Case Study: Culligan achieves reduced salt usage and balanced hydrodynamic and structural performance with ANSYS engineering simulation

Simulation Balances Hydrodynamic Performance with Structural Integrity to Develop a Water Softener that Uses Less Salt

Culligan Matrix Solutions (Culligan) needed a new water softener that used less salt, minimized pressure loss and used the least material possible. To validate hydrodynamic performance and structural integrity before tooling, Culligan worked with ANSYS, applying ANSYS CFX and ANSYS Mechanical to simulate two‑phase brine/water flow and structural response.

ANSYS used geometry simplification, two‑phase CFX modeling and pressure transfer to ANSYS Mechanical to iterate designs quickly and capture brine draw and suction effects. The simulations cut design cycle time, reduced salt use and material, and avoided hundreds of thousands of dollars in mold costs; the molded valve’s pressure drop was within 4% of the ANSYS prediction and it passed pressure cycling and burst tests on the first try.

Culligan

Kerry Quinn

Vice President, New Product Development