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Ing-Ind/09 3 From Design to Flow solutions In Industrial Fluid Machinery Team Research Assistant & PostDoc Giovanni Delibra, Paolo Venturini Ph.D. Candidates David Volponi, Alessio Castorrini Ph.D. students Tommaso Bonanni, Lorenzo Tieghi, Gino Angelini SSD: ING IND-09 Fluid Machinery R&D Environment Selection Smart environment is configured in order to give the user DESIGN the possibility to customize the experience selecting tools optimizing time and accuracy. VIRTUAL Configure TEST RIG Tool Chain B OPTIMIZATION C A D Duty Selection Design Verify Te s t CentrLab Fan Selector AxLab TM MixLab Design BigData Prototyping In Fluid ADM ALM Der. Design Machinery CFD & FSI BD Opt P-Track SSD: ING IND-09 Integrated tool for industrial design of turbomachinery blades DESIGN • Develepod in Python, based on an axisymmetric solution of DESIGN the indirect problem. • Designed to be Multi-Platform and Expandable. VIRTUAL • It allows to test innovative design solutions. TEST RIG • Save, Export, Share and Compare different Designs. OPTIMIZATION SSD: ING IND-09 VIRTUAL TEST RIG DESIGN The virtual test rig consists of different analysis tools: TM DESIGN • Reduced Order Solvers: AxLab, MixLab, CentrLab • Actuator Disk Model • Actuator Line Model VIRTUAL TEST RIG • Ljungstrom Heat Exchanger OPTIMIZATION MixLab AxLab CentrLab • Each tool is designed for performance analysis on different level; from a AADM quasi-3D steady state approach to transient problems. • Set of instruments for fan performance analysis in order to simplify fans performance prediction. ALM • Designed both for axial and centrifugal machinery SSD: ING IND-09 Reduced Order Solvers: AxLab – MixLab DESIGN MixLab TM DESIGN AxLab CentrLab VIRTUAL TEST RIG AxLab and MixLab software are python programs for performance analysis of ducted axial or mixed-flow fans. • Based on a blade element axisymmetric principle whereby the rotor blade is divided into a number of streamlines. • For each streamline, relations for velocity and pressure are CentrLab software is a python program derived from incompressible conservation laws for mass, centrifugal fans performance analysis. tangential momentum and energy. • Based on the blade-to-blade analysis of a • Produce dependable results with small computing costs two-dimensional inviscid flow requiring solution of a simplified radial equilibrium • Continuity and vorticity equation in equation at only one axial station. cylindrical coordinates are reduced to the blade-to-blade equation by defining a stream function Ψ • Equation solved on a unstructured grid can be easily automated through well- known algorithms of triangulation SSD: ING IND-09 • Re-design of High-pressure combustion fan SSD: ING IND-09 AERODYNAMIC DESIGN OF AGRICULTURAL SPRAYERS UNIT DIMA Blade Inverse design CFD verification of perfomance & FEA Fieni Industrialization and lab tests SSD: ING IND-09 DESIGN OF A FAN FOR A SNOW GUN SSD: ING IND-09 D800 vs D800+ normalised P Z dBA weight [kW] rot of rotor blade D800 18.5 12 84.8 1 D800+ 17.4 6 83.2 0.6 ∆ -1.1 -50% -1.6 dBA -40% Power requirements of the D800+ blade was 1,1kW lower than D800 Number of blades was halved and an overall 40% of weight reduction was achieved 1.6 dBA reduction of noise was achieved SSD: ING IND-09 CFD and then? … adventure & experiments me SSD: ING IND-09 SYNTETIC METHODS CFD & FSI NUMERICAL RECIPIES Models for devices in ventilation systems U • ADM and ALM for axial flow fans (see other slides) • Rotating heat exchangers • collaboration with ENEL • Gravity dampers and fire shutters • collaboration with GE Oil & GAS SSD: ING IND-09 ACTUATOR DISK MODEL DESIGN AADM TM DESIGN VIRTUAL The Actuator Disk Model is implemented in Open Foam (C++ language) and TEST RIG allows a synthetic rotor simulation • We have developed and validated a Advanced Actuator Disk Model for OPTIMIZATION industrial turbomachinery performance prediction in complex industrial system layouts • Limitations of AADM: able to reproduce only the average behavior of the fan within the ventilation system, without giving information on the unsteady flow field SSD: ING IND-09 LJUNGSTROM HEAT EXCHANGER DESIGN A Ljungstrom heat exchanger is used in thermal power plant to preheat the primary air with the exhaust gasses of the combustion process TM DESIGN To reproduce the effect of the Ljungstrom heat exchanger on the fluid, a synthetic model has been implemented in OpenFOAM (C++) The operating principle of the device is dicretized by: VIRTUAL TEST RIG • A porous mean, modelling the fluid pressure drop • A source term, added in the temperature equation, modeling the complex OPTIMIZATION heat exchange mechanism Modelization and coefficients have been derived from experiments and empirical formulations from literature- SSD: ING IND-09 ACTUATOR LINE