Large Eddy Simulation of Film Cooling for the Real Additive Manufactured Fan-Shaped Holes

2020 ◽  
Author(s):  
Wei Shi ◽  
Xueying Li ◽  
Lang Wang ◽  
Jing Ren ◽  
Hongde Jiang
Keyword(s):  
Heat Transfer ◽  
Large Eddy Simulation ◽  
Film Cooling ◽  
Separation Bubble ◽  
Leading Edge ◽  
Widespread Application ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Eddy Simulation ◽  
Large Eddy

Abstract Additive Manufacturing (AM) is a process for making complex parts that were once difficult to machine using traditional manufacturing processes such as forging, casting, and welding. As a new and promising processing technology, AM is being increasingly applied to the manufacturing of high temperature turbine parts. However, before the widespread application of AM can become feasible, the influence of such processes on the performance of turbine hot ends — especially during the film cooling flow heat transfer — requires further study. This paper focuses a large eddy simulation study done in order to understand the physical phenomena involved in the random roughness caused by the AM of fan-shaped film holes. This paper proposes a set of workflows to connect the AM, CFD simulation, Computed Tomography (CT) and reverse modeling, so that the effect of AM on the flow and heat transfer of film cooling can be studied. The results of this preliminary workflow reveal several observations. First, that the film cooling effectiveness (η) of AM fan-shaped holes decreases. The area averaged η of the ideal hole is 0.32, while the area averaged cooling effectiveness of the AM hole is 0.29. As such, the η of the AM fan-shaped hole has a significant bifurcation phenomenon. This is because the separation bubble in-tube moves forward, and blocks the flow channel, which bifrucates the flow in-tube. Second, a pressure gradient towards the trailing edge generated at a random rough surface near the leading edge squeezes the fluid. The combined effect of these two mechanisms causes the fluid to flow out of the air film pores mainly from the leading edge with a smaller lateral expansion.

Large Eddy Simulation of Film Cooling over a Flat Plate in Supersonic flow

2020 ◽  
pp. 1-29
Author(s):  
Hitesh Sharma ◽  
Dushyant Singh ◽  
Ashutosh Kumar Singh
Keyword(s):  
Heat Transfer ◽  
Supersonic Flow ◽  
Large Eddy Simulation ◽  
Flat Plate ◽  
Film Cooling ◽  
Cooling Effectiveness ◽  
Potential Core ◽  
Film Cooling Effectiveness ◽  
Eddy Simulation ◽  
Large Eddy

Abstract In the present work, Large Eddy Simulation (LES) was performed to access the film cooling performance in the supersonic flow over a flat plate with a perpendicular slot injection configuration. The study was carried out for three mainstream Mach No.; Mα = 1.2, 2.67, 3.3 and three coolant stream Mach No.; 0.05, 0.1, 0.15. In supersonic flow, temperature rise inside the boundary layer is a major issue considering it causes high rates of heat transfer to the coolant film. To select a suitable LES Sub-Grid Scale (SGS) model, LES results obtained from the present study using the LES Sub-Grid Scale (SGS) models such as Smagorinky- Lilly, Wale, and WMLES models were compared with DNS results available for flow and heat transfer. The parametric study showed that the higher mainstream Mach No. caused increased wall temperature and reduced effectiveness. The film cooling effectiveness appeared to reduce almost by 10% when the mainstream Mach No. is increased from 1.2 to 2.67, however, no apparent difference was observed in effectiveness between the mainstream Mach No. 2.67 and 3.3. It was found that doubling and tripling the coolant stream Mach No. from 0.05 to 0.1 and 0.15, the length of potential core region also doubled and tripled respectively from 4 X/S to 8 X/S and 13 X/S and hence significant improvement in the film cooling effectiveness was observed.

