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Tutorials
Tutorials show you how to use Simcenter STAR-CCM+ for various applications in a step-by-step format with recommendations for setup, initialization and steps of the solution process specific to the application. Macro and simulation files are available for download for a large proportion of cases.
Multiphase Flow
The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating multiphase fluid flow problems
Smoothed-Particle Hydrodynamics (SPH): Gearbox Lubrication
Gear mechanisms require adequate lubrication for long-term optimum performance and efficiency. Simcenter STAR-CCM+ provides the Smoothed-Particle Hydrodynamics (SPH) model with which you can simulate the flow of lubricant around the parts of a gear mechanism and determine whether adjustments are necessary.
Specifying the Motion of the Gears
The interlocking pinion and gear are counter-rotating, where the pinion spins at a rotation rate of 1222 rpm.

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Tutorials
Tutorials show you how to use Simcenter STAR-CCM+ for various applications in a step-by-step format with recommendations for setup, initialization and steps of the solution process specific to the application. Macro and simulation files are available for download for a large proportion of cases.
- Using Tutorial Macros and Files
  Macros, input files, and final simulation files for a range of tutorials are provided as an optional download package on the Support Center website. These macros and final simulation files are provided as an aid to the written tutorials, so that you can check your final results against the downloaded files, or against a simulation that is built and run using the macros.
- Introduction
  Welcome to the Simcenter STAR-CCM+ introductory tutorial. In this tutorial, you explore the important concepts and workflow. Complete this tutorial before attempting any others.
- Foundation Tutorials
  The foundation tutorials showcase the major features of Simcenter STAR-CCM+ in a series of short tutorials.
- Geometry
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for creating and working with parts and 3D-CAD.
- Mesh
  The tutorials in this set illustrate various STAR-CCM+ features for building CFD meshes.
- Incompressible Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for incompressible fluid flows as well as porosity and solution recording
- Compressible Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for compressible fluid flows as well as harmonic balance.
- Heat Transfer and Radiation
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for heat transfer, radiation, and thermal comfort.
- Multiphase Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating multiphase fluid flow problems
  - VOF: Gravity-Driven Flow
    This tutorial demonstrates how to set up a gravity-driven flow problem in Simcenter STAR-CCM+. It simulates two-dimensional gravity-driven compressible flow through a channel connecting two chambers.
  - VOF: Capillary Effects
    This tutorial demonstrates how to set up a capillary effects problem in Simcenter STAR-CCM+. It simulates two-dimensional forced flow of liquid glycerine through a nozzle and into an air-filled chamber at atmospheric pressure.
  - VOF: Cavitation
    This tutorial demonstrates how to set up a cavitation problem in Simcenter STAR-CCM+. It simulates a two-dimensional forced flow of water through a nozzle and into an air-filled chamber at atmospheric pressure.
  - VOF: Boiling
    This tutorial demonstrates how to set up a boiling problem in Simcenter STAR-CCM+. It simulates water boiling as it flows over a heated surface.
  - VOF: Melting-Solidification
    This tutorial demonstrates how to set up a melting and solidification analysis in Simcenter STAR-CCM+. It simulates the freezing of water in a pipe.
  - VOF: Tank Sloshing with Adaptive Meshing
    To reduce the computational time and resources required for VOF multiphase simulations, Simcenter STAR-CCM+ provides both Adaptive Mesh Refinement (AMR) and Adaptive Time-Stepping. AMR provides adaptation in space and Adaptive Time-Stepping provides adaptation in time. Together, these models improve the resolution of the interface with minimum computational effort by adjusting the mesh and the time-step during the simulation. Additionally, Simcenter STAR-CCM+ offers the Implicit Multi-stepping VOF solver which can be used to decrease computational costs further by sub-stepping the volume fraction transport equation to obtain a sharp interface while allowing for a larger flow time-step.
