ANSYS Research Articles

Influence of vortex generator dimensions on film cooling efficiency

Enhancements in gas turbine blade cooling techniques, such as film cooling, have significantly advanced the aerothermal effi-ciency of turbines, especially in transportation sectors like aeronautics and automotive industries. This study aims to enhance turbine blade cooling by incorporating an obstruction at the jet exit. The vortex generator angle has been modified to 25°, 45°, 60°, 90° and 110°. These five designs were assessed in comparison to the conventional cylindrical hole configurations. Two injection ratios (M = 0.25, and M = 0.5) were studied within the ANSYS CFX 16 software, utilizing the finite volume method to solve the average Reynolds equations and the energy equation. The findings show qualitative alignment with experimental data for the base scenario, indicating that the vortex generator angle notably amplifies film cooling effectiveness. Typically, the vortex generator configured at 90° exhibits a stronger mixing capability compared to the other cases and cylindrical design.

A Comparative Study of Structured and Cut-Cell Grids Applied to an Oil-Injected Screw Compressor

Abstract Discretized Partial Differential Equations (PDEs) for numerical modeling of fluid mechanics systems require the use of various iterative linear solvers. In this study, two different CFD solvers, Ansys CFX and Converge, were employed to develop a transient 3D CFD model of an oil-injected screw compressor. Each solver utilized distinct meshing techniques—Ansys with a structured grid and Converge with a cut-cell grid. The numerical models have been validated utilizing experimental measurements. Presence of turbulent boundary layer and shear flow topology in the rotating fluid domains required implementing k-ω Shear Stress Transport (SST) turbulence model along with the physics needed to capture multifluid interfaces. In CONVERGE CFD, Semi Implicit Pressure Linked Equation (SIMPLE) algorithm was used for initial model development and pressure-velocity coupling in a collocated grid model, eliminating checkerboard numerical oscillations with the Rhie-Chow interpolation scheme. Ansys CFX handles pressure-velocity interactions through its solver framework, which operates without requiring a separately defined pressure-velocity coupling algorithm. These model parameters and pressure velocity coupling algorithms are kept unchanged while comparing preconditioned Successive Over Relaxation (SOR) and Incomplete Lower and Upper triangular (ILU) decomposition. These two solvers yielded to different numerical instabilities and rate of convergence, affecting the simulation clock time.

NUMERICAL SIMULATIONS AND SENSITIVITY ANALYSIS OF ICE FORMATION ON FAN BLADES

Abstract In-flight icing, the formation of ice during flight, poses risks to the safety and reliability of aircraft. Due to environmental conditions, ice accumulation occurs on the low-pressure compressor blades of an engine, diminishing aerodynamic performance and potentially causing damage to the engine. Numerical simulations of ice accretion are conducted on the blades of the NASA Rotor 67 utilizing the Computational Fluid Dynamics (CFD) software ANSYS CFX and the in-flight icing software FENSAP-ICE. One-dimensional and two-dimensional sensitivity studies aim to analyze the influences of temperature, droplet diameter and liquid water content (LWC) on the resulting ice build-up on the blade. The analyses reveal that ice accumulates predominantly at the leading edge of the blade, where collection efficiency is maximal. Additionally, an ice layer forms at the blade root on the pressure side. While LWC and temperature exerts a significant influence on the ice mass, only a marginal impact on droplet diameter is observed.

Studying the Impact of Diffuser Return Guide Vanes on the Energy Performance of a Multistage Centrifugal Pump

The head, efficiency, and cavitation characteristics of centrifugal pumps are highly dependent on the velocity field in front of the impeller inlet. In multistage pumps, the velocity field in front of the second and each subsequent stage is determined by the shape (design) of the diffuser return guide vanes. This current work presents the results obtained by performing a numerical study using ANSYS CFX 14.0 to determine the impact of the shape (design) of diffuser return guide vanes on the head and coefficient of efficiency of one stage of a multistage centrifugal pump. Three RGVs with different Outlet angles are studied: α6 —original RGV with α6=90 deg, RGV1 with α6=110 deg and RGV2 with α6=128 deg. The results obtained after performing CFD modeling indicate that with one of the studied RGVs, the pump stage head increases by nearly 20%, while the hydraulic coefficient of efficiency remains almost constant. Applying entropy production theory is used to determine the impact of the various components of entropy production on the total head loss in the studied pump stage. The impact of the Outlet angle of the RGV on the velocity field of the flow in front of the next impeller (stage) as well as the RGV head is also analyzed. The numerical results of the original RGV are compared with the experimental data obtained from large-scale studies of pumps performed at the Laboratory of Hydraulic Machines of the University “Angel Kanchev” of Ruse, Bulgaria. When using the modified RGVs, the head curve of the original pump can be obtained by operating at a lower speed or with a smaller impeller diameter. This may lead to an overall increase in the energy efficiency of the machine, which could be explored as a future task.

