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Accurate and Efficient Turbomachinery

Simulation
Chad Custer, PhD
Turbomachinery Technical Specialist

Accurate and Efficient Turbomachinery


Simulation
Chad Custer, PhD
Turbomachinery Technical Specialist

Accurate and Efficient Turbomachinery


Simulation
Chad Custer, PhD
Turbomachinery Technical Specialist

Accurate and Efficient Turbomachinery


Simulation
Chad Custer, PhD
Turbomachinery Technical Specialist

Outline

Turbomachinery simulation advantages


Axial fan optimization

Description of design objectives


Optimization algorithm
Model setup
Design space
Results

STAR-CCM+
Integrated multi-physics simulation environment
Single environment for the complete simulation process

CAD
Geometry Modifications
Mesh
Physics
Post-processing

Geometry Handling
Direct of native and neutral CAD formats
Defeaturing
Fluid extraction

Mesh Generation

Key Capabilities
Automatic mesh generation
Polyhedral cells

Pipelined meshing
Simple global size settings
Local refinement control
Automatic solution interpolation
Fewer cells required

Mesh Generation

Critical for blade cooling


and turbocharger analyses

Key Capabilities
Polyhedral cells
Accurately capture complex geometry

Conformal interfaces
One-to-one communication between the fluid and solid

Prism layer generation


Body-fitted boundary layer mesh on all fluid walls

Mesh Generation

Key Benefits
Geometry capturing
High quality mesh
Smooth cell growth
Low skewness

Boundary layer capturing


Accurate heat transfer

Physics

Coupled Flow & Energy Model


Solves for conservation of mass, momentum, and energy simultaneously
Uses a time-marching (or pseudo-time-marching) approach
Preconditioned form allows for rapid convergence independent of Mach
number

Segregated Flow & Energy Model Also Available


Often used for low-Mach simulations
Solves flow & energy equations in an uncoupled manner
Linkage between the momentum and continuity equation achieved with a
predictor-corrector approach

Physics

Grid Sequencing Initialization


Modeling Time
Steady solver
Frozen rotor
Mixing plane

Implicit unsteady
Full wheel
Periodic sector

Harmonic balance

Steady Simulation
Frozen rotor
Solving for a particular instant in time
Achieved with in-place interfaces
Solution can vary from one blade to the next
The entire machine must be meshed
Common for cases where there are large difference in the flow solution from
one blade to the next (radial machines with volute)

Steady Simulation
Mixing Plane
Capable of using a non-reflecting treatment
Non-reflecting option should always be used with explicit interfaces
Eigen-mode analysis performed on interface
Pressure allowed to vary within each bin such that reflections are eliminated

Steady Simulation
Non-reflecting treatment critical for cut-on cases

Reflecting

Non-reflecting

Unsteady Simulation
Model equal sectors of each row

Harmonic Balance Basics


The harmonic balance method allows for the rapid computation of
periodic, unsteady flows
By recasting the governing equations in the frequency domain, it is
possible to converge to the unsteady solution
The HB method can be applied to many applications including:
Turbomachinery
Aeroelasticity (flutter and limit cycle oscillations)
Aeroacoustics

Outline

Axial fan optimization

Description of design objectives


Optimization algorithm
Model setup
Design space
Results

Model Overview
Fan is installed in a duct with a diameter of 59 cm
Fan inner diameter and shape fixed with a radius of 19 cm
Current straight bladed fan produces 2.5 kg/s using 542 W power
(aerodynamic only)

Analysis Objectives
Optimization study seeks to achieve two objectives:
1. Improve an existing fan design so that the same mass flow rate is
achieved with a lower power requirement

?
Baseline Design
Mass flow rate = 2.5 kg/s
Power = 542 W

Analysis Objectives
Optimization study seeks to achieve two objectives:
2. Obtain a set of fan designs that require the least power for any given
mass flow rate
Best Possible

Wasteful

Possible Design

Lower Power Design

Unfeasible

Optimization Algorithm
The optimization of two competing factors (mass flow and power) is
Pareto optimization
All points on the Pareto Front are the best possible designs
Pareto Front

Wasteful

Unfeasible

Typical Optimization Process


Standard Procedure
Build Baseline Model
Define Optimization Problem
Select Optimization Algorithm
and Set Tuning Parameters
Proposed Solution

Satisfied?

