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www.cfturbo.com © CFturbo ® Software & Engineering GmbH Seite 1/10 www.cfturbo.com Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo ® and STAR CCM+ Ralph Peter Mueller CFturbo Software & Engineering GmbH Munich, Germany in collaboration with Michael Hailfinger, Daniel Poescha, Anne Schubert and Ganeshkumar Udayakumar 兆水科技應用案例
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Page 1: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 1/10www.cfturbo.com

Several Examples of TurbomachineryDesign and CFD-Simulation using

CFturbo® and STAR CCM+

Ralph Peter Mueller CFturbo Software & Engineering GmbH Munich, Germany

in collaboration with Michael Hailfinger, Daniel Poescha, Anne Schubert and Ganeshkumar Udayakumar

兆水科技應用案例

Page 2: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 2/10www.cfturbo.com

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

兆水科技應用案例

Page 3: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 3/10www.cfturbo.com

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

兆水科技應用案例

Page 4: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 4/10www.cfturbo.com

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

兆水科技應用案例

Page 5: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 5/10www.cfturbo.com

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

兆水科技應用案例

Page 6: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 6/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

CFturbo Model Overview Pumps

兆水科技應用案例

Page 7: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 7/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

CFturbo Model Overview Compressors, Turbines

兆水科技應用案例

Page 8: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 8/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

CFturbo Model Overview Fans, Blowers

兆水科技應用案例

Page 9: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 9/10www.cfturbo.com

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

兆水科技應用案例

Page 10: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 10/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

兆水科技應用案例

Page 11: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 11/10www.cfturbo.com

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

兆水科技應用案例

Page 12: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 12/10www.cfturbo.com

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

兆水科技應用案例

Page 13: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 13/10www.cfturbo.com

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

兆水科技應用案例

Page 14: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 14/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 2. Initial Design Axial Pump

Leading edge blade tip cavitation

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 15/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

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

兆水科技應用案例

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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

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

兆水科技應用案例

Page 17: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 17/10www.cfturbo.com

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

兆水科技應用案例

Page 18: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 18/10www.cfturbo.com

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

兆水科技應用案例

Page 19: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 19/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

兆水科技應用案例

Page 20: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 20/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

0

500

1000

1500

2000

2500

3000

3500

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

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 21/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

0

500

1000

1500

2000

2500

3000

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

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 22/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

0

100

200

300

400

500

600

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

兆水科技應用案例

Page 23: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 23/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

0

100

200

300

400

500

600

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

兆水科技應用案例

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Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

0,0000

0,1000

0,2000

0,3000

0,4000

0,5000

0,6000

0,7000

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

兆水科技應用案例

Page 25: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 25/10www.cfturbo.com

Several Examples of Turbomachinery Design and CFD-Simulation using CFturbo® and STAR CCM+

Example 3. Radial Blower

0,000

0,100

0,200

0,300

0,400

0,500

0,600

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

兆水科技應用案例

Page 26: QFl4yÑb aÉu(hHO

www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 26/10www.cfturbo.com

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

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 27/10www.cfturbo.com

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?

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 28/10www.cfturbo.com

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

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 29/10www.cfturbo.com

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

兆水科技應用案例

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www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 30/10www.cfturbo.com

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

兆水科技應用案例

Page 31: QFl4yÑb aÉu(hHO

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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

兆水科技應用案例