Turbocharger

Design&AnalysisSolutions
BillHolmes
BradHutchinson
Detroit,October2012
Agenda
ANSYSoverview
ANSYSTurboSystem
Bladerowsolutions
TheANSYS
Transformation
methods
Anexample:
turbocharger
compressoranalysis
Summary
ANSYSVisionforRotatingMachinery:
Fullmachinesimulation
Highfidelitysimulationof
allcomponents
Simulatecomplex
phenomenaandprocesses
Unsteadycombustion,
compressorstall,cavitation,
noise,fracture,component
interactions,advanced
materials.....
Integratedtoolsetforall
geometryandphysics
LargescaleHigh
PerformanceComputing
(HPC)enabled
ANSYSTurboSystem
Turbomachinery@ANSYS
Axialandcentrifugal
compressors
Axialandradialturbines
(Steam&gas)
Centrifugal,mixedflow
andaxialpumps
Axialandradialfans
Automotive
turbomachinery
Waterturbines
Windturbines
ANSYSTurboSystem
Completeturbomachinery
designandanalysisin
ANSYSWorkbench
Geometry
Throughflow
Meshing
CFD
Thermal
Combustion
Structuralmechanics
Rotordynamics
Postprocessing
Optimization
Thispresentationwillfocuson
ANSYSbladerowfluid
dynamicsforturbocharger
compressors
ANSYSWorkbench
Parametric Geometry (Meanline & Through-Flow)
Mesh
Analysis Robust Design
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
ANSYSWorkbench
BladeModeler MeanlineDesign
VistaCCD
Centrifugal
compressorrotor
design
Realgascapability
BladeModeler Meanline Design
VistaRTD
Radialturbine
preliminarydesign
ANSYSBladeModeler
Designcomparison
Visibleinmeridional
sketches,angle/thickness
views,bladetobladeview
and3Dview
ANSYSTurboGrid
Automatedgrid
generationforbladed
turbomachinery
components
Highqualityhexahedral
grids
Repeatable
Minimizemesh
influenceindesign
comparison
Scalable
Maintainqualitywith
meshrefinement
CentrifugalCompressor
ANSYSCFD@Turbomachinery
Fast&scalablesolver
Lowspeedtosupersonic
Steady/transient
TurbospecificBCs
Turbulence&heattransfer
MultipleFrameofReference
Multiphaseflow
Realfluids
Fluid/structureinteraction

SST
Model
Laminar
turbulent
transition
Streamline
curvature&
rotation
'Automatic'
wall
functions
Stagnation
lineflows
EARSM
Wall
roughness
Scale
Adaptive
Simulation
Detached
Eddy
Simulation
TurbulenceModel
ANSYSDesignExploration
Sensitivityanalysis
Designoptimization
Robustnessevaluation
initial
Mechanical
Mechanicaldeformation
Rotationalforces
Surfacepressureloads
Thermalstress
Temperature,Heatflux,

Modalanalysis
Frequencies
Bladeflutter
Aerodynamicdamping
Forcedresponse
TransientRotorStator
Full2wayFSI
ANSYSTransientBladeRowMethods
TBRwithpitchchange:TheANSYSTransformation
methods
Problem:Howtoobtainthefullwheeltransient
solution,butatlowcost?
Solution:TheANSYSTBRTransformation familyofmethods
oNewmodelsminimizenumberofsimulatedpassages,
providingenormousefficiencygainsandreduced
infrastructurerequirements
Transient
with Pitch Change
Transient
with Pitch Change
Steady
with Pitch Change
Transient
Full-Domain
Transient
Full-Domain
Profile
Transformation
Profile
Transformation
Time
Transformation
Time
Transformation
Fourier
Transformation
Fourier
Transformation
TimeDomain
Status:
Release&Beta
Harmonic
Transformation
Harmonic
Transformation
FrequencyDomain
FastBladeRowSolutions
Status:
Development
ANSYSTBRApplications
Turbine
Gustpitch
BladePassagepitch
Gustspeed
GustAnalysis GustAnalysis
Turbine
Gustpitch
BladePassagepitch
Gustspeed
GustAnalysis
BladeFlutter BladeFlutter
Period Period
d
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p
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IBPA IBPA
D
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D
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BladeFlutter
Period
d
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p
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( ) 1 0
2
= - = = Nb j j
Nb
IBPA
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IBPA
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TBRApplications
MultiStage MultiStage MultiStage
SingleStage
Trends@Turbocharging
UnsteadyState
RotorStatorInteraction
(OffDesign)
Inletdistortion
Acoustics
Turbulentflowwith
conjugateheattransfer
Multiphysics
Forcedresponse
Thermal
Optimization&Robust
Design
MapWidthEnhancement,
mixedflowturbinewheels,
voluteconfiguration
ETHZurich
ANSYSWorkbench
ANSYSTurboSystem
Geometry Mesh Analysis
C
A
D
Throughflow
Robust Design
ExampleApplication:Turbocharger
Compressor
TurbochargerCompressorAnalysis:ABestPractice
Example
Methodology
PreliminaryDesign
Geometry&Meshing
Impelleronlyanalysis
Impellerdiffuser
voluteanalysis
Postprocessingand
interpretation
Methodology
PreCFD
Startwithgeometrythatmeetsdesignspecifications
FromVistaCCD,CCM,TFandBladeModeler
Impelleronlyanalysis
Theimpelleristheheartofthecompressionsystem
understanditfirst
Overallperformance:howgoodcanitbe,canitbebetter?
