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HIGH-FIDELITY SIMULATION OF THE TURBULENT FLOW IN A TRANSONIC AXIAL COMPRESSOR A. Gomar - N. Gourdain - G. Dufour CFD Team, 42 avenue Gaspard Coriolis, CERFACS, Toulouse, France, [email protected] ABSTRACT The present work proposes to use LES in a 3D transonic axial compressor configuration, the NASA Rotor 37. Three meshes are investigated: a 10 million, a 25 million and a 100 million grid points mesh. The convergence criteria, the choice of the numerical schemes and the determina- tion of the time-step are investigated to propose a methodology for LES calculations. The time needed to compute such simulations and comparison with the experimental results are given. Finally, an analysis of the mesh dependency for LES is assessed. NOMENCLATURE LES, Large Eddy Simulation RANS, Reynolds-Averaged Navier-Stokes CFD, Computational Fluid Dynamics SGS, Sub-Grid Scale CPU, Central Processing Unit CFL number, Courant-Friedrich-Levy number DFT, Discrete Fourier Transform Re, Reynolds number x + , y + , z + , mesh spacings in wall units f c , Cut-off frequency N ds , Number of data samples INTRODUCTION Numerical simulation is now a central tool for engineers, as it is well integrated in the design process of aerodynamic components. In fact, Reynolds-Averaged Navier-Stokes simulations give accurate information on the global performance (pressure ratio and efficiency for a turbomachine, lift coefficient for a wing . . . ), but fail to predict phenomena where turbulence plays a salient role. Indeed, turbulence models associated with RANS simulations are validated on particular test case, and are therefore not universal. LES resolves turbulent structures by applying a space filter (Sagaut, 2009) to the Navier-Stokes equations, as opposed to RANS simulations, where a statistical or time filter is applied to obtain the equations that will be resolved. In fact, LES is based on the idea of resolving the large eddies whilst modeling the small ones. The former characterize most of the energetics structures, that is to say the large-eddies dominate the structure of the flow, whereas the latter is dissipative and universal (see Pope (2000)). Therefore, LES can be viewed as a high resolution simulation, which could help understand the physical phenomena conducted by turbulence. Since CFD codes need to be validated, blind tests are frequently performed on open test cases, as for example the NASA Rotor 37 (see Dunham et al. (1998), Suder and Celestina (1996) and Suder (1996)). However discrepancies, concerning the physical reason of the pressure deficit downstream of the rotor below 40% span, remains between the RANS results and the experiments. Two explanations have been pointed out: on the one-hand, some believe that the pressure ratio deficit observed near 1

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Page 1: HIGH-FIDELITY SIMULATION OF THE TURBULENT …cfdbib/repository/TR_CFD_11_24.pdfHIGH-FIDELITY SIMULATION OF THE TURBULENT FLOW IN A TRANSONIC AXIAL COMPRESSOR A. Gomar - N. Gourdain

HIGH-FIDELITY SIMULATION OF THE TURBULENT FLOW INA TRANSONIC AXIAL COMPRESSOR

A. Gomar - N. Gourdain - G. Dufour

CFD Team, 42 avenue Gaspard Coriolis, CERFACS, Toulouse, France, [email protected]

ABSTRACTThe present work proposes to use LES in a 3D transonic axial compressor configuration, theNASA Rotor 37. Three meshes are investigated: a 10 million, a 25 million and a 100 million gridpoints mesh. The convergence criteria, the choice of the numerical schemes and the determina-tion of the time-step are investigated to propose a methodology for LES calculations. The timeneeded to compute such simulations and comparison with the experimental results are given.Finally, an analysis of the mesh dependency for LES is assessed.

