Beruflich Dokumente
Kultur Dokumente
a r t i c l e
i n f o
Article history:
Received 5 January 2010
Received in revised form 5 October 2010
Accepted 3 February 2011
Available online 18 February 2011
Keywords:
Large-eddy simulation
Finite-difference method
Immersed-boundary method
Turbomachinery ows
Mixed-ow pump
a b s t r a c t
Computations of turbulent and transitional ows in rotating machinery applications are very challenging
due to complexity of the geometry, which usually consists of multiple rotating and stationary parts. The
application of well-established, body-tted methods frequently utilizes overset grids and different reference frames, which have an adverse impact on the overall accuracy and cost-efciency of the method. In
the present work we explore the feasibility of performing computations of such ows using a single reference frame and an immersed-boundary approach. In particular, we report one of the rst large-eddy
simulation in this class of ows, where a structured cylindrical coordinate solver with optimal conservation properties is utilized in conjunction with an immersed-boundary method. To evaluate the accuracy
of the computations the results are compared to the experimental measurements in [1]. Results using the
standard Smagorinsky model and the Filtered Structured Function model are presented. We demonstrate
that the overall approach is well suited for the ow under consideration and the results with the more
advanced subgrid scale model are in good agreement with the experiment. We also briey discuss some
of the features of the instantaneous ow dynamics, to provide a glimpse of the wealth of information that
can be extracted from such computations.
2011 Elsevier Ltd. All rights reserved.
1. Introduction
The development of computational tools to model uid ow
and heat transfer in rotating machinery applications has been at
the forefront of computational mechanics for the past few decades.
The primary challenge that needs to be addressed by all numerical
techniques is the complexity of the geometry, which consists of
multiple rotating and stationary parts. The application of wellestablished, body-tted methods to such problems is not trivial
due to the presence of the moving parts. A frequently adopted
strategy utilizes overset grids and different reference frames to
simulate the ow in the rotor and in the stator respectively (see
for example [14,11]). This approach usually allows for better grid
quality, but the transfer of the solution between reference frames
involves interpolations, which have an adverse impact on the overall accuracy and efciency of the formulation. If a single reference
frame approach is adopted on the other hand, frequent grid deformation/regeneration is necessary, which makes grid quality control problematic [24].
Corresponding author. Tel.: +1 301 405 8268; fax: +1 301 405 9953.
E-mail addresses: antonioposa_81@alice.it (A. Posa), lippolis@poliba.it (A.
Lippolis), roberto.verzicco@uniroma2.it (R. Verzicco), balaras@umd.edu (E. Balaras).
0045-7930/$ - see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.compuid.2011.02.004
An alternative class of methods that are well suited for applications involving moving boundaries are the so-called immersedboundary type methods, which have been gaining popularity in
the past few years. In such case the requirement for the computational grid to be conform to the body is relaxed and structured
Cartesian or generalized coordinate solvers can be utilized in
highly complex congurations. The presence of a complex boundary is introduced by a discrete forcing function, which is designed
to mimic the effect of the body on the ow. Compared to the
boundary tted strategies above, immersed-boundary methods
greatly simplify the grid generation and the same frame of reference can be used for systems with bodies in relative motion. In
addition, the conservative non-dissipative structured solvers utilized by most immersed-boundary approaches can be ideally coupled to eddy-resolving methods such as direct numerical
simulations (DNS) and large-eddy simulations (LES), thus substantially enhancing the overall predictive capability of the computational tools. Today, immersed-boundary methods have been
utilized in a variety of elds. Early applications were mostly conned to biological ows (see for example [17,18]), but over the
past years a variety of applications in very diverse elds has been
reported. Verzicco and co-workers, for example, analyzed the ow
in a piston-cylinder assembly [6], and an impeller-stirred tank [26],
using a direct-forcing, immersed-boundary approach. More
34
Nomenclature
DEk
D
hi
hhii
s
mt
x
xs
/
w
~
p
e
S
~
u
e
F2
Ain
i
Ck
Cs
Din
d
Dout
d
Din
i
cyclic unsteadiness
local grid size
phase average operator
passage average operator
subgrid scale stress (SGS) tensor
eddy viscosity
rotational speed of the impeller
specic-speed of the pump
ow coefcient
head coefcient
resolved pressure
resolved strain rate tensor
resolved velocity vector
angle dening the position of the impeller
second-order ltered velocity structure function
area of the impeller at the inow
Kolmogorov constant
Smagorinsky model constant
diameter of the diffuser at the inow
diameter of the diffuser at the outow
diameter of the impeller at the inow
recently applications ranging from complex uid-structure interactions [29,4] to magnetohydrodynamics (MHD) [8] appeared in
the literature. Details on the available immersed-boundary formulations as well as their range of applicability can be found in recent
reviews in [10] and [15].
