NUMECA. Advanced Developments for Better Products

NUMECA

Advanced Developments for Better Products

A new wave in fluid dynamics

3

NUMECA International

Why NUMECA?

Major Benefits to Your Organization

• Improved performance, leading to a more effective design process.

• Significant time and cost reduction throughout the whole CFD chain. NUMECA grid generation automated systems

AutoMeshTM_{, combined with the significant speed-up in}

CPU with its CPU-BoosterTM_{, guarantee a reduction of one}

to three orders of magnitude in your engineering and CPU time, on large test cases and complex geometries.

• Improve overall engineering efficiency and productivity.

• Improve decision support with reliable simulation.

• Effective design through optimization.

Services

Customer satisfaction is our main objective and we continuously improve our software and services to help you achieve successful product design. We offer a wide range of services including:

• Consultancy in a wide range of fluid, heat transfer, and multiphysics applications;

• Upgrades, advanced hot line and dedicated training and webinars;

• Flexible licensing arrangements to deal with all specific organizational and business requirements;

• Extended partnership including:

- Special arrangements to meet specific requirements in terms of confidentiality, proprietary developments and know-how;

- Validation and calibration of our software to your specific test cases;

- Customization of the whole CFD chain towards customer specific requests;

- Integration of NUMECA software into customer design cycle chain;

- Access to software routines and R&D program through priviledged partnerships.

About Us

NUMECA has been providing Computational Fluid Dynamics (CFD) Software, grid generation systems and consulting services worldwide since 1993. NUMECA’s soft-ware systems are used for the simulation, design, and optimization of fluid flow and heat transfer. They are used

by product developers and design and research engineers, allowing them to reach superior product quality and per-formances, at a reduced engineering cost.

NUMECA International corporate headquarters is located in Brussels with offices, resellers and service centers in the USA, Japan, China, Hong Kong, India, Belgium and dis-tributors in Germany, Spain, Italy, Slovenia, Poland, Turkey, Russia, South Korea, Indonesia, and Malaysia.

NUMECA has been the first to introduce the following technologies:

• FIRST in automatic grid generator for turbomachinery with AutoGrid5™

• FIRST in unstructured full hexahedral grid generation: HEXPRESS™

• FIRST in automatic grid generation & integrated CAD cleaning for extremely complex geometries: HEXPRESS™/ Hybrid

• FIRST for full unsteady rotor-stator interactions, with gains of 1 to 3 orders of magnitude in CPU time: NLH Module (Nonlinear Harmonic)

• FIRST for impressive gain in convergence speed, up to 3-5: CPU-Booster™

• FIRST in commercial Open CFD environment: OpenLabs™

• FIRST to introduce a tool for Uncertainty Quantification: UQ Module

Application-Driven Grid Generation

and CFD Software

NUMECA’s product strategy is based on the development of automated, integrated and customized software

systems allowing optimal and rapid simulation, design and optimization. Our software closely follows industry

requirements and needs:

• In grid generation, with AutoMeshTM_{, covering the whole} range of applications with tuned meshing solutions, as the pre-processor of most commercial CFD tools.

• In CFD, with FINETM_{/Turbo, FINE}TM_{/Open with OpenLabs}TM_, and FINETM_{/Marine, dedicated respectively to} Turbomachinery, Aeronautics, Automotive, Multi-Physics and Marine applications.

• In design and optimization with FINETM_/Design3D.

• FIRST to offer a fully coupled and integrated CFD + acous-tic propagation software system: FINE™/Acousacous-tics

• FIRST in offering a new design system, from preliminary 1D to 2D and full 3D, including multi-objective optimiza-tion at all stages of this process, in AutoDesign™.

Advanced Development

for Better Products

NUMECA’s R&D team is a worldwide center of excellence comprising highly-skilled engineers and PhDs, of more than 20 nationalities, in Computer Science, Mathematics, Physics and Fluid Dynamics. NUMECA International participates in a large number of research projects with university departments, research laboratories and leading industrial partners, allowing us to offer the latest breakthroughs in technology to our customers.

By choosing NUMECA you will gain access to the most advanced technology in the field of application-driven, fast and accurate CFD simulation software, automated full hexahedral mesh generation, solution-adaptive grid optimization, dedicated post-processing, CAD modeling, and optimization 2 3

Contents

© Julien DEBOCK 2010 © JULIEN DEBOCK 2010 © JULIEN DEBOCK 2010 © JULIEN DEBOCK 2010 © JULIEN DEBOCK 2010

PRODUCTS

• _{AutoMesh™ . . . 4-5} • _{FINE™/Turbo . . . 6-7}

• _{FINE™/Open with OpenLabs™ . . . 8}

• _{FINE™/FSI-Oofelie and FSI modules . . . 9}

• _{FINE™/Marine . . . 10-11} • _{FINE™/Acoustics . . . 12-14} • _{AutoDesign™ . . . 15}