Loss Predictions in the High-Pressure Film-Cooled Turbine Vane of the FACTOR Project by Mean of Wall-Modeled Large Eddy Simulation

2020 ◽  
Author(s):  
Mael Harnieh ◽  
Nicolas Odier ◽  
Jérôme Dombard ◽  
Florent Duchaine ◽  
Laurent Gicquel
Keyword(s):  
Spatial Distribution ◽  
Large Eddy Simulation ◽  
Film Cooling ◽  
Total Pressure ◽  
Mean Flow ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Eddy Simulation ◽  
Large Eddy ◽  
Turbine Vane

Abstract The use of numerical simulations to design and optimize turbine vane cooling requires precise prediction of the fluid mechanics and film cooling effectiveness. This results in the need to numerically identify and assess the various origins of the losses taking place in such systems and if possible in engine representative conditions. Large-Eddy Simulation (LES) has shown recently its ability to predict turbomachinery flows in well mastered academic cases such as compressor or turbine cascades. When it comes to industrial representative configurations, the geometrical complexities, high Reynolds and Mach numbers as well as boundary condition setup lead to an important increase of CPU cost of the simulations. To evaluate the capacity of LES to predict film cooling effectiveness as well as to investigate the loss generation mechanisms in a turbine vane in engine representative conditions, a wall-modeled LES of the FACTOR film-cooled nozzle is performed. After the comparison of integrated values to validate the operating point of the vanes, the mean flow structure is investigated. In the coolant film, a strong turbulent mixing process between coolant and hot flows is observed. As a result, the spatial distribution of time-averaged vane surface temperature is highly heterogeneous. Comparisons with the experiment show that the LES prediction fairly reproduces the spatial distribution of the adiabatic film effectiveness. The loss generation in the configuration is then investigated. To do so, two methodologies, i.e, performing balance of total pressure in the vanes wakes as mainly used in the literature and Second Law Analysis (SLA) are evaluated. Balance of total pressure without the contribution of thermal effects only highlights the losses generated by the wakes and secondary flows. To overcome this limitation, SLA is adopted by investigating loss maps. Thanks to this approach, mixing losses are shown to dominate in the coolant film while aerodynamic losses dominate in the coolant pipe region.

Film Cooling on Highly Loaded Blades With Main Flow Separation—Part I: Heat Transfer

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
Reinaldo A. Gomes ◽  
Reinhard Niehuis
Keyword(s):  
Heat Transfer ◽  
Flow Separation ◽  
Film Cooling ◽  
Separation Bubble ◽  
Leading Edge ◽  
Local Heat Transfer ◽  
Local Heat ◽  
Main Flow ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness

Film cooling experiments were run at the high speed cascade wind tunnel of the University of the Federal Armed Forces Munich. The investigations were carried out with a linear cascade of highly loaded turbine blades. The main objectives of the tests were to assess the film cooling effectiveness and the heat transfer in zones with main flow separation. Therefore, the blades were designed to force the flow to detach on the pressure side shortly downstream of the leading edge and reattach at about half of the axial chord. In this zone, film cooling rows are placed among others for a reduction of the size of the separation bubble. The analyzed region on the blade is critical due to the high heat transfer present at the leading edge and at the reattachment line after the main flow separation. Film cooling can contribute to a reduction of the size of the separation bubble reducing aerodynamic losses, however, in general, it increases heat transfer due to turbulent mixing. The reduction of the size of the separation bubble might also be twofold, since it acts like a thermal insulator on the blade and reducing the size of the bubble might lead to a stronger heating of the blade. Film cooling should, therefore, take both into account: first, a proper protection of the surface and second, reducing aerodynamic losses, diminishing the extension of the main flow separation. While experimental results of the adiabatic film cooling effectiveness were shown in previous publications, the local heat transfer is analyzed in this paper. Emphasis is also placed upon analyzing, in detail, the flow separation process. Furthermore, the tests comprise the analysis of the effect of different outlet Mach and Reynolds numbers and film cooling. In part two of this paper, the overall film cooling effectiveness is addressed. Local heat transfer is still difficult to predict with modern numerical tools and this is especially true for complex flows with flow separation. Some numerical results with the Reynolds averaged Navier-Stokes (RANS) and large eddy simulation (LES) show the capability of a commercial solver in predicting the heat transfer.

