Siemens Star CCM+ 2502.0 (20.02.007) with Verification Suite & Tutorials

Improved battery safety simulations
Battery manufacturers face the critical challenge of ensuring safety, particularly the risk of thermal runaway during short circuits or other failures. Traditional modeling tools have struggled to accurately predict these complex chemical and electrochemical reactions.

To address this, the latest release of Simcenter STAR-CCM+ 2502 features the “Homogeneous Multiphase Complex Chemistry Model,” designed to provide a detailed simulation of battery cell behaviors under adverse conditions. Although a general model, the homogenous multiphase complex chemistry model can allow designers to explicitly model the fundamental reactions that are triggered during a thermal runaway event, providing detailed insight into the electrochemical and thermal response to a short circuit or nail penetration incident in a battery. This allows engineers to gain deeper insight and design batteries with high degrees of safety without the cost of physical testing. This improved capability ultimately helps in preventing accidents, enhancing consumer trust, and complying with stringent safety regulations.

Advanced corrosion analysis


Corrosion is a pervasive issue across many industries, leading to significant maintenance costs and equipment downtime. Traditional analysis tools often fail to predict the onset and progression of corrosion effectively, leading to unexpected failures. Simcenter STAR-CCM+ 2502 integrates Corrdesa’s Corrosion Djinn Database for advanced corrosion analysis. High-quality polarization data describes the relationship between the potential drop at the material interface and the specific electric current and are important inputs to the Electrodynamic Potential solver of Simcenter STAR-CCM+. The Corrdesa Corrosion Djinn material database hosts collection of data, including surface polarization, derived through rigorous experimental quantification.

This feature offers engineers robust tools to simulate and predict corrosion under various environmental conditions, using high-fidelity data. As a result, industries can proactively design out potential corrosion issues, extend equipment lifespan, and significantly reduce maintenance costs.

Accurate modeling of complex fluids
In the food processing industry, accurately predicting the behavior of complex fluids, such as mayonnaise, which exhibit non-Newtonian characteristics, presents significant challenges. These fluids can behave like a solid at lower shear stress levels before moving like a fluid at elevated stress levels. This behavior is complicating production processes and quality control. In response, Simcenter STAR-CCM+ 2502 introduces Generalized Non-Newtonian Fluid Models, namely the Yield Stress Threshold and Yielding Viscosity for Non-Newtonian Cross and Carreau-Yasuda laws. These advanced viscosity models capture the intricate behaviors of such complex Bingham fluids under stress more accurately than ever before.

By simulating these fluids’ behaviors, engineers can precisely predict how they will act in the real world, thereby optimizing manufacturing and filling processes.

Uniform spray coverage for various applications
Achieving uniform spray coverage is imperative in industries ranging from agriculture to automotive manufacturing, where it impacts everything from crop yields to paint finishes. Variability in this process can lead to inefficiency and wastage, posing a substantial logistical challenge. In many such cases the flat fan nozzle Injector provides a uniform, flat spray pattern of a thin, fan-shaped sheet of liquid. In agriculture, flat-fan nozzles are e.g. essential for providing uniform spray coverage in aerial pesticide applications. Similarly, these types of injectors are used for cleaning and degreasing, coating and painting, cooling and humidifying, lubrication, surface Treatment and dust control.

The Flat Fan Nozzle Injector model in Simcenter STAR-CCM+ 2502 makes it easy to set-up such injectors quickly and easily. Accurate results are achieved by the Linear Instability Sheet Atomization (LISA) method. This technology ensures uniform application across varied operations, improving resource utilization and process efficiency. Ultimately, this leads to reductions in waste and costs, contributing to more sustainable and eco-friendly production practices.

Faster adjoint-based optimization
Adjoint optimization methods rely on a series of multiple simulations, in which the adjoint solver is executed at each step. Considering that the adjoint solver is very expensive in terms of computational resources, these optimization studies easily reach the limit of feasibility.

The algorithmic improvements made in Simcenter STAR-CCM+ 2502 to the adjoint solver with second order discretization drastically improve the convergence rate, thus lowering significantly the total turnaround time. Furthermore, this improvement reduces the need for falling back to first order adjoint discretization for a robust convergence, hence improving the accuracy of the computed adjoint sensitivities.

