Design Optimization and Automation for port development

Anthony Coffey (Harley Davidson)

CHALLENGE - Port development used to be a very manual and time consuming process: iterative process utilizing engineering; prototypes; test; grid; clay. Process was not optimized and work continued even after production. Process was not optimized and work continued even after production. Optimization is extremely beneficial for power, fuel economy and emissions.

SOLUTION - Sculptor and Star-CCM+ software have been integrated in modeFRONTIER for CFD optimization. The optimization involved 7 input variables, 2 objectives needed to be maximized (mass flow and tumble) and mass constraint for model convergence. The mesh deformed designs from Design of Experiments and then the optimization, performed by using MOGA-II algorithm, led to create a Pareto tradeoff curve between mass flow and tumble.












BENEFITS - The use of process automation and optimization technology allowed to achieve: better engine performance (more power / torque); better fuel economy (increased tumble and mixture motion); better understanding of port geometrics and how they affect flow, tumble, and velocity; better set based design (able to select port  through trade-off curve analysis); better engineer efficiency (automated processes allows engineer to be working on other items as the process works in the background; faster development time, reduced prototypes and flow room testing.