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Engineering and

Software Solutions

for CFD and FEA

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For the dedicated modelling of

DHCAE Tools has, based on the renowned CFD toolbox OpenFOAM®, made extensions for a comfortable and professional usage of open source solver technology in an industrial environment.

Development of FSI coupling of OpenFOAM® and CalculiX

The simulation tool can be deployed in every field of filtration of solid particles from gases or liquids with thin filter media in a plant or a unit.

Modelling of filter applications

Already in the development, the inflow on the filter can be optimised without building a prototype. This leads to a

Your benefits from filter modelling

Modelling approach

The utilised modelling is based on the so-called Euler-Lagrange approach, that takes account of the coninuous flow and the dispersed solid particles. In the simulation tool, especially the reaction of the particles on the filter is considered, e.g. the continuous shift of the flow into zones with lower resistance.


The filter is modelled by a region. This allows a simple setup in the CAD system and poses a much lower requirement to the mesh generation than a volume based modelling.


For the work with the filter solver, the user can choose between two options:


Modelling for filter applications

Modelling for filter applications is made especially easy for the user:

Support and adaptations included

A support and adaptation package is always included in the package for the filter solver. By this, we adapt the solving possibilities of the tools to your specific requirements. If you need, for example, a special form of loading characteristic for your filters, it will be provided by us immediately. We also support you with the usage of the solver.

Modelling of plastics processing applications

By the simulation of polymer melts, production processes can be reduced considerably.

Overall, the costs for the production of extrusion dies and the production costs during operation are reduced significantly.

DHCAE Tools has created a tool that enables the solving of static fluid structure applications directy from a modelling environment. CalculiX (open source) as well as Abaqus can be used as structure solver, in case Abaqus is available in your company.


The solver is suitable for solid fields and shell elements.


It uses an iterative coupling with a consistent transfer of the pressure forces and shear stresses on the structure. The shifted geometry, as simulated by the structure solver, is transferred back to OpenFOAM®. Here, a geometry update takes place, and the flow forces are transferred from the deformed geometries on the structure solver. This procedure is continued as long as a convergence between the flow forces and the shifted structure is achieved.


By the data conversion from CalculiX results to ParaView, which was made available by DHCAE Tools, the results of flow and structure can be shown simultaneously.


Your benefits for modelling for plastics applications

Non-Newtonian fluid models

For the simulation of Non-Newtonian fluid behaviour of polymers, all common viscosity

models are supported, for example:

DHCAE Tools' polymer solver provides additional user friendly features for stable and reliable simulation runs:

Automatic initialisations: The fields and initial conditions are automatically predefined with stable settings resulting in fast convergence of non-Newtonian fluid simulations.


Stabiliser for the solver settings: An additional stabiliser module manages the automatic change from stable to accurate solver settings (discretisation methods, relaxation factors etc.) during the simulation run.

Gaining results rapidly with stable and accurate numerical methods

Temperature dependent rheological behaviour of polymer melts

Many steps of plastics processing operations must consider the working temperature of the polymer melt.


Fluid-Structure-Interactions (FSI)

Coming soon:

FSI coupling between OpenFOAM® and CalculiX/Abaqus

Fluid-Structure-Interactions (FSI) occur when forces exert on an elastic solid by a flow and cause stresses, distensions or shifts. On the other hand, the flow can be influenced when shifts in the flow field are generated by external forces on an elastic solid. In both cases, the assumption of a solid wall, which is typical in the mere flow simulation (CFD), is quitted and replaced by the elastic modelling of the solid. By this, the fluid structure analysis shows the coupling of a CFD simulation with a solid problem.

Fluid-Structure-Interaction: Extension of an extrusion die by flow forces

Particle distribution on the filter surface of a water filter

Filter plant for air purification

Are you looking for a proven expert who councels you also in the optimisation of extrusion dies with simulation methods, and who trains your employees to lay out extrusion processes efficiently?


Contact our distribution partner for extrusion applications:

INO - Ingenieurbüro für Numerische Optimierungsmethoden

Website: http://www.extrusionswerkzeuge.de/


A test environment is available for you

For a test of the filter simulation, a comfortable test environment with examples is available for you via the Internet. Here, you can directly test your filter application and evaluate, which hardware resources will be required by you later.

The combination of the GUI based pre-processing abilities of CastNet with the extended solution possibilities of the excellent flow simulation solver OpenFOAM® allows an efficient tool design for a great number of application areas in the plastics processing industry.

Varied results from the polymer solver

Optimisation of extrusion dies

Workflow with the polymer solver

Temperature distribution

Click on the icon for more information

Click on the icon for more information

CFD-filter CFD-filter plant

You will find our article "Smart simulation solution" in the May online edition of the technical magazine  International Process Engineer (on page 36).


CFD-filter simulation CFD-plastics applications CFD optimisation CFD workflow CFD temperature distribution CFD-FSI CFD FSI coupling
OpenFOAM simulation methods and computational services.png

All-round carefree  package

for open source solver technology

DHCAE Tools supports the whole CFD/FEA workflow: software additions (CastNet), services, training courses, support and solver extensions.

FSI-extrusion tool