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Workbench MeshingANSYS 12.0Workbench MeshingANSYS 12.0
Erling EklundBen KlinkhammerErling EklundBen Klinkhammer
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Workbench MeshingIntroductionWorkbench MeshingIntroduction
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Workbench Meshing Overview
• Workbench process automation:– Physics-aware meshing
– Meshing in batch – Parametric/Persistent meshing
• Adding controls for meshing flexibility:– mesh type/method– mesh sizing
– mesh alignment– mesh quality
– mesh feature capturing
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Workbench process automation
• Meshing comes as a cell of a Workbench Analysis System (Mesh/Model)
• Or as it’s own Component System.
• Regardless of what System the Mesh/Model cell is invoked from the meshing tools are the same
• However, the meshing defaults are based on the physics preference of the system
• The mesh is provided to any downstream system– Downstream systems can be linked to the Mesh
cell of any system
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Physics-aware meshing
• There are four physics preferences in the Meshing application, each using appropriate defaults for that physics
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Meshing in batch
• Because the meshing is highly automated, the meshing application can be run in batch and a user can essentially skip the meshing step. For example:
For demonstration purposes we will use a Mesh system, but keep in mind any system could work in essentially the
same way.Create a geometry, or load an existing
geometry
The Geometry cell is checked off when the file is
attached
Use Update to generate the mesh
in batch,Status monitor gives progress
When meshing is complete, the Mesh cell is checked off, the user could
then proceed to the simulation setup, or Edit
the Meshing application to visualize the default mesh
Let’s view the default mesh in
the Meshing application
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Parametric/Persistent meshing
• In the following slides, we will see how mesh methods and mesh controls can be inserted to control the properties of the mesh.
• These controls persist with any geometry changes.
• The process of updating the mesh is the same as in the batch meshing – Added controls continue to apply
– Well controlled mesh is automated for subsequent design iterations in batch
• This makes parametric/persistent meshing inherent to the process
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Adding Controls for Flexibility
• As demonstrated, Meshing in Workbench is designed to be invisible to the user
• However, since a well controlled mesh is often required for higher solution accuracy and efficiency, there is a great deal of flexibility to control:
– mesh type/method– mesh sizing
– mesh alignment– mesh quality– mesh feature capturing
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Adding Mesh Controls
• Let’s look at an assembly model:
Global controls: Physics preferences, sizings, inflation, etc.
• You can see in this case that Workbench automatically assigns:
• Physics based sizing
• Interfaces between parts
• User can go into these defaults and adjust as they see fit.
Contact is automatically
defined between parts
Mesh object: additional controls
can be inserted
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Default meshing:
Sweepable parts can be
found/displayedSome parts are
meshed with general sweep
Some parts are meshed with
patch conforming tetrahedral method
Adding Mesh Controls
• Mesh Methods:• Parts are meshed as
appropriate, hex where possible, else tets
• User can insert mesh methods to override the defaults.
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To improve the mesh we can add
some mesh controls
Let’s see how we can coarsen mesh
in non-critical regions
Mesh is refined to respect each face
Grouped faces become
1 Virtual Face
Mesh walks over details
Adding Mesh Controls
• Mesh Controls (Virtual Topology):
Virtual Topologies can be created
automatically, or manually as shown here.
• Geometry and mesh defeaturing tools are available to reduce the element/cell count in non-critical regions
• Manual virtual topologies help user control which features to capture
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Let’s take a look at Automatic Virtual
Topologies.
Let’s hide all parts but the piston
Let’s examine ways to quickly
defeature this part
Mesh without Virtual Topogies
Automatic Virtual Topologies
Mesh after automatic
Virtual Topologies
Adding Mesh Controls
• Mesh Controls (Auto VT):
Notice mesh ignores smooth boundaries but captures hard
boundaries
• Automatic virtual topologies can be created and then user can edit these manually for optimum control
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Now let’s apply a body sizing to
improve uniformity of
mesh
Insert body sizing,
cross hatch represents
size
Resulting mesh
Adding Mesh Controls
• Mesh Controls (Sizing):• Sizing controls are available
at the body, face, edge, and vertex level
• Other sizing controls include:
• Sphere of influence• Body of influence• Curvature/Proximity
sizing
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Now let’s see if we can remove
some other small unwanted
features
Notice bad mesh in areasInsert manual pinch controls to remove unwanted features
Manual pinch feature removes features at mesh level allowing for easier simplification than geometry level
for some configurations. Like Automatic Virtual Topologies,
there is Automatic Pinch
Adding Mesh Controls
• Mesh Controls (Pinch):• If Virtual Topologies (VTs)
aren’t enough for geometry simplification, pinch features can further simplify the model
• The pinch controls use mesh based defeaturing and can be applied manually or automatically like VTs.
