Numerical Simulation of Complex Air Flow in an Aeroengine Gear Box

2009 ◽  
Author(s):  
Zixiang Sun ◽  
John W. Chew ◽  
Neil Fomison
Keyword(s):  
Porous Media ◽  
Test Data ◽  
Air Flow ◽  
Three Dimensional ◽  
Operating Conditions ◽  
Cfd Model ◽  
Complex Flow ◽  
Pressure Loss Coefficient ◽  
Geometry Modeling ◽  
Gear Box

The internal gear box (IGB) of an aeroengine represents a severe challenge in computational fluid dynamics (CFD). In the present study, an axisymmetric CFD model was assessed to investigate the complex internal air flow in an aeroengine IGB. All the non-axisymmetric components and geometry features inside the gear box, such as bearings, gears, bolts and slots, as well as the radial drive system and vent pipes, were simulated using porous media models. Their flow resistance was estimated either by empirical correlations or by preparatory CFD studies and comparison with measurements. To evaluate the CFD technique adopted in the present investigation, a separate bolt windage study was conducted using a similar axisymmtric CFD model with the porous media approach. Good agreement of the bolt windage with other workers’ rig test data was observed. The present application of the porous media approach into a complex gear box flow represents a first attempt to use state of art CFD to assist an industrial design. Both maximum take-off (MTO) and ground idle (GI) running conditions were investigated. The complex flow patterns in the gear box were obtained. The results show a similar dimensionless performance of intermediate pressure (IP) and high pressure (HP) gears between the two operating conditions. For the present gear box arrangement under investigation, the CFD results suggest that the airflows induced by the HP gear and HP bearing are higher than their IP counterparts. A comparison with power absorption rig test data for the similar HP crownwheel in isolation shows that an assumption of pressure loss coefficient of 10 for the porous media of bevel gears may be appropriate, as the HP gear torque coefficient obtained in the CFD prediction is equal to 0.05, very close to its expected value. In addition, the effects of an assumed stationary IP gear and a large seal clearance on the HP gear performance were also investigated. The numerical results show that their impacts are insignificant, probably due to the strong pumping effects of the HP gear. Further discussion on the possible influence of the airflow on the oil motion within the gearbox and assistance to improve the traditional internal airflow models used for bearing chamber sealing analysis was also made. Three dimensional geometry modeling and inclusion of the oil phase are considered feasible. Such further investigations would aid the understanding of the interaction between the induced airflow due to the rotating components and oil motion, and their impact on oil scavenging behaviour and ‘windage’ contribution to heat oil.

Experimental and Numerical Investigation of Stator Exit Flow Field of an Automotive Torque Converter

1996 ◽  
Vol 118 (4) ◽  
pp. 835-843 ◽  
Author(s):  
B. V. Marathe ◽  
B. Lakshminarayana ◽  
Y. Dong
Keyword(s):  
Flow Field ◽  
Secondary Flow ◽  
Numerical Investigation ◽  
Three Dimensional ◽  
Axial Flow ◽  
Torque Converter ◽  
Operating Conditions ◽  
Navier Stokes ◽  
Complex Flow ◽  
Rate Of Decay

The objective of this investigation is to understand the nature of the complex flow field inside each element of the torque converter through a systematic experimental and numerical investigation of the flow field. A miniature five-hole probe was used to acquire the data at the exit of the stator at several operating conditions. The flow field is found to be highly three dimensional with substantial flow deviations, and secondary flow at the exit of the stator. The secondary flow structure, caused by the upstream radial variation of the through flow, induces flow overturning near the core. Flow separation near the shell causes flow underturning in this region. The rate of decay of stator wake is found to be slower than that observed in the wakes of axial flow turbine nozzles. The flow predictions by a Navier–Stokes code are in good agreement with the pressure and the flow field measured at the exit of the stator at the design and the off-design conditions.

Prediction of Raceways in a Blast Furnace

2006 ◽  
Author(s):  
Naresh K. Selvarasu ◽  
D. Huang ◽  
Zumao Chen ◽  
Mingyan Gu ◽  
Yongfu Zhao ◽  
...  
Keyword(s):  
Particle Size ◽  
Blast Furnace ◽  
Three Dimensional ◽  
Operating Conditions ◽  
Gas Oil ◽  
Cfd Model ◽  
Coke Particle ◽  
Fuel Gas ◽  
Computational Fluid Dynamics Cfd ◽  
Insight Into

In a blast furnace, preheated air and fuel (gas, oil or pulverized coal) are often injected into the lower part of the furnace through tuyeres, forming a raceway in which the injected fuel and some of the coke descending from the top of the furnace are combusted and gasified. The shape and size of the raceway greatly affect the combustion of, the coke and the injected fuel in the blast furnace. In this paper, a three-dimensional (3-D) computational fluid dynamics (CFD) model is developed to investigate the raceway evolution. The furnace geometry and operating conditions are based on the Mittal Steel IH7 blast furnace. The effects of Tuyere-velocity, coke particle size and burden properties are computed. It is found that the raceway depth increases with an increase in the tuyere velocity and a decrease in the coke particle size in the active coke zone. The CFD results are validated using experimental correlations and actual observations. The computational results provide useful insight into the raceway formation and the factors that influence its size and shape.

