several examples of turbomachinery design and … examples of turbomachinery design and...
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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 1/10www.cfturbo.com
Several Examples of TurbomachineryDesign and CFD-Simulation using
CFturbo® and STAR CCM+®
Dipl.-Ing. Ralph Peter Mueller CFturbo Software & Engineering GmbH Munich, Germany
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
CFturbo® Software & Engineering GmbH
Engineering CAD & Prototyping
• Turbomachinery Conceptual Design
• CFD/FEA Simulation
• Optimization
• 3D-CAD Modeling
• Prototyping
• Testing, Validation
CFturbo® Software
• Turbomachinery Design Software
• Automated Workflows
Company
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
ConceptualDesign
CFturbo®
Meshing, CFD-Simulation, Post-ProcessingSTAR CCM+
3D-CADCATIA, Creo, UG NX,
SolidWorks, SpaceClaim, …
ProductionComputation, optimization:interactively or automated
ExperimentsPrototyping, Testing,
Validation, …
Turbomachinery Design Process
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Manual „Optimization“ Workflow
Transsonic Radial CompressorTraditional common workflow: 5 … 25 model variations, 1 to 4 weeks,
Design point (BEP)Total pressure ratio: ∏tt = 4Mass flow rate: ṁ = 0.11 kg/sSpeed: n = 90.000 min-1
Power (limitation): Pm < 30 kW
20 Designs 20 Performance Curves 1 Prototype
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Automated Optimization Workflow Available
HEEDS
PerformanceDesign goals
Optimization
CCM+CFturbo
Centrifugal Pump Impeller Optimization300 automated model variations, time & cost depending on available resources
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
CFturbo Model Overview Pumps
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
CFturbo Model Overview Compressors, Turbines
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
CFturbo Model Overview Fans, Blowers
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 1. Radial Pump with Inducer
Comments- Generic CFturbo design, 5 design variations- Q=600 m³/h, P=120 bar, n=12000 rpm- Compare CFD-simulation
• Steady State, no cavitation• Transient flow, no cavitation• Transient flow, with cavitation
- No experimental are data available
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 1. Radial Pump with Inducer
0.2
0.4
0.6
0.8
1
1.2
1.4
0.4 0.6 0.8 1 1.2 1.4 1.6
Hea
d / H
ea
d D
es
ign
Po
int
Flow Rate / Flow Rate Design Point
steady state w/o cavitation
transient w/o cavitation
transient w/ cavitation
Design Point
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
,
Example 1. Radial Pump with Inducer
Volume Flow, Vapor Fraction
,
He
ad P
ress
ure
• Rising vapor fraction determines lower pressure• Transient flow simuation with cavitation modeling is
essential for NPSH calculations
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 2. Initial Design Axial Pump
- Typical design point for axial pump defined- First initial conceptual design by CFturbo- No diffuser or inlet guide vane. Rotor in pipe.
• n = 780 rpm• H = 15.6 feet• Q = 23,400 gpm• NPSHr = 27 feet• Tip diameter = 23 inches• Shroud diameter = 23.25 inches• 0.3 hub/tip ratio
- Steady state & transient Simulation, - Cavitation
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 2. Initial Design Axial Pump
Leading edge blade tip cavitation
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
0
10000
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400 900 1400 1900 2400
Dp
to
tal [
Pa]
Massflow [kg/s]
steady state transient transient with Cavitation model
Steep performance curve with saddle point, that is typical for axial pumps
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
0
0.1
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400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
effi
cie
ncy
[-]
MassFlow [kg/s]
transient stady state transient with Cavitation model
Very first initial design >> hydraulic efficiency should be significantly improved
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial BlowerComments- Customer design- CFD-Solver-Benchmark - Steady state (MFR) and transient flow- Coarse mesh (approx. 1 Mio. nodes)- Experimental data available
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial BlowerComments- Customer design- CFD-Solver-Benchmark - Steady state (MFR) and transient flow- Coarse mesh (approx. 1 Mio. nodes)- Experimental data available
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
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0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
Stat
icP
ress
ure
Dif
fere
nce
[Pa]
Q [m^3/s]
dp_InOut CCM+
dp_InOut CCM+ (transient)
dp_InOut Solver I
dp_InOut Solver II
dp_InOut Messung
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
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3500
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Stat
icP
ress
ure
Dif
fere
nce
[Pa]
Q [m^3/s]
dp_InOut Solver Mean
dp_InOut Solver Max
dp_InOut Solver Min
dp_InOut Messung
Example 3. Radial Blower
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
0
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0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
Pow
er P
I [W
]
Q [m^3/s]
PI CCM+
PI CCM+ (transient)
PI Solver I
PI Solver II
P Messung
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
0
100
200
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0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Pow
er P
I [W
]
Q [m^3/s]
PI Mean Solver
PI Max Solver
PI Min Solver
P Messung
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
0.0000
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0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
Effi
cien
cy [
-]
Q [m^3/s]
eta_InOut CCM+
eta_InOut CCM+ (transient)
eta_InOut Solver I
eta_InOut Solver II
eta_InOut Messung
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 3. Radial Blower
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0.700
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Effi
cien
cy [
-]
Q [m^3/s]
eta_InOut Solver Mean
eta_InOut Solver Max
eta_InOut Solver Min
eta_InOut Messung
Reasons of discrepancy between simulation and measurement should be investigated - mesh, time step, turbulence models,…
- check experimental set-up
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 4. Virtual Automotive Cooling Fan Test Rig
Downstream channelwith or w/o blockage
HeatExchanger
Impeller
Stator
- Customers supplier design- CFturbo impeller re-design - Performance curve simulations, Steady state
(MFR) + transient flow on a virtual testbench- Scientific investigation on downstream flow
patterns and performance curves- A challenge: PACKAGING
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Example 4. Virtual Automotive Cooling Fan Test Rig
Mixing Plane (Stage Inteface)
Mean values of pressure and momentumare used to provide radial distribution
Frozen Rotor
1:1 direct transfer of all physical valuesto the other side of the interface
Are these steady state models a good alternatives compared to transient simulation of axial automotive cooling fans?
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Frozen Rotor TransientMixing Plane
Downstream flow patterns
Example 4. Virtual Automotive Cooling Fan Test Rig
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Stat
icP
ress
ure
Dif
fere
nce
[Pa]
Transient
Mixing Plane (MP)
Frozen Rotor (FR)
Steady state CFD-solutions aredependent on the position ofthe Rotor-Stator-Interfaces!
>> Computation of energytransmission within theimpeller is affected!
Volume flow Q/Qref
Performance Curves
Example 4. Virtual Automotive Cooling Fan Test Rig
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Frozen Rotor
Transient
Mixing Plane
Example 4. Virtual Automotive Cooling Fan Test Rig
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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+
Summary
CFturbo® and STAR CCM+ is a powerful combination for conceptual Turbomachinerydesign and 3D-CFD-simulation
For different Turbomachinery applications different methodologies may be necessary
Transient simulations do provide more accurate results im most cases
Automated workflows and multi-objective optimization processes are available byadditional application of OPTIMATETM and HEEDSTM
Various types of Turbomachinery can be designed and investigated effectively• pumps, blowers, compressors, turbines• radial, mixed-flow and axial type• incompressible and compressible flow• without and with cavitation