Investigation of Tool Cooling and Heat Transfer Using Computational Fluid Dynamics Simulations

Thermal errors remain one of the biggest challenges for the precision of cutting machine tools. Aside from optimizations in the machine tool design and behaviour, optimal cutting process parameters and targeted usage of cutting fluid or alternative methods of tool cooling are required for improved process efficiency with minimal energy demand and maximal tool life. A simulation-based study is presented which compares both different methods of tool cooling, specifically air cooling, flooded cooling and minimum quantity lubrication and also different simulation methods and models. Using a case study, which models an existing thermal test stand comprised of motor spindle, tool holder, tool and coolant nozzle, different cooling scenarios were tested and compared. The simulations were performed in ANSYS CFX. Comparisons were made between simulations with and without buoyancy, with and without tool rotation, transient and steady-state, with laminar flow and with different turbulence models and between the different cooling scenarios. Some insight on different time step sizes and the resulting increase in simulation time and precision was also gained. These results will make future studies on the thermal behaviour of both tool and cutting process easier by showing suitable simulation techniques and viable model simplifications.

Research on unsteady flow characteristics of turbocharger turbine stage with coupling inlet and exhaust casings

The inlet and exhaust casings of marine turbochargers are closely coupled to the axial flow turbine. These are crucial parts that work with the axial flow turbine and have the ability to raise the power plant’s output power even higher. Their final stage of the axial flow turbine and the exhaust casing’s complex flow due to their close relationship will have a significant effect on each other’s aerodynamic performance. However, most existing studies have not paid sufficient attention to this coupled transient interaction. In this paper, the flow interaction between the axial flow turbine and the inlet and exhaust casings is studied. Particular attention is paid to the study of the coupled flow characteristics under design and variable operating conditions. This study is carried out using coupled computational fluid dynamics (CFD) simulation. The computational domain consists of an inlet casing, 28 stator blades, 43 rotor blades, and an exhaust casing. The commercial CFD software ANSYS CFX solver and the SST turbulence model are used to simulate the unsteady flow field of the turbocharger axial turbine coupled to the inlet and exhaust casings. In this paper, the turbine flow field and the inlet and exhaust casings flow fields are analyzed, and the influence of the exhaust casing on rotor surface pressure fluctuation is discussed. In addition, the flow field distribution and performance parameters of the axial flow turbine coupled with the inlet and exhaust casings under three different operating conditions have been calculated and analyzed. The results show that the inlet casing affects the circumferential distribution of the stator leading edge pressure, while the asymmetric back pressure caused by the exhaust casing flow field causes the low-frequency pressure fluctuation at the rotor blade surface. At the trailing edge of the suction surface, the complex flow separation and vortex structure in the exhaust casing are the main factors causing rotor-stator interaction. The low-frequency fluctuation amplitude caused by the exhaust casing is greater than that caused by the high-frequency fluctuation of the rotor-stator interaction. Moreover, as the flow coefficient increases, the low-frequency fluctuation amplitude is much greater than the high-frequency fluctuation amplitude.

