ANSYS Aeromechanical Simulation Update

Sunil Patil, Andy Madden, Laith Zori

ANSYS, Inc.
April 2016
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2015 ANSYS, Inc.

April 12, 2016

Outline
Aeromechanical Simulation
Transient Blade Row Methods
Blade Flutter
Forced Response

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April 12, 2016

Aeromechanical Analysis
Fatigue and fracture of rotating components is a
challenge for industry

High temperature environment

Highly stressed
Low damping
Many vibration cycles

Industry trends point towards light weighting

More integrally bladed rotors (or blisks)

Wear or damage can demand complete replacement
Maintenance/downtime costs can be very high
Slender blades can be more susceptible to failure

Advanced aeromechanical simulation is becoming

standard practice

Demands a standard commercial tool that is easy to use

for design engineers
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April 12, 2016

Severe damage to bladed disk

(Zielinski, 2005)

Aeromechanical Analysis
Machine operability & durability
Flutter margin , High Cycle Fatigue (HCF)
Fundamentally transient multiphysics problem
FSI (expensive)
Practical, Efficient One Way Coupling Solutions
Blade Flutter & Aerodamping Calculations:
Mechanical Fluid
Determine if the aerodynamic loads damp out
blade vibration at natural frequencies

Forced Response:
Fluid Mechanical
Determine blade response (motion & stresses)
due to excitations from neighboring blade rows.

Tuned
Mistuned

2015 ANSYS, Inc.

April 12, 2016

Outline
Aeromechanical Simulation
Transient Blade Row Methods
Blade Flutter
Forced Response

2015 ANSYS, Inc.

April 12, 2016

Aero part of the Aeromechanical Analysis

Aerodamping

EO Forcing

Flutter Margin

m&x& + (c + caero ) x& + (k + k aero ) x = F (t )

Forced Response

Blade Flutter
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TBR Methods With Pitch-Change

Solve on
Reduced Geometry

ANSYS CFX transient pitch-change models

Full-wheel
Model

Profile
Transformation
(PT)

Time
Transformation
(TT)

Fourier
Transformation
(FT)

Small/Moderate Pitch

Small/Moderate Pitch

Large Pitch

Single Stage
Multistage

PT

Reduced
Model

Transient interaction

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April 12, 2016

Frozen gust
Single Stage
Multistage

TT

Frozen gust
Single Stage
Multistage
Blade Flutter

FT

Transient interaction
+
Correct blade passing frequencies

Time-Transformation (TT) Method

Capturing upstream and downstream blade passing influences

Provide engine order forcing to Forced Response analysis

Purdue Transonic Compressor
flow reconstruction from
TT Solution obtained on single
passage per row.

(Animation)
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Provide Forcing For Forced Response Analysis

Pressure Harmonics
Suction Side

EO 20

Pressure Side

Re

Im

Suction Side

Pressure Side

Re
20

EO 16
Im

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EO Forcing

ANSYS CFX TBR with pitch-change methods covers wide range of

turbomachinery configurations

FT or TT -TRS
Single-Stage

FT- ID
Fan inlet distortion

TT-TRS for 1.5 Stage

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FT-TRS
Impeller in Vaneless volute

FT-TRS
Impeller in Vaned volute

FT-ID multi-disturbance

Outline
Aeromechanical Simulation
Transient Blade Row Methods
Blade Flutter
Forced Response

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Blade Flutter/Aerodynamic Damping Calculations

Performance map based on

aerodynamic analysis

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Performance map based on

Aeromechanical analysis

Blade Flutter/Aerodynamic Damping Calculations

Blade Flutter Analysis:
Determine if the aero
loads will damp out blade
vibration at natural
frequencies

Performance map based on

aerodynamic analysis

Flutter Margin

Performance map based on

Aeromechanical analysis

Aerodamping in
Forced Response
analysis

(Animation)
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Blade Flutter Workflow

