TwinMesh for Positive Displacement Machines: Structured Meshes and reliable CFD Simulations
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1 TwinMesh for Positive Displacement Machines: Structured Meshes and reliable CFD Simulations Dipl.-Ing. Jan Hesse, Dr. Andreas Spille-Kohoff CFX Berlin Software GmbH Karl-Marx-Allee 90 A Berlin
2 Contents Introduction Methods for chamber modelling TwinMesh Simulation results Summary ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 2
3 Introduction Positive displacement machines (examples) Screw compressor Lobe pumps GHH Boerger Gear pumps ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 3
4 Introduction Characteristics of the geometries Two rotating rotors (often screwed) Size-changing chambers with very small clearances between the lobes and between rotors and casing Characteristics of the flow Cavitation (Multiphase) Non-newtonian fluid Compressibility Real-gas properties Turbulence Viscous heating, etc. Lobe pump ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 4
5 Methods for chamber modelling How can I model this complex behavior in my CFD-simulation? ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 5
6 Methods for chamber modelling Immersed-Solid Advantages Fast only one mesh for fluid and solid volumes Variable time step control Disadvantages Insufficient wall treatment Multiphase is not available (e. g. Cavitation) Only incompressible fluids Possible numerical instabilities depending on local pressure gradients (e. g. gap flow), small time steps necessary Very large number of elements depending on geometry especially for unstructured meshes Schwotzer, T.: Simulation einer Drehkolbenpumpe mit der Immersed-Solid-Methode, Bachelorarbeit, Technische Universität Berlin, 2009 ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 6
7 Methods for chamber modelling Mesh Deformation and Remeshing Advantages Automatic mesh generation (less manpower required) Fluid volume is represented by the mesh Full model support (e.g. Multiphase with Cavitation, turbulence model) Disadvantages Mesh-generation for almost each iteration (increasing computation time) Mesh generation leads to very high element numbers in gaps (increasing computation time) Mesh quality issues due to mesh deformation and element topology when using remeshing Numerical errors due to frequent interpolation of calculation results between different meshes ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 7
8 Methods for chamber modelling Manual Generation of Structured Hexahedral Meshes Idea Manual grid generation in ANSYS ICEM CFD Hexa for many rotor positions per rotation Advantages Best mesh and numerical quality High resolution of gaps is possible Element topology allows manageable model size No interpolation errors since the grid topology remains the same block structured grid Disadvantages Extremely high manual effort: grid generation for 2D-models would need 4 weeks Fuchs, M.: Numerische Simulation der instationären Strömung in einer Drehkolbenpumpe, Bachelorarbeit, Technische Universität Berlin, 2010 ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 8
9 TwinMesh Seven steps from CAD to Mesh TwinMesh is a novel software, developed by CFX Berlin Software GmbH which generates high-quality hexahedral meshes for the rotating parts of axis parallel rotary positive displacement machines. Simulation Workflow Stator Rotor 1 Rotor 2 Split of the simulation domains into steady and rotating parts Grid generation for the rotors with TwinMesh and for the Steady parts with ANSYS ICEM CFD or ANSYS Meshing Numerical calculation with ANSYS CFX ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 9
10 TwinMesh 1. Geometry import File format (2D cross section of the machine) IGES CSV-File with point coordinates ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 10
11 TwinMesh 2. Boundary definition Boundary types Rotor curvature Casing curvature Additional curvature for interface creation ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 11
12 TwinMesh 3. Geometric characteristics Options Number of lobes Rotorposition Rotor curvature modifications Screwing Angle per timestep ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 12
13 TwinMesh 4. Interface generation Automatic contact definition for the rotor meshes Interfaces between the rotor meshes are automatically generated depending on rotor curvature Stator Rotor 1 Rotor 2 ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 13
14 TwinMesh 5. Mesh properties Definition of node distribution On curves In radial and axial direction Inflation layer ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 14
15 TwinMesh 6. Mesh generation and quality check Automatic mesh generation for each rotation angle Smoothing algorithm depending on orthogonality and volume change Different methods of mesh connection available (non-conforming or 1to1) Visual and quantitative quality check tools available Mesh quality Mesh ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 15
16 TwinMesh 7. Mesh export Export Mesh export to ANSYS CFX (format.cfx5) for the first rotor position Export of mesh displacement coordinates for each rotor position Including ANSYS CFX Session File for easy setup in ANSYS CFX ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 16
17 Simulation results Lobe pumps Challenges Incompressible fluids with cavitation (multiphase) Non-newtonian fluids even with high viscosity ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 17
18 Simulation results Gear pumps Challenges Complex rotor geometry High pressure gradients Incompressible fluids with cavitation Non-newtonian fluids even with high viscosity ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 18
19 Simulation results Screw compressor Challenges Highly screwed rotors Compressible fluids High flow velocities Real-gas properties could be defined Simulation conditions ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg Rotational speed: rpm (male) Air (Ideal Gas, constant properties) 2 bar pressure difference Axial gap not modeled 19
20 Simulation results Screw compressor General analyses (Torque, Power and massflow) Power: 41.2 kw Averaged volume flow: 890 m³/h Torque Massflow Outlet Torque [Nm] Massflow [kg/s] Rotation angle [ ] Rotation angle [ ] ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 20
![2 kw Averaged volume flow: 890 m³/h Torque Massflow Outlet Torque [Nm]](/docs-images/40/8044014/images/page_20.jpg "Massflow [kg/s] Rotation angle [ ] Rotation angle [ ] ANSYS Conference & 32nd")
21 Simulation results Screw compressor Detailed analyses (Pressure change) Pressure at different measurement points Absolute Pressure [Pa] Point 2 Point 1 Point 1 Point 2 Behind the chamber Rotation angle [ ] ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 21
22 Summary There is now an efficient workflow for the simulation of rotary positive displacement machines with ANSYS CFD Software Key features of TwinMesh Generation of high quality structured meshes with smoothing algorithm Easy to use (comfortable GUI) Works with ANSYS CFD Works already for many different machine types Works with gap sizes down to 1 m Individual node distribution and rotation angle steps ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg 22
23 CFX Berlin Software GmbH ANSYS Conference & 32nd CADFEM Users' Meeting 2014, June 4 6, 2014, NCC Ost, Messe Nürnberg Folie 23
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