CFD-Simulations
Understanding flow, improving products
CFD simulations make invisible physical processes visible – for greater efficiency, in-depth process understanding, and targeted optimizations right from the development phase.
Computational fluid dynamics (CFD) refers to the computer-aided simulation of flow and temperature behavior in liquids and gases. Complex physical processes such as flow, heat transfer, mass transport, and chemical reactions are realistically modeled. With the help of CFD, pressure losses, flow distributions, temperature fields, and mass concentrations, as well as other relevant physical variables, can be analyzed and visualized.
CFD simulations enable the investigation of a wide variety of physical phenomena:
The flow of gases and liquids through complex geometries, both in closed and open flow areas, is a fundamental field of application for CFD calculations. Both laminar and turbulent flow conditions can be recorded and evaluated. In addition, CFD allows the analysis of thermal effects: heat conduction in solids, convection in fluids, and heat radiation in thermally stressed structures can be represented in detail.
Another important aspect is the simulation of multiphase flows. This involves simultaneously considering different phases such as liquid, gas, and solids, for example in droplet formation or sedimentation. Phase transitions such as evaporation, condensation, melting, or solidification can also be modeled using suitable models. The associated energy transport is taken into account in order to capture thermal effects.
It is also possible to map individual particles as a discrete phase. This allows the movements of dust, sand, cement, or liquid droplets to be simulated, for example. This is particularly helpful for evaluating inertia and deposition effects in rooms or facilities.
CFD simulations are a powerful tool when it comes to developing products efficiently and optimizing technical processes in a targeted manner. They help to better understand real operating conditions, identify weak points at an early stage, and make targeted optimizations—even before a physical prototype is created. This significantly reduces development time, materials, and testing costs. CFD analyses make a decisive difference, especially in complex development projects. That is why CFD simulations are indispensable in many branches of industry.
Want to know whether CFDs are right for you?
Where flow matters, simulation gives you the edge
No innovation without CFD calculation
Whether it's aerodynamics in vehicles, cooling in data centers, or airflow in operating rooms, modern products require a deep understanding of fluid dynamics. This is precisely where CFD comes in: in the automotive industry, it reduces air resistance and fuel consumption; in aviation, it enables lighter and more efficient wings. Medical technology uses CFD to develop flow-optimized stents and artificial heart valves—safe, precise, and vital.
High-tech products such as the Airbus A350, the Porsche Taycan, and modern wind turbines would be virtually inconceivable without CFD calculations. Simulation supports complex testing, saves time, and provides insights that are difficult to measure physically. Anyone who wants to develop innovative products today can leverage modern CFD simulation as a powerful tool.
Examples of efficient product development
Identify vulnerabilities before they become a risk!
CFD in analysis
Detect errors early, prevent damage
If efficiency levels are too low or temperatures too high or too low, systems too loud or mixing processes inadequate, targeted flow simulations provide clarity:
Virtual flow analyses allow malfunctions such as uneven flow, pressure losses, hot spots, or cavitation to be investigated in a targeted manner—quickly, clearly, and without expensive test series.
Whether it's leaky cooling channels in the mold, unexpected vibrations in the pump, or power losses in the heat exchanger, CFD helps to visualize complex relationships and specifically correct design errors.
With CFD, you can systematically analyze, document in a comprehensible manner, and gain valuable insights for optimization. The result: greater safety, fewer failures, and better products.
Design smarter – with CFD-Simulation
Driver for innovative product development
Whether it's cooling in electronics, flow control in machines, or comfort in vehicle interiors, CFD provides a clear basis for decision-making. Quickly vary different designs without the need for costly prototypes. An enormous time saver!
CFD shows how a design works under real conditions – before it is even manufactured. This is because flow behavior, heat distribution, and pressure conditions often cannot be intuitively grasped. New manufacturing methods such as 3D printing also open up completely new design freedoms – but many of these possibilities can only be fully exploited with CFD.
CFD is becoming a key technology, especially for complex geometries and new technologies (e.g., cooling channels, geometries, or air ducts), enabling the creation of functional, energy-efficient, and marketable products. Use CFD from the outset to develop your products faster and more efficiently.
Sie möchten wissen, ob CFD für Sie Sinn macht?
CFD calculations compliant with standards
Security through correctly validated data
CFD simulations are already recognized in many industries as a verification method for standards and guidelines. Compliance with industry-specific standards, the quality of modeling, the verification and validation of results, and the technical expertise of the calculation engineers are crucial for standard compliance. At Merkle CAE Solutions, you receive precise CFD simulations for complex flow scenarios and any geometry – tailored to the requirements of relevant standards and guidelines, including in the following areas:
- VDI 6020 – CFD verification method for thermal comfort
- DIN EN 16798 (formerly EN 15251) – Indoor air quality and energy efficiency
- ASHRAE guidelines – Comfort analysis (e.g., drafts, temperature distribution)
- NASA CFD Verification & Validation Guide – Industry standard for CFD quality
- MIL-HDBK-1797A – Requirements for aerodynamic data (including CFD-based)
- EASA / FAA – CFD recognized as part of the certification process with appropriate validation
- FDA (USA) – for analyzing blood flow, heart valves, inhalers
- MDR (Medical Device Regulation, EU) – possible as part of technical documentation
- ISO 5840 – heart valves: CFD as a supplement to design analysis
- ISO 10993 – biocompatibility: CFD as a supplementary tool
- ISO 26262 – Functional safety: CFD as a supporting method
- OEM-specific CFD guidelines (e.g., grid resolution, turbulence model)
- Euro 7 – CFD for exhaust gas and temperature control
- DIN 18232-2 – Smoke control, smoke extraction systems
- ISO 16730 – Fire modeling: Guidelines for CFD verification and validation
- FDS (Fire Dynamics Simulator) – Internationally recognized CFD software for fire simulation
- ERCOFTAC Best Practice Guidelines
- ASME V&V 20 – Verification and validation for CFD and heat transfer
- VDI 2048 – Uncertainty analysis for measurement and calculation results (CFD-relevant)
CFD simulations are becoming increasingly important in many industries and are increasingly accepted as an official verification method in standards and guidelines. Careful application of industry-specific standards, high-quality simulation results, and comprehensive verification and validation are crucial for compliance with these requirements. At Merkle CAE Solutions, we offer CFD calculations for a wide range of flow scenarios and geometries – always in accordance with applicable standards and requirements.
Simulation replaces speculation: find out more!
CFD – Indispensable for new technologies
Accelerate innovation with CFD calculations
CFD simulations are indispensable for new technologies such as hydrogen technology. They enable complex flow and reaction processes to be analyzed digitally and safety-related scenarios—such as explosions in electrolysers—to be realistically represented. This allows developments to be driven forward more quickly, efficiently, and safely. Find out more in the podcast! (only available in German)