Turbomachinery applications are a great challenge for immersed-boundary formulations and a stringent test for their
robustness and accuracy. As of today very few applications can
be found in the literature, which usually deal with simplied congurations. You et al. [30,31], for example, performed LES using an
immersed-boundary method and a structured generalized curvilinear coordinate solver, to study the viscous losses associated to
the tip-clearance ow in a linear cascade. To reduce the cost of
the computations a single vane was considered, using periodic
boundary conditions. Their results revealed some interesting
dynamics and the importance of the tip-leakage jet on the vorticity
and turbulence generation. They also demonstrate the importance
of utilizing eddy-resolving methods in such applications, where
experimental measurements are very challenging and classical
Reynolds Averaged Navier Stokes (RANS) models cannot capture
the highly three-dimensional and complex ow physics. As of today, immersed-boundary methods have not been utilized in more
complex turbomachinery ows. The aim of the present work is to
explore the feasibility of utilizing such an approach in the case of
turbopumps, where the complete machine is simulated. In addition, we will investigate the accuracy and applicability of standard
subgrid scale (SGS) models available in the literature. We should
also note, however, that due to cost considerations, the proposed
approach targets primarily laboratory scale pumps. Extension to
industrial scale pumps would require further developments in
approximate wall boundary conditions and sophisticated adaptive
mesh renement methods (see for example [25]).
Currently the majority of turbopump computations are conducted with body-tted meshes utilizing different frames of reference for the stationary and moving parts. These methods usually
employ stable, dissipative, discretizations and are therefore better
suited to RANS modeling strategies. Within this modeling framework, Goto and co-workers [7,23] reported three-dimensional simulations of mixed-ow pumps. They focused on the mechanism of
generation of secondary ow patterns and the formation of the
jet-wake like ow. They also investigated the sensitivity of these
Dout
diameter of the impeller at the outow
i
H
head
N
number of the blades passages
NU
number of phase averages
Nd
number of the diffuser blades
Ni
number of the impeller blades
number of the impeller revolutions
Nr
Q
ow rate
r, h, z
coordinates of the cylindrical system
Re = UL/m Reynolds number based on a reference velocity, U,
length, L, and the kinematic viscosity m.
T
period of the passage of the rotor blades
t
time
t0
initial time instant for the evaluation of the phase-averaged elds
uin
tangential velocity of the tip of the impeller blades at
i
the inow
uout
tangential velocity of the impeller blades at the outow
i
~0
ru
~
@u
1
~u
~ rp
~ f;
~ r s r2 u
ru
@t
Re
35
Fig. 1. (a) Schematic of the ray-tracing procedure used to classify the nodes on the Eulerian grid into interior, uid, and h interface ones. Symbol is a control point and
the dashed lines represent control rays. (b) Linear reconstruction of the solution in the vicinity of the immersed body [6]. Cyan: uid domain; Gray: solid body.
where e
S is the resolved strain rate tensor. In the case of the SM
model the eddy viscosity is dened as:
mSM
C s D2 j e
Sj; and j e
Sj 2 e
Se
S1=2 ;
t
where e
F 2 is a ltered, second-order, velocity structure function (see
[5] for details).
The governing equations are advanced in time using a fractional
step method. The viscous terms in the momentum equation are
treated implicitly with a CrankNicolson scheme and all other
terms are treated with an explicit AdamsBashfort scheme. All spatial derivatives are approximated with second-order nite differences on a staggered grid. The large-band matrix associated with
the solution of the Poisson equation is rst reduced to pentadiagonal problems using FFTs in the azimuthal direction, and then each
problem is solved with a generalized cyclic reduction algorithm
[22]. Details on the overall formulation can be found in [27].
To simulate the ow in a complex conguration, which is immersed in the cylindrical coordinates grid, the direct-forcing approach proposed by Fadlun et al. [6] is utilized. The body is
represented by a series of triangles in stereo-lithography (STL) format, where their density depends on the local curvature of the surface. Initially all points on the Eulerian grid are tagged according to
l12
~l
1
Vl1
u
i
RHSl2
Dt
where l; l 12 and l + 1 refer to the time level, and the RHS includes the
discrete convective, viscous, and SGS terms in Eq. (2). More details on
the implementation of the above method can be found in [6].