NOMENCLATURELES, Large Eddy SimulationRANS, Reynolds-Averaged Navier-StokesCFD, Computational Fluid DynamicsSGS, Sub-Grid ScaleCPU, Central Processing UnitCFL number, Courant-Friedrich-Levy numberDFT, Discrete Fourier TransformRe, Reynolds number∆x+, y+, ∆z+, mesh spacings in wall unitsfc, Cut-off frequencyNds, Number of data samples

INTRODUCTIONNumerical simulation is now a central tool for engineers, as it is well integrated in the design

process of aerodynamic components. In fact, Reynolds-Averaged Navier-Stokes simulations giveaccurate information on the global performance (pressure ratio and efficiency for a turbomachine,lift coefficient for a wing . . . ), but fail to predict phenomena where turbulence plays a salient role.Indeed, turbulence models associated with RANS simulations are validated on particular test case,and are therefore not universal.

LES resolves turbulent structures by applying a space filter (Sagaut, 2009) to the Navier-Stokesequations, as opposed to RANS simulations, where a statistical or time filter is applied to obtainthe equations that will be resolved. In fact, LES is based on the idea of resolving the large eddieswhilst modeling the small ones. The former characterize most of the energetics structures, that is tosay the large-eddies dominate the structure of the flow, whereas the latter is dissipative and universal(see Pope (2000)). Therefore, LES can be viewed as a high resolution simulation, which could helpunderstand the physical phenomena conducted by turbulence.

Since CFD codes need to be validated, blind tests are frequently performed on open test cases, asfor example the NASA Rotor 37 (see Dunham et al. (1998), Suder and Celestina (1996) and Suder(1996)). However discrepancies, concerning the physical reason of the pressure deficit downstream ofthe rotor below 40% span, remains between the RANS results and the experiments. Two explanationshave been pointed out: on the one-hand, some believe that the pressure ratio deficit observed near

1

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the hub in the wake region is due to injection and recirculation while on the other-hand, Hah and co-workers expect that this deficit is due to a corner flow separation (Denton, 1996). In this respect, theflow effects that occur in the Rotor 37, such as vortex shedding, tip-leakage vortex interaction with theshock and boundary layer-shock interaction, limit the predictability of RANS simulations and couldaccount for these discrepancies.LES has been performed on the NASA Rotor 37 configuration by Hah(2009) showing that the results were closer to the experimental data than the RANS ones.

LES calculations have been performed on academic or limited turbomachine configurations suchas: 1. small Reynolds numbers (see Carolus et al. (2006), Eastwood et al. (2009) and Guleren et al.(2010)) 2. configurations where an incompressible assumption was made (see Guleren et al. (2008)and Guleren et al. (2010)) 3. real-life configuration with relatively coarse mesh (see Hah et al. (2008),Black et al. (2005), Hah et al. (2009) and Hah (2009)) as compared to standard LES mesh require-ment (Sagaut and Deck, 2009). These academic simulations demonstrate the ability of LES to betterpredict turbulent flows (see Ref Dufour et al. (2009)), but it appears that the assessment on industrialconfigurations needs to be pursued.

The aim of this study is to develop a methodology for LES computations on industrial turboma-chinery cases regarding the mesh size, the numerical parameters and the convergence criteria. Thecomparison with experimental results will help to assess the benefit of LES calculations on such anindustrial system. The open test case investigated is presented in Sect. 1, the methodology and thenumerical procedure are then presented in Sect. 2. Finally, results on 100 million, 25 million and 10million-grid-point meshes are analyzed to assess the benefit of LES computation.

THE NASA ROTOR 37 TEST CASEThe open test case under investigation is the well-known high-pressure-ratio axial compressor

NASA Rotor 37. Overall characteristics of the nominal operating point is summarized in Fig. 1.

Number of Rotor Blades 36Tip radius at leading edge 252 mmAspect ratio 1.19Hub-tip radius ratio 0.70Tip solidity 1.288Tip clearance height 0.356 mmRotation speed 17188.7 r/minTip speed 454 m/sTotal pressure ratio 2.106Mass flow (corrected) 20.19 kg/sChoked mass flow 20.93 kg/s

Figure 1: Design parameters and cross section of the NASA Rotor 37 (Suder, 1996).

