WEBSEM Aero Acoustic Simulation Dec2013

Restricted LMS International 2013 All rights reserved.
Flow-induced noise simulation

Virtual.Lab Acoustics Rev12
Raphael Hallez Product Manager Acoustics
20XX-XX-XX
Page 2
Flow phenomena
What happens in the presence of flow ?
Wave convection:
- Significant at high Mach (M=v
flow
/c>0.3)
- Flow is NOT the noise source
- Flow influences the wave propagation
- Example: Aeroengine Inlet, muffler,
Steady
Flow
Noise Source
Wave propagation is modified by flow
Flow-induced vibrations:
- Fluctuations from unsteady turbulent flow
- Flow acts as a loading of the flexible structure
- Example: Aircraft fuselage TBL loading, train
door,
Turbulent
Flow
Structural vibrations
Structure-borne noise
Flow-induced noise Aeroacoustics:
- Fluctuations from unsteady turbulent flow
- Flow acts as a noise source
- Acoustic waves propagate in medium at rest or are
convected by the mean flow component
- Example: pantograph, landing gear, cooling fan,
Turbulent
Flow
Flow fluctuations
Flow-induced noise
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Page 3
Flow-Induced Noise phenomena
Flow-induced noise = noise generated by turbulent flow
phenomena
Vortices, turbulent eddies
Vortex shedding (von Karman vortex street)
Turbulent boundary layers and boundary layer separation
Rotating surfaces in a fluid (propellers, fans)
Level of turbulence in the flow, characterized by Reynolds number:
Low Re Large flow scales
High Re Large flow scales + smaller flow scales
Unsteady vortices on many scales interact with each other and with
steady or moving surfaces Noise generation
VL
= Re
Speed Sound
Velocity Flow
Mach =
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Page 4
Flow-induced noise simulation examples
External Aeroacoustics:
Turbulent flow interacts with static body and radiates noise outside
Challenge: Capture the sources and reflection/scattering on large
surfaces
Train bogie, Landing Gear, Wiper
Internal Aeroacoustics / Confined flow:
Propagation of sources (duct noise and blower noise) in ducting
system and radiation through outlet
Challenge: Capture the acoustic reflections on duct walls (guided
waves)
HVAC, exhaust, intake, ECS
Mixed Internal-External Aeroacoustics
Transmission through flexible panel Aero-Vibro-Acoustics
Challenge: Capture Hydrodynamic+Acoustic loading, capture
dynamics of system
Windnoise (side mirror, A-pillar), fuselage TBL
20XX-XX-XX
Page 5
Flow-Induced Noise : A Challenge for Numerical
Simulation
Acoustic field = part of the flow field most straightforward approach: Direct
Computational AeroAcoustics (CAA) (=direct numerical simulation of both the unsteady
turbulent flow and the noise it generates)
But not practical because :
High order schemes needed to capture acoustic propagation (numerical instabilities)
High numerical cost of a direct CAA
prohibitive at low Mach and high Reynolds numbers