3. Computational setup
We will consider a mixed-ow pump conguration, which has
been studied experimentally by Boccazzi et al. [1]. They reported
Particle Image Velocimetry (PIV) measurements inside the vaned
diffuser at two stations. The geometry of the pump is shown in
Fig. 2a. To better distinguish the different elements each one is represented by a different color: the rotor blades are drawn in red1,
the hub in white and the diffuser blades in blue. Note that the shroud
(green), the diffuser throat and the volute (gray) are partially shown,
for the internal pump elements to be visible. A meridian cut of the
volute geometry is also shown in Fig. 2b. The number of blades for
the rotor and the stator are Ni = 6 and Nd = 7 respectively. The specic-speed, xs, the ow coefcient, /, and the head coefcient, w,
are dened as follows:
xs
x Q
gH
3
4
Q
in
Ain
i ui
w
gH
2 ;
uout
i
36
Fig. 2. Geometry of the mixed-ow pump used in the experiments by Boccazzi et al. [1]. (a) Cross cut of the volute; (b) meridian cut of the volute.
Table 1
Main parameters of the mixed-ow pump used in the experiments by Boccazzi et al.
[1].
x = 55.4[rad/s]
xs = 1.08
/opt = 0.314
wopt = 0.443
Dout
i
Ni = 6
Din
d
Dout
d
0:224m
0:233m
0:361m
Din
i 0:154m
Nd = 7
the tangential velocities at the impeller inow and outow respectively. For the inow the speed is referred to the blades tip. All the
geometric and operating parameters are summarized in Table 1,
and are the ones considered in all computations below. Note that
out
Din
are the impeller diameters at the inlet and the outlet,
i and Di
out
while Din
are the corresponding values for the diffuser.
d and Dd
The spanwise dimension of the diffuser is Ls = 44[mm]. The ow
rate corresponding to /opt is Q = 0.025[m3/s]. The Reynolds number,
based on the average inow velocity and the external radius of the
rotor, is equal to Re = 1.5 105.
The pump is fully immersed in the computational domain,
which is discretized with a structured cylindrical coordinates grid.
An example is shown in Fig. 3, where two grid slices in the r z
and r h planes are included. The blue portion of the gure represents the part of the structured grid that falls within the uid
domain. The red portion marks the grid nodes that are wasted.
For clarity the volute, the shroud and the inow channel are not
Fig. 3. Pump geometry immersed in the computational mesh. (a) Computational grid in the rz plane; (b) computational grid in the rh plane. Blue color represents the part
of the structured grid that falls within the uid domain. The red color marks the wasted gird nodes. Note that only the impeller and the diffuser blades are shown for clarity.
hf ih; r; z; u
Fig. 4. Detail of the computational grid in the divergent channel between the
diffuser blades (an r h plane is shown).
included in this gure. The inow and outow locations are also
indicated. In all computations reported in this study we prescribe
a uniform velocity at the inow plane, while we use a convective
condition at the outow [16]. The convective condition is applied
on the local ow direction, using the averaged velocity on the outow surface as convective speed. The immersed-boundary technique described in the previous section is used to enforce the
boundary conditions on all solid boundaries.
The computational grid consists of 801 350 101 points in
the azimuthal, radial and axial directions respectively (a total of
28 million). It is uniform in the azimuthal and axial directions
and is stretched in the radial one to cluster points in the areas of
high velocity gradients. Since the grid does not conform to the
body, a signicant number of nodes falls outside the useful computational domain, which in the present case is approximately 50%.
This grid, which has a total of 14 million useful nodes, provides
adequate resolution in many critical areas of the computational
box. In the divergent channel between the diffuser blades, for
example, along the direction normal to the blades surface, respectively 40, 45 and 52 computational cells are utilized over the lines
a, b, and c in Fig. 4. Each computation on the above grid requires
approximately 56 CPU hours/revolution on a single 2-way quadcore Opteron 2.1 GHz node with 16 GB of RAM. All eight cores on
the node were utilized using OpenMP. Due to cost considerations,
we could not perform a detailed grid renement study on the full
computational domain, and the above resolution is the maximum
we could achieve with the available computational resources at
the time of the preparation of the manuscript. We did, however,
conduct a grid renement study on a reduced domain, where only
one diffuser passage is considered using periodic boundary conditions. In particular, we compared the results between a coarse grid
with equivalent resolution to the one utilized above in the full domain, and a ne grid with double resolution in the azimuthal and
radial directions. The mean velocities, although are not directly
comparable to the experiment in [1], due to the simplications in
the geometry, were in good agreement and the largest discrepancies (order of 10%) were observed near the walls.