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The face mesh
structure can be changed by
adding mapped face
controls
Select face(s) to have a mapped
mesh
Face is meshed with
mapped quads split to tris
Adding Mesh Controls
• Mesh Control (Mapped Face):
Since the face has a cutout, sub-mapping is done to get a mapped mesh
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The bolt is an important aspect
of this model. Refining the mesh
and using hex elements will
improve results
Let’s look at just the bolt
Default tet mesh Hex mesh would improve solution
accuracy
Add Virtual Faces to aid in hex
meshing
Add MultiZone method for pure
hex meshPure hex mesh is
able to be generated
Apply body sizing with smaller mesh
size
Refined hex mesh for better accuracy
Section plane of hex mesh
Adding Mesh Controls
• Mesh Methods and Controls:• This example shows how a
variety of mesh controls and methods can combine to provide great flexibility
• There is an extensive list of additional mesh methods/controls, but this gives a general overview of the use of these controls.
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Adding Controls for Flexibility
• The controls that were added are stored as objects in the mesh folder
• These controls persist to design changes– If a new design makes it impossible to update controls
from a previous design, the software puts a ? to indicate a control that has become invalid and should be inspected by the user.
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12.0 Feature Update12.0 Feature Update
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R12 Meshing Goals
• Next generation solution for GAMBIT and CFX-Mesh customers:– Follows Workbench guiding principles:
Parametric, Persistent, Highly-Automated, Flexible, Physics-aware, Adaptive Architecture
• Integration of TGrid and ICEM CFD meshing methods to increase power and flexibility of Workbench meshing solution
• Further evolution of meshing tools and technologies for Mechanical, EMAG, Explicit and CFD meshing
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Mesh controls
• Physics-based mesh controls• Support for CAD instances• Arbitrary mesh matching• Mapped mesh controls
– Corner controls to help define mapping strategy
• Pinch feature• Advanced Size Functions• Interface/contact handling between parts
– Contact sizing– Arbitrary mesh matching– Patch independent option: Match mesh where
possible
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Fluids Physics-based
mesh controls
• R12 first release targeting Fluent needs using Fluent meshing components
• Better CFD meshing defaults:– Automated CFD meshing process
• CFD/Fluent shape check controls
– Support for FLUENT boundary conditions, mesh size functions, etc.
– Improved inflation controls • Program controlled inflation• Smooth transition controls
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CFD Meshing
• Automated CFD meshing process:– CFX/Fluent solver preference added to tailor mesh
based off solver
– Added appropriate defaults– Added “Skewness” quality metric for FLUENT
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CFD Meshing
• 3D Bodies (Zones) Solid/Fluid: – CAD parts can be marked in DM as Air/Fluid
– Display of Solid/Fluid indicates type– FLUENT will use this for 3D Zone creation
• 2D Zones– Named Selections (for Boundary Conditions) pass through
Workflow (CAD�Geometry�Meshing�FLUENT)
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Improved CFD inflation
• Program Controlled Inflation: – Will inflate off all faces that are not in a named selection– Or user can inflate off a named selection, or insert inflation control
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Structural Physics-based
mesh controls
• Efficient meshing for physics:
– Rigid body contact meshing• Edges/Faces in contact area are
only things meshed
• Centroid defined for mass
– Gasket meshing• Quadratic edges/faces on top and bottom • Linear edges/faces on side
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Rigid Body Meshing (3D)
• Only faces of rigid body in contact get meshed
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Rigid Body Meshing (2D)
• Only edges of rigid sheet in contact get meshed
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Gasket Elements
• More automated way of meshing Gaskets
Quadratic faces on source/target
Linear faces on sides
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Support for CAD Instances
• Instances defined in Pro/E, Solidworks, etc. are used in meshing (geometry/mesh is copied)– Geometry transfer/meshing speedup
• Selection by instance
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Meshing of Instances
• Meshing speed improvement– 58% time reduction in meshing
• Instance selection:
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Meshing of Instances
• Overall speed improvements1. Geometry transfer: 77% time reduction2. Meshing speedup: 55% time reduction3. Total import and meshing of this model reduced from
533 to 192 seconds (64% time reduction)
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Arbitrary mesh matching
• Match control to copy mesh to similar topologies based off 2 coordinate systems
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Improved Mapped Control
• Support for side/corner controls to define strategy for sub-mapping
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Pinch Feature
• Mesh pinch out feature added for defeaturing at mesh level• Automated based off shell thickness or user defined tolerance
• Works in conjunction with Virtual Topologies to simplify meshing constraints
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Automatic Pinch Generation
• With automatic pinch generation user can pinch features under a defined size and remove small features from the mesh
Use shell thickness, or define a tolerance
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Manual Pinch Feature
• With Auto-pinch, software figures out basic areas to pinch• User can then add additional manual pinch controls
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Shell Example