• _{AutoBlade™ and FINE™/Design3D . . . 16-17}

KEY FEATURES

• _{Open CFD Approach . . . 18}

• _{OpenLabs™ Membership for} Academic Research and Education . . . 19

• CPU-Booster™ . . . 20

• Modal and Flutter Analysis . . . 21

• Uncertainty Quantification. . . 22

• Non-Deterministic Simulations . . . 23

• FINE™/Open with OpenLabs™

for Combustion and

Radiation Modeling . . . 24-25

• Multifluid and Multiphase Flows . . . 26-27

• Unsteady Phenomena Predicted

in Hours, Superior Solutions with

Nonlinear Harmonic Approach (NLH) . . . 28-29

• Cooling flow and Thermal Effects

in Turbomachinery . . . 30-31

EXAMPLES OF NUMECA SOLUTIONS

• Aerospace Applications . . . 32-33

• Automotive Industry . . . 34-35

• Wind Turbine Industry . . . 36-37

4 5

AutoMesh™

New Generation of Innovative High-Quality Full-Hex

and Hex Dominant Meshing Tools

for Whole CAE Applications

HEXPRESS™

Unstructured—Full Hex- Non Conformal - body fitted grid generator for arbitrary geometries.

No prism, no tetrahedra, no pyramid cells.

Customization to User-Specific Features:

• Python based commands accessible through scripts

• User-defined scripts for batch mode operations in design process

HEXPRESS™/Hybrid

Integrated CAD cleaning and parallel grid generation system creating conformal body-fitted meshes on com-plex arbitrary geometry.

HEXPRESS™/Hybrid produces a 100-million cell grid on a full car including the underhood in 1 hour on 48 cores, starting from unrepaired STL files.

F1 racing car grid

HEXPRESS™ and HEXPRESS™/Hybrid use a similar volume-to–surface approach,

suppressing the need for a surface mesh. Both systems run in batch or interactive mode

and are interfaced to all major commercial CFD codes.

Centrifugal compressor structured/unstructured performed with Autogrid5™ (impeller) and HEXPRESS™ (Centrifugal Volute) Fully-Hexaedral mesh on appended hull configuration

AutoGrid5™

Full automatic hexahedral block structured grid generator for all types of rotating machinery and turbomachinery: complex axial, radial and mixed-flow configurations.

AutoGrid5™ generates grids in a few minutes, with just a few clicks through a wizard-based interface.

Axial multi-stage turbine Counter-Rotating Open Rotor

Centrifugal multi-stage pump

Parametric design and meshing of cooled turbine blade. Turbocharger - Courtesy of Honeywell Non axi-symmetric end walls Automatic multistage mesh topology Wind turbine mesh

IGG™

Interactive Geometry Modeler and Multi-Block Structured Grid Generator for arbitrary geometry

• Simple and intuitive block creation tools • Automatic mapping and block connections • Automated meshing based on Python scripts • Meshing replay can be used in optimization loops.

Viscous layers around main plate and flap

Increase your Productivity

by One Order of Magnitude

HEXPRESS

™

HEXPRESS

Hybrid

™

/

AutoGrid5

™

IGG

™

Hydro turbine casing and stay vane

High Performance Computing

Advanced CFD Technology for Turbomachinery

FINE™/Turbo HPC Capabilities Extend Beyond

1-Billion-Cell Grids on Thousands of Processors

FINE™/Turbo

FINE™/Turbo is an accurate and powerful block struc-tured Navier-Stokes CFD software dedicated to the simulation of internal, multi-stages rotating and tur-bomachinery flows.

FINE™/Turbo integrates:

• fully hexahedral automated grid generator AutoGrid5™ & IGG™;

• advanced density-based numerical algorithms with robust local preconditioning for incompressible flow;

• automatic performance curve construction & summary reports;

• easy-to-use and intuitive interface for fast solution set-up;

• dedicated post-treatment for turbomachinery in CFView™;

• batch process for transparent integration in a design cycle;

• multi-physics: aero-acoustics, fluid structure interaction, real gas modeling, particle tracking, cavitation, conju-gate heat transfer, etc.

Multi-stage axial

compressor (Courtesy RR)

Automatic Performance Curve construction starting from design point within user-specified range

Integrated Nacelle & Rotating Fan Counter Rotating

Open Rotor

Propeller Wind Turbine Centrifugal

Compressor Space Pump Casing/hub treatment Hydro Energy applications Fan 7 6

CPU-Booster

TM

_:

Convergence in 50 cycles

CPU-BoosterTM _{– Axial Compressor}

• Allowing higher CFL number ~1000

• Very fast convergence

• Gain: 1 to 2 orders

of magnitude faster CPU time

NASA Stage 67: Recirculated Injector calculated with Full Unsteady NLH simulation - 175 million grid cells (left: B2B view, right: 3D view)

FINE™/Turbo

Fully transparent and virtual domain decomposition

allowing the launch of a grid with a small number of blocks

on an arbitrary number of processors.

