8/18/2019 SCG2015 CFturbo Mueller
1/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 1/10
www.cfturbo.com
Several Examples of Turbomachinery
Design and CFD-Simulation usingCFturbo® and STAR CCM+®
Dipl.-Ing. Ralph Peter Mueller
CFturbo Software & Engineering GmbH
Munich, Germany
8/18/2019 SCG2015 CFturbo Mueller
2/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 2/10
www.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
8/18/2019 SCG2015 CFturbo Mueller
3/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 3/10
www.cfturbo.com
Several Examples of Turbomachinery Design and CFD-Simulation
using CFturbo® and STAR CCM+
Conceptual
Design
CFturbo®
Meshing, CFD-Simulation, Post-Processing
STAR CCM+
3D-CAD
CATIA, Creo, UG NX,SolidWorks, SpaceClaim, …
ProductionComputation, optimization:
interactively or automated
Experiments
Prototyping, Testing,Validation, …
Turbomachinery Design Process
8/18/2019 SCG2015 CFturbo Mueller
4/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 4/10
www.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 = 4
Mass flow rate: ṁ = 0.11 kg/s
Speed: n = 90.000 min-1
Power (limitation): Pm < 30 kW
20 Designs 20 Performance Curves 1 Prototype
8/18/2019 SCG2015 CFturbo Mueller
5/31
8/18/2019 SCG2015 CFturbo Mueller
6/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 6/10
www.cfturbo.com
Several Examples of Turbomachinery Design and CFD-Simulation
using CFturbo® and STAR CCM+
CFturbo Model Overview
Pumps
8/18/2019 SCG2015 CFturbo Mueller
7/31www.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
8/18/2019 SCG2015 CFturbo Mueller
8/31www.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
8/18/2019 SCG2015 CFturbo Mueller
9/31www.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
8/18/2019 SCG2015 CFturbo Mueller
10/31www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 10/10www.cfturbo.com
Several Examples of Turbomachinery Design and CFD-Simulation
using CFturbo® and STAR CCM+
8/18/2019 SCG2015 CFturbo Mueller
11/31www.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
H e a d
/ H e
a d
D e s i g n
P o i n t
Flow Rate / Flow Rate Design Point
steady state w/o cavitation
transient w/o cavitation
transient w/ cavitation
Design Point
8/18/2019 SCG2015 CFturbo Mueller
12/31www.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
,
H e a d P r e s s u r e
• Rising vapor fraction determines lower pressure
• Transient flow simuation with cavitation modeling is
essential for NPSH calculations
8/18/2019 SCG2015 CFturbo Mueller
13/31
8/18/2019 SCG2015 CFturbo Mueller
14/31www.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
8/18/2019 SCG2015 CFturbo Mueller
15/31
8/18/2019 SCG2015 CFturbo Mueller
16/31www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 16/10www.cfturbo.com
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
e f f i c i e n c
y [ -
]
MassFlow [kg/s]
transient stady state transient with Cavitation model
Very first initial design >> hydraulic efficiencyshould be significantly improved
8/18/2019 SCG2015 CFturbo Mueller
17/31www.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 Blower
Comments- Customer design
- CFD-Solver-Benchmark
- Steady state (MFR) and transient flow
- Coarse mesh (approx. 1 Mio. nodes)
- Experimental data available
8/18/2019 SCG2015 CFturbo Mueller
18/31www.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 Blower
Comments- Customer design
- CFD-Solver-Benchmark
- Steady state (MFR) and transient flow
- Coarse mesh (approx. 1 Mio. nodes)
- Experimental data available
8/18/2019 SCG2015 CFturbo Mueller
19/31
8/18/2019 SCG2015 CFturbo Mueller
20/31www.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
S t a t i c P r e s s u r e D i f f e r e n c e [ P a ]
Q [m^3/s]
dp_InOut CCM+
dp_InOut CCM+ (transient)
dp_InOut Solver I
dp_InOut Solver II
dp_InOut Messung
8/18/2019 SCG2015 CFturbo Mueller
21/31
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
S t a t i c P r e s s u r e D i f f e r e n c e [ P a ]
Q [m^3/s]
dp_InOut Solver Mean
dp_InOut Solver Max
dp_InOut Solver Min
dp_InOut Messung
Example 3. Radial Blower
8/18/2019 SCG2015 CFturbo Mueller
22/31
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
P o w e r P I [ W ]
Q [m^3/s]
PI CCM+
PI CCM+ (transient)
PI Solver I
PI Solver II
P Messung
8/18/2019 SCG2015 CFturbo Mueller
23/31
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
P o w e r P I [ W ]
Q [m^3/s]
PI Mean Solver
PI Max Solver
PI Min Solver
P Messung
8/18/2019 SCG2015 CFturbo Mueller
24/31
www.cfturbo.com© CFturbo® Software & Engineering GmbH Seite 24/10www.cfturbo.com
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
E f f i c i e n c y [ - ]
Q [m^3/s]
eta_InOut CCM+
eta_InOut CCM+ (transient)
eta_InOut Solver I
eta_InOut Solver II
eta_InOut Messung
8/18/2019 SCG2015 CFturbo Mueller
25/31
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
E f f i c i e n c y [ - ]
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
8/18/2019 SCG2015 CFturbo Mueller
26/31
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 channel
with or w/o blockage
Heat
Exchanger
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
8/18/2019 SCG2015 CFturbo Mueller
27/31
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 momentum
are used to provide radial distribution
Frozen Rotor
1:1 direct transfer of all physical values
to the other side of the interface
Are these steady state models a good alternatives compared to transient
simulation of axial automotive cooling fans?
8/18/2019 SCG2015 CFturbo Mueller
28/31
8/18/2019 SCG2015 CFturbo Mueller
29/31
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+
S t a t i c P r e
s s u r e D i f f e r e n c e
[ P
a ]
Transient
Mixing Plane (MP)
Frozen Rotor (FR)
Steady state CFD-solutions aredependent on the position of
the Rotor-Stator-Interfaces!
>> Computation of energy
transmission within the
impeller is affected!
Volume flow Q/Q ref
Performance Curves
Example 4. Virtual Automotive Cooling Fan Test Rig
8/18/2019 SCG2015 CFturbo Mueller
30/31
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
8/18/2019 SCG2015 CFturbo Mueller
31/31
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 by
additional 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
Top Related