Prospects for reducing resistance of ash collecting apparatus

Various variations of reducing the aerodynamic resistance of devices with a complex flow-through configuration are considered. About 50% of power plants in the Russian Federation operate on coal, with two-stage cleaning used in the ash collection process. Modern coarse ash collectors allow achieving an efficiency of 55 – 80% depending on their service life. It is advisable to reduce the number of cleaning stages by upgrading them with modern cleaning devices that allow achieving high efficiency of cleaning the dusty flow and subjecting this cleaning complex to less repair work. IVACis an inertial-vacuum ash collector, which can achieve the capture of a wide range of studied particles (1 – 100 μm) with an efficiency of up to 99%. This device was tested at the Omsk CHP Plant, but it was found to feature an increased aerodynamic resistance, as well as high efficiency. The objective of this work is to keep an aerodynamic resistance to 660 Pa (the resistance of the cyclone apparatus so that the apparatus can be used as the first and, consequently, as two stages of purification) while maintaining the efficiency of the apparatus. The results of changing the configuration of the flow part of the IVAC are analyzed, the model submitted for patenting after numerous is considered. The research methodology is the analysis of a numerical experiment in ANSYS CFX using the k-ε mathematical model (ash mass content of 70 g / kg; One-Way Coupling). In conclusion, recommendations are proposed for further prospects of IVAC research.

Study Of Tandem Rotor Dual Wake Interaction With Downstream Stator Under Unsteady Numerical Approach

Abstract This paper highlights the intricate rotor-stator interaction between a tandem bladed rotor and a single-bladed stator in the light of unsteady numerical simulations. A low speed tandem bladed compressor stage has been conceptualized and experimentally validated against targeted performance goal. With the evident pressure rise capability of the tandem bladed compressor stage, it becomes obligatory to investigate the rotorstator interaction owing to its dominant effect on overall stage performance. The multi-passage rotor-stator unsteady simulations have been performed using blade transformation methods in ANSYS CFX. Due to the presence of two highly loaded rotor blades, the tandem rotor exhibits peculiar rotorstator interaction in terms of multiple wake impingement on the stator. Incorporating tandem blading on the rotor instead of the stator (which is more common) constricts the design envelope in terms of choice of blade axial overlap and percentage pitch. The variation of aerodynamic loading from hub to tip for both the rotor blades results in spanwise varying wake strength. The initially distinct wake structures merge resulting into a thicker wake. Additionally, the rotor blades are highly loaded in the tip region which results in the complex interaction between end-wall boundary layer and tip leakage flow. Cumulatively, these conditions constitute a challenging aerodynamic field for the downstream stator. The study focuses on the qualitative interaction between the rotor wakes and blockage with the downstream stator and put forwards some aspects of the tandem rotor-single stator stage design especially for core compressors of aero engine application.

Rotationally Induced Local Heat Transfer Features in a Two-Pass Cooling Channel: Experimental–Numerical Investigation

Turbine blades for modern turbomachinery applications often exhibit complex twisted designs that aim to reduce aerodynamic losses, thereby improving the overall machine performance. This results in intricate internal cooling configurations that change their spanwise orientation with respect to the rotational axis. In the present study, the local heat transfer in a generic two-pass turbine cooling channel is investigated under engine-similar rotating conditions (Ro={0…0.50}) through the transient Thermochromic Liquid Crystal (TLC) measurement technique. Three different angles of attack (α={−18.5°;+8°;+46.5°}) are investigated to emulate the heat transfer characteristics in an internal cooling channel of a real turbine blade application at different spanwise positions. A numerical approach based on steady-state Reynolds-averaged Navier–Stokes (RANS) simulations in ANSYS CFX is validated against the experimental method, showing generally good agreement and, thus, qualifying for future heat transfer predictions. Experimental and numerical data clearly demonstrate the substantial impact of the angle of attack on the local heat transfer structure, especially for the radially outward flow of the first passage, owing to the particular Coriolis force direction at each angle of attack. Furthermore, results underscore the strong influence of the rotational speed on the overall heat transfer level, with an enhancement effect for the radially outward flow (first passage) and a reduction effect for the radially inward flow (second passage).