4. Results
In this section we will report a series of computations conducted in the conguration presented above. The primary aim of
the simulations is to establish the accuracy and robustness of the
immersed-boundary methods in rotating machinery applications
by direct comparisons to the experimental results by Boccazzi
et al. [1]. We will also present the results from different SGS models, as well as, an overall view of the instantaneous ow dynamics
in the particular conguration. To facilitate comparisons with the
experiment, for any ow variable f(h, r, z, t), which is a function of
space and time, the following phase average operator is dened:
N
1 X
f h; r; z; t 0 n 1T;
N n1
37
where h, r and z are the azimuthal, the radial and the axial coordinates respectively; u is the angle which denes the position of the
impeller with respect to the stator, for which the phase average is
evaluated; in the present case its value is variable between 0 and
60, since after one blade passage the same impeller-diffuser conguration is repeated; N = NiNr is the total number of blades passages,
i.e., the number of times that the impeller is in the same position
relative to the diffuser (Nr is the number of the impeller revolutions); t0 is the initial time instant and T the period of the passage
of the rotor blades. We can also dene the passage average operator
as follows:
hhf iih; r; z
NU
1 X
hf ih; r; z; u;
NU i1
38
Fig. 5. Phase-averaged velocity magnitude at the diffuser midspan for window A shown in Fig. 6a. (a) PIV measurements [1]; (b) FSF-LES; (c) SM-LES. The velocity magnitude
shown ranges from 0[m/s] (blue) to 4[m/s] (red).
Fig. 6. (a) Experimental measurement windows, blade numbers, and velocity prole locations. Also the following abbreviations are dened: RBSS: rotor blade suction side;
RBPS: rotor blade pressure side; SBPS: stator blade pressure side; SBSS: stator blade suction side. (b) Phase-averaged tangential velocity prole at location a (10% of the chord
of the blade 5); (c) Phase-averaged tangential velocity prole at location b (50% of the chord of the blade 4); (d) Phase-averaged tangential velocity prole at location c (90% of
the chord of the blade 4). experiment [1], 33 SM-LES,
FSF-LES.
Fig. 7. Phase-averaged velocity magnitude at the diffuser midspan for window B shown in Fig. 6a. (a) PIV measurements [1]; (b) FSF-LES; (c) SM-LES. The velocity magnitude
shown ranges from 0[m/s] (blue) to 4[m/s] (red).
39
Fig. 8. Phase-averaged tangential velocity proles at the diffuser midspan. (a) location d (10% of the chord of the blade 0); (b) location e (50% of the chord of the blade 0).
experiment [1], 33 SM-LES,
FSF-LES.
Fig. 9. Passage-averaged velocity magnitude (top part) and cyclic unsteadiness (bottom part) at the diffuser midspan for window A shown in Fig. 6a. (a) and (c) PIV
measurements [1]; (b) and (d) FSF-LES.
conserve mass the velocity increases away from the wall and a local maximum is generated at the edge of the boundary layer. The
FSF is in better agreement with the experiment. At location c near
the trailing edge of blade 4 (Fig. 6d) both computations agree well
with the experiment except for a small area near the wall.
Fig. 7 shows the phase-averaged velocity magnitude at the midspan of the diffuser throat in window B, near the nose of the volute.
The results with the FSF model agree well with the experiment. For
the SM-LES the ow separates much earlier on blade 0 and
40
1
DEk h; r; z; u hv i2 h; r; z; u hhv ii2 h; r; z;
2
10
Fig. 10. Instantaneous snapshots of the vorticity magnitude at the midspan of the diffuser for the FSF-LES. Consecutive positions of the impeller blades are shown every 15.
41
Fig. 11. Instantaneous vorticity magnitude at the midspan of the diffuser for the
FSF-LES. Representation of the vorticity values on the pressure side of the rotor and
the stator blades. The same instant in time is shown as in Fig. 10a from a different
angle, in order for the pressure side of the blades to be visible.
(i) The packet of vortices within the area a in the gure, which
is produced near the shroud. In general, the divergent geometry of the shroud generates large adverse pressure gradients
and at the same time the ow turns rapidly by 90, resulting
in complex separation phenomena. The vortices shown in
area a are probably related to the above phenomena and
are not as coherent as the ones in other areas of the machine.