w/out pinch feature w/pinch feature
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Shell Example
w/out pinch feature w/pinch feature
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Solid Example
w/out pinch feature w/pinch feature
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Advanced Size Function
• Incorporate Fluent size function
• Curvature based sizing controls • Proximity based sizing controls
• Body/Face/Edge sizing
• Improve consistency of controls across mesh methods
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Advanced Size Function
• Advanced size functions added for explicit control for:– Curvature Normal Angle
– Number of cells in a thin gap– Minimum Size
– Maximum Face Size– Maximum Tet Size– Growth Rate
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Advanced Size Function
• Standard Size Function
• Advanced Size Function
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Advanced Size Function
• Standard Size Function
• Advanced Size Function
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Advanced Size Function
• Standard Size Function
• Advanced Size Function
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Advanced Size Function
• With curvature
• With curvature and proximity (5 cells in gap)
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Scoped sizes
• Scoped size controls:– Edge– Face
– Body
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Body of influence
• Bodies can be used to define a region of influence
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Interface/Contact modeling of parts
• There are several techniques to model the common faces between parts
– As parts– As multibody part with
common nodes
– As multibody part with duplicated nodes• Shared/matched face(s)• Shared/matched edge(s)
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Interface/Contact modeling of parts
• There are several techniques to model the common faces between parts
– As parts– As multibody part with
common nodes
– As multibody part with duplicated nodes• Shared/matched face(s)• Shared/matched edge(s)
2 faces
1 face
2 faces
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Interface/Contact modeling of parts
• As Parts:
– 2 Faces at contact region– Parts meshed separately
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Interface/Contact modeling of parts
• As Multibody part:
– No contacts, since parts share common face
– Multibody part meshed as a whole
DM Attribute
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Interface/Contact modeling of parts
• As Multibody part (w/Imprints):
– Contacts, since each body has a face
– Multibody part meshed as a whole
DM Attribute
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Interface/Contact modeling of parts
• Depending on how the user wants the interface modeled/meshed between two bodies, user can choose appropriate option
• Using the imprint option in a multibody part ensures a common interface between 2 parts
• If using Imprint option, there are a few controls to keep in mind:– Contact sizing– Match control: Arbitrary– Patch independent option:
Match mesh where possible
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Interface/Contact modeling of parts
• Contact Sizing– Drag and Drop Contact Region into Mesh folder
– Influences the mesh sizing between parts
Mesh isn’t always coincident
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Interface/Contact modeling of parts
• Match Control: Arbitrary
– Enforces same node spacing based off common topology between parts
Undesired penetration of individual parts
Desired coincident nodes with multi-body part using IMPRINT method and Match control
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Interface/Contact modeling of parts
• Patch Independent option: Match mesh where possible
– If “yes” software will try to enforce common nodes between common faces of a multibody(imprint) part
– If “no” software will not try to enforce common nodes between common faces of a multibody(imprint) part
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Meshing ImprovementsMeshing Improvements
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Surface meshing
• Improved surface mesh quality– Eliminate poor-quality mesh clusters
– Improved curvature based refinement controls
• 2D inflation controls
– 2D Planar models
– Shell models
• Respect new sizing controls
• Improved auto-blocker robustness/consistency
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Meshing Update
More uniform surface mesh:R11 R12
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Meshing Update
More uniform surface mesh:R11 R12
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Meshing Update
More uniform surface mesh:
R12
R11
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2D inflation controls
• 2D planar model
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2D inflation controls
• 2D shell model
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Tetrahedral meshing
• Mix and Match Tetrahedral and Sweep methods
• TGrid Tetra AFT meshing method• Improved patch independent robustness
• Improved consistency of controls
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Combination of methodsMapped bodies
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Tetrahedral meshing
R11 R12
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Inflation
• Refactor inflation for ease of use – best of what Fluent, CFX and ICEM CFD have to offer
• Improved Multibody part handling
• Smooth Transition • Collision avoidance:
– Stair-stepping – Layer compression
• Preview Inflation• Pre vs. Post inflation• Sweeping:
– Pure hex or wedge
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Inflation: Multibody partsMapped bodies
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Smooth Transition:
• Smooth Transition option added to provide layer by layer smoothing to achieve good transition to tet mesh
• Transition ratio controls inflation to tet transition
CFX Default Fluent Default
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Inflation: Stair-stepping vs.
