Workshop 07 Cavitating Centrifugal Pump

14. 5 Release

Introduction to ANSYS CFX

2012 ANSYS, Inc. December 17, 2012 1 Release 14.5

Introduction
Workshop Description:
The problem consists of a five-blade centrifugal pump operating at 2160 rpm.
The working fluid is water and flow is assumed to be steady and incompressible. Due to rotational periodicity a single-blade passage will be modeled. The initial flow-field will be solved without cavitation. It will be turned on later.

Learning Aims:
This workshop introduces several new skills:
Working with rotating domains Modeling cavitation in ANSYS CFX

Learning Objectives: To model cavitation in a centrifugal pump, which involves the use of a rotation
domain and the cavitation model.
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
2

Cavitation

Summary
Release 14.5

Workbench
1. Start Workbench and save the project as centrifugalpump.wbpj
2. Drag a CFX system into the Project Schematic from the Component Systems toolbox 3. Start CFX-Pre by double clicking Setup

4. When CFX-Pre opens import the mesh by right-clicking on Mesh and selecting Import Mesh > ICEM CFD
5. Browse to pump.cfx5 (workshop_input_files\WS_07_Cavitating Pump) 6. Keep Mesh units in m 7. Click Open

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
3

Cavitation

Summary
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Creating Working Fluids

Modifying the material properties:

1. Expand Materials in the Outline tree 2. Double-click Water 3. On the Material Properties tab change Density to 1000 [kg/m3] 4. Expand Transport Properties and change Dynamic Viscosity to 0.001 [kg m^-1 s^-1] 5. Click OK

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
4

Cavitation

Summary
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Setting up the Fluid Domain

1. 2. 3. 4. 5. Double-click on Default Domain Under Fluid and Particle Definitions, delete Fluid 1 and then create a new Fluid named Water Liquid Set Material to Water Create another new Fluid named Water Vapour Next to the Material drop-down list, click the icon, then the Import Library Data icon (on the right of the form), and select Water Vapour at 25 C under the Water Data object

6.

Click OK Click OK

Back in the Material panel, select Water Vapour at 25 C

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
5

Cavitation

Summary
Release 14.5

Setting up the Fluid Domain

7.
8. 9.

Set the Reference Pressure to 0 [Pa]

Set Domain Motion to Rotating Set Angular Velocity to 2160 [rev min^-1]

10. Switch on Alternate Rotation Model. The Alternate Rotation Model is used to avoid False swirl which could occur when a significant amount of the fluid is flowing in the axial direction. 11. Make sure Rotation Axis under Axis Definition is set to Global Z 11. Switch to the Fluid Models tab and set the following: 12. Turn on Homogeneous Model in the Multiphase section 13. Under Heat Transfer set the Option to Isothermal, with a Temperature of 25 C 14. Set Turbulence Option to Shear Stress Transport 15. Click OK

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
6

Cavitation

Summary
Release 14.5

Inlet Boundary Condition

1. Insert a boundary condition named Inlet 2. On the Basic Settings tab, set Boundary Type to Inlet 3. Set Location to INLET

4. Set Frame Type to Stationary

5. Switch to the Boundary Details tab 6. Specify Mass and Momentum with a Normal Speed of 7.0455 [m/s] 7. Switch to the Fluid Values tab 8. For Water Liquid, set the Volume Fraction to a Value of 1 9. For Water Vapour, set the Volume Fraction to a Value of 0 10. Click OK

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
7

Cavitation

Summary
Release 14.5

Outlet Boundary Condition

1. Inset a boundary condition named Outlet 2. On the Basic Settings tab, set Boundary Type to Opening 3. Set Location to OUT

4. Set Frame Type to Stationary

5. Switch to the Boundary Details tab 6. Specify Mass and Momentum using Entrainment, and enter a Relative Pressure of 600,000 [Pa] 7. Enable the Pressure Option and set it to Opening Pressure 8. Set Turbulence Option to Zero Gradient 9. Switch to the Fluid Values tab 10. For Water Liquid, set the Volume Fraction to a Value of 1 11. For Water Vapour, set the Volume Fraction to a Value of 0 12. Click OK
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
8