The reduced simulation time and higher-quality results, enables engineers to explore and realize optimal designs much more efficiently and effectively.

Fast and scalable simulations of moving objects
Many applications, such as paint dipping and bottle filling, involve the movement of a solid body that affects the motion of a fluid. To capture the motion the overset meshing approach offers both flexibility and accuracy by utilizing a background mesh combined with a body-fitted moving mesh. This configuration ensures high mesh quality near the boundaries of moving objects, leading to precise results.

However, this accuracy comes at the cost of increased complexity, which results in higher computational expense and suboptimal scaling.

The new Virtual Body approach that is available in the new version of Simcenter STAR-CCM+ 2502 eliminates the need for two separate meshes and provides a more cost-effective, scalable, and easier-to-setup alternative to overset for various validated application. Furthermore, it also offers a more stable solution in scenarios involving tight gaps.

Faster sliding mesh simulations on GPUs and CPUs
Many applications like external vehicle aerodynamics with rotating wheels, require rigid body motion (RBM) to capture transient, unsteady flow phenomena. This employs the sliding mesh interfaces, also known as non-conformal interfaces. Traditionally, in such scenarios the interface intersection is performed at every time step. Because of the complexity of the intersector algorithm and its high interface data requirement, the performance of the sliding meshes when deployed on large core counts or used with GPUs, has been restricted.


The new Boundary Interface Caching strategy that is available in the new version of Simcenter STAR-CCM+ 2502 allows for the interface data to be calculated only once and reused for the subsequent time steps, thereby significantly reducing sliding mesh simulation time on both CPUs and GPUs.

Faster Vehicle Thermal Management simulations on GPUs
The automotive industry is constantly pushed to enhance energy efficiency while managing the heat generated during operation, a demanding aspect of vehicle design. At the same time the benefits of GPUs to solve CFD simulations faster and in a more energy efficient way are without a doubt.

With Simcenter STAR-CCM+ 2502 we are further expanding the range of thermal management applications you can tackle on CPUs and GPUs through the porting of more GPU-native solvers: The new GPU-native Actual Flow Dual Stream Heat Exchanger method leverages GPU acceleration to perform complex VTM simulations. Further applications covered include faster CHT simulations of headlamps with the GPU-native segregated and coupled energy solvers for solid shell regions as well as faster Batteries CHT and Electronics cooling analyses thanks to GPU-native Orthotropic, Anisotropic and Transverse Isotropic material property methods.

This will increase your throughput and hardware options while a unified solver architecture for CPU and GPU ensures consistent results. As a result, you can perform more thermal management simulations in less time, enhancing productivity and accelerating the development cycles.

Native automation of advanced aerodynamics and turbomachinery workflows
Complex simulations involving multiple physical phenomena or varied operational stages can be cumbersome to set up, often requiring intricate scripting and setup. The Stages feature within Simcenter STAR-CCM+ streamlines this process. It provides a user-friendly interface for defining and managing simulation stages, cutting down setup time and allowing engineers to focus more on analysis and less on setup.

With Simcenter STAR-CCM+ 2502 stages become available for a further extended range of applications: With the support of harmonic balance and harmonic balance turbulence models you can tackle turbomachinery simulation workflows with ease. Stages support for Moving Reference Frame and Rigid Body Motion simplifies workflows with a change from steady state to transient, such as external aerodynamics with rotating parts.

The Stages method not only accelerates the simulation workflow but also significantly boosts productivity and mitigates potential setup errors.

Streamlined data exchange for E-Machine design
Collaboration between electric machine designers and computational fluid dynamics engineers is often hindered by incompatible data formats and systems. The “Simcenter Data Exchange (SCDX)” format, newly implemented in Simcenter STAR-CCM+ 2502, resolves these issues by ensuring smooth and efficient data transfer across different software tools and teams. This integration capability facilitates a more cohesive workflow, reducing errors, and enabling faster project completion through improved collaboration.

These are just a few highlights in Simcenter STAR-CCM+ 2502. These features will enable you to design better products faster than ever, turning today’s engineering complexity into a competitive advantage.

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