Optimized Solution

Modern Optimization Process


HEEDS Procedure
Build Baseline Model
Define Optimization Problem
Select Optimization Algorithm
and Set Tuning Parameters
Proposed
Solution
SHERPA

Satisfied?

Optimized Solution

Hybrid
Adaptive
No Tuning
Parameters
No Optimization
Expertise Required

Optimization Workflow
HEEDS Procedure
Build Baseline Model
Define Optimization Problem

Setup Complete.
SHERPA takes care of
the rest.
SHERPA

Optimized Solution

Model Setup

Mesh
Fan generated in STAR-CCM+ 3D CAD
Single blade passage meshed using periodic interfaces
Polyhedral mesh with body-fitted prism layers
Baseline design contained 690,000 cells

Model Setup

Physics
Steady MRF simulation
Coupled solver (CFL = 20)
Grid sequencing initialization
Realizable k- turbulence model

Design Space
Blade generated from three section profiles
Fan defined with 17 design parameters:

Number of blades
Rotation rate
Chord, camber, angle, x-translation and y-translation of each section
With these parameters it is possible to define blade shape, twist, sweep, and
stacking

Section 0

Section 1

Section 2

Visual Representation of Design Space

Examples of Possible Designs

Previous movie shows design parameters varied one-at-a-time


Optimate is able explore all combinations of design parameters

Computational Setup

Total of 300 trials


Each trial run on 16 cores
Ten trial run concurrently

Trial Process

Assign new design parameters


Mesh new configuration
Run grid sequencing initialization
Converge solution
Report results to SHERPA

Process takes ~1
hour for each trial.

Controlled by
Optimate. No user
intervention needed.

Pareto Optimization
Optimate will run cycles of cases used to explore the design space
Using the results from previous cycles, the optimization algorithm is able
to find better fan designs

Results of Objective #1
Improve the existing fan design so that the same mass flow rate is
achieved with lower power
Baseline Design
Optimized Design

m = 2.5 kg/s
p = 542 W
m = 2.6 kg/s
p = 242 W

Investigation of Optimized Fan


Baseline Design

Optimized Design

Investigation of Optimized Fan


Baseline Design

Optimized Design

Investigation of Optimized Fan


Baseline Design

Optimized Design

Investigation of Optimized Fan


Baseline Design

Optimized Design
10% Span

Investigation of Optimized Fan


Baseline Design

Optimized Design
50% Span

Investigation of Optimized Fan


Baseline Design

Separation at the tip results in low


mass flow near the outer diameter

Optimized Design

Optimized design results in uniform


exit profile

Review of Objective #1

Reduced power required for 2.5 kg/s flow rate by 55%


Design parameters and number of runs were the only inputs to the
optimization algorithm
Algorithm produced a case that resulted in:
Attached flow at all span-wise stations of the blade
High camber
High mass flow & Low power

Results of Objective #2
Obtain a set of fan designs that require the least power for any given mass
flow rate

Pareto Convergence
Converged Pareto optimization gives geometry requiring the lowest
power for a given mass flow rate
For each rank one response, there is no design that produces a higher
mass flow at a lower power

Results of Objective #2

Review of Objective #2

20 optimal fan designs produced


Mass flow rates up to 17 kg/s

Conclusions

Fan optimization study achieved two objectives:


1. Improve an existing fan design so that the same mass flow rate is
achieved with lower power

Baseline Design

Optimized Design

Mass flow rate = 2.5 kg/s


Power = 542 W

Mass flow rate = 2.6 kg/s


Power = 242 W

Conclusions
Fan optimization study achieved two objectives:
2. Found a set of fan designs that require the least power for any given
mass flow rate from 0 kg/s to 17 kg/s

Outline

Turbomachinery simulation advantages


Axial fan optimization

Description of design objectives


Optimization algorithm
Model setup
Design space
Results

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