Cavitation

Summary
Release 14.5

Periodic Interface
1. Click to create an Interface, and name it Periodic 2. On the Basic Settings tab set the Interface Type to Fluid Fluid 3. For Interface Side 1 set the Region List to DOMAIN INTERFACE 1 SIDE 1 and DOMAIN INTERFACE 2 SIDE 1 (use the icon and the Ctrl key) 4. For Interface Side 2, set the Region List to DOMAIN INTERFACE 1 SIDE 2 and DOMAIN INTERFACE 2 SIDE 2 5. Set the Interface Models option to Rotational Periodicity 6. Under Axis Definition, select Global Z 7. Switch to the tab labelled Mesh Connection and set Option to 1:1 8. Click OK
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
9

Cavitation

Summary
Release 14.5

Wall Boundary Conditions

1. 2. 3. Insert a boundary condition named Stationary Set it to be a Wall, using the STATIONARY location On the Boundary Details tab, enable a Wall Velocity and set it to Counter Rotating Wall
By default, all walls in a rotating domain rotate with the rotating reference frame. Since this wall is stationary in the absolute frame it must be counter rotating in the rotating frame.

4.

Click OK

5.

In the Outline Tree right-click on the Default Domain Default boundary and Rename it to Moving

The default behavior for the Moving boundary condition is to move with the rotating domain. So there is nothing that needs to be set

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
10

Cavitation

Summary
Release 14.5

Initialization
1. 2. Click to initialize the solution On the Fluid Settings form, set Water Liquid Volume Fraction to Automatic with Value, and set the Volume Fraction to 1

3.
4.

Set Water Vapour Volume Fraction to Automatic with Value, and set the Volume Fraction to 0
Click OK

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
11

Cavitation

Summary
Release 14.5

Solver Control
1. 2. Double click Solver Control in the Outline tree Set Timescale Control to Physical timescale A commonly used timescale in turbomachinery is 1/omega, where omega is the rotation rate in radians per second. You can use an expression to determine a timestep from this. In this case, 2/omega will be used to achieve faster convergence. 3. 4. 5. Enter the following expression in the Physical Timescale box: 1/(pi*2160 [min^-1]) Set Residual Target to 1e-5 On the Advanced Options tab turn on Multiphase Control. Then turn on Volume Fraction Coupling and set the Option to Coupled. This will speed up convergence Click OK

6.

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
12

Cavitation

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Release 14.5

Output Control
1. 2. 3. 4. 5. 6. 7. 8. Double-click on Output Control in the Outline tree On the Monitor tab turn on Monitor Objects Under Monitor Points and Expressions, create a new object and call it InletPTotalAbs Set Option to Expression Enter the following expression: massFlowAve(Total Pressure in Stn Frame )@Inlet Create a new object called InletPStatic and set Option to Expression Enter the following expression: areaAve(Pressure )@Inlet Click OK

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
13

Cavitation

Summary
Release 14.5

Solver
1.
2. 3.

Close CFX-Pre and switch to the Workbench Project Schematic window

Save the project Now double-click on Solution in the Project Schematic to start the CFXSolver Manager When the CFX-Solver Manager opens click Start Run

4.

This run takes about 9 minutes. To save time you can stop the run after a few iterations (in the Project Schematic right-click on the Solution cell and choose Interrupt Solution) and continue with an existing results file

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
14

Cavitation

Summary
Release 14.5

Solver
If running to completion, then when the solution has finished close the CFXSolver Manager and return to the Project Schematic window. Save the project. OR

If you have stopped the run early, save the project. Drag and drop the provided results file, CFX_001.res, into the Project Schematic

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
15

Cavitation

Summary
Release 14.5

Post-processing
1. View the results in CFD-Post by double-clicking Results cell in the component system, in the Project Schematic, that contains the completed solution.
Insert a Contour by clicking

2.

3.
4. 5. 6. 7.

For the Location click , , expand Regions and then select BLADE
Set Variable to Absolute Pressure from the extended list Set Range to Global On the Render tab switch off Lighting and Show contour Lines Click Apply

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
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Cavitation

Summary
Release 14.5

Post-processing
8. Create a contour on the HUB location, using the variable Absolute Pressure over the Local Range. Turn off Lighting and Show Contour Lines.
Create a contour on the SHROUD location, using the variable Absolute Pressure coloured by Local Range. Turn off Lighting and Show Contour Lines. The minimum pressure is above the saturation pressure of 2650 Pa for water here. In the next step the outlet pressure will be reduced so as to induce cavitation. 9.

