Embed Size (px)
Citation preview
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Axial Compressor Design withAixCompFlow 2D and STAR-CCM+
STAR USER CONFERENCE 2011
23rd March 2011
Amsterdam, The Netherlands
N. Moritz, K. Kusterer
B&B-AGEMA GmbH,Aachen, Germany
F. Mendonca, A. Shalina
CD-adapco,London, U.K.
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
B&B-AGEMA GmbH
B&B- AGEMA GmbH is an independent engineering
service company providing consultancy, expertise,
design and calculation for turbo machinery and power
plants. Established in 1995 and located in Aachen
(Germany), B&B-AGEMA GmbH operates worldwide
and independently for the benefits of its customers.
Contact:
B&B-AGEMA GmbH
Juelicher Strasse 338
52070 Aachen, Germany
Phone: +49 (0) 241 – 56878 – 0
Fax: +49 (0) 241 – 56878 – 79
E-mail: [email protected]
Web: www.bub-agema.de
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Outline
• Compressor Design Process from 1D to 3D
• AixCompFlow2D
• Example compressor
• Export data from AixCompFlow2D
• STAR-CCM+ TurboWizard
• Mesh generation
• Initialisation procedure
• Summary & outlook
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Compressor Design Process
1D Basic geometrycalculation
AixCompFlow 2D
2D performancecalculation
3D multi-stage calculation
AixCompDesign 1D
contour geometryblade parameters
compressor performancecompressor map
STAR-CCM+
3D flow phenomenaperformance confirmation
superior3D compressor design
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
AixCompFlow 2D – Main Structure
Ø Interactive User InterfaceInteractively define, modify and plot all geometrical parameters (blade geometry, blade position and contour geometry), material properties, operating conditions, etc...
Ø Built-in Loss and Deviation Correlationsfor the typical axial compressor profile families (NACA, DCA, CDA, MCA, ...)Of course the software can be customized for integrating other client specific profiles
Ø Built-in Leakage, Bleeding and Radial Gap Models
Ø Fast & Accurate SolverThe proven solver of AixCompFlow 2D has been validated on several running machines. It provides the ability to rapidly and accurately calculate multiple operation points in a single run
Ø Comprehensive Post ProcessingSeveral plot options and settings guarantee a fast & easy visualization and reporting of all calculation results (plot of radial distributions and axial distributions, screening of streamlines, generating compressor maps, etc.)
Ø Efficient Export of 3D GeometryAixCompFlow 2D provides simply formatted geometrical blade data, which can be easily converted into common CAD formats
SKG-FVV 2.2SKG-3.6
MTU-ARK1DCA-V2NACA-65-(12).0.69C7/32.5 C50L030-4L030-6DCA-A3MCA-A4MTU-1MTU-2MTU-3ARL-2 DPC
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
AixCompFlow 2D – Overview
Ø AixCompFlow 2D is a powerful, efficient and reliable design tool for axial compressors, which enables the compressor designer to check the compressor performance within a 2D calculation approach prior to moving to comprehensive 3D CFD analysis.
Ø Its proven and very fast solver allows the designer to systematically increase the compressor efficiency and operation range in an efficient way.
Ø Besides its basic functionality as stream line curvature code, AixCompFlow 2D provides additional valuable functionalities e.g. consideration of stator leakage, bleedings, rotor radial gaps, etc.
Ø AixCompFlow 2D is a software product provided by B&B-AGEMA.
Ø For further information on its functionality and licensing options, please, contact Dipl.-Ing. Norbert Moritz (e-mail: [email protected]).
surge line
compressor cross-section
compressor map
3D geometry
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Example Compressor
• 16 stage axial compressor including IGV (all NACA65 profiles)
• Mass flow: 502.3 kg/s
• Pressure ratio: 11.7
• Computational time: approx. 5 seconds
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Export to STAR-CCM+
• Airfoil geometry settings:
• Grid points along airfoil
• Grid points for leading & trailing edges
• NACA profiles: trailing edges definition
• Optional: geometry extrapolation
• Grid settings:
• Rotational axis
• Radial sections
• Optional: rotor radial gaps
• Initial hub & shroud grid spacing
• Boundary conditions:
• Inlet total pressure & temperature
• Outlet static pressure
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Export Files
compressor.trbw:
Steering file for TurboWizard
hub.bdny, shroud.bdny:
Hub & shroud contour
inlet.bdny, outlet.bdny, mixingplane_NN.bdny:
Definition of axial positions at hub and shroud for inlet, outlet and all mixing planes
IGV.estg, rotor_NN.estg, stator_NN.estg:
Sectional definition of airfoils
initial.csv:
Static pressure, static temperature & velocities at leading edge & trailing edge
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
STAR-CCM+ TurboWizard I
compressor.trbw settings:
o Number of blade rows
o Rotational speed
o Hub & shroud rotation
o Flow axis
o File name with airfoil geometry
o Number blades
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
STAR-CCM+ TurboWizard II
compressor.trbw settings:
o Mixing plane files
o Tip clearance settings
o Hub & shroud geometry
o Radial grid lines
o Initial hub & shroud spacing
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Mesh generation
The mesh has a H-O-H type structure for each airfoil. Each airfoil in 1 region.
The mesh generation for the full compressor took about 0.5 hour and requires 5 GB of RAM.
The mesh consists of 7.1 million cells.
All mixing plane & periodic interfaces automatically established.
The mesh has a H-O-H type structure for each airfoil. Each airfoil in 1 region.
The mesh generation for the full compressor took about 0.5 hour and requires 5 GB of RAM.
The mesh consists of 7.1 million cells.
All mixing plane & periodic interfaces automatically established.
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Initialisation process
Initial distribution of static pressure, static temperature & flow vectors from AixCompFlow 2D result.
Performing Grid Sequencing: • 5 grid levels• convergence tolerance 0.05• CFL number 5.0
Initial distribution of static pressure, static temperature & flow vectors from AixCompFlow 2D result.
Performing Grid Sequencing: • 5 grid levels• convergence tolerance 0.05• CFL number 5.0
initialisation example for rows 1 to 5
engineering your visions
B&B-AGEMA
© by B&B-AGEMA
Summary & outlook
• AixCompFlow 2D is an efficient, reliable and accurate tool for
axial compressor design.
• With the link to the STAR-CCM+ TurboWizard set up of full 3D
multi-stage calculations is possible in semi-automated way.
• Model set-up, grid generation and initialisation can be done
in 1 or 2 hours (not days!).
• Insights in the 3D flow phenomena can be taken into account
during the design process.
• Influences of geometry modifications on 3D flow can be
analysed quickly.