Fig. 12. (a) Isosurfaces of Q = 5 104[1/s2], colored with the instantaneous vorticity magnitude, for the FSF-LES. Green: shroud; Gray: impeller blades, diffuser wall and
volute; Cyan: hub; Blue: diffuser blades; (b) magnication of area b shown in part (a) of the gure (note that Q = 1 105[1/s2] isosurfaces are shown in this case); (c)
instantaneous vorticity magnitude in the section AA shown in part (a) of the gure. DWSS: diffuser wall on the shroud side; DWHS: diffuser wall on the hub side.
42
Fig. 13. Instantaneous azimuthal (top) and radial (bottom) vorticity elds on the circumferential section at the impeller mean radius from the FSF-LES: (a) 3D view (white:
hub, gray: impeller blades, green: shroud, blue: inow channel); (b) top view of the unrolled plane (RBPS: rotor blade pressure side, RBSS: rotor blade suction side).
(ii) The vortices within the area b in the gure, which is located
at the suction side of the impeller blades. These are much
more coherent, compared to the ones above. These vortices
appear approximately at the same location in all impeller
vanes. In Fig. 12b a closer view of the same area is shown
and one can identify strong co-rotating vortices, which are
aligned with the ow.
(iii) The smaller eddies within the area c in the gure, which are
associated with the wake of the impeller blades. The wake
area is strongly inuenced by the interaction of the vortices
in b and the boundary layer on the impeller blades. The wake
vortices quickly lose their coherence as they move away
from the trailing edge and appear to be the main source of
turbulent uctuations for the ow entering the diffuser
throat.
(iv) Vortical structures inside the diffuser and particularly in the
wake of the diffuser blades (area d in the gure). These form
larger vortices which are shed from the trailing edge, but
they are weaker than the corresponding ones at the rotor
outlet.
To better characterize the coherent structures in the diffuser,
Fig. 12c shows the instantaneous vorticity magnitude at a plane
perpendicular to the ow direction (section AA in Fig. 12a). The
selected position is close to the leading edge on the pressure side
of the blade 2, and to the trailing edge on the suction side of the
blade 1. On the pressure side there are still high vorticity values,
due to the proximity of the wake of the impeller blades. On the
suction side, non-uniformities in the vorticity distribution along
the blade span can be observed, which are probably caused by
the ow coming from the impeller shroud. Fig. 13 shows the
instantaneous azimuthal and radial vorticity on a circumferential
section at the impeller mean radius. Part (a) shows the location
of the section inside the impeller, while in part (b) the plane is unrolled and shown from the top. Referring to part (a) in the gure,
the ow enters the impeller axially, from left to right, and exits
radially. Consistent with the observations above, close to the
shroud (area a) and at the blade suction side (area b), the footprint
of strong vortices can be seen, with the latter being more coherent
as well as having the same vorticity sign (co-rotating). We should
also note that, even if the machine geometry is not symmetric, similar eddy patterns can be identied at all impeller vanes.
results in the underestimation of the wall stresses and early separation. The results with the FSF model are in very good agreement
with the experiments, indicating that it is a much better choice for
such ows, especially considering that its computational overhead
is not much higher than the one of the SM model. We should also
note, however, that due to cost considerations, a comprehensive
grid renement study was not feasible. Simulations on a reduced,
periodic domain, at comparable and ner grid resolutions, provided mean velocity statistics which differed no more than 10%,
giving us some condence in the results reported here. We are currently working on improving the parallel performance of the solver, which will enable us to do detailed grid renement studies
in the full domain as well.
Finally an outline of the instantaneous ow dynamics is presented. It is evident that the vortical structures generated on the
suction side of the impeller blades, and consequently shed in the
wake, interact strongly with the suction side of the stator blades,
indicating that transition to turbulence on the latter occurs
through a bypass transition mechanism. The inuence of the
impeller wake is noticeable also on the pressure side of the stator
blades, but in this case the effects on the boundary layer on the
blades surface are not as profound.
From a practical perspective, the LES approach is probably
much more valuable for off-design conditions, for which it can offer unique insights into the complex physics of such pumps. The
purpose of the present study, however, is to demonstrate the feasibility/accuracy of the overall simulation strategy, and for this reason we only considered optimal operating conditions, where
comprehensive laboratory data were available. We will consider
off-design and compare with RANS/DES in a future paper.
Acknowledgments
The authors are grateful to Ing. A. Boccazzi and Ing. R. Miorini
for providing their experimental results. Computational resources
were provided by CASPUR (Consorzio interuniversitario per le
Applicazioni di Supercalcolo Per Universit e Ricerca). EB is partially supported by the National Science Foundation (Grant CBET0932613).
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43