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
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Cavitation

Summary
Release 14.5

Adding another Analysis

1. 2. Close CFD-Post and return to the Project Schematic Click the arrow next to the A cell and select Duplicate

3. 4.

A copy of the first CFX system is created

Change the name of the new system to Cavitation Use the arrow next to the A cell to Rename it to No Cavitation

5.
6.

Save the Project

Double-click Setup for the Cavitation simulation to open CFX-Pre

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
18

Cavitation

Summary
Release 14.5

Physics Modifications
1. Edit the Default Domain

2.
3. 4.

On the Fluid Pair Models tab set Mass Transfer to Cavitation

Set Option to Rayleigh Plesset. Leave the Mean Diameter (mean nucleation site diameter) set to 2e-6 [m]. This is a reasonable value. Turn on Saturation Pressure

5.
6. 7. 8.

Set a Saturation Pressure of 2650 [Pa]

Click OK Edit the Outlet Boundary Condition On the Boundary Details tab, set the Relative Pressure to 300,000 [Pa]

9.

Click OK

Most cavitation solutions should be performed by turning cavitation on and then successively lowering the system pressure over several runs to induce cavitation gradually. To speed up this workshop a sudden change in pressure is introduced. Note that this approach may not be suitable for modelling some industrial cases.
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
19

Cavitation

Summary
Release 14.5

Physics Modifications
1.
2. 3. 4. 5. 6.

Edit Solver Control

Set the Max. Iterations to 150 Set the Residual Target to 1e-4 Click OK Close CFX-Pre and save the project In the Project Schematic drag cell A3 on to cell B3 or B2 on to C3

7.

The non-cavitating solution will be used as the initial guess for the cavitating solution

Double-click Solution for the Cavitation system

In the CFX-Solver Manager note that the initial conditions have been provided by the Project Schematic

8.

Click Start Run

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
20

Cavitation

Summary
Release 14.5

Cavitation Solution
There is a significant spike in residuals, in part due to the outlet pressure difference, but also due to the fact that the absolute pressure is low enough to induce cavitation.
1. This run takes about 12 minutes. Either allow the run to complete, close the CFXSolver Manager and return to the Project Schematic or stop the run after a few iterations. Save the project

2.

3.

If you ran the simulation to completion, double-click Results for the Cavitation project to open CFD-Post. If you stopped the run early then drag and drop CFX_002.res, provided, into the schematic and open those results in CFD-Post.
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
21

Cavitation

Summary
Release 14.5

Post-processing
1. If it is not enabled, turn on visibility for the Wireframe and turn off visibility for any User Locations and Plots
Create an XY Plane at Z = 0.01 [m] Colour it by Absolute Pressure ( Range ). Use a Global

2. 3.

The minimum absolute pressure is equal to the saturation pressure specified earlier. This suggests that some cavitation has occurred

4. 5.

Change the Colour Variable to Water Vapour.Volume Fraction Change the Colour Map to Blue to White

Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
22

Cavitation

Summary
Release 14.5

Post-processing
1.
2. 3. 4. 5. 6. 7. 8. 9.

Turn off visibility for Plane 1

Create a Volume using the Isovolume method Set the Variable to Water Vapour.Volume Fraction Set Mode to Above Value, and enter a value of 0.5 To view 360 degrees of the model, double-click Default Transform Uncheck Instancing Info from Domain Set Number of Graphical Instances to 5 Make sure that Apply Rotation is checked Under Axis Definition set Method to Principal Axis and select the Z axis

10. Under Instance Definition set Number of Passages to 5

11. Click OK
Introduction
2012 ANSYS, Inc. December 17, 2012

No cavitation
23

Cavitation

Summary
Release 14.5

Summary
The main area of cavitation exists between the suction side of the blade and the shroud in this geometry. A secondary area of cavitation is just behind the leading edge of the blade on the pressure side.

Further steps to try:

1. 2. 3. 4. Calculate torque on the BLADE using the function calculator (hint, use the extended region list to find the BLADE and use Global Z axis) Plot velocity vectors on Plane 1, using the variable Water Liquid.Velocity in Stn. Frame Calculate the mass flow through the pump (hint: use the function calculator to evaluate massFlow at the Outlet region) Using a similar method to step 2, calculate the drop in Total Pressure from Inlet to Outlet

5.

Plot Streamlines, starting from the Inlet location

Introduction No cavitation
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Cavitation

Summary
Release 14.5

2012 ANSYS, Inc.

December 17, 2012