Chapter 69: Simulation of Fuel Tank Filling

69 Simulation of Fuel Tank Filling


Summary 1254

Problem Description 1255

MD Nastran SOL700 Model 1255

Results 1266

Input File(s) 1268
1254 MD Demonstration Problems
CHAPTER 69

Summary
Title Chapter 69: Fuel Tank Filling
Features Multiple Adaptive Euler Domains for Multiple Material
Geometry

Material properties • Fuel:

Density: 8.5E-7 Kg/ mm3
Bulk modulus: 2.0E+4 kPa
• Air:
Density: 1.29E-9 kg/mm3
Gamma 1.4
Specific internal energy 1.938E11 Kg-mm2/s2
• Tank and pipes are modeled as rigid materials
Analysis characteristics Transient explicit dynamic analysis (SOL700) – Fluid Structure Interaction (FSI)
Boundary conditions The tank is fixed in position by defining zero velocity in all directions and zero rotation in
all directions.
Applied loads Flow velocity of fuel at inlet of fuel pip: the velocity is defined such that the flow rate
keeps 2.0 liter/second over 2 seconds
Element type • The Euler domains in this model handle multiple hydrodynamic materials (air and fuel).
• Dummy shell elements for fuel tank structure.
FE results FMATPLT Material fraction of material times the volume uncovered fraction
 CHAPTER 69 1255
Simulation of Fuel Tank Filling

Problem Description
The process of filling up an automobile fuel tank must be safe and comfortable for the customer. Effects like premature
switch off of the gasoline pump or the back splash of fuel must be avoided. Furthermore, the legal and government
regulations must be met. The space available for the whole system is constantly minimized, leading to additional
complications in fulfilling the above criteria. Costly and time-consuming experiments are usually necessary for this
optimization. Numerical simulation is a desirable tool to avoid excessive experimental testing.
This example demonstrates the application of Multiple Adaptive Euler Domains with Multiple Material to predict fuel
tank filling process. The problem simulates a fuel tank that contains a filling pipe and a vent pipe. The tank is filled
with fuel up to 80 mm from the bottom. The rest is filled with air. In the simulation, the fuel is made to flow into the
tank through the inlet of the filling pipe. The air and the fuel escape out of the tank through the outlet of the vent pipe.

MD Nastran SOL700 Model

The tank and pipes are modeled as rigid bodies. The fuel/air region is modeled by three Euler meshes. The first domain
models the inside of the tank, the second domain models the inside of the filling pipe, and the third domain models the
inside of vent pipe. For the interaction between the structure and Euler domains, three coupling surfaces are needed.
• Units
• Length = mm, Mass = Kg, and Time = second
• Tank and Pipes
Figure 69-1 shows the structure mesh. All elements are defined as dummy shell elements. A surface is created and
defined as a rigid body. The tank is fixed in position by defining zero velocity in all directions and zero rotation in all
directions.

Figure 69-1 Tank and Piping Structure Mesh

1256 MD Demonstration Problems
CHAPTER 69

Euler Domain 1
The first Euler domain has the fuel and air inside of the tank.
The properties of fuel are:

Density 8.5E-7 Kg/mm3

Bulk modulus 2.0E+4 KPa

This is a reduced bulk modulus (1/100) to increase the time step and reduce CPU time.
In the input file:
MATDEUL 2 8.5E-7 2
EOSPOL 2 20000
The air properties are:

Density 1.29E-9 Kg/mm3

Gamma 1.4
Specific internal energy 1.938E11 Kg-mm2/s2

In the input file:

MATDEUL 1 1.29E-9 1
EOSGAM 1 1.4
TICVAL,21,,DENSITY,1.29E-9,SIE,1.938E11
The Euler region is modeled by using the MESH entry. The ADAPT option is used:
PEULER1,1,,MMHYDRO,100
MESH,1,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,1
To initialize the whole first Euler mesh, a TICEUL entry is defined. Tank is full with fuel up to 80mms from the bottom.
The rest is full with air. The initial air pressure is set to 100 KPa. Fuel hydrostatic pressure is defined starting from 100
KPa at the surface and increasing going down. The four layers with different pressures are defined:
TICEUL1,100,1
TICREG,1,1,CYLINDER,31,1,21,1.0
TICREG,2,1,CYLINDER,32,2,22,2.0
TICREG,3,1,CYLINDER,33,2,23,3.0
TICREG,4,1,CYLINDER,34,2,24,4.0
TICREG,5,1,CYLINDER,35,2,25,5.0
$
CYLINDR,31,,-350.,150.,-10000.,50.,150.,-10000.,+
+,20000.
CYLINDR,32,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10020.
 CHAPTER 69 1257
Simulation of Fuel Tank Filling

CYLINDR,33,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10040.
CYLINDR,34,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10060.
CYLINDR,35,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10080.
$
TICVAL,21,,DENSITY,1.29E-9,SIE,1.938E11
TICVAL* 22 DENSITY 8.54254E-7*
* SIE 0.
TICVAL* 23 DENSITY 8.5426E-7*
* SIE 0.
TICVAL* 24 DENSITY 8.54268E-7*
* SIE 0.
TICVAL* 25 DENSITY 8.54275E-7*
* SIE 0.