  - Lagrangian: Particle-Laden Flow
    This tutorial demonstrates how to set up a simple Lagrangian multiphase analysis in Simcenter STAR-CCM+. It simulates a particle-laden flow of air through a partially blocked elbow duct.
  - Lagrangian: Solid Particle Erosion
    This tutorial demonstrates how to set up an erosion modeling analysis in Simcenter STAR-CCM+. It simulates the erosion that is caused by solid particles in a liquid flow.
  - Eulerian: Hibiki’s Bubble Column
    This tutorial demonstrates how to model a Eulerian multiphase turbulent flow in Simcenter STAR-CCM+.
  - Eulerian: Mixture Settling
    Settling tanks/separators are widely used in the industry for the purpose of separating a fluid mixture into its gaseous and liquid phases. Separator designs include horizontal and vertical configurations that account for different stages of the process, ranging from absorbing the momentum of incoming fluid to achieving the desired phase separation.
  - Eulerian: Bubble Formation in a Fluidized Bed
    This tutorial demonstrates how to model bubble formation in a fluidized bed in Simcenter STAR-CCM+. It simulates the injection of gas into a fluidized bed and monitors the formation and growth of the bubble.
  - Eulerian: Aeration Tank Degassing
    In industry, aeration tanks facilitate the exchange of gases in various processes within a liquid medium. Degassing is a procedure that actively removes gases from a liquid, such as eliminating excess gases that can build up during the biological treatment of organic pollutants, a process particularly common in waste-water treatment.
  - Eulerian: Wall Boiling
    This tutorial validates the wall boiling model in Simcenter STAR-CCM+ against experimental void and temperature data for high-pressure forced convective boiling.
  - Eulerian: Conjugate Heat Transfer Wall Boiling
    This tutorial demonstrates how to set up a conjugate heat transfer wall boiling analysis in Simcenter STAR-CCM+. It simulates a nuclear fuel pin that is cooled using subcooled boiling under flow conditions typical in the first meter of a 3.7-m long BWR6 reactor channel.
  - Eulerian Multiple Flow Regimes: Pressurized Water Reactor
    This tutorial demonstrates how to use the Multiple Flow Regimes model in Simcenter STAR-CCM+ to simulate the counter-current air-water flow in a pressurized water reactor.
  - Eulerian: Pipe Flow with Multi-Speed AMUSIG
    The Adaptive Multiple Size-Group (AMUSIG) model predicts the size distribution of particles (droplets or bubbles) in a dispersed multiphase flow regime. This tutorial demonstrates how to use the AMUSIG model for predicting the size distribution of hexane droplets in water. The water is flowing up a vertical pipe in which a concentric orifice increases turbulence and so accelerates droplet breakup.
  - Eulerian: Suspension Rheology
    This tutorial demonstrates how to set up a Simcenter STAR-CCM+ simulation that models the flow of a non-Newtonian concentrated suspension.
  - Fluid Film: Liquid Film Flow
    This tutorial demonstrates how to use the fluid film modeling capability of Simcenter STAR-CCM+. It simulates the progress of a rectangular film of water flowing down the wall of a three-dimensional duct.
  - Fluid Film: Binary Liquid Film Flow with Evaporation and Edge Stripping
    This tutorial demonstrates how to use the fluid film modeling capability of Simcenter STAR-CCM+ to set up a multi-component film scenario with evaporation and edge stripping. It simulates the progress of a film mixture of water and ethylene glycol flowing down a partially heated wall.
  - Fluid Film - VOF: Rivulets on an Inclined Plane
    Situations occur where a thin film of liquid forms on a solid surface, for example, rainwater on the windshield of a car. This film can flow and accumulate, and gradually grow into a "thick" film, or a pool of liquid that can no longer be described as a fluid film. These situations are multi-scale problems which, if resolved on all scales (using the VOF multiphase model), would require significant computer resources.
  - Dispersed Multiphase: Airfoil Icing
