Essentials of Turbo Machinery in CFD: Ideen Sadrehaghighi
Essentials of Turbo Machinery in CFD: Ideen Sadrehaghighi
Essentials of Turbo Machinery in CFD: Ideen Sadrehaghighi
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Essentials of Turbo
machinery in CFD
Ideen Sadrehaghighi, Ph.D.
Flow in Axial
turboMacines (CD-
Adapco)
Unsteady Flow
in Axial
TurboMachines
(ANSYS)
Unsteady Flow in
Radial
TurboMachines
(ANSYS)
ANNAPOLIS, MD
2
Contents
List of Tables......................................................................................................................................................................... 6
List of Figures ....................................................................................................................................................................... 6
1 Introduction ................................................................................................................................ 11
List of Tables
Table 3.1 Prescribed Boundary zone for Mixing Plane ..................................................................................... 31
Table 4.1 Glossary of Turbomachinery Terms ...................................................................................................... 44
Table 6.1 Parameters of the grids used .................................................................................................................... 97
Table 7.1 Rotor/Stator Interaction Schemes ...................................................................................................... 122
List of Figures
Figure 2.1 Vortex created by the passage of an aircraft wing, revealed by colored smoke ............... 13
Figure 2.2 A rigid-body vortex ..................................................................................................................................... 14
Figure 2.3 3D visualization of a vortex curves ...................................................................................................... 15
7
Figure 5.5 Coriolis and Centripetal forces created by the Rotating Frame of Reference .................... 68
Figure 5.6 Compression process ................................................................................................................................. 69
Figure 5.7 Expansion process ...................................................................................................................................... 69
Figure 6.1 Complex Flow phenomena compressors ........................................................................................... 71
Figure 6.2 Fan Tip section geometry......................................................................................................................... 72
Figure 6.3 Flow structures with 5 to 6 orders of magnitudes variations in length and time scales
....................................................................................................................................................................................................... 74
Figure 6.4 Shock Structure in Transonic Fan......................................................................................................... 75
Figure 6.5 Pressure Contour of Wake Flow ........................................................................................................... 76
Figure 6.6 Unsteady wakes convecting in blade passage ................................................................................. 76
Figure 6.7 Instantaneous absolute velocity contour pattern at nozzle exit .............................................. 77
Figure 6.8 Flow over an unshrouded tip gap ....................................................................................................... 78
Figure 6.9 Typical high-pressure turbine stage showing rim seal and wheel-space ............................ 79
Figure 6.10 Classical Secondary Flow Model ......................................................................................................... 81
Figure 6.11 Modern Secondary Flow Model .......................................................................................................... 82
Figure 6.12 Vortex pattern of Latest secondary flows ....................................................................................... 83
Figure 6.13 Turbine Secondary Flow Model (Takeishi et al.) ........................................................................ 84
Figure 6.14 Illustration of formation of hub corner stall together with..................................................... 86
Figure 6.15 Illustration of the near wall flows as taken through oil and dye surface flow
visualization (reproduced with permission of the publisher from ASME) .................................................. 87
Figure 6.16 Classic Secondary flow pattern for a turbine airfoil passage (L. S. Langston)................. 87
Figure 6.17 (Top)-Measurements of the horseshoe vortex just .................................................................... 88
Figure 6.18 Illustration of different vortical .......................................................................................................... 89
Figure 6.19 Contours of non-dimensional heat transfer coefficients (reproduced with ASME)...... 90
Figure 6.20 Measured adiabatic wall temperatures for coolant exiting a combustor/vane leakage
slot (reproduced with permission from ASME)........................................................................................................ 91
Figure 6.21 Contours of adiabatic effectiveness for two film-cooling hole patterns (left and center)
with a mid-passage gutter for the cooling hole pattern in the center (right) (reproduced with
permission from the publisher of ASME) .................................................................................................................... 93
Figure 6.22 fillet and bulb designs as shown by (Becz et al.)........................................................................... 94
Figure 6.23 CFD prediction of streamlines across a ........................................................................................... 95
Figure 6.24 Blade passage and slice of the computational domain .............................................................. 96
Figure 6.25 Computed mid-span Mach number distribution ......................................................................... 98
Figure 6.26 End-wall Stanton number (103) distributions computed with grid B in comparison
with the measurement data: (1) k-ω turbulence model, (2) M-SST, (3) v2-f, (4) Experiment .......... 99
Figure 6.27 Effect of grid refinement on the end-wall Stanton number (x103) prediction with the
M-SST turbulence model: (1) grid С, (2) grid D, (3) grid E, (4) experiment. ............................................. 100
Figure 6.28 End-wall streak line visualization................................................................................................... 101
Figure 6.29 Geometry of Swept and Dihedral Blades ..................................................................................... 102
Figure 6.30 Experimental Pressure iso-surfaces ; Left - without sweep ;Right - with forward
sweep. Courtesy of RÁBAI and VAD [93] .................................................................................................................. 103
Figure 6.31 The schematic of a modern gas turbine blade with common cooling techniques
(Courtesy of Je-Chin Han) ................................................................................................................................................ 103
Figure 6.32 Vane section with ten cooling channels and Temperature distribution computed ... 104
Figure 6.33 Surface temperature distribution on the suction side (left) and the pressure side
(right) of the vane............................................................................................................................................................... 105
Figure 6.34 Flow Streamlines Colored Cooling Air Temperature into Passages ................................. 106
Figure 6.35 Profile view of showerhead film cooled vane ............................................................................ 106
Figure 6.36 CAD model of simulated blade (left) and its internal passages (right) ........................... 107
9
Figure 6.37 T106-300 Cascade geometry and aerodynamic design conditions (Courtesy of De La
Calzada et al.) ....................................................................................................................................................................... 110
Figure 6.38 2-D hybrid mesh around the T106 blade .................................................................................... 111
Figure 6.39 Blade profile vs. pressure coefficient (Courtesy of De La Calzada et al.) ........................ 111
Figure 6.40 Flow field at the front and middle parts of the separation bubble (Courtesy of De La
Calzada et al.) ....................................................................................................................................................................... 112
Figure 6.41 Heat Transfer Coefficient for different negative incidences (Courtesy of Calzada et al.)