MODEL DESIGN The Actuator Line Model is implemented in Open Foam ALM (C++ language) allows a synthetic rotor simulation TM DESIGN • Created to overcome the limitations of AADM : blades are physically reproduced in the computational geometry assigning force source terms only to some cells VIRTUAL TEST RIG • This kind of approach can be used CFD environment that can be based on any kind of unsteady approach (URANS, LES, hybrid LES/RANS, DNS) providing OPTIMIZATION unsteady system effect on the behavior of the fan SSD: ING IND-09 ADVANCED Multi-Physics MODELLING FOR Industrial FLOWS CFD & FSI Advanced URANS modelling based on recovery of Reynolds NUMERICAL stress anisotropy implemented and validated in X++ and OF: RECIPIES • cubic k-ε model U VIRTUAL ζ • -f model TEST RIG (Selected) papers A Corsini, F. Rispoli. Flow analyses in a high-pressure axial ventilation fan with a non-linear eddy-viscosity closure, International Journal of Heat and Fluid Flow G. Delibra, D. Borello, K. Hanjalić, F. Rispoli, URANS of flow and endwall heat transfer in a pinned passage relevant to gas-turbine blade cooling, International Journal of Heat and Fluid Flow Hybrid LES/RANS models implemented and validated in X++ and OF and applied to TM flows • ζ-f model • No -model LES based on DCDD discontinuity capturing operator (Selected) papers L. Cardillo, A. Corsini , G. Delibra, F. Rispoli, T. E. Tezduyar, Flow Analysis of a Wave-Energy Air Turbine with the SUPG/PSPG Method and DCDD, Advances in Computational Fluid-Structure Interaction and Flow Simulation, 2016 G. Delibra, D. Borello, K. Hanjalić, F. Rispoli, Vortex structures and heat transfer in a wall-bounded pin matrix: LES with a RANS wall-treatment, International Journal of Heat and Fluid Flow 2010 SSD: ING IND-09 DCDD inner working POSEIDONE consortium DIMA_FP Wells Turbine 1.5 kW ννDCDD/ mol LES mesh approx 100 M elements DCDD mesh 3.5 M elements SSD: ING IND-09 CAE tool development for FSI applications on rotating blades PARTICLE TRACKING Direct FSI study on FAN blades: improvement in numerical testing capabilities for virtual prototyping FSI CFD & FSI FLOW CONTROL Castorrini et al. Fluid-structure interaction study of large and light axial fan blade, Proceedings of ASME TurboExpo 2017 Passive morphing control Numerical testing of new concepts for passive flow control Castorrini, A., et al. Numerical Study on the Passive Control of the Aeroelastic Response in Large Axial Fans. Proceedings of ASME TurboExpo 2016 Castorrini et al., Numerical testing of a trailing edge passive morphing control for large axial fan blades, Proceedings of ASME TurboExpo 2017 SSD: ING IND-09 VMS for particle-cloud tracking in turbomachinery flows Results, particle impact on fan blades – non-spherical Simulated particles D=4µm D=4µm L=20µm sphere (red line) non-sphere (green line) particles SSD: ING IND-09 Prediction of erosion/deposit effect on shape and performance of aerodynamic bodies PARTICLE TRACKING Material wearing on turbomachinery blades can produce after years of working, a change in the CFD & FSI aerodynamic shape of the profile. ONE-WAY COUPLING The capability to predict the performance degradation INTERFACE during the design phase can be of great help to plan the 1. STEADY RANS 2. PARTICLE CLOUD maintenance interventions MOTION 3. MATERIAL WEARING 4. BOUNDARY Normalized erosion patterns (Blue: no erosion, 0; red: 1) DISPLACEMENT and aerodynamic field (pressure and streamlines) on the 5. MESH MOTION first iteration and at the end of the process As example, taking a metal cylinder immersed in a flow transporting coal ash Presentation example (magnified) particles, we can see that after 16 months of operation the eroded shape brings to a change in flow field symmetry and thus to a change of the expected aerodynamic behavior Castorrini et al., Numerical simulation with adaptive boundary method for predicting time evolution of erosion processes, Proceedings of ASME TurboExpo 2017 SSD: ING IND-09 Projects on Flow Control PARTICLE TRACKING FSI CFD & FSI Stall control on axial-flow fans: leading edge bumps FLOW Anti-stall ring in tunnel and metro axial flow fans CONTROL NUMERICAL Axial thrust control in multistage pumps RECIPIES U SSD: ING IND-09 STALL CONTROL ON AXIAL FANS: LEADING EDGE BUMPS CFD & FSI FLOW CONTROL 1 BIOMIMICRY Stall control is a key issue to be addressed for R&D of WHALES ARE THE ONLY EXAMPLE OF compressors and fans. 2 EVOLUTION AT HIGH BUMPS ON FINS OF REYNOLDS A number of active and passive techniques were HUMPBACKS (COMPARABLE WITH ALLOW WHALES TO TM APPLICATIONS) developed aiming at increasing the aerodynamic stability EXECUTE SHARP MANOUVERS of compressors, eg: 3 LEADING EDGE • variable pitch in-motion BUMPS tubercles Corsini and Rispoli, 2004, Using sweep to extend the stall-free
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