This test case is frequently used as a validation case for CFD codes as it is well described experi-mentally (see Fig. 1):

1. radial distributions of the total pressure ratio, temperature ratio, of the absolute angle and theisentropic efficiency are available at two stations upstream and downstream of the rotor: station1 (z=-4.19 cm) and station 4 (z=10.67cm),

2. pitchwise distributions of the relative mach number are available at three stations: station 2(20% x/c), station 3 (z=4.57cm) and station 4 (z=10.19cm), at 30%, 50%, 70%, 90%, 95% of

2

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the spanwise direction, allowing to compare the position of the calculated shock to the experi-mental one,

3. performance parameters are computed using the radial distributions, the pressure ratio beingenergy averaged and the temperature ratio being mass averaged across the annulus, allowing tocompute the adiabatic efficiency.

Despite its use as a validation case, RANS simulations often fail to predict the global and localparameters of the NASA Rotor 37, probably because of the physical phenomena that develop in thiscompressor (shock, shock/tip leakage vortex interaction). In fact, a noteworthy discrepancy is thetotal pressure ratio deficit near the hub at design mass flow. This pressure deficit is believed to bedue to injection/recirculation or to a corner flow separation (see Denton (1996)) but no agreement hasbeen found yet. Since corner flow separation stems from an unsteady behavior of the flow field, thisconfiguration seems relevant for assessing the benefit of LES on a complex geometry. Furthermore,this compressor is isolated, i.e. the computational domain is small enough to allow a high density ofmesh cells for given CPU resources.

TOOLS AND NUMERICAL PROCEDUREelsA CFD code PresentationThe results presented in this study are performed with the elsA CFD code developed by ON-

ERA and CERFACS. elsA solves the Favre-averaged compressible Navier-Stokes 3D equations witha cell-centered finite-volume formulation on multi-block structured meshes. A backward Euler in-tegration with implicit LU schemes and SSOR correction is used for the integration of the discreteequations. Temporal discretization uses a standard second order accurate dual time-stepping algo-rithm with Newton’s sub-iterations. [More information about this flow solver can be found in Ref.(Cambier and Veuillot, 2008) and validation for turbomachinery applications is assessed by Castillonet al. (2002). Furthermore, the ability of the elsA CFD code to predict turbulent flows with LES isdetailed in Leonard et al. (2010).]

Numerical ModelsThe numerical model used in the present study is outlined in the following. For the RANS sim-

ulations, a second-order Roe scheme is used for the discretization of the convective fluxes (using aVan Albada limiter) and a k − ω Menter (Menter (1993)) was employed to estimate the eddy viscos-ity. For LES, the convective fluxes are discretized using a third order Roe scheme since decenteredscheme are better for predicting discontinuities like shocks. The SGS model is the Wall-AdaptingLocal Eddy-Viscosity (WALE) model, which is build to have the right behavior near walls as opposedto Smagorinsky SGS. All details of this SGS model and its validation can be found in Nicoud andDucros (1999).

Computational GridThe 3D computational domain corresponds to a single blade channel. The geometry is meshed

using an 04H topology: a 2 million-grid-point mesh for RANS computation, a 10 million-grid-pointmesh for LES computation, a 25 and a 100 million-grid-point meshes for computing LES. For allcases, the size of the first mesh cell is set to 3µm to ensure y+ ∼ 1. All quality details of thesemeshes are summarized in Table 1.

In Georgiadis et al. (2010), the recommended quality details for meshing an LES configurationare:

50 < ∆x+ < 150

3

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2MRANS 10MLES 25MLES 100MLES

mean ∆x+ 490 302 169mean y+ 1,8 1.2 1.37 1.43

mean ∆z+ 55 62 37points in the axial direction 209 229 289 485

points in the radial direction 105 457 649 1161points in the azimuthal direction 57 89 105 109

spanwise points in tip 29 57 81 117

Table 1: Mesh quality details.

y+ < 1

15 < ∆z+ < 40

One can notice that the results for the 100 million-grid-point mesh are in the upper limit of therecommended quality details. This explain roughly why a LES is so costly from the computationalressources point of view.

