Multi-physics simulation

Product optimisation to minimise cost, rather than just to increase a single performance discipline's design quality, often requires multi-physics simulations. This can raise major problems in pre-processing for complex geometry, as the true manufacturing CAD is often necessary for accurate FEA & casting simulations, whilst the CFD-side requires very high-quality meshes. Furthermore, matching between different physical models at the geometry boundary is often best achieved on meshes that match exactly - especially for highly complex shapes. This example shows a fluid/solid mesh for an automotive brake caliper and disk - 20M cells or so in about 5 minutes - and the two sides' meshes match exactly at the interface between.