Workshop 06 Axial Fan Stage (MFR)

14.5 Release

Introduction to ANSYS CFX

1 2012 ANSYS, Inc. December 17, 2012 Release 14.5

Introduction
Workshop Description: This Workshop deals with an Axial
Fan stage operating at 2880 rpm. The working fluid is Air Ideal Gas and flow is assumed to be steady.
Shroud Outlet m = 0.3kg/s

Stator Blade (20) w = 2880 rev/min

Due to rotational periodicity a

single blade passage will be modeled.

Learning Aims: Working outside Workbench Working with rotating domains Basic setup using multiple frames
of reference Turbo-specific post-processing
Introduction
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Inlet pt = 1.0 bar Tt = 288 K

Rotor Blades (30) Hub

No cavitation

Cavitation

Summary
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Multiple Frames of Reference

Axial, radial & mixed turbo machines, mixing vessels

Diverse component installations Gaps, tip clearance,

Available models: Stage: stationary calculation, circumferential averaging Frozen Rotor: stationary calculation, frozen blade position Transient Rotor Stator: transient calculation, rotating interface mapping, rotor-stator interaction 3 Transient Blade Row methods: Time Transform - Inlet Disturbance, Stage TRS Fourier Transform - Inlet Disturbance, Stage TRS & Blade Flutter
Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
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Pre-processing Goals
Using Stand-Alone CFX Mode(outside of
Workbench) Launch CFX-Pre from CFX-Launcher Define stationary and rotating domain Define boundary conditions Define rotor stator interface Set up monitor points using simple expressions Define turbomachinery specific solver parameters Launch CFD-Post Rotate, zoom and pan the view Initialize turbo postprocessing Define turbo surface Use turbo coordinates for contour plots.

Launch the CFX Solver Manager

Introduction
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Setup
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Solving

Postprocessing

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Start a CFX-Pre
Start CFX-Launcher

Start > All Programs > ANSYS 14.5

> Fluid Dynamics > CFX 14.5

Start CFX-Pre from CFX-Launcher

Choose New Case

General
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Setup
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Import Mesh
Select File > Import > Mesh Change Files of Type: CFX Mesh (*.gtm *.cfx) Browse to workshop_input_files\WS_06_ \AxialFanStage
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Select Rotor.gtm
Click on Open Next Import the Stator.gtm
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Imported meshes

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Define Expressions
Create expressions that will be used later to define the speed of rotation and the physical timescale for convergence control

Right-click on Expressions > Insert > Expression Name: myRotationSpeed Value: 2880 [rev min^-1] Define physical timescale for solver control Name: myPhysicalTimescale Value: 1 [rad]/myRotationspeed Dependency on rotation speed
Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
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Create Domain: Stator (S1)

Select (Basic Settings): Create Domain: S1 Location: Passage 2 Material: Air Ideal Gas Reference Pressure: 1[bar] Domain Motion: Stationary

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Setup
December 17, 2012

Solving

Postprocessing

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Create Domain: Stator (S1)

Select (Fluid Models): Heat Transfer: Total Energy Turbulence: Shear Stress Transport Click OK

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Setup
December 17, 2012

Solving

Postprocessing

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Create Domain: Rotor (R1)

Select (Basic Settings): Create Domain: R1 Location: Passage Material: Air Ideal Gas Reference Pressure: 1[bar] Domain Motion: Rotating Angular Velocity: myRotationSpeed
Use expression symbol to enter expression! Right-click in box and select expression Rotation Axis: Global Z

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Setup
December 17, 2012

Solving

Postprocessing

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Create Domain: Rotor (R1)

Select (Fluid Models): Heat Transfer: Total Energy Turbulence: Shear Stress Transport Click OK Note: By default Constant Domain Physics is active (Case Options > General Options > Settings) and so these options should already be set.
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Setup
December 17, 2012

Solving

Postprocessing

Summary
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Create Boundary: Inlet (in R1)

Select: Right-click on Domain R1 > Insert > Boundary Name: R1 Inlet Boundary Type: Inlet Location: INFLOW Frame Type: Stationary

