations, offering engineers a detailed view of fluid behaviour over space and time.
The Synergy Between CFD and Additive Manufacturing
The combination of Computational Fluid Dynamics and Additive Manufacturing (AM) is revolutionising engineering design. AM enables the creation of intricate geometries that traditional manufacturing methods cannot achieve, while CFD ensures these designs are optimised for efficiency and performance. Together, they offer:
- Rapid prototyping and reduced lead times
- Design freedom to create lightweight, complex structures
- Cost-effective iteration of high-resolution models
At Domin, this synergy has been pivotal. For example, AM allowed the production of highly complex valve galleries, while CFD simulations validated the designs digitally before manufacturing. This approach ensures that designs are not only innovative but also reliable and efficient.
CFD in the Fluid Power Industry
In the fluid power sector, CFD has become indispensable. Combined with Additive Manufacturing (AM), it enables rapid design iteration and performance validation. Engineers can test and refine designs digitally, significantly reducing the time and cost of physical prototyping. At Domin, CFD simulations have been used to address complex problems, such as:
- Identifying cavitation risks in pump designs
- Reducing inefficiencies in fluid pathways within valves
- Optimising flow-force dynamics for torque reduction
For instance, the image below demonstrates fluid streamlines within a static CFD model of a valve body. By simulating real-world conditions, engineers can pinpoint inefficiencies and explore design improvements.
One notable success story involved the development of a miniature rotary-actuated valve. Using CFD modelling, Domin achieved a 40% reduction in torque through flow-force optimisation while maintaining flow capabilities. This outcome underscores the transformative potential of CFD and additive manufacturing in driving high-performance, cost-effective solutions.
Why CFD is a Game-Changer
CFD empowers engineers to make informed decisions rapidly. It enables the evaluation of alternative solutions, whether for achieving specific flow targets or managing stress for fatigue resistance. High-resolution simulations, coupled with post-processing analyses, help engineers navigate complex design challenges efficiently.
At Domin, the iterative design process is streamlined by combining CFD analysis with AM. This approach allows single engineers to holistically address design specifications, delivering innovative, high-performing products without unnecessary delays or costs.
Driving Innovation Through CFD
The integration of CFD into the design process is a step-change innovation, providing engineers with actionable insights into:
- Modelling fluid flow under various conditions
- Analysing flow and heat transfer dynamics
- Simulating real-world performance to validate design choices
The combination of CFD and additive manufacturing ensures Domin’s products are not only optimised for performance but also aligned with modern demands for efficiency and sustainability.
Learn More
Interested in how CFD drives innovation at Domin? Explore our whitepaper on Transforming Motion Control or check out our article, Evolution or Revolution, to see how we’re pushing boundaries in fluid power engineering.