Also, specific issues related to CFD discretisation techniques applied to acoustics
Dissipation and dispersion errors
Non-reflecting Boundary conditions
p = 4.4934739 Pa
hydrodynamic
field
acoustic
field
at low - moderate Mach numbers: orders of magnitude of
difference between
Length scales:
ac
= L
turb
/ M
Magnitudes: O(M
4
) of the flow energy radiates into the
far field
20XX-XX-XX
Page 6
AeroAcoustic Analogy : a more suited approach...
Decoupling flow simulation from the acoustic simulation
Flow computation : creating source field data
Acoustic computation : post-processing of source field data
Fundamental assumption = one-way coupling
Unsteady flow produces sound and affects its propagation
BUT: sound waves do not affect flow field significantly
Principal application of the hybrid approach: flows at low Mach
numbers, no strong coupling like in sunroof buffeting case
source
region
observer
position
L
d
Preferred simulation tools for the flow description
Reynolds Averaged Navier-Stokes (RANS) solver
time-averaged data (some hope with SNGR, RPM)
Unsteady RANS unsteady, but only large scale
Large Eddy Simulation (LES)
Detached Eddy Simulation (DES)
unsteady, broadband turbulence (up to grid & scheme cut-off
frequency)
Important: Low-Mach number limitation
Incompressible LES / DES data supported to reduce CPU cost
http://www.lmfa.ec-lyon.fr/recherche/turbo
U-RANS
LES
20XX-XX-XX
Page 7
Aero-Acoustic Sources
Turbulent Flow
Moving Surfaces
Steady Surfaces
No Surfaces
(or smooth surfaces)
Quadrupoles
Dipoles on surfaces (+ Quadrupoles in wake)
Rotating Dipoles (+ Quadrupoles in wake)
20XX-XX-XX
Page 8
Source Generation in Virtual.Lab
Dipole Sources
Flow-induced noise in presence of static surfaces with compact regions
Requires pressure data on the walls (compressible or incompressible)
Quadrupole Sources :
Flow-induced noise without presence of surfaces (turbulent jets) or non-
compact regions
Requires velocity vector data in flow volume
Fan Sources = Rotating Dipoles Sources
Flow-induced noise caused by rotating surfaces (fan)
Requires pressure data on one or all blades surface for multiple
revolutions
20XX-XX-XX
Page 9
Simulation Process based on Aeroacoustic analogy
Fluid Dynamics
Acoustics
Transient CFD
Simulation
Aeroacoustic sources
Virtual.Lab Acoustics
Computation
Data Mapping + Fourier
Transform
Acoustics Results
Turbulent Flow
Field
20XX-XX-XX
Page 10
CFD-Acoustics Coupling in Virtual.Lab
VIRTUAL.LAB supports CFD data stored in CGNS
format files (CFD General Notation System)
Following commercial CFD codes already support
CGNS export for aero-acoustical data :
CFX (Ansys)
FLUENT (Ansys)
STAR-CD 4 / STAR-CCM+ (CD Adapco)
PowerFlow (EXA)
CFD++ (Metacomp)
SCRYU/Tetra (Cradle Software)
Fine Turbo (Numeca)
OpenFoam
20XX-XX-XX
Page 11
What can Virtual.Lab do more than CFD alone?
Effect of
acoustics on
flow (strong
feedback)
far-field
scattering
Absorbing
materials
Flow-
induced
vibration
CFD Direct CAA