Effect of Induced Wheel and Impeller Inlet Diameter on the Hydrodynamic Performance of High-speed Centrifugal Pumps

The high-speed centrifugal pump plays a crucial role in fields such as aerospace and petrochemical industries, owing to its characteristics of elevated rotational speed and high head. During high-speed operation, the centrifugal pump is prone to cavitation, which alters the fluid flow state within the pump, leading to vibrations, noise, and a sudden decrease in pump head and efficiency. Simultaneously, the collapse of cavitation bubbles generates impact pressure that can damage the pump's internal flow components, significantly reducing its operational lifespan and causing severe consequences. Moreover, under constant-flow conditions, the absolute and relative velocities of the fluid at the impeller inlet are functions of the suction pipe diameter. Therefore, there exists an optimal value for the impeller inlet diameter to enhance the centrifugal pump's resistance to cavitation. Similarly, the different geometric and structural parameters of the inducer also influence the hydraulic performance of the centrifugal pump. The focus of this study is on the external characteristics and internal flow patterns of an optimized high-speed centrifugal pump. In this paper, the entire flow field of the model pump is numerically simulated using ANSYS CFX software. The performance and overall flow field state of the high-speed centrifugal pump under different impeller configurations and inlet diameters are explored. The influence of blade wrap angle and inlet diameter on the high-speed centrifugal pump is revealed, providing a theoretical basis for subsequent optimal design.

Analysis of hydrofoil tip leakage vortex dynamic characteristics

The clearance exists inevitably between the turbine guide vanes and the fixed wall, and the resulting tip leakage vortex leads to the increase of hydraulic loss. Based on the fluid simulation software ANSYS CFX, the hydrofoil was numerically simulated under different flow velocity conditions. The trajectory and energy dissipation of the tip leakage vortex are discussed. The results show that the jet entrainment with the main flow to form the tip leakage vortex, which is mainly divided into main leakage vortex and separation vortex. The flow evolution of tip leakage vortex can be divided into three stages. The evolution of tip leakage vortex can be divided into three stages: independent development of main leakage vortex and separation vortex, fusion stage, and dissipation of main leakage vortex. The strongest turbulent kinetic energy dissipation occurs in the clearance, which confirms that the clearance causes non-negligible energy dissipation for hydraulic machinery. The results provide guidance for tip leakage vortex control of hydraulic hydrofoil.

Addressing thermal challenges in hydrodynamic bearings: A contemporary review of strategies and technologies

Hydrodynamic bearings are integral components in various industrial sectors, including aerospace, defense technologies, and power generation units etc. Advancements in modern technology have driven the evolution of bearings to withstand the high temperatures, increased speeds, and additional load demands of contemporary operations. Some of the prime consequences of high temperatures include thermal deformation, misalignment, viscosity degradation, reduced oil film thickness, reduced load carrying capacity and premature failure due to bearing seizure. Researchers have rigorously addressed the persistent thermal challenges posed to hydrodynamic bearings, achieving significant advancements over the years. Key developments include innovative bearing pad designs, optimal materials, coating technologies, advanced computational software, novel lubrication methods, and efficient monitoring techniques. The introduction of materials with tailored properties such as high heat conductivity, high strength, and low-friction coatings has greatly enhanced bearing performance. Additionally, advanced computational software like ANSYS CFX, Fluent, and COMSOL, adaptive lubrication methods, and real-time temperature sensors have significantly improved the performance of critical systems, including hydro power plants. This review paper summarizes significant developments and investigations carried out to mitigate thermal effects in hydrodynamic bearings, and hence provides a comprehensive in depth details of the subject matter. Even though there has been a lot of progress in the field of hydrodynamic bearings, continuous research is important to tackle issues related to sustainability, industry-specific obstacles, developing technologies, and dynamic operating conditions.

CFD Simulations of a Loss of Heat Sink Experiment in the McMaster Nuclear Reactor

The McMaster nuclear reactor (MNR) is an important research facility that not only provides researchers with neutrons for fundamental science, but also supplies the medical industry with isotopes used for cancer treatment. To ensure the safety and performance of the MNR, modeling of the thermal hydraulics during nominal and accidental conditions is required. For such a task, system codes are customarily used. While system codes can assess the safety aspects of complex thermal–hydraulic systems, the question arises whether such systems can be modeled appropriately in a three-dimensional manner, such as computation fluid dynamics (CFD), while capturing the thermal mixing of the coolant. Modeling the thermal hydraulics of nuclear research reactors using CFD is relatively new. Therefore, validating such methods against experimental data is of utmost importance. The validation of CFD is the main focus of this work. More specifically, the influence of the loss of heat sink on the pool temperature is assessed using the CFD code Ansys CFX. The validation basis was provided by an experiment performed at the MNR in March 2023. In this experiment, the secondary heat removal system was intentionally shut down, and the pool temperature was measured in a few positions. The results obtained by modeling the loss of heat sink in the MNR using Ansys CFX agree well with the experiment.

