This summary provides an overview of the key points from the document:
The document discusses a co-op project where the goal was to create a baseline of Francis turbines and study how changes to blade geometry affect stress levels in the blades. This involved computational fluid dynamics (CFD) simulations using ANSYS CFX and finite element analysis (FEA) using ANSYS Mechanical. The co-op involved tasks like modeling turbine geometry, meshing, running CFD and FEA simulations, and post-processing results. The results were compiled into a database to allow studying the effects of minor blade geometry changes on stresses. Macros were developed to help speed up the post-processing of CFD results.
Exploring the capabilities of the tight integration of HyperWorks and ESACompAltair
More than 3 years ago RUAG Space started to look into ways how the very powerful meshing and post-processing capabilities of Altair HyperWorks could be combined with the advanced composite failure analysis methods provided by the ESAComp software from Componeering. RUAG’s vision behind this idea was to streamline the time consuming composite analysis process by a tight integration of the two pieces of software, thus eliminating as much as possible unnecessary breaks in the data flow. Both Altair and Componeering carefully listened to RUAG’s needs and eventually it was decided to make a common effort in providing step by step the requested functionality. The initially slow process accelerated considerably when Componeering joined the Altair Partner Alliance in 2012. Today the bi-directional interface between HyperWorks and ESAComp is considered mature enough to be challenged by a demanding real world use case: the dimensioning and verification of the load carrying structure of the MetOp-SG satellite (Meteorological Operational Satellite - Second Generation). The presentation will focus on how HyperWorks and ESAComp were used to set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results. It will be shown in which way HyperWorks and ESAComp can support the process, what the benefits of a tight integration are and which limitations still exist.
Speakers
Ralf Usinger, Product Lead Engineer Satellite Structures, RUAG Schweiz AG
The Return on Investment of Computational Fluid DynamicsAnsys
Measuring the ROI of Fast and Reliable Computational
Fluid Dynamics (CFD) is not always straightforward. In this presentation, we are demonstrating the positive ROI of CFD using different point of views.
(1) Advantages and cost-savings of using CFD simulation both early and often during the development.
(2) Avoiding costly downtime or product failures.
(3) The ROI of CFD simulation to optimize product performance.
(4) The cost of choosing the wrong simulation tool.
(5) Some tips for you to answer the questions: “Would I benefit from using fast and reliable CFD?”.
For more information on ANSYS Fluid Dynamics Software ROI, you can read the white paper http://bit.ly/ROICFD
Case Study: Blast Furnace Gas DistributionFlex Process
Flex Process developed a complex dynamic simulation of a gas distribution network handling the off-gas from multiple blast furnaces. By modelling the continuous changes across the low-pressure system, we were able to identify the co-incident events which had the biggest effects, and recommend modifications to improve energy use.
Exploring the capabilities of the tight integration of HyperWorks and ESACompAltair
More than 3 years ago RUAG Space started to look into ways how the very powerful meshing and post-processing capabilities of Altair HyperWorks could be combined with the advanced composite failure analysis methods provided by the ESAComp software from Componeering. RUAG’s vision behind this idea was to streamline the time consuming composite analysis process by a tight integration of the two pieces of software, thus eliminating as much as possible unnecessary breaks in the data flow. Both Altair and Componeering carefully listened to RUAG’s needs and eventually it was decided to make a common effort in providing step by step the requested functionality. The initially slow process accelerated considerably when Componeering joined the Altair Partner Alliance in 2012. Today the bi-directional interface between HyperWorks and ESAComp is considered mature enough to be challenged by a demanding real world use case: the dimensioning and verification of the load carrying structure of the MetOp-SG satellite (Meteorological Operational Satellite - Second Generation). The presentation will focus on how HyperWorks and ESAComp were used to set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results. It will be shown in which way HyperWorks and ESAComp can support the process, what the benefits of a tight integration are and which limitations still exist.
Speakers
Ralf Usinger, Product Lead Engineer Satellite Structures, RUAG Schweiz AG
The Return on Investment of Computational Fluid DynamicsAnsys
Measuring the ROI of Fast and Reliable Computational
Fluid Dynamics (CFD) is not always straightforward. In this presentation, we are demonstrating the positive ROI of CFD using different point of views.
(1) Advantages and cost-savings of using CFD simulation both early and often during the development.
(2) Avoiding costly downtime or product failures.
(3) The ROI of CFD simulation to optimize product performance.
(4) The cost of choosing the wrong simulation tool.
(5) Some tips for you to answer the questions: “Would I benefit from using fast and reliable CFD?”.
For more information on ANSYS Fluid Dynamics Software ROI, you can read the white paper http://bit.ly/ROICFD
Case Study: Blast Furnace Gas DistributionFlex Process
Flex Process developed a complex dynamic simulation of a gas distribution network handling the off-gas from multiple blast furnaces. By modelling the continuous changes across the low-pressure system, we were able to identify the co-incident events which had the biggest effects, and recommend modifications to improve energy use.