CFD postprocessing
(FWH)
Hybrid Approach
(CFD + Virtual.Lab)

20XX-XX-XX
Page 12
Dipole sources from Compressible CFD Curle
Curles solution (1955) to Lighthills equation in presence of solid rigid boundaries (neglecting
viscous effects)
Quadrupole incident field negligible for low Mach numbers (Power ratio = M
2
)
Mathematically exact solution But: P
f
must satisfy acoustic boundary conditions
OK if the flow description is compressible
if the flow description is incompressible and surface is not acoustically
compact, the solution is inaccurate (missing acoustic reflection and scattering
effects)
Quadrupoles (negligible
at low Mach numbers)
Dipole Surface pressure
20XX-XX-XX
Page 13
Curles analogy: what the compactness assumption
means
Curle assumes the CFD captures all acoustic effects on the source surfaces
(hydrodynamic pressure+acoustic scattered pressure)
Not true for incompressible CFD or non-compact surfaces
Surface with sources will be seen as acoustically transparent!
20XX-XX-XX
Page 14
Dipole sources from Incompressible CFD
Neumann Dipoles
Import CFD
pressure P
f
and
define surface
dipoles
Transform
dipoles into
acoustic
(Neumann) BCs
Compute acoustic
solution
flow wall pressure can be used to define appropriate boundary conditions of an equivalent
acoustic boundary value problem
If flow is compressible equivalent to Curle
If flow is incompressible, G is the Greens function of Laplace problem (infinite sound speed)
More flexible: can be applied to Indirect BEM and FEM
More accurate than standard Curle (recomputes acoustic scattering and reflection effects)
20XX-XX-XX
Page 15
Example: Trailing edge noise prediction based on
incompressible-flow pressure
Reference solution
Curle
New formulation
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Page 16
Virtual.Lab AeroAcoustics - Slide 16
Flow:
Acoustic:
Example: Rod-Airfoil Noise prediction based on
FEM mesh
20XX-XX-XX
Page 17
17 copyright LMS International - 2010
Example: Rod-Airfoil Noise prediction based on
Comparison with measurements
Neumann dipoles
1 freq 495 freq 4 cores
FEM Neumann Incompressible 2min+10s 11min+1h20 3min+20 min
20XX-XX-XX
Page 18
Virtual.Lab Aero-Acoustics
Dipole Source Generation Step by step
Import CFD surface pressure data
(centroids/nodes)
Map CFD pressure on acoustic mesh + Fourier transform
20XX-XX-XX
Page 19
Dipole Source Generation Step by step
Define Surface Dipole Boundary Condition (distributed dipoles are defined on
acoustic mesh boundary condition)
Solve the acoustic response case (FEM or BEM) + post-process
20XX-XX-XX
Page 20
Special feature : Conservative mapping
Specific conservative mapping algorithm to preserve information
over a large range of flow scales:
Fine CFD mesh Coarse Acoustic mesh
Map turbulent
flow field
Flow scales very small
CFD mesh has extremely
small cells (Millions of DOFs)
Acoustic wavelength large
compared to Flow scales
Acoustic mesh coarser than
CFD mesh (Lelement=~/6)

=
Mesh Acoustic Mesh CFD
PdS pds
20XX-XX-XX
Page 21
Quadrupole sources for more complex problems
(for high Reynolds number,
isentropic flow and low Mach
number)
Lighthills equation : incident field from quadrupoles + scattering on surfaces
more generic :
non compact source regions
Aero-vibro-acoustics
Higher flow speed
But:
Difficult to deal with volume data set
Singularity for sources close to walls
Mapping from CFD to coarse acoustic mesh
20XX-XX-XX
Page 22
Quadrupole sources
New formulation in Virtual.Lab R13
New implementation in Virtual.Lab R13:
Best performance: supported by FEMAO solver (Adaptive order FEM)
Improved Usability: CFD data directly read by solver (linux support)
Improved Accuracy: No mapping required on intermediate mesh, no singularity issue.
FEMAO = FEM Adaptive Order solver:
Start from coarse mesh (less than 1 element /
wavelength!)
Solver automatically increases the element order
at high frequency
Most efficient FEM solver for broad frequency
computation
Most accurate scattering modeling
Up to 20 times Less memory and faster
computation time than standard FEM!
FEMAO Acoustic mesh
36 000 nodes
Max freq FEM: 200 Hz
Max freq FEMAO: 4000 Hz
20XX-XX-XX
Page 23
Fan noise components
Aeronautical
Energy
Automotive
Fan Noise
Tonal
(Discrete Frequency)
Broadband
Unsteady pressure fluctuations
on the blade surface
Incoming turbulence (Leading edge)
Self-noise (Trailing edge)
Tip vortex shedding
Component Source
20XX-XX-XX
Page 24
Rotor-stator configuration noise generation mechanisms
1 Rotor leading-edge noise 2 Rotor trailing-edge noise 3 Wake interaction noise on stator
Interaction of inflow
turbulence with leading
edge
Depends on inflow
turbulence
Modeled with fan
source
Interaction of boundary
layer with trailing edge
Important for high
rotation speed
Modeled with fan
source
Flow
R RO OT TO OR R S ST TA AT TO OR R
Interaction of rotor
wake with stator
Modeled with surface
dipoles
20XX-XX-XX
Page 25
FWH formulation for fan noise
Constructive interference:
sound of the total fan =
B x (sound of a single blade)
Sound
emitted at
BPFHs
Sum over
BLHs
Bessel function: modulation of
the Doppler frequency shift
during blade revolution
Radius where
force is applied
Thrust
harmonic
Drag
harmonic
Tonal fan noise formulation:
Fan blade represented by a rotating point dipole (force obtained by
integration of CFD surface pressure)
Rotation effects (Doppler shift) accounted for analytically (no rotating
mesh)
If blade is large, automatically split into compact segments
Captures both Tonal and Broadband components
Needs unsteady pressure for multiple blade revolutions
20XX-XX-XX
Page 26
Industrial Case Study
Radial Fan Noise : internal pressure distribution
Internal SPL distribution in the blower
ducts (around 3 kHz)
Observe intake and outlet
noise maxima in external SPL
distribution
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7 8 9
Microphones
P
r
e
s
s
u
r
e

