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g.

Boolean Subtract:
i. Select the blade-hub body and the frustum body.
ii. Right click and select Boolean>Subtract.
iii. Set the target body to the frustum.
iv. Right click on each surface under the Subtract part and select “Split By Patch”
v. Create: 3 separate blades, hub, inlet, outlet, and boundary

h. Create Volumetric Control shape part


i. Create New Shape Part>Cylinder
ii. Set “Snap to Part” to the Subtract Hub
iii. Set the Start and End coordinates to (1350, 0, 0) and (600, 0, 0)
iv. Set the Cylinder Radius to 120mm
v. Select Create.
vi. Change “Snap to Part” to Blade3.
vii. Set Start and End coordinates to (900, 0, 0) and (900, -420, -270 )
viii. Set Radius to 100mm
ix. Select Create, then close.
x. Select the second cylinder, and duplicate twice.
xi. Rotate duplicates about the x-axis 2.0944 radians (120 degrees) and 4.18879
radians (240 degrees)
xii. Select all created cylinders, and preform a Boolean Unite

i. Create Derived Parts: Blade Sections and Hub Cut


i. Right click on Derived Parts, select New Part>Section>Plane
ii. Select Region for the input parts
iii. Snap to Hub
iv. Set as Normal to the positive Z-axis
v. Select New Scalar Displayer
vi. Click Create. Do not close.
vii. Snap to Blade1
viii. Set origin-Z at 135, 275, and 380. Click create for each span cut

3. Star-CCM+: Creating Regions and Mesh Generation


a. Right click on Subtract part. Select “Assign Parts to Region”
b. Set “Create One Region for All Parts”, “Create a Boundary for Each Part Surface”,
and “Create a Feature Curve for Each Part Curve”. Select Apply, and then close.
c. Under the new Region, click on the boundary “Subtract.Inlet”, and under
properties,change Type to “Velocity Inlet”.
d. Change Subtract.Boundary and Subtract.Outlet Type to “Pressure Outlet”
e. Create Physics Continua
i. Create a new Physics Continuum
ii. Select the following Models in order: Three Dimensional, Steady, Liquid,
Coupled Flow, IAPWS-IF97, Turbulent, Spalart-Allmaras Turbulence. Auto
select should select the required models. Note: this is where a new turbulence
model can be selected if desired.

f. For Subtract.Inlet, under the Physics Conditions, change “Flow Direction


Specification” to Components, and then under Physics Values, change Velocity
Magnitude to 1.5 m/s.
g. Create the rotating reference frame
i. Under Tools>Reference Frames: New>Rotating
ii. Select the new Rotating frame, and under properties, set Axis Direction to [1.0,
0.0, 0.0] and set the rotation rate to -97 rpm
iii. Go back to the created Region. Under Physics values, change the Reference
Frame to Rotating
h. Create Mesh Continua
i. Right click Continua, select New>Mesh Continuum
ii. Right click Mesh 1, select “Select Meshing Models”.
iii. Select the following models: Polyhedral Mesher, Prism Layer Mesher, and
Surface Remesher.
iv. Under Reference values, set Base Size to 100 mm
v. Under Volumetric Control, right click and select New. Set Part to the shape part
created earlier. Check the box for “Customize Polyhedral Mesher” and
“Customized Prism Layer Mesher”. Then, under Mesh Values, set Size Type to
“Absolute Size”, and then set to 5mm. Set Number of Prism Layers to 10, Prism
Layer Stretching to 1.3, and Prism Layer Thickness: Percentage of Base to 20.
Note, this is where an alternative mesh can be created.
i. Click Generate Volume Mesh on ribbon panel

4. Star-CCM+: Setting up Plots and Scenes


a. Create two new Reports: Reports>New Report> [Element Count …] > Moment,
and then also Force. Under Parts, select all three blades. Change the axis to [1.0,
0.0, 0.0]. Change type to “Pressure + Shear”
b. Create Power Report:
i. Create a new Expression Report. Rename to Power
ii. Under Properties, Change Dimensions to Power
iii. Add the Definition: ${Moment1Report}*-10.15782
c. Create Cp Report:
i. Create new Expression Report named Cp
ii. Add Definition: ${PowerReport}/(.5*1000*acos(-1)*pow(.45,2)*pow(1.5, 3))
d. Create Ct Report:
i. Create new Expression Report named Ct
ii. Add Definition: ${Force1Report}/(.5*1000*acos(-1)*pow(.45,2)*pow(1.5, 2))
e. Right click on Cp and Ct reports, select “Create Monitor and Plot from Report”, and
select Single Plot.
f. Create Static Pressure Scene:
i. Under scenes, right click and select New Scene>Scalar. Rename Static Pressure
ii. Under Pressure>Displayers>Scalar>Parts, select the boundaries for each blade
and the hub
iii. Under Pressure>Displayers>Scalar>Scalar Field>Function, select Static Pressure
g. Create Hub and Blade Sections Relative Velocity Magnitude and Pressure
Coefficient
Scene
i. Create four new Scalar Scenes with the Relative Velocity>Magnitude Function
ii. Set each scene to a different Span cut: hub, 10%, 50%, and 80%
iii. For Pressure Coefficient, change scalar function to Pressure Coeffiecient
5. Run Simulation