    When aircraft pass through air containing supercooled liquid water droplets, it is possible for the droplets to impact the aircraft surface and form layers of ice. Ice formation on an aircraft wing changes the aerodynamic properties of the wing, and leads to loss of lift, increase in drag, and a change in pressure distribution. Simcenter STAR-CCM+ provides a technique for simulating the formation of ice on airfoils. This technique relies on the Dispersed Multiphase model to represent the liquid droplets in the air surrounding the airfoil.
  - Hybrid Multiphase: Fountain
    In Simcenter STAR-CCM+ modeling, the term hybrid multiphase refers to modeling multiple flow regimes of a phase material using a combination of several different multiphase models. This modeling capability widens the range of real life multiphase flows that you can simulate.
  - Mixture Multiphase with Large Scale Interfaces: Gear Lubrication
    The Mixture Multiphase (MMP) model is suitable for modeling dispersed multiphase mixtures, where the mixture of phases is represented by weighted physical properties. A single set of conservation equations for mass, momentum, and energy is solved for the mixture together with transport equations for phase volume fractions.
  - Viscous Multiphase: Two-Layer Pipe Co-Extrusion
  - Smoothed-Particle Hydrodynamics (SPH): Gearbox Lubrication
    Gear mechanisms require adequate lubrication for long-term optimum performance and efficiency. Simcenter STAR-CCM+ provides the Smoothed-Particle Hydrodynamics (SPH) model with which you can simulate the flow of lubricant around the parts of a gear mechanism and determine whether adjustments are necessary.
    - Prerequisites
      The instructions in the Smoothed-Particle Hydrodynamics: Gearbox Lubrication tutorial assume that you are already familiar with certain techniques in Simcenter STAR-CCM+.
    - Importing the Gearbox Geometry
      You start from a new simulation and import four geometries in .stl file format. The files contain the closed surfaces of the gear housing, gear, pinion, and injector.
    - Assigning the Geometry Parts to a Surface Region
      You assign the imported geometry parts to a surface region. You create a single wall boundary within this region, that represents the surfaces of the gear housing, gear, pinion, and injector.
    - Selecting the Physics Models
      You use the Smoothed-Particle Hydrodynamics (SPH) model to simulate the laminar and incompressible flow of oil inside a gear box. You select the Particle Remediation model to be able to remove individual oil particles that leave the vicinity of the gearbox.
    - Defining the Oil Phase
      The gearbox lubricant is oil with a density of 845.1 kg/m^3 and a viscosity of 0.074 Pas.
    - Orienting Face Normals
      Fluid particles consider a boundary condition only if the boundary normals are facing away from the particles. For closed surfaces, the boundary normals are facing inwards by default. For this reason, you must reverse the orientation of the face normals for the gear housing so that the boundary normals are facing outwards.
    - Specifying the Motion of the Gears
      The interlocking pinion and gear are counter-rotating, where the pinion spins at a rotation rate of 1222 rpm.
    - Improving Robustness and Stability of the Simulation
      In the course of the SPH simulation, it can occur that individual oil particles cross the closed surface of the gear housing and escape from the domain of interest. To avoid the computational effort that is associated with tracking these outliers, Simcenter STAR-CCM+ removes the escaping particles as soon as they meet a certain position-based criterion. You define this criterion in the form of a bounded shape box that encloses the housing.
    - Setting Up Adaptive Time-Stepping
      By default, the time-step size is adapted dynamically in the course of an SPH simulation. The time-step size remains as large as possible while at the same time fulfilling the Courant-Friedrichs-Lewy (CFL) condition for stability.
    - Preparing for Post-processing
      You prepare visualization of the oil velocity and the oil volume fraction on the gears. The oil volume fraction on the gears shows the extent to which the gears are wetted after contact with the liquid. You monitor and plot the evolution of gear torque against physical time. Additionally, you plot the accumulated number of particles that are removed from the simulation as they cross the bounding box.
    - Setting Up the Initial Oil Bath