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Setup
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Solving

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Create Boundary: Inlet (in R1)

Select: Mass And Momentum Option: Stat. Frame Tot. Press. Relative Pressure: 0 [Pa] Flow Direction: Normal to Boundary Condition Turbulence: Medium Stat. Frame Total Temperature: 288 [K] Click OK
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Setup
December 17, 2012

Solving

Postprocessing

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Create Boundary: Blade and Hub (in R1)

Select: Right-click on Domain R1 > Insert >
Boundary Name: R1 Blade Boundary Type: Wall Location: BLADE Frame Type: Rotating Boundary Details tab: Mass And Momentum: No Slip Wall Wall Roughness: Smooth Wall Heat Transfer: Adiabatic

Click OK

Similarly define new Wall Boundary R1 Hub Location: HUB

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Setup
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Solving

Postprocessing

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Create Boundary: Shroud (in R1)

Select:

Right-click on Domain R1 > Insert >

Boundary Name: R1 Shroud Boundary Type: Wall Location: SHROUD Frame Type: Rotating Click on the Boundary Details tab Check the box for Wall Velocity Set the Option to Counter Rotating Wall (Counter Rotating in rotating system = stationary in global system)
Click OK
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Setup
December 17, 2012

Solving

Postprocessing

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Create Boundary: Outlet (in S1)

Select: Right-click on Domain S1 > Insert > Boundary Name: S1 Outlet Boundary Type: Outlet Location: OUTFLOW 2

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Setup
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Solving

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Create Boundary: Outlet (in S1)

Select: Mass Flow Rate: 0.3 [kg s^-1] Click OK

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Setup
December 17, 2012

Solving

Postprocessing

Summary
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Create Wall Boundaries in S1

Create additional Wall boundaries: S1 Hub: Location: HUB 2 S1 Shroud: Location: SHROUD 2 S1 Blade: Location: BLADE 2 Set Boundary Conditions to: Mass And Momentum: No Slip Wall Heat Transfer: Adiabatic

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Setup
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Solving

Postprocessing

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Periodic Interfaces
Periodic Interface are defined to connect the two sides of each domain

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Setup
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Periodic Interface: Rotor Domain

Select: Domain Interface Name: R1 Periodic Interface Type = Fluid Fluid Domain (Filter): R1 (for both sides) Region List: PER1 (Side 1) PER2 (Side 2) Interface Model: Rotational Periodicity Rotation Axis: Global Z Click OK

NOTE: Each side of the interface is a

boundary in the domain!
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Setup
December 17, 2012

Solving

Postprocessing

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Periodic Interface: Stator Domain

Select: Domain Interface Name: S1 Periodic Interface Type= Fluid Fluid Domain (Filter): S1 (for both sides) Region List: PER1 2 (Side 1) PER2 2(Side 2) Interface Model: Rotational Periodicity Rotation Axis: Global Z Click OK
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Setup
December 17, 2012

Solving

Postprocessing

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Stage Interface: Rotor to Stator

Select: Domain Interface Name: R1 to S1 Domain (Filter):
R1 (Side 1) S1 (Side 2) Region List: OUTFLOW (Side 1) INFLOW 2 (Side 2) Frame Change/Mixing Model: Stage Downstream Velocity Constraint: Stage Average Velocity
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Setup
December 17, 2012

Solving

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Check boundaries/interfaces defined

Check the outline tree for the boundaries and interfaces defined!

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Setup
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Solving

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Solver Control
Double-click Solver Control Advection Scheme: High Resolution

Turbulence Numerics: First Order

Max Iterations: 200 Physical Timescale: myPhysicalTimescale Click on expression symbol Right-click in box and select expression

Residual Type: MAX

Residual Target: 0.001
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Setup
December 17, 2012

Solving

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Output Control
Switch on Efficiency Output Double-click on Output Control

Select Monitor Tab > Monitor Objects

Tick Efficiency Output Efficiency Type : Compression Value: Total to Total NOTE: The efficiency calculates both
the Isentropic and Polytropic efficiencies

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Output Control
Define expressions for monitoring during the run. Pdiff gives the pressure rise developed by the fan.