CFD Best Practices and Troubleshooting - with speaker notesHashan Mendis
CFD Best Practices and Troubleshooting for FSAE - with speaker notes.
Let me know if you need me to clarify anything, due to work commitments my reply may be slow, email: hashan.mendis@leapaust.com.au
i m constantly looking for a job and this this portfolio is to give you a deeper insight into my experience and skills I have gained over my recent history.
In Principles of mechanical engineering class, we have been asked for design a vacuum cleaner. We have designed it as a team. My part is about flow analysis of fan which will attract people to the presentation.
The Powerpoint presentation discusses about the Introduction to CFD and its Applications in various fields as an Introductory topic for Mechanical Engg. Students in General.
Thank you for taking time to view my design portfolio. This file includes some of my major design experience during my academic and professional career. This portfolio can show you that I am a future engineer with comprehensive theoretical skill sets, and a designer with creation and innovation. I believe I will be a valuable member of your team. If you have more questions, please reach out with the contact information below.
Effect of spikes integrated to airfoil at supersonic speedeSAT Journals
Abstract
The objective of this is to analyse the flow field over an aerofoil section integrated with spikes at supersonic speed (Mach number
greater than 1). Use of spike integrated with aerofoil changes the flow characteristics over aerofoil and hence aerodynamic lift
and drag. The experiment consists of flow visualization graphs and measurement of coefficient of aerodynamic drag and lift.
Here we are using different shapes of spike like sharp edge and hemi spherical edge. In this we will compare the flow over
aerofoil with spike and without spike. The flow analysis is done by using Computational fluid dynamics (CFD). CFD is the study
of external flow over a body or internal flow through the body. CFD is aiding aero-dynamist to better understand the flow physics
and in turn to design efficient models. In short, CFD is playing a strong role as a design tool as well as a research tool.
Keywords: NACA 651-412 airfoil, spike, Ansys Fluent, Ansys ICEM CFD, Pressure Coefficient
CFD Best Practices and Troubleshooting - with speaker notesHashan Mendis
CFD Best Practices and Troubleshooting for FSAE - with speaker notes.
Let me know if you need me to clarify anything, due to work commitments my reply may be slow, email: hashan.mendis@leapaust.com.au
i m constantly looking for a job and this this portfolio is to give you a deeper insight into my experience and skills I have gained over my recent history.
In Principles of mechanical engineering class, we have been asked for design a vacuum cleaner. We have designed it as a team. My part is about flow analysis of fan which will attract people to the presentation.
The Powerpoint presentation discusses about the Introduction to CFD and its Applications in various fields as an Introductory topic for Mechanical Engg. Students in General.
Thank you for taking time to view my design portfolio. This file includes some of my major design experience during my academic and professional career. This portfolio can show you that I am a future engineer with comprehensive theoretical skill sets, and a designer with creation and innovation. I believe I will be a valuable member of your team. If you have more questions, please reach out with the contact information below.
Effect of spikes integrated to airfoil at supersonic speedeSAT Journals
Abstract
The objective of this is to analyse the flow field over an aerofoil section integrated with spikes at supersonic speed (Mach number
greater than 1). Use of spike integrated with aerofoil changes the flow characteristics over aerofoil and hence aerodynamic lift
and drag. The experiment consists of flow visualization graphs and measurement of coefficient of aerodynamic drag and lift.
Here we are using different shapes of spike like sharp edge and hemi spherical edge. In this we will compare the flow over
aerofoil with spike and without spike. The flow analysis is done by using Computational fluid dynamics (CFD). CFD is the study
of external flow over a body or internal flow through the body. CFD is aiding aero-dynamist to better understand the flow physics
and in turn to design efficient models. In short, CFD is playing a strong role as a design tool as well as a research tool.
Keywords: NACA 651-412 airfoil, spike, Ansys Fluent, Ansys ICEM CFD, Pressure Coefficient
1. Abstract
This Co-op with Voith Hydro took place between the months of August and December
under the supervision of Mr. Michael Graf. My primary project was to create a baseline
of Francis turbines in order to study how making changes to blade geometry will effect
the stress levels in the blades. This multi-disciplinary study consisted of Computational
Fluid Dynamics (CFD) using ANSYS CFX and Finite Element Analysis (FEA) using
ANSYS Mechanical. The following tasks were performed…
Flow and Structural Analysis
Acquired Knowledge and Experience
Useful Information to Know
At Voith Hydro the hydraulic engineers incorporate structural analysis early in the
design process of creating the hydraulic design for the turbine. This process provides
an early detection system for possible structural problems prior to more enhanced FEA
analysis as their runner design moves towards release. My project was to compile a
baseline of Francis turbines for various Specific Speeds (Nq). The CFD analysis and
post processing provided the pressures on the runner wetted surfaces to be used as
input for the FEA calculation. Once this was completed, I could start a sensitivity
analysis by making minor changes in the blade geometry to see how it effects the
stresses on the runner. To accomplish this I...