.................................................................................................................................................................................................... 114
Figure 6.42 Stanton number for different negative incidences (Courtesy of De La Calzada et al.)
.................................................................................................................................................................................................... 115
Figure 6.43 Stanton Number Vs. Reynolds Numbers (Courtesy of De La Calzada et al.) ................. 116
Figure 6.44 Heat Transfer Coefficient Vs. Reynolds Number (Courtesy of Calzada et al.) .............. 116
Figure 6.45 Pressure Ratio by Normalized Mass Flow (Courtesy of Simoes) ....................................... 118
Figure 7.1 Schematics of 3D concept at IGV/Rotor/Stator interface........................................................ 121
Figure 7.2 Interface between Rotor/Stator ......................................................................................................... 122
Figure 7.3 Difference between Passage and Stages ......................................................................................... 122
Figure 7.4 Axial Rotor/Stator Interaction (Schematics Illustrating the Mixing Plane concepts) . 123
Figure 7.5 Block Computational domain for a Rotor with guiding vanes ............................................... 123
Figure 7.6 A compressor Pressure Distribution on a surface using a Mixing Plane ........................... 124
Figure 7.7 Mesh for Transonic Turbine Stage - Upper Image Depicted the Mesh at the Hub Surface
while the Lower Image Represented Mesh used for the Blade Span ............................................................ 125
Figure 7.8 Results of the Velocity Contours for a Radial Section at Stator Mid Span using the
Mixing Plane Approach .................................................................................................................................................... 126
Figure 7.9 Total Pressure Calculated by the Frozen Rotor ........................................................................... 127
Figure 7.10 Half stencil and full stencil reconstruction with: A) Intersection, B) Halo-cell............ 128
Figure 7.11 Relative velocities obtained using HB techniques ................................................................... 129
Figure 7.12 Phase shifted Periodic Boundary .................................................................................................... 130
Figure 7.13 Phase Shifted Periodic Boundary Conditions............................................................................. 131
Figure 7.14 Stagnation Pressure Contours under inlet distortion for NASA Rotor 67 ..................... 136
Figure 7.15 Computational mesh for HB and TRS methods ........................................................................ 136
Figure 7.16 Instantaneous pressure distribution within the compressor stage using (NLHB) .... 137
Figure 7.17 Instantaneous predictions of turbulent viscosity at mid-span turbine for the TRS... 137
Figure 7.18 Instantaneous predictions of turbulent viscosity at mid-span turbine for the HB .... 138
Figure 7.19 velocity profile on interface line between two rows............................................................... 138
Figure 8.1 Centrifugal impeller with a highly polished surface likely to improve performance .. 139
Figure 8.2 Cut-Away View of a Turbocharger showing the Centrifugal Compressor ........................ 140
Figure 8.3 Jet engine cutaway showing the centrifugal compressor and other parts. ...................... 141
Figure 8.4 Ninety degree inward-flow radial turbine stage ......................................................................... 143
Figure 8.5 Outward Flow Radial Turbine ............................................................................................................. 144
Figure 9.1 Different Flow (2D, Q3D, and full 3D) .............................................................................................. 147
Figure 9.2 Full Blade Simulation using Harmonic Balanced Method (Courtesy of CD-adapco) .... 149
Figure 9.3 Transient Blade Row extensions enable efficient multi-stage CFD simulation (Courtesy
of ANSYS.com) ..................................................................................................................................................................... 151
Figure 9.4 Typical meshing of a Turbomachinery stage ................................................................................ 152
Figure 9.5 Multi-block grid for the space shuttle main engine fuel Turbine ......................................... 153
Figure 9.6 Pressure contour plot, 2nd order spatial discretization scheme.......................................... 157
Figure 9.7 Analysis provided vibration required for flutter analysis ....................................................... 159
Figure 9.8 Examples of Nodal Diameter ............................................................................................................... 160