Attention: The monitor name must differ from the expression name!

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Setup
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Solving

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Output Control
Create the following expressions to calculate Power consumed by the fan

Define number of rotor blades expression

Name: nRotor Value: 30

Define power expression

Name: power Value: (torque_z()@R1 Blade +

torque_z()@R1 Hub)*myRotationSpeed/1 [rad] *nRotor

Define Monitor Point for Power

Name: Power Expression Value: power

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Obtaining a solution
Launch CFX-Pre from CFX-Launcher Define stationary and rotating domain Define boundary conditions Define rotor stator interface Set up monitor points using simple expressions Define turbomachinery specific solver parameters Launch CFD-Post Rotate, zoom and pan the view Initialize turbo postprocessing Define turbo surface Use turbo coordinates for contour plots.

Launch the CFX Solver Manager Check solution process

Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5

Write the definition file

Right-click on Simulation Control and select Start Solver > Define Run Save the definition (def) file when prompted

The CFX-Solver Manager will open automatically

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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5

Run the CFX-Solver

The Solver Input File (definition file) for the run will already be specified If possible, set up a local parallel run

Click on Start Run

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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5

Monitor (Power)
The monitors for power and pressure difference will automatically appear in a window labelled User Points The pressure rise developed by the fan is about 1155 Pa The power consumed is about 6452 W

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Setup
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Solving

Postprocessing

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Monitor (Efficiency)
To view the Efficiency Output you will need a new monitor windows Select Workspace > New Monitor Right-click in the window and select Monitor Properties Click on the Plot Lines tab and expand EFFICIENCY in the tree Check the boxes for both the Isentropic and the Polytropic Compression For both the value is about 87.5%

Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5

Post-processing Goals
Launch CFX-Pre from CFX-Launcher Define stationary and rotating domain Define boundary conditions Define rotor stator interface Set up monitor points using simple expressions Define turbomachinery specific solver parameters Launch CFD-Post Rotate, zoom and pan the view Initialize turbo post-processing Define turbo surface Use turbo coordinates for contour plots.

Launch the CFX Solver Manager Check solution process

Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5

CFD-Post
Launch CFD-Post from CFXLauncher Load results: File Load Results

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Setup
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CFD-Post
Enter Turbo-Post Auto-initialize turbo components Based on naming conventions Blade Hub Shroud Inlet Outlet

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Setup
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Solving

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Summary
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CFD-Post
After initialization, turbospecific locations are available in CFD-Post Turbo Surface Turbo Line For details, please refer to Appendix A Turbo

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Setup
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Solving

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CFD-Post
Define turbo surface Constant Span = 0.5

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Setup
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Solving

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CFD-Post
Define Contour Plots for

Mach Number Total Pressure Total Pressure in Stn Frame

Note that, when there are rotating frames, some extra variables are created, e.g. Total Pressure in Stn Frame, Velocity in Stn Frame. These are referred to the stationary rather than the rotating frame and so are useful for visualization.
Introduction
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Setup
December 17, 2012

Solving

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CFD-Post
Change transformation Blade-to-Blade (ThetaM)

For details, please refer to Appendix A Turbo

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Setup
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Solving

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CFD-Post
Generate Vectors on Turbo-surface In Blade-to-Blade-view

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Setup
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Solving

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CFD Post
Quantitative Postprocessing

Evaluating Fan stage performance using

Gas Compressor Performance Macro Go to Tools > Macro calculator Select Macro: Gas Compressor Performance Specify Inputs as shown in picture Click on Calculate Click on View Report

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Summary
This workshop has shown a basic setup using multiple frames of reference An interface dealing with the frame change has been defined (frozen rotor) Post-processing in turbo-specific coordinate system has been defined Transformation of coordinates for visualisation has been set

Introduction
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Setup
December 17, 2012

Solving

Postprocessing

Summary
Release 14.5