Interactions of Separation Bubble With Oncoming Wakes by Large-Eddy Simulation

2015 ◽  
Vol 138 (2) ◽  
Author(s):  
S. Sarkar ◽  
Harish Babu ◽  
Jasim Sadique
Keyword(s):  
Heat Transfer ◽  
Boundary Layer ◽  
Large Eddy Simulation ◽  
Separation Bubble ◽  
Leading Edge ◽  
Constant Thickness ◽  
Eddy Simulation ◽  
Large Eddy ◽  
Flow Past A Cylinder ◽  
Rotor Stator Interaction

The unsteady flow physics and heat transfer characteristics due to interactions of periodic passing wakes with a separated boundary layer are studied using large-eddy simulation (LES). A series of airfoils of constant thickness with rounded leading edge are employed to obtain the separated boundary layer. Wake data extracted from precursor LES of flow past a cylinder are used to replicate a moving bar that generates wakes in front of a cascade (in this case, an infinite row of the model airfoils). This setup is a simplified representation of the rotor–stator interaction in turbomachinery. With a uniform inlet, the laminar boundary layer separates near the leading edge, undergoes transition due to amplification of disturbances, becomes turbulent, and finally reattaches forming a separation bubble. In the presence of oncoming wakes, the characteristics of the separated boundary layer have changed and the impinging wakes are found to be the mechanism affecting the reattachment. Phase-averaged results illustrate the periodic behavior of both flow and heat transfer. Large undulations in the phase-averaged skin friction and Nusselt number distributions can be attributed to the excitation of the boundary layer by convective wakes forming coherent vortices, which are being shed and convect downstream. Further, the transition of the separated boundary layer during the wake-induced path is governed by a mechanism that involves the convection of these vortices followed by increased fluctuations, where viscous effect is substantial.

Film Cooling on Highly Loaded Blades With Main Flow Separation—Part II: Overall Film Cooling Effectiveness

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
Reinaldo A. Gomes ◽  
Reinhard Niehuis
Keyword(s):  
Heat Transfer ◽  
Flow Separation ◽  
Film Cooling ◽  
Separation Bubble ◽  
Leading Edge ◽  
Local Heat Transfer ◽  
Local Heat ◽  
Main Flow ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness

Film cooling experiments were run at the high speed cascade wind tunnel of the University of the Federal Armed Forces Munich. The investigations were carried out with a linear cascade of highly loaded turbine blades. The main targets of the tests were to assess the film cooling effectiveness and the heat transfer in zones with main flow separation. Therefore the blades were designed to force the flow to detach on the pressure side shortly downstream of the leading edge and it reattaches at about half of the axial chord. In this zone, film cooling rows are placed among others for reduction of the size of the separation bubble. The analyzed region on the blade is critical due to the high heat transfer present at the leading edge and at the reattachment line after main flow separation. Film cooling can contribute to a reduction of the size of the separation bubble reducing aerodynamic losses but increases in general heat transfer due to turbulent mixing. The reduction of the size of the separation bubble might also be two-fold since it acts like a thermal insulator on the blade and reducing the size of the bubble might lead to stronger heating of the blade. Film cooling should therefore take into account both: firstly, a proper protection of the surface, and secondly, reduce aerodynamic losses diminishing the extension of the main flow separation. The overall effectiveness of film cooling for a real engine has to combine heat transfer with film cooling effect. In this paper, the overall effectiveness of film cooling, combining results from measurements of the adiabatic film cooling effectiveness and the local heat transfer coefficient are shown. The tests comprise the analysis of the effect of different outlet Mach and Reynolds numbers at engine relevant values and film cooling ratio. A new parameter is introduced which allows for the evaluation of the effect of film cooling accounting at the same time for the change of local heat transfer coefficient. To the authors’ opinion this parameter allows a better, physically based assessment than the strategy using the so-called heat flux ratio. A parameter study is carried out in order to benchmark the effect of changes of the blade design.

