Fluid Simulation – An Optimized Solution for Design and Industrial Operation

In the era of smart manufacturing, fluid simulation (CFD) is a key tool that helps optimize design and reduce the cost of physical testing for businesses. SDE Tech is a pioneer in providing breakthrough fluid simulation solutions from Prometech (Particleworks), which applies a particle-based method instead of traditional meshing. This approach enables fast and accurate solving of complex flow problems, ranging from automotive lubrication systems to electronic device cooling.

1. Concept and Importance of Fluid Simulation in Engineering

Fluid simulation is the process of using mathematical algorithms and computer computing power to solve the governing equations of fluid flow.

1.1. Why do businesses need fluid simulation?

In reality, observing fluid flow inside an operating system (such as lubrication oil in an engine or molten plastic inside an injection mold) is extremely difficult and costly. Installing physical sensors can alter flow characteristics or may not withstand harsh operating environments. CFD solutions provide a “virtual laboratory”, allowing engineers to observe every detail at any location within the system without interrupting operations. This enables more accurate design optimization decisions.

1.2. Risk reduction and cost optimization

Detecting a flow-related design flaw—such as cavitation in pumps or overheating in electric vehicle battery systems—during physical prototyping can result in billions in losses and project delays. Fluid simulation enables engineers to test hundreds of design scenarios on a computer, helping them identify the optimal solution before actual production, significantly reducing risk and development cost.

2. Difference Between Mesh-Based and Particle-Based Methods

To understand why solutions from Prometech are increasingly preferred today, it is necessary to compare the two main approaches in fluid flow analysis.

2.1. Traditional Mesh-Based CFD Method

This method divides the fluid domain into millions of small grid cells (finite volume elements). The Navier–Stokes equations are solved within these cells. 

• Advantages: Very high accuracy for steady-state flows in closed domains.
• Limitations: Meshing complex geometries or moving boundaries (such as rotating gears) is extremely time-consuming, prone to convergence issues and numerical errors during simulation setup

2.2. Particle-Based (Meshless) Simulation Technology

Solutions such as Particleworks use the MPS (Moving Particle Simulation) method, where the fluid is represented by freely moving particles.

Advantages: No mesh generation is required, helping to reduce model preparation time by up to 90%. It is particularly powerful for simulating free-surface phenomena, such as splashing, as well as complex moving components. This makes it an ideal fluid simulation solution for lubrication and engine cooling applications.

3. Real-World Applications of Fluid Simulation in Industry

SDE Tech has successfully implemented numerous fluid simulation projects for clients across different industries, helping them solve highly specialized engineering challenges.

3.1. Automotive and Electric Vehicle (EV) Industry

• Gearbox lubrication simulation: Analyzes how oil is splashed to lubricate gears and bearings. This helps optimize oil volume, reduce churning losses, and improve overall transmission efficiency.
• Battery and electric motor cooling: Fluid simulation helps design cooling channels around battery cells, ensuring uniform temperature distribution and preventing thermal runaway.

3.2. Electronics and Telecommunications Industry

For high-power-density electronic devices, thermal design optimization is essential. Simulation helps identify hot spots and optimize the placement of cooling fans or heat sinks, thereby extending component lifespan and improving reliability.

3.3. Consumer Goods and Medical Industry

• Liquid filling simulation: Analyzes bottling processes for food and pharmaceutical products to prevent air bubbles and spillage.
• Medical devices: Simulates blood flow in artificial heart valves or airflow in ventilators to ensure biocompatibility and performance stability.

4. Particleworks – Particle-Based Simulation Technology from Prometech

In the Vietnamese market, SDE Tech is a provider of Particleworks software. This is a specialized solution designed to address challenges that traditional CFD software often struggles to solve.

• Handling complex free-surface phenomena: Using particle-based algorithms, Particleworks accurately simulates highly dynamic flow behaviors such as ship sloshing, liquid mixing, or oil splashing in gearboxes without being constrained by mesh boundaries.
• Multiphysics integration (FSI – Fluid-Structure Interaction): The software supports fluid–structure interaction by connecting with FEA tools, enabling precise analysis of how fluid pressure affects structural deformation in components such as impellers or engine housings.
• High-performance GPU computing: Fully optimized for GPU architecture, Particleworks significantly accelerates computation speed—up to dozens of times faster compared to traditional CPU-based CFD methods

5. Frequently Asked Questions about Fluid Simulation

5.1 Is Particleworks’ particle-based method as accurate as traditional mesh-based CFD?

For free-surface problems and highly complex moving flows, the MPS particle method often produces more realistic results and avoids mesh distortion issues. However, for stable laminar flow inside closed pipes, mesh-based CFD may still offer advantages in local resolution and refinement. SDE Tech will recommend the most suitable approach depending on your specific engineering problem.

5.2 What kind of computer configuration is required for efficient fluid simulation?

For Particleworks, the most important requirement is a powerful GPU with high VRAM capacity and a large number of CUDA cores (such as NVIDIA Quadro or RTX professional series). A strong GPU workstation delivers significantly better performance compared to expensive multi-CPU systems.

5.3 Do I need advanced mathematical knowledge to use the software?

Although a fundamental understanding of physics and mathematics is helpful, modern solutions from Prometech have significantly simplified the user interface. SDE Tech provides structured training and technology transfer programs, enabling mechanical engineers to master the simulation workflow in a relatively short time. 

Fluid simulation is no longer limited to research institutes or aerospace corporations. With particle-based technology and the power of GPU computing, manufacturing companies of all sizes can now access advanced simulation tools to enhance engineering capabilities. Contact SDE Tech today for expert consultation and to experience the breakthrough power of advanced fluid simulation solutions! 

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