Experimental and Numerical Investigation of the Flow in a Low-Pressure Industrial Steam Turbine With Part-Span Connectors

2016 ◽  
Vol 138 (7) ◽  
Author(s):  
Markus Häfele ◽  
Christoph Traxinger ◽  
Marius Grübel ◽  
Markus Schatz ◽  
Damian M. Vogt ◽  
...  
Keyword(s):  
Flow Field ◽  
Steam Turbine ◽  
Numerical Study ◽  
Three Dimensional ◽  
Low Pressure ◽  
Operating Conditions ◽  
Engineering Practice ◽  
Cfd Model ◽  
Wide Range ◽  
The Impact

An experimental and numerical study on the flow in a three-stage low-pressure (LP) industrial steam turbine is presented and analyzed. The investigated LP section features conical friction bolts in the last and a lacing wire in the penultimate rotor blade row. These part-span connectors (PSC) allow safe turbine operation over an extremely wide range and even in blade resonance condition. However, additional losses are generated which affect the performance of the turbine. In order to capture the impact of PSCs on the flow field, extensive measurements with pneumatic multihole probes in an industrial steam turbine test rig have been carried out. State-of-the-art three-dimensional computational fluid dynamics (CFD) applying a nonequilibrium steam (NES) model is used to examine the aerothermodynamic effects of PSCs on the wet steam flow. The vortex system in coupled LP steam turbine rotor blading is discussed in this paper. In order to validate the CFD model, a detailed comparison between measurement data and steady-state CFD results is performed for several operating conditions. The investigation shows that the applied one-passage CFD model is able to capture the three-dimensional flow field in LP steam turbine blading with PSC and the total pressure reduction due to the PSC with a generally good agreement to measured values and is therefore sufficient for engineering practice.

Development of a Two-Dimensional Computational Fluid Dynamics Approach for Computing Three-Dimensional Honeycomb Labyrinth Leakage

2004 ◽  
Vol 126 (4) ◽  
pp. 794-802 ◽  
Author(s):  
Dong-Chun Choi ◽  
David L. Rhode
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Three Dimensional ◽  
Labyrinth Seal ◽  
Operating Conditions ◽  
Two Dimensional ◽  
Cfd Model ◽  
Resource Requirement ◽  
Three Dimensional Flow ◽  
Dimensional Flow

A new approach for employing a two-dimensional computational fluid dynamics (CFD) model to approximately compute a three-dimensional flow field such as that in a honeycomb labyrinth seal was developed. The advantage of this approach is that it greatly reduces the computer resource requirement needed to obtain a solution of the leakage for the three-dimensional flow through a honeycomb labyrinth. After the leakage through the stepped labyrinth seal was measured, it was used in numerically determining the value of one dimension (DTF1) of the simplified geometry two-dimensional approximate CFD model. Then the capability of the two-dimensional model approach was demonstrated by using it to compute the three-dimensional flow that had been measured at different operating conditions, and in some cases different distance to contact values. It was found that very close agreement with measurements was obtained in all cases, except for that of intermediate clearance and distance to contact for two sets of upstream and downstream pressure. The two-dimensional approach developed here offers interesting benefits relative to conventional algebraic-equation models, particularly for evaluating labyrinth geometries/operating conditions that are different from that of the data employed in developing the algebraic model.