Import solid model

Generate CFD grid in TurboGrid

Pre-stressed modal
analysis in
ANSYS Mechanical

Steady CFX solution

Export mode shapes

and frequencies

Setup CFX for unsteady,

oscillating blade

Aerodynamic damping

Obtain CFX solutions for a range

of mode shapes + frequencies,
amplitudes and nodal diameters

Post process results and examine

for stability (damping)
Wall Power Density

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Blade Flutter Workflow

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Faster Transient Blade Row Flow Solution

Transient
Full Domain

Transient
With
Pitch-change
Reduced geometry
+
Fast convergence

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Harmonic Analysis
With
Pitch-change
Reduced geometry
+
Faster convergence

Harmonic Analysis
Blade Flutter/ Aerodynamic damping
On going V&V of aerodamping under HA method

Rotor-67
Axial Fan

Low Pressure Annular Turbine

All Calculations done with: 1 mode , 15 pseudo-time-step per oscillation cycle

starting from steady-state solution
FT-HA (1 mode) about 20x to 30x Faster than FT-Transient ( based +100 tspp)
FT-Transient about 5x to 7x faster than Full-wheel solution

10-to-100X faster
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STCF-11 Subsonic

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Outline
Aeromechanical Simulation
Transient Blade Row Methods
Blade Flutter
Forced Response

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Motivation For Faster Forced Response Analysis

Previous methods too costly or cumbersome
Some sectors alone can be upwards of 1 million DOF

m&x& + (c + caero ) x& + (k + k aero ) x = F ( )

Work flow is not streamlined

Fluid Model

Fluid Solve

ANSYS can handle these

details to improve forced
response workflow

FluidMechanical
Mapping

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Mechanical
Model

Mechanical
Solve

Mistuning

Postprocess

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Lifing

Forced Response
Forced response computes displacements and stresses for fatigue analyses
Frequency domain (harmonic response)
Forcing is oscillatory
EO Forcing
Aerodamping
Steady state -> HCF
More information, faster
Cyclic space
Less memory, less disk space
Faster
Modal domain (MSUP)
Faster

Excitation Reduced
frequency mass

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Reduced
damping

April 12, 2016

Reduced
stiffness

Mistuning
terms

Aero
Stiffness

Projection to modal
space and expansion
from cyclic domain

Single sector engine

order forcing

Core Technology: Cyclic Symmetry Analysis

Cyclic symmetry analysis

Reduce Finite Element DOF by using a sector of the system

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Increase computational speed

Saves disk space and memory
Dynamical properties are kept
(eigenvalues, eigenvectors)

April 12, 2016

+10Xfaster

Core Technology: Mode Superposition Analysis

Mode Superposition Analysis

Upfront costs for future speedup

+10X faster

Upfront cost Modal analysis on all DOF

Downstream speedup Solve each frequency with only modal DOF

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Forced Response Analysis: Tuned and Mistuned

Tuned System
All sectors are identical in every way
All sectors respond with the same amplitudes
Can be modeled with a single sector
A starting point for nominal design and analysis

Mistuned System
Sectors have deviations in material, shape, size, etc.
due to damage, manufacturing differences, and wear
Sectors have different response amplitudes
Can result in dramatically increased amplitudes!

Must model entire 360 structure or do other special

treatment for modeling
Statistical analyses on various mistuned systems are
used to further explore the nominal design

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Fast and Efficient Forced Response Method

Computation Cost

TUNED ANALYSIS
+100X faster

Frequency Based
Forced Response
FR

Cyclic FR

MSUP FR

Cyclic MSUP FR

Modal Reduction
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Fast and Efficient Forced Response Method

MISTUNED
Computation Cost

+100,000 X
faster with
mistuning
+100X faster
statistics

Frequency Based
Forced Response
FR

Cyclic FR

MSUP FR

Cyclic MSUP FR

Modal Reduction
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Forced Response Workflow