      For the simulation of oil bath lubrication, you describe the initial shape and position of the oil bath in the form of a geometry part that forms a closed surface. Within this geometry part, oil particles of a specified diameter are created during initialization. The size of the particles represents the discretization of the fluid. For this part of the tutorial, you use a particle diameter of 1 mm.
    - Running the Oil Bath Lubrication Simulation
      The oil bath lubrication simulations runs for a physical time of 0.5 s.
    - Analyzing the Oil Bath Lubrication Results
      After the oil bath lubrication simulation has finished, you analyze the results.
    - Modifying the Simulation Setup for Injection Lubrication
      In this part of the tutorial, you modify the simulation setup to model injection lubrication. As a first step, you clear the solution of the preceding simulation, remove the oil bath initialization, and increase the rotation rate of the gears.
    - Setting Up the Injector
      The imported injector geometry consists of a single part surface, by default. To introduce oil particles from the bottom of the injector, you define a separate inlet surface. With this surface, you create an inlet boundary, where you inject the oil particles with a mass flow rate of 0.06 kg/s and a particle diameter of 0.3 mm.
    - Running the Injection Lubrication Simulation
      You run the injection lubrication simulation for a physical time of 0.01 s.
    - Analyzing the Injection Lubrication Results
      After the injection lubrication simulation is complete, you analyze the results.
- Discrete Element Method
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating Discrete Element Method problems
- Motion
  The tutorials in this set illustrate various STAR-CCM+ features for simulating problems with moving geometries and meshes, dynamic fluid body interaction, and rigid body motion:
- Reacting Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating reacting flows such as combustion.
- Solid Stress
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for computing deformation, strain, and stresses in solid regions. They also show how such computations can be coupled to the fluid behavior in an analysis of fluid-structure interaction.
- Aeroacoustics
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for solving aeroacoustic simulations.
- Electromagnetism
  The following tutorials illustrate features for solving problems that involve electromagnetic fields.
- Electrochemistry
  The following tutorial demonstrates chemical reactions induced by an electrical current.
- Battery
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for setting up a battery model:
- Automation
  The tutorials in this set illustrate various Simcenter STAR-CCM+ automation and macro features.
- Design Exploration
  The tutorials in this set illustrate various features for running design exploration studies in Design Manager.
- Coupling with CAE Codes
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for coupling with CAE codes:
- Analysis Methods
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for analysing and visualizing simulation data.
- Simcenter STAR-CCM+ In-cylinder
  The tutorials in this set illustrate features for simulating internal combustion engines in Simcenter STAR-CCM+ using the dedicated add-on Simcenter STAR-CCM+ In-cylinder.

Specifying the Motion of the Gears

The interlocking pinion and gear are counter-rotating, where the pinion spins at a rotation rate of 1222 rpm.

The rotation rate of the gear can be calculated as:

ω_{g e a r} = \frac{ω_{p i n i o n} \cdot n_{t e e t h, p i n i o n}}{n_{t e e t h, g e a r}} = \frac{1222 r p m \cdot 18}{37} \approx 594.5 r p m

You allocate the rotation rates to the parts using per-part values.

To specify the motion of the gears:

Select the Regions > gearbox > Physics Values > Direct Rotating Motion node and activate Specify by Part Subgroup.

Edit the Direct Rotating Motion > By Part Subgroup node and specify the rotation rates using the right-hand rule around the axes of rotation as follows:


Node	Property	Setting
Gear
Direct Rotating Motion Values	Axis Direction	[0.0, 1.0, 0.0]
Direct Rotating Motion Values	Rotation Rate	-594.49 rpm
Pinion
Direct Rotating Motion Values	Axis Direction	[0.0, 1.0, 0.0]
	Axis Origin	[-0.056, 0.0, 0.0]
	Rotation Rate	1222 rpm

Save the simulation.