Natureoftheflow,strengthsandweaknesses
Whatfactorsaffectperformance?Predictions?
Wholesystem
Impellerdiffuservoluteanalysis
Voluteonlyanalysis useful?
Postprocessing
Quantitativeandqualitative
Geometry
1DdesigndevelopedinVISTACCD
Basedonprescribedduty,designconstraints
ImpellerGeometry
VISTACCD,CCMBladeModelerVISTATF
Makeadjustmentsaccordingtopackageconstraints,designrules,
approachetc.
Meridionalpath
Bladeprofile/thickness
Hub/backface
Tipclearance
VoluteGeometry
Spreadsheetbaseddesign
Mass+angularmomentumconservationapproach(freevortex)
DrivesaparameterizedDesignModelergeometry
CompressorDesignRequirements
Parameter Value
Diameter 48[mm]
NumberofVanes 6+6
InletTemperature 288[K]
InletPressure 101.35[kPa]
MassFlow Rate 0.12[kg/s]
PressureRatio 2.15
TipSpeed 391[m/s]
ShaftSpeed 155,733[revmin^1]
HighSpecificFlow
impellerwithvaneless
diffuserofradiusratio
1.7
Typicalforagasoline
enginewithcapacityof
1.6L.
Midmapoperatingpoint
InitialSizing
VistaCCDusedtocreateageometryfromdesign
requirements
VistaCCD:Output
IterateinCCDtoachieveacceptablepreliminary
design
VistaCCM:Input
VistaCCMusedtocreateapreliminarycompressor
map
VistaCCM:Output
Turbochargercompressoristypicallyoperatingat
offdesign
InitialGeometryCreation
VISTATFrequiresageometry:fromBladeModeler
PushbuttonsolutionfromVistaCCD
CompressorShroudSection
InitialGeometryCreation
CompressorHubSection
VistaTF:2DAnalysis
VistaTFisathroughflow(streamlinecurvature)solver
Usedtoprovidefurtherinsightintodesign
Contourplotsshowcircumferentiallyaveraged
quantities
2DChartsshowvariousdesignparameterssuchas
loading,incidenceanddeviation
Basedonresults,geometrycanbequicklymodifiedand
analyzedagain
Bladeandflowpathdesignimproved
Canbeparametricandoptimizationcanbe
performed
VistaTF:QualitativeOutput
Tangential
velocity
Solution
error
Meridional
velocity
Static
pressure
VistaTF
FinalImpellerDesign
Finalimpellergeometrystepspriortomeshing
DirecttoTurboGridforhex
Createfluidflowpathfortetmeshing
Volutegeometryisgeneratedtomatchimpeller
Detailslater
FinalGeometries
Impellerandvaneless diffuser
Volute
Meshing
ImpellerMesh
Useahexahedralmesh:TurboGridATM
Payattentionto:
Targetmeshsize
Balance
Boundarylayerresolution
Y+
Tipclearance
Aspectratio
Volutemesh
ANSYSmeshing
Tets+prismsforboundarylayerresolution
Localmeshrefinementneartongue
Matchdiffuseroutlet/voluteinletspanwisemeshdistribution
ImpelleronlyAnalysis
Impeller+partofvaneless diffuser
Howmuchofthevaneless spacetomodel?
Gridrefinementstudy
Grid:Thebiggestfactoraffectingpredictions
TetrahedralElementsVs.HexahedralElements
Understandtheeffectofgridsizeonprediction
Target:workinggridsizewithY+=2
Ideally,double/halfthegridsizeineachdirection
1/8X,1X,8Xworkinggridsize
Estimateofgridindependentsolution
Effectoffillets
Lookatkeypointsonthemap
Nominaldesign,nearsurgeline,nearchoke,choke
Example:MeshIndependenceStudy
Impeller+VanelessDiffuserAnalyzedat155,733rpm
Threeoperatingpoints
DesignFlowRate
NearChoke
NearStall/Surge
ComparedHexmeshvs.Tetmesh
MeshSummary
# of
Nodes
Blade
Y+
Meshing
Tool
Meshing
Method
Meshing
Time
Mesh
FileSize
MaxVol
Ratio
MaxLength
Ratio
0.142m 8 TurboGrid ATM 1min 3.67MB 159 2132
1.12m 4 TurboGrid ATM 1min 34.8MB 88 4308
8.58m 2 TurboGrid ATM 3min 273MB 34 3547
# of
Nodes
Blade
Y+
Meshing
Tool
Meshing
Method
Meshing
Time
Mesh
FileSize
Min
Angle
Min
Quality
0.143m 8 ICEMCFD Octree ~5 min 56.7MB 0.65 0.01
1.08m 4 ICEMCFD Octree ~30min 601MB 0.31 0.0029
7.50m 2 ICEMCFD Octree ~1.5hr 4.4GB 0.23 1.3e06
Hexahedral
Tetrahedral
HexCoarseMesh
HexMediumMesh
HexFineMesh
TetCoarseMesh
TetMediumMesh
TetFineMesh
MeshIndependence:Hexvs.Tet
TotalPressure
Tet meshat
approximately8million
nodesstillisnotas
accurateasHexmeshat
125thousandnodes!