Euler Domain 2
The second Euler region represents the fuel and air inside the filling pipe. For smooth start of the simulation, the part
near the inlet of the filling pipe is initially filled with fuel. The rest is full with air. For the second Euler region, a MESH
entry is used:
PEULER1,2,,MMHYDRO,200
$
MESH,2,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,2
$
TICEUL1,200,2
TICREG,21,2,CYLINDER,51,2,41,1.0
TICREG,22,2,CYLINDER,52,1,21,2.0
CYLINDR,51,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10260.
CYLINDR,52,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10205.

$
$
TICVAL,41,,DENSITY,8.5425-7,SIE,0

Euler Domain 3
The third Euler region represents the fuel and air inside the vent pipe. The vent pipe is initially full with air. For the
third Euler region, a MESH entry is used:
PEULER1,3,,MMHYDRO,300
$
MESH,3,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,3
1258 MD Demonstration Problems
CHAPTER 69

$
TICEUL1,300,3
TICREG,31,3,CYLINDER,51,1,21,1.0

Fluid Structure Interaction

For each Euler domain, a separate surface is required. The surface definition makes use of the properties of the
elements.
1. Tank surface:
BCPROP,101,7,8,12,THRU,16
The surface has been closed to constitute valid coupling surface (Figure 69-2).

Holes

Outside of Tank Inside of Tank

Figure 69-2 Coupling Surface of Euler Domain 1

The Euler domain 1 is constrained by surface 101. All elements outside the volume are not active. The covered
option is, therefore, set to OUTSIDE. Attached to this surface is the first Euler MESH:
COUPLE,1,101,OUTSIDE,,,,,,+
+,,,,,,,,,+
+,,1
$
 CHAPTER 69 1259
Simulation of Fuel Tank Filling

2. Filling pipe surface:

BCPROP,201,4,THRU,8
The surface has been closed to constitute valid coupling surface (Figure 69-3).

Figure 69-3 Coupling Surface of Euler Domain 2 (filling pipe)

The Euler domain 2 is constrained by surface 201. For this volume, the outer Euler elements are covered:
COUPLE,2,201,OUTSIDE,,,22,,,+
+,,,,,,,,,+
+,,2

Surface 101 and surface 201 share some elements (with property number 7, 8). A hole is modeled as a
subsurface consisting of quads (with property number 8) that are fully porous. The elements in this subsurface
connect the two coupling surface and are included in the definition of both coupling surfaces.
A flow definition is required for one of the coupling surfaces. The flow entry is referenced from the second
coupling surface. The input to define flow between the two regions:
LEAKAGE,2,22,2,PORFCPL,2,,1.0
PORFCPL,2,LARGE,,BOTH,1
BCPROP,2,8
1260 MD Demonstration Problems
CHAPTER 69

3. Vent pipe surface:

BCPROP,301,9,THRU,14

The surface has been closed to constitute valid coupling surface (Figure 69-4).

Figure 69-4 Coupling Surface of Euler Domain 3 (vent pipe)

The Euler domain 3 is constrained by surface 301. For this volume, the outer Euler elements are covered:
COUPLE,3,301,OUTSIDE,,,33,,,+
+,,,,,,,,,+
+,,3

Surface 101 and surface 301 share some elements (with property number 12, 13, 14). A hole is modeled as a
subsurface consisting of quads (with property number 14) that are fully porous.
The elements in this subsurface connect the two coupling surface and are included in the definition of both
coupling surfaces.
A flow definition is required for one of the coupling surfaces. The flow entry is referenced from the third
coupling surface. The input to define flow between the two regions:
LEAKAGE,3,33,3,PORFCPL,3,,1.0
PORFCPL,3,LARGE,,BOTH,1
BCPROP,3,14

Inlet and outlet

Two flow boundaries are defined to the coupling surface (pipe ends, see Figure 69-5). The first is to define fuel flow
into the tank at a predefined flow rate (velocity × area). The second is to allow air (or fuel) to escape out of the tank.
Pressure at the second boundary is defined as 1.0 at (100 kPa).
 CHAPTER 69 1261
Simulation of Fuel Tank Filling

Inlet Outlet

Figure 69-5 Flow Boundaries

1. Inlet
The flow entry of inlet is referenced from the second coupling surface. As input, the velocity is defined such
that the flow rate keeps 2.0 liter/second over two seconds. Since the area of the inlet hole is 1256 mm2, the
velocity is 1592 mm/s.
LEAKAGE,21,22,21,PORFLOW,21,,1.0
PORFLOW,21,,XVEL,-1592.,DENSITY,8.5425-7,FLOW,IN,+
+,YVEL,0.,ZVEL,0.,MATERIAL,2,,,+
+,SIE,0
BCPROP,21,4

Note: 1. In the case of material flow into a multi-material Euler mesh, the density and specific energy
has to be set.
2. Prescribing both pressure and velocity may lead to the instabilities.