L
e
v
e
l

d
B
(
A
)
Measurement
Computed
20XX-XX-XX
Page 27
Fan noise application
Contra-rotating open rotors
Interesting fuel efficiency
Very loud tonal noise: interaction
tones from each rotor:
Freq1=1BPF1+1BPF2
Freq2=1BPF1+2BPF2
Freq3=2BPF1+1BPF2

Each tone has a specific directivity
(interaction tones tend to radiate
radially)
Incident field captured with
Aeroacoustic Fan source
Installation effects captured with
FEMAO solver
20XX-XX-XX
Page 28
Aero-acoustics
Example HVAC Duct
Source regions
(vorticity)
Flow:
Acoustic:
Dipoles on the flap Far-field acoustic radiation
10
1
10
2
10
3
30
40
50
60
70
80
90
100
110
frequency (Hz)
S
P
L

(
d
B
)
CFD
experiments (Jaeger et al. 2008)
Instantaneous velocity
From consortium of German car manufacturers - Audi, BMW, Daimler, Porsche and
Volkswagen where LMS participated
20XX-XX-XX
Page 29
10
1
10
2
10
3
30
40
50
60
70
80
90
100
110
frequency (Hz)
S
P
L

(
d
B
)
CFD
CFD results: pressure on the wall
C
10
1
10
2
10
3
30
40
50
60
70
80
90
100
110
frequency (Hz)
S
P
L

