HPC Midlands - Loughborough University and Rolls Royce HPC Collaboration


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Dr Gary Page from Loughborough University and Dr Leigh Lapworth from Rolls Royce discuss their supercomputing collaboration around the Hydra Computational Fluid Dynamics (CFD) code, and the Rolls Royce University Technology Centre programme. For more information, please see http://hpc-midlands.ac.uk

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HPC Midlands - Loughborough University and Rolls Royce HPC Collaboration

  1. 1. HPC Midlands Launch: Loughborough Rolls-Royce Collaboration Leigh Lapworth Gary PageChief Design Systems Aeronautical & Automotive Architect Engineering Rolls-Royce Plc Loughborough University
  2. 2. Introduction Background to Loughborough Rolls-Royce University Technology Centre (GJP) Rolls-Royce System Design and Future Directions (LL) Loughborough CFD Examples (GJP) Future Directions (LL) 2 HPC-Midlands Launch Event 20 March 2013
  3. 3. University Technology Centres Rolls-Royce policy to focus academic research with selected University partners Established Global network of University Technology Centres (UTCs) Long term research relationships covering fundamental research through to engine projects 3 HPC-Midlands Launch Event 20 March 2013
  4. 4. UTC Global Research Network Performance in a Seaway Trondheim Hydrodynamics Lightweight Structures High-Mach Propulsion Chalmers, Gothenberg and Materials Dresden Purdue, USA Heat Transfer and Multidisciplinary Process Turbines Aerodynamics Power Electronics Centre Integration Cottbus Madrid (ITP) Xi’an China Virginia Tech Thermal Management Pusan, Korea Fuel Cell Systems Turbines and Combustion Genoa Darmstadt Aerospace Materials NIMS Japan Design partnership Cambridge, Sheffield, Southampton Solid Mechanics Oxford Advanced Technology Systems & Software Engineering Centre Singapore York Gas Turbine Transmission Systems Nottingham Control & Systems Engineering Sheffield Materials Partnership Manufacturing TechnologyCambridge, Birmingham & Swansea Nottingham Materials Damping Technology Vibration Sheffield University Gas Turbine Partnership (UGTImperial College Cambridge Electrical Power Systems Performance Strathclyde Adv. Manufacturing Research Centre Research Cranfield Sheffield AMRC centres Combustion System Advanced Electrical Machines and Drives Aerothermal Processes Sheffield Loughborough UTCs Heat Transfer and Aerodynamics Electrical Systems for Extreme Environments Oxford (Osney lab) Manchester Noise Thermo-Fluid Systems Southampton Surrey
  5. 5. University Technology Centres Loughborough UTC in ‘Combustion Aerodynamics’ created in 1991 (third to be established) In 1991: 3 academics, 2 technicians, 5 researchers In 2013: 7 academics, 4 technicians, 1 expt officer, 1 administrator, 5 senior research staff, 19 researchers Typically around £1.6M per year turnover with 40 ongoing projects Name updated to ‘Combustion System Aerothermal Processes’ to reflect increased interest in heat transfer, acoustics, two-phase flow 5 HPC-Midlands Launch Event 20 March 2013
  6. 6. Combustion Systems ~75% projects on combustion system ~25% other: compressor, ducts, military nozzle, jet noise, instrumentation Experimental and Computational studies (Computational Fluid Dynamics) 6 HPC-Midlands Launch Event 20 March 2013
  7. 7. Computational Fluid Dynamics Research Access to RR corporate CFD codes Hydra and Precise as well as associated grid generation (Padram) and visualisation (ss02) Access to source code where required Develop capability (e.g. Hydra Large Eddy Simulation) that is incorporated back into production software Good network with CFD researchers from other UTCs Royal Society funded secondments of RR staff to Loughborough (Leigh Lapworth and Indi Tristanto) Focus on pushing the boundaries of simulation 7 HPC-Midlands Launch Event 20 March 2013 capabilities using HPC
  8. 8. 8 Simulation in Design Rolls-Royce uses a wide variety of analysis techniques for design verification from whole engine to component, many relying on HPCComputational fluid Cost modelling is useddynamics is used to to identify cost drivers Finite element structuralunderstand the and maximise value analysis is used foraerodynamics of engines vibration, lifing andin order to maximise thermals analysis, bothperformance. linear and non-linear at component and sub- system level. Multi-disciplinary Whole Engine Design Systems predict the behaviour of the integrated product Combined CFD and Structural analysis is used to study forced vibration on turbomachinery Materials designed for required properties © 2013 Rolls-Royce plc
  9. 9. Impact of HPC Simulating the stability boundary  Steady multistage CFD performs well at the design point, but cannot predict stability boundary.  Unsteady multistage CFD with sliding planes performs much better near the stall boundary. 0.6 90 85 0.5 Pressure Rise Coefficient, y 80 Efficiency, h 0.4 75 0.3 EXP UNSTEADY 70 STEADY EXP 4 stage research 0.2 UNSTEADY 65 STEADY compressor 0.1 60 0.38 0.43 0.48 0.53 0.58 Vx/Umid © 2013 Rolls-Royce plc
  10. 10. Our HPC Ambitions 10 Component Level •Increased component capabilities Sub-system Level •Reduced component unit cost (e.g. Integrated HP Spool) •Reduced component life-cycle cost •Multi-component •Multi-physics •Multi-fidelity •Optimised sub-systemsRoutine today •Improved Product Performance •Reduced Environmental Impact Full Virtual Engine •Virtual Product Systems •Optimised & Robust Systems •Step change in: Some routine today • Through life operational & Some less frequent environmental performance • Number & range of complex product systems The future © 2013 Rolls-Royce plc
  11. 11. Compressor CFD Simulations(Andrew McMullan, RR/TSB) Modern research compressor at Cambridge University Unsteady Large Eddy Simulation to resolve all but the smallest scales of turbulence RR Hydra CFD code Need ≈ 30 million grid points per blade giving total of 156 million points, grid file 26 GB run on 360 cores using ≈ 150GB memory for >1 month 11 HPC-Midlands Launch Event 20 March 2013
  12. 12. Compressor Flow Visualisation12 HPC-Midlands Launch Event 20 March 2013
  13. 13. Prediction of High Speed Jets(Tim Coates, EPSRC CASE, RR Bristol)  Mesh for CFD High speed jet rig in  Steady RANS and UTC high pressure Unsteady LES facility  Current LES 150 million grid points  using 800 cores on Hera 13 HPC-Midlands Launch Event 20 March 2013
  14. 14. Unsteady LES Flow Visualisation14 HPC-Midlands Launch Event 20 March 2013
  15. 15. Improvement in Accuracy Jet Centreline Velocity 15 HPC-Midlands Launch Event 20 March 2013
  16. 16. Study of Curvature feeding Jet Total pressureMach number 16 HPC-Midlands Launch Event 20 March 2013
  17. 17. 17CFD Simulation future directions There are 5 strands to the future direction of CFD simulation – all requiring appropriate HPC resources and offering improved predictive accuracy. All are required to meet the goal of a truly virtual engine. The strands are: l Increased geometric fidelity in the model l Removal of simplifying (steady state) assumptions and artificial boundaries - Increased use of unsteady CFD l Increased coupling between components and disciplines - Particularly between the CFD and the stress and thermo-mechanical models to get the true running shape of the engine l Software engineering to allow calculations of the order of 1 billion nodes to scale to very large numbers of cores and to be set-up and post processed. l Increased physical fidelity - e.g. transition and turbulence modelling that truly represent reality These need to be supported by geometry models and mesh generators of commensurate capability and quality.© 2013 Rolls-Royce plc