Mathematical Modelling of Hydrogen-Enriched Combustion

This article presents a mathematical model developed in ANSYS CFX 17.2 software to analyse the combustion process of hydrogen-enriched natural gas. The study investigates the concentrations of various flue gas components at hydrogen enrichments of 10% and 20%, compared to a baseline of pure natural gas. A three-dimensional model of the experimental setup was created allowing for detailed simulation of combustion dynamics under controlled conditions. The model incorporates the governing equations for mass conservation, momentum, energy, and turbulence, facilitating comprehensive analysis of combustion behaviour and pollutant formation. The simulations reveal that increased hydrogen enrichment raises combustion temperatures but also leads to higher carbon monoxide (CO) emissions due to incomplete combustion. The results indicate a corresponding decrease in carbon dioxide (CO₂) emissions, showcasing the environmental implications of hydrogen mixing. However, nitrogen oxide (NOx) emissions increase significantly with higher combustion temperatures. The mathematical model was validated against experimental data, demonstrating less than 10% deviation in temperature measurements and providing accurate predictions for pollutant concentrations.

Influence of axial distance between impeller and diffuser on the hydraulic performance and flow loss characteristics of bulb tubular pump

Abstract Bulb tubular pumps used in regional water transfer projects consume substantial power. Optimizing the geometric parameters of tubular pumps is crucial for enhancing efficiency and minimizing hydraulic losses. ANSYS CFX is used to investigate the axial distance between the impeller and the diffuser on the hydraulic performance and flow loss characteristics of the rear-bulb tubular pump, and the numerical simulation results are compared with the experimental data. Then, the entropy production theory is introduced to analyze flow losses. As the axial distance increases, the diffuser’s rectification effect on the flow at the impeller outlet deteriorates, leading to increased flow losses and decreased head and efficiency of the device. Flow losses in the bulb tubular pump are ranked from largest to smallest as follows: impeller, outflow channel, diffuser, inlet channel. The impeller exhibits the highest entropy production ratio, reaching 61.05% at an axial distance of 25 mm. By elucidating the energy loss distribution of each component under varying axial distances, this paper offers insights for the hydraulic optimization design of bulb tubular pumps.

An Optimization Approach for Enhancing Energy Efficiency, Reducing CO2 Emission, and Improving Lubrication Reliability in Roller Bearings using ABC Algorithm

Friction and energy waste pose significant challenges in various industrial processes. Lubrication plays a crucial role in reducing friction and optimizing energy consumption. This study focuses on analyzing, simulating and calculation the oil film thickness, friction levels, energy losses, and CO2 emissions. The objective is to optimize lubrication conditions to enhance performance, improve energy consumption, and maximize lubrication efficiency for rolling bearings in a centrifugal fan. The simulation utilizes ANSYS CFX software, MATLAB programming. The optimal oil viscosity grade is determined based on two objectives by using artificial bee colony algorithm (ABC): minimizing energy consumption (thus reducing CO2 emission) and achieving the optimal oil film thickness and viscosity ratio. The findings reveal that, under the current lubrication conditions and normal fan operation, energy losses due to oil friction amount to 36.3 MWh per year, with CO2 emissions resulting from power losses reaching 18,750 kilograms per year. By transitioning to the optimized oil grade, energy savings of 1.08 MWh per year and a corresponding reduction of 557 kilograms in CO2 emissions per year can be achieved.