(
d
B
)
CFD
10
1
10
2
10
3
30
40
50
60
70
80
90
100
110
frequency (Hz)
S
P
L

(
d
B
)
CFD
B
A
B
C
- Very good agreement
downstream the flap
- Overprediction in the elbow
separation region
A
20XX-XX-XX
Page 30
Acoustic modeling
Source region
(dipoles)
exterior field points
Inlet (absorbent
panel Z = c)
Aeroacoustic sources: distributed dipoles defined from CFD pressure
Implementation in FEM: transformation of CFD pressure into equivalent
Neumann BCs (more details in AIAA2012-2070)
267 030 TETRA4 elements
computation time: 10 s/freq
PML
FEM model
20XX-XX-XX
Page 31
HVAC Flap Application case - accuracy
Acoustic radiation Averaged over all measurement points:
New Neumann-based source modeling
Experimental
Numerical (FEM)
20XX-XX-XX
Page 32
Noise Radiated from a Train Bogie
High speed train - CFD done with EXA Powerflow (Lattice-Boltzman) Courtesy of Bombardier
Surface Velocity magnitude Vorticity
Pressure coefficient
Velocity magnitude
20XX-XX-XX
Page 33
Noise Radiated from a Train Bogie
Comparison with measurements
(Pressure at 6 m on the side):
Source distribution on the train bogey
Sound radiated in far-field
20XX-XX-XX
Page 34
Flow-induced Vibrations
Flow acts as a structural pressure loading:
pump vibration
Windnoise (turbulence around A-pilar, mirror)
turbulent Boundary layer loading on fuselage or hull
How to get pressure loading?
Directly from CFD (compressible)
From Aeroacoustic source propagation (side mirror
noise)
From analytical models (Corcos, Chase)
How to compute vibro-acoustic response
Apply loading on structural model (modal or direct)
Compute vibration in a weakly or strongly-coupled
model
Apply vibration as Boundary Condition for acoustic
model with FEMAO
20XX-XX-XX
Page 35
Windnoise application case
Description and modeling process
A-pillar Turbulence
Mic.
Glass
Interior Walls
Outer Walls (Rigid)
External CFD
Model Transient
Flow
Vibrating Surfaces
(Side Glass, Windshield)
Acoustics Model
(Car Interior)
Coupled Vibration & Acoustics Model
LMS Virtual.Lab Acoustics
Inflow
CFD Model
ANSYS Fluent
Noise prediction at interior of the HSM (Hyundai Simplified Model released by
HKMC) caused by transient external aerodynamic sources around A-pillar
20XX-XX-XX
Page 36
CFD Model
CFD Domain consists of 45 million cells
2
nd
order implicit transient formulation (time step: 2.0e-
5s)
Total physical time = 1 s (5120 time steps)
4 different cases: 110 and 130 km/h, 0 and 10 deg.
Yaw
Solver : ANSYS Fluent (Pressure Based, Double
Precision, Transient , Gradient Least Square Cell
Based)
Turbulence Model Transient : DDES SST K-Omega
Total computation time: 15 days for the transient run
and 12 Hours for steady run with Intel 2*6 core Xeon
5680, 4 m/c connected via infiniband (total 48 cores)
20XX-XX-XX
Page 37
Transient Flow Field of 110kph, 10deg Yaw
Velocity Contours at Z = 0.5 m Pressure Contours at Z = 0.5 m
Iso-surface of Q-Criterion colored by velocity magnitude
20XX-XX-XX
Page 38
Flow
Vibration
Acoustics
Aero-Vibro-acoustic modeling strategy
compressible flow simulation captures Unsteady Turbulent flow
contains both hydrodynamic and acoustic components
Directly applied as structural pressure loading
Assume vibration has no influence on the flow uncoupled flow-
vibration approach
Structural FE model captures dynamics of structure
Modal approach is used (with uniform modal damping)
Windows vibration defined as Boundary condition for Acoustic
model.
Assume Vibration is independent from fluid loading weakly
coupled vibro-acoustic approach (OK for target frequencies)
Acoustic radiation computed with FEM-AO solver (adaptive
order)
20XX-XX-XX
Page 39
Structural model
CFD loading
CFD Surface Pressure is mapped onto Structural mesh in LMS Virtual.Lab
5120 time steps, dt = 2e-5s, T = 0.1s
Pressure is transformed from time to frequency (df=10Hz) and applied as distributed
pressure loading
No time averaging is performed here (could be done if time history is long enough to
improve convergence of predictions)
Structural modes computed with LMS Virtual.Lab structural solver
CFD Pressure 500 Hz Structural mode shape
Window FRF
20XX-XX-XX
Page 40
SPL Results
Excellent match with measurements both for SPL and effect of flow speed
Computation time: 6 hours for 400 frequencies with 4 cores Win64
Thanks to Ashok Khondge and Myunghoon Lee from Ansys Inc. for running CFD.
More details: See proceedings of KSNVE Conference 2013
0 deg. Yaw 130 km/h
Effect of flow speed
20XX-XX-XX
Page 41
Conclusions
Virtual.Lab Acoustics powerful tool for aero-acoustics
simulation
Various aeroacoustic sources for accurate modeling:
Dipole sources for compressible and
incompressible flow description
Quadrupole sources in FEMAO solver
Fan sources for tonal and broadband noise
Virtual.Lab for Flow-induced vibrations:
Integrated vibro-acoustic solver
Poro-elastic and visco-elastic material modeling
20XX-XX-XX
Page 42
Pour toutes informations complmentaires
Pour toutes informations complmentaires, vous pouvez contacter :
Yohann MESMIN :
yohann.mesmin@lmsintl.com
T : +33 (0) 1 34 52 17 55
M : +33 (0) 6 18 55 17 60

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Flow-induced noise simulation

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