Simulation ProcedureChoice of the Time-Step

The methodology used in this study is to consider a CFL number close to one with a characteristiclength of the size of the boundary layer thickness close to the leading edge, and a characteristicvelocity assumed to the speed of sound. The idea is that we want the smallest structures, correctlycomputed with the LES approach (i.e. no low pass filtering is done on these structures), to be of thesize of the boundary layer. This means that the time-step does not act as a low pass filter, this functionbeing done by the mesh. One definition of the CFL number is:

CFL = (u+ a)∆T

∆X⇒ ∆T = CFL

∆X

(u+ a)

where u denotes the axial velocity, a the local speed of sound, ∆T the time-step and ∆X a charac-teristic length of the cell. As mentioned before, the authors consider the characteristic length to be ofthe size of the boundary layer (extracted from a RANS computation near the leading edge) and thespeed of sound for the axial velocity:

∆X ∼ δ ∼ 2.10−4m, and (u+ a) ∼ 2.a ∼ 680 m.s

−1.

Finally,∆T ∼ 3.10−7

s

Statistics on the Flow-Field

The period considered to perform the statistics is the through-flow time (let us recall that thethrough-flow time is the convective time that a particle needs to travel all the numerical domain). Onethrough-flow time is computed in 4000 iterations and 100 samples are used to average the flow-field.

Convergence AssessmentOne of the main issue when conducting unsteady flow calculations is to determine when the

computation is statistically converged, so that statistics on the flow field are relevant. For a steadysimulation, the iterative convergence criteria (see Casey and Wintergerste (2000) for instance) is a

4

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well-established criteria to stop the computation but is hard to extend to unsteady flow computations.In fact, the difficulty with this type of simulation is that data can be periodic or fully unsteady, yieldingto the impossibility to apply the former criteria. A way to solve the problem is to consider the time-average of the data. Although this approach works well with URANS simulations, this is not true withLES computations, since the spectrum of turbulent scales is large. Therefore, the frequency contentof a LES signal might be of prior interest.

The Fast Fourier Transform is an efficient mathematical method to compute the Discrete FourierTransform (DFT). If x(t = n∆T/N) is a discrete signal where n ∈ [0;N ], the kth Fourier coefficientXk is defined as:

Xk =

N−1�

n=0

x(n)e−i 2πknN

The convergence criterion of Ahmed and Barber (2005) relies on the DFT to evaluate the con-vergence of the ”physical amplitudes”. In fact, when computing the Fourier transform of a sig-nal, a cutoff-frequency corresponding to the spectral resolution fits in with the error contained inthe signal (since the signal is discrete, Fourier transform cannot be resolved for scales smaller thanfc = 1/Nds∆T , where Nds denotes the number of data samples). The criterion of Ahmed and Barber(2005) states that a computation is converged if the amplitude of the physical frequencies of the prob-lem (frequencies that appear during the simulation and that are higher than fc) is very large comparedto the dominant frequency in the cutoff region and if these amplitudes are stable between consecutivetime intervals. When this criteria is satisfied, one can perform statistics on the flow-field. To assessthis convergence criterion, 15 probes were placed in the computational domain at locations of inter-est. The spatial mean of the mass flow rate at outlet has also been extracted to assess this criterionon a conservative and spatially averaged variable. It should be noted that the probes are placed in therelative frame.

0

0.2

0.4

0.6

0.8

1

−2000 −1500 −1000 −500 0 500 1000 1500 2000

Norm

alized

am

plitu

de

ofm

ass

flow

outlet

Frequency in Hz

Through-flow 1Through-flow 2Through-flow 3

(a) Zoom near the cutoff-frequency, fc ∼ 120 Hz, of threeconsecutive through-flows. Transitory part.

0

0.2

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1.2

−10000 −5000 0 5000 10000

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Frequency in Hz

Through-flow 35Through-flow 36

(b) Comparison of two consecutive through-flows after140,000 iterations.

Figure 2: Assessment of the convergence criterion.

The results presented in Fig. 2 are Fourier transform of the outlet mass flow signal. In fact, thecriterion has also been assessed on probes signal but these have a relatively chaotic frequency content,preventing the assessment of the criterion on such signals.