2. Outlet
The flow entry of outlet is referenced from the third coupling surface.
LEAKAGE,31,33,31,PORFLOW,31,,1.0
PORFLOW,31,,MATERIAL,1,DENSITY,1.29e-9,SIE,1.938e+11,+
+,PRESSURE,100.
BCPROP,31,9
1262 MD Demonstration Problems
CHAPTER 69

Note: a) Since tank flow is in general subsonic, a prescribed pressure condition to the flow condition
is necessary. The boundary condition without the prescribed pressure actually assumes that
flow is supersonic.
b) When material flows out of a multi-material Euler mesh, it is assumed that each of the
materials present in the outflow Euler element contributes to the out flow of mass. The
materials are transported in proportion to their relative volume fractions.

Miscellaneous
1. Fast coupling is to used:
DYPARAM,FASTCOUP,

2. Gravity is applied to the whole model:

TLOAD1 1 444 0
GRAV 444 -9800. 1.

3. In order to output results of the flow boundaries, a history request is created:

DYPARAM,LSDYNA,BINARY,D3PLOT,4.E-2
DYTIMHS,,1E-4,,,,,,,+
+,SUBSOUT

Abbreviated SOL 700 Input File

$ UNIT: mm/kg/s/K
SOL 700,NLTRAN STOP=1
CEND
SUBCASE 1
$ for QA purpose, run shorter time
TITLE= Jobname is: tank_filling
DLOAD=1
IC=1
SPC=1
TSTEPNL=1
$
BEGIN BULK
TSTEPNL 1 10 2.E-01 1
$------- Parameter Section ------
DYPARAM,FASTCOUP,
PARAM*,DYINISTEP,1E-7
PARAM*,DYMINSTEP,1E-8
$------- BULK DATA SECTION -------
$
DYPARAM,LSDYNA,BINARY,D3PLOT,4.E-2
DYTIMHS,,1E-4,,,,,,,+
+,SUBSOUT
$
 CHAPTER 69 1263
Simulation of Fuel Tank Filling

$
TLOAD1 1 444 0
GRAV 444 -9800. 1.
$
$ ========== PROPERTY SETS ==========
$
$ * Shell_1 *
$
PSHELL,4,888,1E-3
PSHELL,9,888,1E-3
$
PSHELL,5,999,1E-3
PSHELL,6,999,1E-3
PSHELL,7,999,1E-3
PSHELL,8,999,1E-3
PSHELL,10,999,1E-3
PSHELL,11,999,1E-3
PSHELL,12,999,1E-3
PSHELL,13,999,1E-3
PSHELL,14,999,1E-3
PSHELL,15,999,1E-3
PSHELL,16,999,1E-3
$
MATD009,888,1E-20
$
MATRIG,999,,,,1.0E1,0.00,0.00,0.00,+
+,1.E10,0.0,0.0,1.E10,0.0,1.E10,,,+
+,,,,,,,,,+
+,,,,1,7,7
$
$ -------- Material air_mat id =1
$
MATDEUL 1 1.29E-9 1
$
$ -------- Material oil_mat id =2
$
MATDEUL 2 8.5E-7 2
EOSPOL 2 20000
$
$ ======== Load Cases ========================
$
$
$-----------------------------Domain 1------------------------------
$
MESH,1,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,1
$
COUPLE,1,101,OUTSIDE,,,,,,+
+,,,,,,,,,+
+,,1
$
BCPROP,101,7,8,12,THRU,16
$
1264 MD Demonstration Problems
CHAPTER 69

