Computational Fluid Dynamics (CFD)
Fundamentals, modelling workflow, equations, verification and engineering applications
Mesh + Physics Results
CAD Geometry
BCs + Solver Velocity, P, T
Typical CFD workflow
Engineering Reference / Concept Document
This document is intended as a concise engineering reference. It summarises the operating principle, system
architecture, design inputs, core calculations, verification approach, and major risks.
Computational Fluid Dynamics (CFD) Page 1
1. CFD Fundamentals and Workflow
Computational Fluid Dynamics (CFD) predicts fluid flow, heat transfer and related transport phenomena by
solving discretised conservation equations over a numerical domain.
- Pre-processing: simplify CAD, define the fluid domain, choose dimensionality and create the mesh.
- Physics definition: select material properties, turbulence model, heat-transfer model and any rotating or
multiphase treatment.
- Boundary conditions: prescribe inlet, outlet, wall, symmetry, periodic or moving-wall conditions.
- Solution: iterate the discretised governing equations until residuals and engineering monitors converge.
- Post-processing: review velocity, pressure, temperature, forces, flow rate and derived quantities.
Core engineering equations
Continuity: mass conservation; for incompressible flow, div(V) = 0.
Momentum: rho(DV/Dt) = -grad(p) + mu nabla^2(V) + body forces.
Reynolds number: Re = rho V L / mu.
Dynamic pressure: q = 0.5 rho V^2.
Pressure coefficient: Cp = (p - p_ref) / q_ref.
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2. Meshing and Boundary Conditions
Mesh quality strongly affects both accuracy and solver stability. The finest mesh should be concentrated where
gradients are high rather than applied uniformly everywhere.
Design area Recommended engineering check
Near-wall region Use inflation layers and an appropriate first-cell height for the selected wall treatment.
Wake / jet / separation Apply local refinement where strong velocity gradients are expected.
Curvature and small gaps Resolve geometry only when it materially affects the flow path.
Mesh independence Repeat the solution with successively finer meshes and compare key outputs.
Outlet placement Keep the outlet far enough downstream to avoid contaminating the region of interest.
Turbulence selection
For many engineering flows, k-epsilon is robust for fully developed free-stream flow, while k-omega SST is
commonly preferred when wall behaviour, adverse pressure gradients and separation are important.
Convergence checks
- Residual reduction alone is not sufficient.
- Track mass imbalance, pressure drop, force, temperature or other project-specific engineering monitors.
- Confirm that monitored outputs have stabilised and are insensitive to further iterations.
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3. Typical Mechanical-Engineering CFD Applications
- Pressure-drop estimation in ducts, valves, manifolds and cooling passages.
- Fan and blower flow distribution.
- Electronics and enclosure thermal management.
- Vehicle external aerodynamics and underbody flow.
- Pump, impeller and turbomachinery performance.
- Heat exchangers and conjugate heat transfer.
- Ventilation, HVAC and room airflow.
- Wind loading and flow-induced force estimation.
Example design study
For an enclosure cooling problem, compare inlet position, fan flow rate, vent area and internal component
placement. The useful outputs are peak component temperature, pressure loss and recirculation zones rather
than only a visually attractive velocity plot.
Verification hierarchy
- Hand calculation or analytical estimate.
- Mesh-independence study.
- Sensitivity to boundary conditions and material properties.
- Comparison with experimental or supplier data where available.
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4. CFD Reporting Checklist
A technically strong CFD report makes the modelling assumptions visible and gives enough information for
another engineer to reproduce the analysis.
Report item What should be stated
Geometry Domain dimensions, simplifications and excluded features.
Mesh Element type, cell count, local refinement and quality indicators.
Physics Steady/transient, incompressible/compressible, turbulence and heat transfer.
Boundary conditions Numerical values and physical justification.
Solver Pressure-velocity coupling, discretisation order and convergence criteria.
Results Quantitative values, not only contour plots.
Validation Mesh sensitivity and comparison against an independent reference.
Limitations Assumptions and phenomena not represented in the model.
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