Design and Off-Design Numerical Investigation of a Transonic Double-Splitter Centrifugal Compressor

2008 ◽  
Author(s):  
Michele Marconcini ◽  
Filippo Rubechini ◽  
Andrea Arnone ◽  
Seiichi Ibaraki
Keyword(s):  
Flow Field ◽  
Centrifugal Compressor ◽  
Cross Sections ◽  
Pressure Ratio ◽  
Three Dimensional ◽  
Secondary Flows ◽  
Operating Conditions ◽  
Complex Flow ◽  
Flow Measurements ◽  
Vaned Diffuser

The flow field of a high pressure ratio centrifugal compressor for turbocharger applications is investigated using a three-dimensional Navier-Stokes solver. The compressor is composed of a double-splitter impeller followed by a vaned diffuser. The flow field of the transonic open-shrouded impeller is highly three-dimensional, and it is influenced by shock waves, tip leakage vortices and secondary flows. Their interactions generate complex flow structures which are convected and distorted through the impeller blades. Both steady and unsteady computations are performed in order to understand the physical mechanisms which govern the impeller flow field while the operation ranges from choke to surge. Detailed Laser Doppler Velocimetry (LDV) flow measurements are available at various cross-sections inside the impeller blades at both design and off-design operating conditions.

3D Numerical Simulation of the Airflow in a Pneumatic Splicer

2011 ◽  
Vol 130-134 ◽  
pp. 2345-2348
Author(s):  
Xiao Xing ◽  
Guo Ming Ye
Keyword(s):  
Numerical Simulation ◽  
High Speed ◽  
Air Flow ◽  
Three Dimensional ◽  
Flow Characteristics ◽  
Swirling Flows ◽  
Computational Results ◽  
Cfd Model ◽  
3D Numerical Simulation ◽  
Computational Fluid Dynamics Cfd

To investigate the effect of air flow in an pneumatic splicer on splicing performance, a computational fluid dynamics (CFD) model has been developed to simulate the air flow characteristics in an splicing chamber. Three-dimensional numerical simulation is conducted and standard K-ε turbulence model is used. Velocity distributions in the chamber are presented and analyzed. The computational results show that the velocities in the chamber are transonic. The air flows in the chamber are two swirling flows with opposite directions. This work also shows that CFD technique can provide a better understanding of the behavior of the high speed air flow in the air splicing chamber.

scholarly journals Thermal and Electrochemical Three Dimensional CFD Model of a Planar Solid Oxide Electrolysis Cell

2005 ◽  
Author(s):  
Grant Hawkes ◽  
Jim O’Brien ◽  
Carl Stoots ◽  
Steve Herring ◽  
Mehrdad Shahnam
Keyword(s):  
National Laboratory ◽  
Three Dimensional ◽  
Operating Conditions ◽  
Solid Oxide ◽  
Cathode Side ◽  
Electrolysis Cell ◽  
Gas Composition ◽  
Cfd Model ◽  
Solid Oxide Electrolysis ◽  
Solid Oxide Electrolysis Cell

A three-dimensional computational fluid dynamics (CFD) model has been created to model high-temperature steam electrolysis in a planar solid oxide electrolysis cell (SOEC). The model represents a single cell, as it would exist in an electrolysis stack. Details of the model geometry are specific to a stack that was fabricated by Ceramatec, Inc. and tested at the Idaho National Laboratory. Mass, momentum, energy, and species conservation and transport are provided via the core features of the commercial CFD code FLUENT. A solid-oxide fuel cell (SOFC) model adds the electrochemical reactions and loss mechanisms and computation of the electric field throughout the cell. The FLUENT SOFC user-defined subroutine was modified for this work to allow for operation in the SOEC mode. Model results provide detailed profiles of temperature, Nernst potential, operating potential, anode-side gas composition, cathode-side gas composition, current density and hydrogen production over a range of stack operating conditions. Mean model results are shown to compare favorably with experimental results obtained from an actual ten-cell stack tested at INL.

Experimental and Numerical Investigation of Stator Exit Flow Field of an Automotive Torque Converter

1994 ◽  
Author(s):  
B. V. Marathe ◽  
B. Lakshminarayana ◽  
Y. Dong
Keyword(s):  
Flow Field ◽  
Secondary Flow ◽  
Numerical Investigation ◽  
Three Dimensional ◽  
Axial Flow ◽  
Torque Converter ◽  
Operating Conditions ◽  
Navier Stokes ◽  
Complex Flow ◽  
Rate Of Decay

The objective of this investigation is to understand the nature of the complex flow field inside each element of the torque converter through a systematic experimental and numerical investigation of the flow field. A miniature five-hole probe was used to acquire the data at the exit of the stat or at several operating conditions. The flow field is found to be highly three-dimensional with substantial flow deviations, and secondary flow at the exit of the stator. The secondary flow structure, caused by the upstream radial variation of the through flow, induces flow overturning near the core. Flow separation near the shell causes flow underturning in this region. The rate of decay of stator wake is found to be slower than that observed in the wakes of axial flow turbine nozzles. The flow predictions by a Navier-Stokes code are in good agreement with the pressure and the flow field measured at the exit of the stator at the design and the off-design conditions.