$---------Euler initial condition---------------

TICEUL1,100,1
TICREG,1,1,CYLINDER,31,1,21,1.0
TICREG,2,1,CYLINDER,32,2,22,2.0
TICREG,3,1,CYLINDER,33,2,23,3.0
TICREG,4,1,CYLINDER,34,2,24,4.0
TICREG,5,1,CYLINDER,35,2,25,5.0
$
PEULER1,1,,MMHYDRO,100
EOSGAM 1 1.4
$
CYLINDR,31,,-350.,150.,-10000.,50.,150.,-10000.,+
+,20000.
CYLINDR,32,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10020.
CYLINDR,33,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10040.
CYLINDR,34,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10060.
CYLINDR,35,,-350.,150.,-10000.,50.,150.,-10000.,+
+,10080.
PEULER1,2,,MMHYDRO,200
PEULER1,3,,MMHYDRO,300
CYLINDR,51,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10260.
CYLINDR,52,,-150.,150.,-10000.,250.,150.,-10000.,+
+,10205.
$
TICVAL,21,,DENSITY,1.29E-9,SIE,1.938E11
$2345678$234567812345678$234567812345678$234567812345678$234567812345678$2345
678
TICVAL* 22 DENSITY 8.54254E-7*
* SIE 0.
TICVAL* 23 DENSITY 8.5426E-7*
* SIE 0.
TICVAL* 24 DENSITY 8.54268E-7*
* SIE 0.
TICVAL* 25 DENSITY 8.54275E-7*
* SIE 0.
$
$-----------------------------Domain 2------------------------------
$
MESH,2,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,2
$
COUPLE,2,201,OUTSIDE,,,22,,,+
+,,,,,,,,,+
+,,2
$
BCPROP,201,4,THRU,8
$
LEAKAGE,2,22,2,PORFCPL,2,,1.0
PORFCPL,2,LARGE,,BOTH,1
 CHAPTER 69 1265
Simulation of Fuel Tank Filling

BCPROP,2,8
$
LEAKAGE,21,22,21,PORFLOW,21,,1.0
PORFLOW,21,,XVEL,-1592.,DENSITY,8.5425-7,FLOW,IN,+
+,YVEL,0.,ZVEL,0.,MATERIAL,2,,,+
+,SIE,0
BCPROP,21,4
$
$---------Euler initial condition---------------
TICEUL1,200,2
TICREG,21,2,CYLINDER,51,2,41,1.0
TICREG,22,2,CYLINDER,52,1,21,2.0
$
$
TICVAL,41,,DENSITY,8.5425-7,SIE,0
$-----------------------------Domain 3------------------------------
$
MESH,3,ADAPT,8.,8.,8.,,,,+
+,,,,,,,,,+
+,,,,,,,EULER,3
$
COUPLE,3,301,OUTSIDE,,,33,,,+
+,,,,,,,,,+
+,,3
$
BCPROP,301,9,THRU,14
$
LEAKAGE,3,33,3,PORFCPL,3,,1.0
PORFCPL,3,LARGE,,BOTH,1
BCPROP,3,14
$
LEAKAGE,31,33,31,PORFLOW,31,,1.0
PORFLOW,31,,MATERIAL,1,DENSITY,1.29e-9,SIE,1.938e+11,+
+,PRESSURE,100.
BCPROP,31,9
$
$---------Euler initial condition---------------
TICEUL1,300,3
TICREG,31,3,CYLINDER,51,1,21,1.0
$
$INCLUDE tank.bdf
$
$ --- Define 1335 grid points ---
$
GRID 1 .00000 .00000 200.000
GRID* 2 .00000 -2.8e-14*A000001
*A000001 1.42e-14
GRID* 3 .00000 -3e-06*A000002
*A000002 180.000
GRID* 4 .00000 2.84e-14*A000003
*A000003 160.000
GRID* 5 .00000 -2.8e-14*A000004
………………………………..
………………………………..
1266 MD Demonstration Problems
CHAPTER 69

$ --- Define 1350 elements

$
$ -------- property set pshell.1 ---------
CQUAD4 1248 4 1121 1259 1258 1120
CQUAD4 1249 4 1122 1260 1259 1121
CQUAD4 1250 4 1123 1277 1260 1122

…………………………………
…………………………………

$ -------- property set pshell.2 ---------

CQUAD4 1103 5 1120 1140 1141 1121
CQUAD4 1104 5 1121 1141 1142 1122
CQUAD4 1105 5 1122 1142 1143 1123
…………………………….
…………………………….

CQUAD4 1099 16 1116 415 416 1117

CQUAD4 1100 16 1117 416 417 1118
CQUAD4 1101 16 1118 417 418 1119
CQUAD4 1102 16 1119 418 419 914
$
ENDDATA

Results
Figure 69-6 shows isosurfaces of the fuel and air. The images are created with CEI.Ensight.
Figure 69-7 shows time history curves of the velocities on the flow boundaries. XVEL-SUB21 is the X-Velocity of
the inlet and XVEL-SUB31 is the X-Velocity of the outlet. The outflow velocity is much higher because the outlet
vent is small. At 1.45 seconds, fuel starts to vent out.
 CHAPTER 69 1267
Simulation of Fuel Tank Filling

Figure 69-6 Isosurfaces of FMAT

1268 MD Demonstration Problems
CHAPTER 69

Figure 69-7 Velocities on the Flow Boundaries

Input File(s)
Files Description
EP4_11_tankfill_2s.dat MD Nastran input.Time period reduced to 0.25 seconds