Made use of Microsoft Excel
to create a database of results
Used Unigraphics NX6 and in-house software
to model the geometry of the runner
Utilized ANSYS CFX and in-house software
to create a mesh of the machinery
to solve the simulation
to post process the simulation data
Utilized ANSYS Mechanical and in-house software
to create a mesh of the runner
to preprocess the data from CFD results
to solve the simulation
to post process the results
I found the following helped me perform the tasks asked of me while I
was on Co-op.
A knowledge of Excel
A knowledge of MATLAB, C, and Perl
A familiarity with Linux
An understanding of Unigraphics, ANSYS CFX and ANSYS
Mechanical
Challenges
Determining the correct mathematics to calculate the desired results
Creating easy to use macros
Generalizing the macros to work in almost any case
Successes
Macros met all requirements in the test suite
The macros require limited input from the user
Relevance to Voith Hydro
Engineers depend on CFD to get a general idea of performance. The
faster they can obtain good results, the more time they have to make
improvements on their designs. These macros will help them be more
productive.
Challenges
Successes
Relevance to Voith Hydro
Name: Chris Schleicher
Date: August – December 2010 (Fall)
Period: Co-op III
Supervisor: Mr. Michael Graf
Advisor: Dr. Celik
Seeing Fluid Mechanics in Action
This past year, I have taken my first class dealing with fluid
mechanics. It was interesting to witness first hand how the concepts
learned in the class room were applied to real world situations.
Ability to Use ANSYS CFX
ANSYS CFX was an important tool during this co-op, and the
majority of my time was spent using this package. I learned to create
different types of meshes and learned what constitutes a good mesh.
Also, I learned how to setup up appropriate boundary conditions to a
mesh so that a desired solution can be obtained. Building from my
last co-op experience I also gained a better understanding of post
processing results.
Understanding Concepts of an Iterative Solver
Because computers can not evaluate the Navier-Stokes equations
directly, simplifications and an iterative solving process is used. The
true solution is not be obtainable, so turbulence models and
convergence criteria are used. I learned what to look for in these
solutions to see if the solution has converged appropriately.
To learn the software
To understand and apply CFD and FEA best practices
To critically analyze the results
There are many checks and balances at Voith Hydro to make sure that their products
perform as expected in the field. There are, however, times when unexpected results
occur. This project is designed to look into how Voith can detect possible structural
faults earlier in the design phase for the turbine runner.
Different Types of Hydraulic Turbines
Fixed Blade
This turbine looks like a propeller of a ship. The blades are fixed in a
single position which limits the operating range of this turbine.
Kaplan
Similar to the fixed blade turbine, but the advantage of this design is that
the blades are adjustable in pitch; allowing a wider operating range than
that of the fixed blade turbine.
Francis
This is one of the most common turbines. The image to the left is an
example of one blade passage for a Francis runner.
Pump Turbine
A pump turbine has a similar geometry to a Francis turbine. What makes
this turbine special is that it can also pump water back to its upper
reservoir during times when energy is cheaper and let it flow back down
when energy costs more; a very large rechargeable battery!
I was able to obtain the necessary computer simulation results and post process the
results in a structured database for further analysis.
The CFD Process
Build the Geometry
I used Unigraphics NX6, but it is possible to use other CAD packages.
ANSYS supports a variety of geometry types.
Create a Mesh
A mesh is a 3D grid of nodes, points in space defining the surface and
volume, that the solver will solve the Navier-Stokes equations. The mesh
should be refined in places such as near walls or corners in order to
resolve the boundary layer between the fluid and the surface. A more
refined mesh will typically provide better results but it will also take longer
to calculate.
Apply Boundary Conditions
Boundary conditions for the inlet, outlet, walls, and free surfaces need to
be defined. In addition, the fluid properties, turbulence model and many
additional solver settings need to be defined to setup a CFD calculation.
Solve the Simulation
High performance clusters (HPC) are employed that have many
processing cores to reduce the solving time. Monitoring points of interest
and residuals for different properties help to determine if the results are
converged.
Process the Results
With the results from your simulation you can add streamlines, contour
and vector plots, and manipulate your results in order to study how the
fluid interacts with your geometry and how it moves.
CFD Post Processing Macros
Macros are used to speed up the post processing of CFD results. These
macros are used in ANSYS CFX Post to quickly generate plots that the
hydraulic engineers can use to help visualize and analyze their simulation
results. To write these macros I needed to...
Learn Perl and the ANSYS CFX Macro language to write the logic to
generate the plots.
Make use of trigonometric functions to convert frames of reference.
Make use of research skills to find references as needed.