Corrosion Study and Modification of Superheater Tubes in a Large Mass Burn WTE Boiler (Abstract)

2005 ◽  
Author(s):  
Greg Epelbaum
Keyword(s):  
Flue Gas ◽  
Three Dimensional ◽  
Flow Distribution ◽  
Large Mass ◽  
Operating Conditions ◽  
Cfd Model ◽  
Gas Temperature ◽  
Unique Problem ◽  
Flux Flow ◽  
Tube Metal

Essex County Resource Recovery Facility (one of American Ref-Fuel Company’s six operating plants) has processing MSW capacity of approximately 2700 TPD and about 60% of this waste comes from NY City. Therefore, availability of the Essex plant boilers is very important not only for the company’s financial performance, it is also critical for the overall garbage disposal situation in the NYC Metropolitan area. One of the main factors affecting plant availability is boiler unscheduled downtime. The most recent data show that approximately 85% of Essex boilers unscheduled downtime is caused by tube failures, the majority of which occur in the superheater tubes. These tube failures are almost exclusively caused by fireside tube metal wastage driven by complicated mechanisms of corrosion in combination with local erosion. The corrosion is caused by chloride salts in the slag that deposits on the boiler tubes, coupled with high temperatures of flue gas going through the boiler. Corrosion rates are known to be very sensitive to flue gas temperature, tube metal temperature, heat flux, flow distribution. Erosion is typically caused by high velocities and flyash particle loading and trajectories. Extensive research revealed that in addition to this typical to WTE boiler corrosion/erosion mechanism, Essex boiler superheater tubes experienced a unique problem, resulting in tube overheating, accelerated wastage, and ultimate failure. In order to address this problem a modification plan was developed, which comprised several redesign options. A specially developed Three-dimensional Computational Fluid Dynamics (3-D CFD) model was utilized for comprehensive technical evaluation of the considered design options and for predicted performance simulations of the selected design at different operating conditions. The economical analysis, conducted in conjunction with the superheater redesign, provided financial justification for this project. The project has been recently executed, and field data collection is still in progress. Some preliminary data analyses have been performed. They have shown that the boiler performance after superheater modification is very close to the predicted target simulated by the CFD model. The plant and the company are already measuring financial benefits as a result of this project, the initial phase of which is presented in this paper.

Exploration of a Potential-Flow-Based Compact Model of Air-Flow Transport in Data Centers

2009 ◽  
Author(s):  
Michael M. Toulouse ◽  
Guislain Doljac ◽  
Van P. Carey ◽  
Cullen Bash
Keyword(s):  
Temperature Field ◽  
Data Center ◽  
Potential Flow ◽  
Air Flow ◽  
Three Dimensional ◽  
Convective Transport ◽  
Compact Model ◽  
Cfd Modeling ◽  
Complex Flow ◽  
Three Dimensional Flow

This paper summarizes an exploration of a compact model of air flow and transport in data centers developed from potential flow theory. Boundaries for the airflow in the data center are often complex due to the numerous rows of servers and other equipment in the facility, and there are generally multiple air inlets and outlets, which produce a fairly complex three-dimensional flow field in the air space in the data center. The general problem of airflow and convective transport in a data center requires accurate treatment of a turbulent flow in a complex flow passage with some buoyancy effects. As a result, full CFD thermofluidic models tend to be time-consuming and tedious to set up for such complex flow circumstances. In this initial study, we formulated an approximate model that retains only the most basic physical mechanisms of the flow. The resulting model of air flow in the data center is based on potential flow theory, which is exact for irrotational inviscid flow. The temperature field resulting from server heat input is determined by solving the convective energy transport equation along potential flow streamlines. This innovative approach, which takes advantage of the irrotational character of the modeled flow, provides a fast computational method for determining the temperature field and convective transport of thermal energy in the data center. Computations to predict the three-dimensional flow and temperature fields with the model typically require less than 60 seconds to complete on a laptop computer. Flow and temperature field results predicted by the model for typical data center flow circumstances are presented and limitations of the model are assessed. Features of an intuitive graphical user interface for the model that simplifies input of the data center design parameters are also described. Results for case studies indicate low sensitivity to mesh size and convergence criteria. Although the flow and temperature field models developed here are more approximate than full CFD methods, they are good first approximations that provide the means to rapidly explore the parameter space for the data center design. This model can be used to quickly identify the optimal region of the design space, whereupon a more detailed CFD modeling can be used to fine-tune an optimal design. The results of this investigation demonstrate that this type of fast compact model can be a very useful tool when used as a precursor to full CFD modeling in data center design optimization.

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