Numerical and experimental examination of performance curve instabilities of a centrifugal fan

Abstract This paper investigates the performance curve instability of centrifugal fans used in industrial applications such as sintering or pelletizing plants. The study focuses on experimental and numerical analyses of the fan’s performance curve during operation. Model measurements of an optimized fan reveal instabilities in the characteristic curve around 73 % and 42 % of the volume flow at best efficiency point (Q/Qref) resulting in a sudden drop in pressure coefficient and the onset of low-frequency noise emission. Numerical investigations using ANSYS CFX predict the flow pattern accurately. Excellent agreement is observed between measured and calculated data for flow conditions, with deviations below 1 % in pressure coefficient. Notably, the calculated instability range occurs earlier at lower flow rates, leading to a 6 % shift in the data. The flow exhibits a detachment zone on the blade suction side and a complete blockage of a single impeller passage, corresponding to the pressure drop in the performance curve. Further investigations reveal that rotor-stator interaction causes the abrupt impeller rotating stall phenomena, significantly impacting pressure generation at lower flow rates. A FFT analysis confirms the presence of rotating stall, with its dominant frequency observed and multiple harmonics. The comparison of separation frequency with existing literature supports the assumption that rotating stall is the cause of the instability.

Numerical simulation of miniature high-speed aviation fuel pump using immersed solid method

Abstract Aviation fuel pumps are developing toward lightweight design and high rotational speeds at the same time that vehicles, such as missiles and unmanned aerial vehicles (UAVs), gradually get smaller. To investigate the internal flow field characteristics of a miniature aviation gear pump under conditions of high rotational speed, three-dimensional numerical simulations are conducted using computational fluid dynamics (CFD) software ANSYS CFX. The simulations use the immersed-solid method and employ the SST k-ω turbulence model. The findings reveal that under identical conditions, augmenting the tooth width by 1mm leads to a notable 27.32% increase in the average outlet flow rate and a corresponding enhancement of 7.22% in maximum efficiency. Furthermore, a 2mm increment in tooth width results in a substantial surge of 62.74% in the average outlet flow rate and a significant enhancement of 14.61% in maximum efficiency. Nevertheless, concurrently, the augmentation of tooth width corresponds with a gradual rise in trapped oil pressure and significant deterioration of the internal flow field. The study findings offer valuable insights into the integrated design of the oil supply system and engine components of aerospace engines.

Effect of baffles on internal flow characteristics of double-inhalation centrifugal pumps under low flow conditions

In order to investigate the impact of baffles in the inhalation chamber on the external characteristics and operational stability of a double inhalation centrifugal pump under low flow conditions, the flow field simulation software ANSYS CFX and the shear stress transport formulation were employed to numerically simulate the internal flow field of a double inhalation centrifugal pump with and without baffles. Two models were subjected to performance curve simulation and prediction, with the internal flow field, pressure pulsation, and impeller force of the two models being compared and analyzed under three small flow conditions of 0.6Qd (rated flow), 0.5Qd, and 0.4Qd. The velocity and vortex distribution inside the semi-spiral inhalation chamber, as well as their impact on the flow state in front of and inside the impeller, were analyzed. Research has demonstrated that the addition of baffles can enhance the pump head and efficiency in flow conditions of 0.5Qd–0.8Qd. However, there is a tendency for obstruction of flow in conditions below 0.5Qd. Baffles can reduce the amplitude of pressure pulsation within the impeller and the radial force exerted by the impeller as a whole. Consequently, the incorporation of baffles within the inhalation chamber during flow conditions of 0.5Qd–0.8Qd can enhance the operational efficacy of the pump. Nevertheless, within the flow range of <0.5Qd, the pump's performance will decline. This study serves as a foundation for the design of double inhalation centrifugal pumps with semi-spiral inhalation chambers.

Research on the Internal Flow Characteristics of an Electric Coolant Pump

Abstract To investigate the internal flow characteristics of an automotive electronic coolant pump, numerical simulations were performed utilizing the ANSYS CFX commercial software suite. The study delved into the velocity distribution, pressure pulsation intensity characteristics, and entropy generation of the electronic coolant pump under varying operational conditions. The findings revealed that with an increase in the flow rate, the coolant flow velocity within the pump also escalated. Concurrently, the separation flow at the trailing edge of the blade diminished, while the flow velocity at the trailing edge of the pressure surface escalated. Notably, the impeller and volute emerged as the primary sites generating pressure pulsations, with pressure pulsation intensity within the pump surpassing that of the design condition in off-design scenarios. Furthermore, entropy generation predominantly manifested at the impeller, volute, and front pump chamber locations, with the impeller exhibiting minimal total entropy generation under design conditions. These insights serve as crucial reference points for optimizing the design of automotive electronic coolant pumps.