Star CCM+ Set-up

**this page is a work in-progress, and will continue to be updated

Importing File into StarCCM+:

Process Options >> Parallel on Local Host >> Compute Process >> 8 (or 6)

License >> Power On-Demand key >> wait for process

STAR Button >> x_t file

• save SolidWorks file as .x_t file

StarCCM+ Workflow:

1. Import Geometry - surface mesh

   1. File >> Import >> Import Surface Mesh (.x_t) file

      1. Alternatively, import into the 3D CAD editor > provides more control

2. Geometry preparation - imported mesh is often inadequate for sims

   1. Surface Repair (manual)

   2. Surface Wrapper

   3. Geometry Operations (Boolean, split faces)

   4. Mesh Operations (Unite, intersect, extract volume)

3. Specify regions/boundaries

4. Meshing

   1. surface

   2. volume/domain

5. Physics

6. Boundary Condition

7. Solver Settings

8. Data Analysis

   1. reports

   2. scenes

9. Run Simulation

10. Post process result

Resources:

• Found a video for simulating a battery but it is all in Korean:

Set-up:

1. Make sure imported model contains all components - Nickel Strips, SigmaClad, Bus Bars and Battery

2. Assign all-components with material-properties - battery, copper, nickel, etc.

   1. For cell, assign density, specific heat capacity and thermal capacity

   2. Refer to this document: Assembly, Geometry and Material Properties of the Battery Box

3. Set-up a continua - physics model

   1. 3D model, gas, define flow (turbulent vs. laminar),

Defining Regions:

1. Define outline & surface for batteries and busbars

2. Add a region for the battery

   1. Applying appropriate materials to the parts being simulated

Creating Mesh:

1. Create an automated THIN mesh and assign the thin-mesh to the busbars

   1. Select appropriate bass size

   2. Minimum surface size - why did he choose 25%? @Shem Kim + I’m not understanding why he chose the other settings

2. Created separate mesh for cooling

   1. Since we are using air-cooling, is this not-needed?

3. Created a prism mesh

   1. Assuming this is due to the video simulating pouch-cells not cylindrical cells

Volume mesh-pattern:

1. Select all-parts, then execute the mesh

2. Adding a “Weak-Contact Creator”

Configuring Battery-Cells (16:50)

To-do:

• Fix Sigma-Clad & Nickel Strip collision on current CAD

• Upload and save files to Bild

• Re-upload model to StarCCM+

• Follow above-steps to simulate for airflow