Compression
Layer Compression: Stairstepping:
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Inflation: Stair-stepping vs.
Compression
Layer Compression: Stairstepping:
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Inflation: Stair-stepping vs.
Compression
Layer Compression: Stairstepping:
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Preview Inflation:
• Inflation preview added to help identify possible problems with inflation
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Hex Meshing
• In Workbench there are several methods for hex meshing:– Default Sweep– Thin Sweep
– Hex Dominant
– MultiZone
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Hex Meshing in R12
• R12 brings the following improvements: – Default Sweep
• Improved inflation
• More control over mesh type: quad, quad/tri, tri
– Thin Sweep• Support for body level (multibody parts)• Multiple elements through thickness for parts
– MultiZone• New option that extends all hex or hex dominant
meshing to more complex parts
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Sweep: Inflation
• Inflation with sweeping generates a hex mesh
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Sweep: Face mesh type
• Option for free face mesh type in sweep
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Thin solid sweep meshing
• Improved robustness• Works at body level with other methods
Thin Sweep
General Sweep
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Thin solid sweep meshing
• Multiple elements through thicknessfor single body parts
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Thin solid sweep meshing
• Multibody part meshing
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Swept meshing - MultiZone
• MultiZone sweep meshing– Automatic geometry decomposition– Multiple/single source/target
– Mapped/Free meshing
– Inflation
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MultiZone
• Automatic geometry decomposition– With the sweep method, this part would have to be sliced into 5
bodies to get a pure hex mesh
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MultiZone
• Automatic geometry decomposition– With MultiZone, this can be meshed with pure hex mesh without
any geometry decomposition.
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MultiZone
• Multiple source imprinting– Imprints from multiple sources and cross sections can be swept
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MultiZone
• Multi-source/multi-directional imprinting
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MultiZone
• Multibody part handling– Multiple parts are meshed with conformal mesh at shared interface.
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MultiZone: Multiple Zones
• Free decomposition– Face topology is used to construct solid regions or blocks.
Each block can be swept independently provided the mesh is conformal.
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MultiZone: Free decomposition
• Using Free Mesh Type, MultiZone can be used to get a hex mesh where possible, and free mesh everywhere else, without slicing.
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MultiZone: Free decomposition
• MultiZone unstructured/free regions can be filled with:
Free Mesh Type = Tetra
Free Mesh Type = Hexa Dominant
Free Mesh Type = Hexa Core
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MultiZone with inflation
• MultiZone with inflation
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MultiZone with inflation
• MultiZone with inflation and free blocks
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Mesh Metrics
• Mesh metrics added– Mesh level, part level and body level
• Worst element display
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Performance & Data-integration
Improvements
• Performance Improvements:– Multibody part mesh memory utilization & speed
improved
– General memory reduction and speed improvements
• Improved Data-Integration:– Named Selections stored to ACMO for use in CFX-Pre– Fluent output improved
– CGNS output added– Write ICEM CFD Files option for easier transfer to
ICEM CFD.
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