Application of the convergence criterion for this industrial configuration raised several issues.As can be seen in Fig. 2(a), in the cutoff region (fc ∼ 120 Hz), the low (unphysical) frequenciesdamp and the larger (physical) ones become predominant between consecutive through-flows. Thisbehavior is seen in all the present LES calculations and occurs in the early time of the calculation:only three through-flows are needed to have the maximum amplitude in the cutoff region at 20%.

5

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However, after 35 through-flows iterations, no convergence on the amplitude is found between twoconsecutive through-flow times (see Fig. 2(b)), despite the fact that the maximum amplitude of thefrequencies cutoff region are smaller than 5%. This behavior is due to the frequency content of LES.In fact, turbulence is a random process, explaining why no stabilization on the amplitude is seen.

Statistics, on the overall and local parameters, have been performed after 40,000 iterations on thepresent LES calculations. The variance σ computed is: σ ∼ 1,0E-5 implying that the computation isclearly converged in mean.

The criterion of Ahmed and Barber (2005) seems to be unadapted to the physics of a LES calcu-lation. In fact, LES computations contain a large range of frequencies, unlike URANS calculations,preventing any convergence in amplitude of the Fourier transform, whereas the convergence in meanis reached. Indeed, LES Fourier transform can not see their amplitude stabilize since no determinis-tic period is a natural phenomenon. Therefore, for LES simulations, a restriction of the criterion ofAhmed and Barber (2005) might be that the physical amplitudes dominate the spectrum.

RESULTSComparison of the Resources Needed

Number of Iteration CPUNehalem processors time (Hour)

RANS2M 1 4,000 12LES10M 32 80,000 6,144

LES100M 512 80,000 ∼ 66 ,000

Table 2: Resources needed for the computations

Table 2 summarizes the time needed to simulate an industrial configuration with a LES approach.The time needed to compute the 100 million grid point mesh is really expensive compared to RANSsimulations (by a factor 5500).

ValidationThe performance maps (pressure ratio and efficiency) obtained by the LES and RANS calculations

are given in Fig. 3. One can see that the RANS calculations are better predicting the pressure ratiowhilst LES simulations seems to be in better agreement with adiabatic efficiency experimental data.Overall, the results are not as good as the one obtained by Hah (2009). Let us recall that thesecalculations were made on a 14 million-grid-point mesh and that the design and the stall calculationsfit perfectly the experimental data. The choked mass flow rate of Hah (2009) is 20, 91 kg.s-1, chokemass flow rate is (since this is the only operating point computed with the LES approach) 20, 95 kg.s-1 for the 10, 25 and 100 million grid-point mesh (the experimental choke mass flow rate is 20, 93kg.s-1).

Local flow characteristicsFig. 4 presents computational results at choke (which is the operating point computed with the

LES approach), therefore the comparison is done between computational results calculated at chokeand experimental results acquired at design point. Unfortunately, local experimental results are notavailable for choke operating point. However, following the comparison performed by Hah (2009),the nominal experimental data are plotted on the graph to assess the present results. Regarding theabsolut angle, since the operating point is not strictly similar, the result are different and might bean explanation of the discrepencies observed. However, concerning the radial distribution of thepressure ratio, the shape of the LES curve is significantly influenced by mesh density. Furthermore,

6

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1.9

2

2.1

0.92 0.94 0.96 0.98 1 1.02

Tota

lpre

ssur

era

tio,P

4/P

ref

Corrected mass flow

Experimental dataRANS

URANS10MLES10MLES25M

LES100M

(a) Total pressure ratio comparison.

0.8

0.82

0.84

0.86

0.88

0.9

0.92 0.94 0.96 0.98 1 1.02

Adi

abat

iceffi

cien

cy

Corrected mass flow

(b) Adiabatic efficiency comparison.

Figure 3: Performance map of the NASA Rotor 37.

