CFD APPLIED TO TURBOMACHINERY

Martin Kessler, PhD

07/04/2011
PAGE 2 Examples - Turbomachinery
PAGE 3 Examples - Hydro
Power and
Efficiency
Cavitation
Flow pattern
PAGE 4 Examples - Wind
Power and
Efficiency
Flow pattern
PAGE 5
Topology
All turbomachines are
topologically identical
Just variations on a theme
Lends perfectly to design
systems and parametric
models
Machines differ by
changing
Hub/shroud shape
Blade leading and trailing
edge shape and location
Blade wrap or angle
Number of blades
Rate of rotation
Hub
Shroud
Blade
PAGE 6
What is CFD (Computational Fluid Dynamics)?
CFD requires a computational
model build as a representation
of physical problem
Usually begins from a CAD
import operation
Mesh generation for fluid region
(domain for CFD analysis).
Solve mathematical equations
Post-processing of results
HVAC ducts - geometry
Mesh
Results
Cleaning
PAGE 7
CFD Methodology
Eqn.
continuidade 1
x-mom. u
y-mom. v
energia h
Fluid flow region
discretized into
finite volumes
(computational
mesh)
Control
volume
Solver is usually based on finite volume method
Domain is dicretized into control volumes
Momentum, mass and energy balance
equations are discretized into algebraic
equations
All equations are solved in order to have the
flow solution
} } } }
+ V I = +
c
c
V A A V
dV S d d dV
t
|
| | | A A V
transitrio conveco difuso gerao
PAGE 8
ANSYS Turbo System Environment
Geometry
Blade Modeler
Meanline Tools
BladeGen
DesignModeler
with
BladeEditor
Mesh
TurboGrid
ANSYS Meshing
ICEM CFD
Analysis
Vista TF
ANSYS CFX
FLUENT
ANSYS FEA
Parameterization
Design Exploration
ANSYS Workbench
PAGE 9
ANSYS Workbench Workflow - CFD
BladeModeler
TurboGrid
TurboPre
CFX Solver
TurboPost
PAGE 10
ANSYS Workbench Workflow
Integrated Process
Within ANSYS Workbench
From initial component
designs to accurate complete
system analysis
BladeModeler
TurboGrid
TurboPre
CFX Solver
TurboPost
Structural Extensions
Mechanical Analysis
PAGE 11
ANSYS Workbench Environment
PAGE 12
Radial
Impeller
Simple
Axial
Radial
Diffuser
Axial
Radial
Turbine
BladeGen: Templates Approach
Radial
Deswirl
Vane
PAGE 13
Initial Blade Setup
Can define wrap angle, thickness, and number of blades
Properties will be constant from hub to shroud
User will need to modify properties on spanwise layers
BladeGen: Template Approach
PAGE 14
Initial Blade Setup
Alternatively, blade can be defined by defining pressure and suction
sides
BladeGen: Template Approach
PAGE 15
BladeGen: Design Environment
Meridional View
Auxilliary View
Angle View Thickness View
PAGE 16 BladeModeler - DesignModeler
DesignModeler
Automatic
Fluid Zone
Creation
Create
assemblies
including non-
turbo
components
PAGE 17
Single Component: Extent
Inlet / outlet too close
Inlet / outlet > blade chord away
PAGE 18
Mesh Types - Meshing
Tet Mesh and
Tet/Prism hybrid
Hex Mesh
PAGE 19
Mesh Types - Meshing
Multiple domain: rotor (blue) + stator (red)
PAGE 20 Grid Quality Guidelines
Grid smoothness:
Avoid sudden changes in grid density
Bad Good
PAGE 21
ANSYS TurboGrid
Automated topology & mesh
generation
Highly defaulted, manual user
controls
Fast volume meshing & pre-
mesh at 2D layers
Pre-defined topologies:
H, J, C, L
Layers, user control points,
edge split controls,
Automatic Topology &
Meshing (ATM) Method
PAGE 22
ATM Method - Hub Mesh
PAGE 23
CFX Turbo Mode
CFX Turbo mode
allows for the
configuration of
the turbomachine
Type of machine:
pump
Axis: z
PAGE 24
CFX Turbo Mode
Rotation
Region information
PAGE 25
CFX Turbo Mode
Fluid type
Analysis type
Boundary conditions
Solver parameters
PAGE 26
CFX Turbo Mode
Periodic boundaries
PAGE 27
CFX Solver
PAGE 28
Qualitative Post-Processing CFD-Post
3-D
View
Blade-to-Blade
View
Meridional
View
PAGE 29
Volute
Rotor
Suction
Full Domain
Examples of Cases with Our Partners CEMIG
PAGE 30 Examples of Cases with Our Partners CEMIG
Computational Domain: ~600.000 nodes
PAGE 31 Examples of Cases with Our Partners CEMIG
Rotor Computational Domain: ~170k nodes (1 blade)
14 blades: ~2.4M nodes
PAGE 32
Modified Baseline
Examples of Cases with Our Partners CEMIG
PAGE 33 Examples of Cases with Our Partners CEMIG
Modified Baseline
PAGE 34
Modified Baseline
Examples of Cases with Our Partners CEMIG
PAGE 35 Examples of Cases with Our Partners CEMIG
PAGE 36