Large Eddy Simulation of Axial and Compound Angle Holes With Varying Hole Length-to-Diameter Ratio

2017 ◽  
Author(s):  
Weihong Li ◽  
Wei Shi ◽  
Xueying Li ◽  
Jing Ren ◽  
Hongde Jiang
Keyword(s):  
Large Eddy Simulation ◽  
Film Cooling ◽  
Vortex Structures ◽  
Diameter Ratio ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Eddy Simulation ◽  
Large Eddy ◽  
Compound Angle ◽  
Length To Diameter Ratio

The effect of hole length to diameter ratio on flat plate film cooling effectiveness and flow structures of axial and compound angle hole is investigated by large eddy simulation (LES). Film cooling simulations are performed for three blowing ratios (M) ranging from 0.4 to 1.2, three hole length-to-diameter ratios (L/D) from 0.5 to 5 and two compound angle (β: 0°, 45°). The prediction accuracy is validated by the reported hydrodynamic data and present film effectiveness data measured by pressure sensitive paint (PSP). Results indicate that discrete hole with L = 0.5 show highest film cooling effectiveness regardless of compound angle. Round hole generally shows an increasing trend as L increases from 2 to 5, while compound angle hole shows a complex trend concerning with blowing ratios and length to diameter ratios. This is associated with the fact that length-to-diameter ratio influences the in-tube flow behavior, formation of Kelvin-Helmholtz (K-H) structures, and development of single asymmetric main vortex (SAMV). Scalar field transportation features are investigated to clarify how different vortex structures affect the temperature distribution and the film cooling effectiveness. It is also demonstrated that the counter rotating vortex pair (CRVP) which is observed in the time-averaged flow field of axial hole is originated in different vortex structures with varying blowing ratios and length to diameter ratios.

Large Eddy Simulation of Leading Edge Film Cooling—Part II: Heat Transfer and Effect of Blowing Ratio

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Ali Rozati ◽  
Danesh K. Tafti
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Large Eddy Simulation ◽  
Transfer Coefficient ◽  
Film Cooling ◽  
Leading Edge ◽  
Blowing Ratio ◽  
Eddy Simulation ◽  
Large Eddy ◽  
Adiabatic Effectiveness

Detailed investigation of film cooling for a cylindrical leading edge is carried out using large eddy simulation (LES). The paper focuses on the effects of coolant to mainstream blowing ratio on flow features and, consequently, on the adiabatic effectiveness and heat transfer coefficient. With the advantage of obtaining unique, accurate, and dynamic results from LES, the influential coherent structures in the flow are identified. Describing the mechanism of jet-mainstream interaction, it is shown that as the blowing ratio increases, a more turbulent shear layer and stronger mainstream entrainment occur. The combined effects lead to a lower adiabatic effectiveness and higher heat transfer coefficient. Surface distribution and span-averaged profiles are shown for both adiabatic effectiveness and heat transfer (presented by Frossling number). Results are in good agreement with the experimental data of Ekkad et al. [1998, “Detailed Film Cooling Measurement on a Cylindrical Leading Edge Model: Effect of Free-Steam Turbulence and Coolant Density,” ASME J. Turbomach., 120, pp. 799–807].

Large Eddy Simulation of Leading Edge Film Cooling: Part II — Heat Transfer and Effect of Blowing Ratio

2007 ◽  
Author(s):  
Ali Rozati ◽  
Danesh K. Tafti
Keyword(s):  
Heat Transfer ◽  
Large Eddy Simulation ◽  
Film Cooling ◽  
Leading Edge ◽  
Turbulent Shear ◽  
Surface Distribution ◽  
Blowing Ratio ◽  
Eddy Simulation ◽  
Large Eddy ◽  
Adiabatic Effectiveness

Detailed investigation of film cooling for a cylindrical leading edge is carried out using Large Eddy Simulation (LES). Part-II of the paper focuses on the effect of coolant to mainstream blowing ratio on flow features and consequently on the adiabatic effectiveness and heat transfer ratio. With the advantage of obtaining unique, accurate and dynamic results from LES, the influential coherent structures in the flow are identified. Describing the mechanism of jet – mainstream interaction, it is shown that as the blowing ratio increases, a more turbulent shear layer and stronger mainstream entrainment occur. The combined effect, leads to a lower adiabatic effectiveness and higher heat transfer coefficient. Surface distribution and span-averaged profiles are shown for both adiabatic effectiveness and heat transfer (presented by Frossling number). Results are in good agreement with the experimental data of Ekkad et al. [12].

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