0

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1.85 1.9 1.95 2 2.05 2.1 2.15 2.2 2.25

%span

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Experimental dataRANS

LES10MLES25M

LES100M

(a)

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Adiabatic efficiency

(b)

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1.25 1.26 1.27 1.28 1.29 1.3 1.31 1.32

%span

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Total temperature ratio, T4/Tref

(c)

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40

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35 36 37 38 39 40 41 42 43 44 45 46

%span

from

Hub

Absolute angle

(d)

Figure 4: Radial distributions downstream of the NASA Rotor 37.

the pressure deficit, which is of paramount interest, is not found in any of the LES calculations. Onlythe RANS simulation reveals a small pressure deficit. Hah (2009) shows that a corner stall develops atdesign and choked mass flow rate. In Figure 5, friction lines for the 10 million-grid-point mesh LESis shown, revealing no corner stall but a separation at ∼ 30% x/c. Even if the results of the presentstudy are at choked mass flow rate, they are in contradiction with the ones given by Hah (2009).Furthermore, Shabbir et al. (1997) studied the effect of a hub leakage flow on the local distribution of

7

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the pressure ratio for the NASA Rotor 37 and the NASA Rotor 35, and their results indicated that thepressure deficit near the hub can be induced by a leakage flow. Moreover, their results highlight thefact that the ratio of hub leakage mass flow over the total mass flow can be set to fit the experimentaldata quite perfectly. In fact, this parameter seems to be a major one and should be set properly, withouttrying to match the experimental data.

Figure 5: Friction line on the blade of the NASA Rotor 37 at choke, LES 10 million-grid mesh-point.

The radial distributions of efficiency of the LES calculations have a good shape compared to theexperimental data, even though the operating point is slightly different. This tendency is visible forall the LES calculations. Since the computations are all at chock mass flow rate, it seems obviousthat the absolute angle is not in agreement with experimental data. One of the major observationthat can be done on the radial distributions is that the phenomenology observed in the three LEScalculations is completely different than the RANS calculations (that is obvious, since the operatingpoint is different) and it seems to have a grid density dependency for these parameters.

Mesh dependencyThe comparison shown in Fig. 6 highlights the mesh dependency that is inherent to a LES simu-

lation. The results presented are at choke mass flow. Indeed, one can see that in the NASA Rotor 37,there is an oblique shock (1), near the leading edge of the rotor, which interacts with the boundarylayer inducing a separation (2). This separation provokes a secondary shock by reducing the passagesection. The flow field near the trailing edge develops vortex shedding. The vortices are better re-solved with the 100 million grid point mesh. Therefore, the structures captured with a finner meshare smaller and gives accurate information on the flow field phenomenology.

One can notice that the shocks are thinner with the 100 million grid point mesh than with the 10million grid point mesh. In fact, this results is emphasized when regarding the secondary shock. Amajor discrepancy is the interaction of the secondary shock with the pressure side, which triggersa turbulent transition for the 100 million grid point mesh (see (4) in Fig. 6(b)) but not with the 10million grid point mesh (see Fig. 6(a)).

CONCLUSIONSThe methodology presented in this study helps choosing the time-step, assessing the quality of the

different mesh and stopping the calculation at the adequate time. The convergence assessment shows

8

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(a) 10 million grid-points mesh (b) 100 million grid-points mesh

Figure 6: LES computations comparison. Contour of density gradient at choke conditions on a bladeto blade plane at 50 % of the span.

that the criterion of Ahmed and Barber (2005) should be restricted to the evacuation of unphysicalfrequencies.

LES helps investigating complex flow fields. However, at that point of the study, the current LESmethod does not show any clear improvements with respect to RANS based simulations. For theparticular test case NASA Rotor 37, the results seem to indicate that no corner stall is represented.Moreover, this observation is true for the finner mesh indicating that this phenomena is not meshdependent.

ACKNOWLEDGMENTThe authors want to thank the Centre Informatique National de l’Enseignement Superieur (CINES,

Montpellier, FRANCE, project name fac6074) for the computational resources made available andCSG for the intern resources made availabe at CERFACS.

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