Mechanical Cold Geometry

CFD
Hot Geometry

Structural Cyclic Model

CFD Unsteady Flow
Pressures

Prestressed Static Analysis

Apply temperature and
OMEGA loading
Linear Perturbation Modal Analysis
[UPGEOM to hot]
Map to
Structure Mesh
Forced Response Solution
Postprocess
Displacements,
Stresses and Strains

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Mistuning

Turbo-Specific Tools

Data from
CFD

Mapping Challenges Addressed

o Geometry alignment tools
o Map CFX or other CFD data
o Check mapping

Align

Map and
Verify

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Turbo-Specific Tools
Engine Order (EO) Forcing
Engine order (or traveling wave) excitation
simulates the behavior in engines
Simple application
Other tools require the user to compute
the blade-blade phase shifts manually

Interference Diagrams
Can be created after the modal solve
Common tool to understand the nominal
system

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Turbo-Specific Tools
Post processing
Specialized tools to fully explore results
Flexible: Can get all of the results or only
selected information
L2 norm for each blade, max anywhere
on the blade, max over a cycle of
motion, etc.
Plots of spatial harmonic response
Plots of responses vs. sector number
Plots of responses vs. frequency
Modal Coordinates

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Response Vs. Sector no.

Response Vs. Frequency

Forced Response Supports SMP Parallel

Cyclic harmonic mode-superposition analysis now supports shared-memory

parallel (SMP, -np on the command line)
1st Principal Stress Sweep Calculation Speedup
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Relative Speedup

Speedup using 1 to 32 processors:

1st Principal stress sweep
1270 nodes on pressure face
18 sectors
23000 total nodes evaluated

10X faster

0
0

10

15

20

25

Number of Processors (SMP)

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New Distributed LANB for Cyclic Modal

Block Lanczos Eigensolver

7
Simulation Speedups

2 million DOFs
Modal analysis w/ 50 modes
4 Intel Xeon E5-4650 (32 cores
total), 512 GB RAM, Linux
RHEL 6.3

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R16.0

5.8

R17.0

1.5X faster

3.5 3.7
2.8 2.9

3
1.7 1.9

2
1

3.9

1.0

0
1 core

2 cores

4 cores

8 cores 16 cores

Example: NASA Rotor 67 (Mistuned) Workbench

NASA R67 transonic fan subjected to inlet distortion
22 rotor blade
Inlet distortion:
1-per-revolution
modeled as Total Pressure cosine variation
with 10% amplitude

Instantaneous Pressure

Resonance response expected at EO=2 crossing

1st bending frequency (1B) @ 16043 RPM

EO excitation was obtained from CFX using FT

method (2 passages)

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Example: NASA Rotor 67 (Mistuned) Workbench

Small industrial sized example

Number of sectors: 22
Number of elements: 3141 per sector
Number of nodes: 18133 per sector

CFD

Structural

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CFD inputs from CFX

Provide Pressure harmonics for:
User-specified engine order (EO) from blade row interaction
Data contained in .CSV file which will be read in mechanical and
contain all the needed information for Forced Response Analysis
Mesh information
Rotation axis
Rotation speed
Engine Order
Pressure Harmonics

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NASA Rotor 67 Mapping

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Mapping
Successful mapping of pressure data from CFX TBR to the mechanical mesh

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NASA Rotor 67 Modal Results

Modal range: 0 3000 Hz

Modal HI: 2

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Interference Diagram

April 12, 2016

NASA Rotor 67 Harmonic Results

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NASA Rotor 67 Harmonic Results

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Summary

ANSYS customers are challenged to deliver reliable, high

performance turbomachinery in a competitive marketplace

Accordingly, ANSYS continues to enhance its turbomachinery

capabilities to enable customers to execute key business initiatives

Specifically,
ANSYS release 17.0 provides state-of-the-art aeromechanical simulation with
streamlined workflow
Aerodynamic performance, Engine-order forcing and aerodamping predictions
are obtained fast and efficiently with ANSYS CFX transient blade row methods
Cyclic Harmonic Mode Superposition provides powerful and scalable tuned
and mistuned forced response analysis

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Thank You
For
Your Attention!

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