MeshIndependence:Hexvs.Tet
IsentropicEfficiency
MeshSensitivity:Hexspeedline
MeshSensitivity:FineTetspeedlineadded
Tet meshat
approximately8million
nodesstillisnotas
accurateasHexmeshat
125thousandnodes!
EffectofFillet
1.5mmfilletincluded
atmainandsplitter
bladeroot
comparedtoblade
geometrywithout
fillet
FilletStudy:EffectonPressureRatio
Differenceonly
apparentat/near
choke
FilletStudy:EffectonIsentropicEfficiency
Differenceonly
apparentat/near
choke
AssemblyAnalysis
HowmuchdoIreallyneedtomodel,andusingwhatmethods?
Impellerdiffuservolute?
Voluteonly(includingpartofvanelessdiffuser)?
Inletspecifiedfromexitofimpelleronlyanalysis
Steadystate,transient?
Wedidthefollowing,forcomparisonpurposes:
Frozenrotor full360degrees
Stageanalysis oneimpellerwithfullvolute
TransientRotorStator full360degrees
Voluteonly
ConstantPt,Tt,flowdirection
Asabovebutwithaspanwiseprofile
VoluteMesh
RelativelyCoarseMesh
usedforStudy
Size:370,000nodes
TetElements=1.1
million
PrismElements=0.32
million
QualityStatistics
AverageElement
Quality=0.71
MinElementQuality=
0.046
EffectsofDiffuserandVolute
Comparisonofthreedifferentconfigurations
ImpellerOnly(SinglePassage)
Impeller+VanelessDiffuser(SinglePassage)
Impeller+VanelessDiffuser+Volute(Full360,
frozenrotor)
Comparespeedlines
155,733rpm
Ptratio=(Ptoutlet/Ptinlet)
IsentropicEfficiency
Pressureratiopredictions
Isentropicefficiencypredictions
ImpellerBehavior
Nowlookatimpelleronlyperformanceintwo
configurations
Impelleronlysimulation
Impellerdiffuservolutesimulation
SpeedlinesshowsImpellerbehavessimilarly
regardlessofdownstreamgeometry
Ptratio=(Ptimpelleroutlet/Ptimpellerinlet)
IsentropicEfficiencyforimpelleronly
Significantvalueinexaminingindividualcomponents
togaininsight
Impellerpressureratiopredictionsfortwo
configurations
Isentropicefficiencypredictionsfortwo
configurations
Effectofrotatingstationaryframeinterfacetype
Comparisonofthreeinterfacetypesbetweendiffuser
andvolute
Stage(singlepassageimpeller/diffuser,fullvolute)
Frozenrotor(full360degrees)
TransientRotorStator
Forallcases
Impeller+vanelessdiffusermodeledinrotating
frame
Volutemodeledinstationaryframe
Effectofinterfacetypeontotalpressure
prediction
Effectofinterfacetypeonisentropicefficiency
prediction
PostProcessing
Beforestarting:
Makesuresolutionsareconverged!
Runwithabigenoughtimestep!
Quantitative
Impeller
Pt,Tt,Abs.flowangle,isentropicefficiency
Distortionfactor
Bladeloading
Volute:recoveryfactor,losscoefficient
Estimategridindependentsolution
Qualitative
Bladetobladeandmeridionalaveraged
Unrolledplotatexitofimpeller
CFDResults
ExamineresultsfromCompressorReportinCFDPost
CFDResults
OrusetablegenerationtoolinCFDPosttoextract
custominformationatvariousstreamwiselocations
BladeLoadingChartnearchoke
Massflow=0.13kg/s
RelativeMachNumbernearchoke
Massflow=0.13kg/s
RelativeVelocitynearchoke
Massflow=0.13kg/s
Meridionalvelocitynearchoke
MassFlow=0.13kg/s
Staticpressurenearchoke
Massflow=0.13kg/s
RelativeMachNumbernearchoke
Massflow=0.13kg/s
Summary
ANSYSofferscompleteturbomachinery
designandanalysissoftware
Geometry
Throughflow
Meshing
CFD
Thermal
Combustion
Structuralmechanics
Rotordynamics
Postprocessing
Optimization