Efficient and optimized automatic load balancing

taking advantage of a large HPC configuration (thousands of processors)

Fully transparent reconstruction of the solution

allowing for the analysis and visualization of the solution

on the original grid or at coarser level in CFView

Linear speed-up up to 500 cores Geometry Overview

Mesh

“ We rely on NUMECA for their entire suite of products that helps from beginning of model creation

to definition, solving and post-processing [...] I would recommend NUMECA: their tools, their people, their services are all top notch.

I recommend them to everybody… except our competitors!”

9

FINE™/Open with OpenLabs™

Unstructured CFD Technology

for Complex Flow Configurations

FINE™/Open with OpenLabs™

FINE™/Open with OpenLabs™ is an accurate unstruc-tured Navier-Stokes solver, with extended turbulence and physical models.

FINE™/Open with OpenLabs™ solves any flow, from incompressible to low and high speed flows. FINE™/ Open with OpenLabs™ integrates HEXPRESS™ or HEXPRESS™/Hybrid. Biomedical flows : Blood simulation in the aorta

Urban environment flows: Brussels, Courtesy Immobilière du Royal Rogiers and AM Art & Build/Montois Partners

Automotive applications

Convergence for complete car geometries in 50 cycle! Jeep (19 million cells)

Solution-adaptive grid optimization for higher accuracy

Aerospace: transonic to hypersonic flows

MPPCI for Flutter Analysis

MultiPhysics

Fluid Structure Interaction

Modal Approach, Coupling through MPPCI

and Strong Coupling in FINE™/FSI-Oofelie

Modal Approach for Forced Response

Analysis

Transonic compressor blade magnitude of deformation on the blade surface [m] and relative mach number at mid span.

Fluid: water & Solid material: steel. Maximum enlargement of the slot: 1.21 mm with no reinforcement, 0.069 mm with cylinders, 0.44 mm with plates.

FINE™/FSI-Oofelie for Curtain Header

Displacement

Composite wind turbine blade displacement.

FSI simulation: Coupling of FINETM_{/Open with OpenLabs}TM _(CFD)

and ABAQUS (Simulia-FEA) through MPCCI.

MPCCI: Mesh-based Parallel Code Coupling Interface from Fraunhofer Institute SCAI

MPCCI interface for codes coupling. Rotor 67 Transonic compressor blade

Flutter on Agard Wing 445.6

Vortex Vibration Beam: Amplitude and Frequency Experiment and CFD Comparison

8

FINE™/Marine

The leading CFD software for naval architects and marine engineers

11 10

FINE™/Marine is a unique integrated CFD software environment for the simulation of mono-fluid and multi-fluid flows around any kind of ships, boats or yachts, including various types of appendages. The

powerful and customized graphical user interface drives the user into the whole simulation process and integrates marine-dedicated features for different applications.

“FINE™/Marine is the first code that gave us confidence in the use of CFD tools, with results never differing much from experimental val-ues.” Dr. Piet Van Oossanen, Van Oossanen Naval Architects

Drastically reduce the engineering time to set-up resistance

and sea keeping simulations with the new C-Wizard!

Sailing yachts, offshore vessels, cruise ships

...and much more!

Mesh Generator

HEXPRESS™

Highly automated mesh generator for high quality and full hexahedral unstruc-tured meshes.

Graphical User Interface

FINE™ GUI

• Marine-dedicated environment • Fully scriptable

Post-processing CFView™

• Powerful post-processing and scien-tific visualization system offering all qualitative and quantitative tools and marine dedicated add-ons for flow visualization and analysis.

• Marine-dedicated add-ons • Fully scriptable Resistance calculation including hydrofoils Resistance calculation at Froude 0.24

Flow Solver ISIS-CFD

6DOF incompressible flow solver, recognized as having the best accuracy for all types of marine applications, including free sur-face capturing. ISIS-CFD is devel-oped by the “Ecole Centrale de Nantes” (ECN) and CNRS and industrialized in partnership with NUMECA.

12 13

FINE™/Acoustics

Efficient Aero-Acoustic Prediction

The FIRST Integrated Aero & Vibro Acoustic Suite

Integrated solution

FINE™/Acoustics is a fully CFD Integrated environment dedicated to Aero-Vibro-Acoustic simulations. It pro-vides the capabilities to solve a wide range of aeroa-coustic and fully coupled vibro-aaeroa-coustic problems, from simple pre-design calculations to detailed large scale analyses of complex systems.

Key features

• Integrated with FINE™/Turbo, NLH method and FINE™/Open • Interfaced to any commercial CFD

software

• Turbulence noise modeling through the Flow-Noise DSNG solver

• FW-H, FEM, BEM coupled propagation modules

• Flexible GUI providing pre/post processing capabilities

13 12

Integrated CFD-Acoustic

approach for tonal noise

• CFD-Acoustic integrated simulation of turbo-machinery applications

• Simultaneous analysis of noise source and propagation (FINE™/Turbo -NLH)

• Analysis of noise radiation (FINE™/Acoustics)

Flow-Noise reconstruction

of turbulence broadband noise

• Unique stochastic method available on the market

• Approach based on a cost-efficient steady RANS simulation

• Exploitation of the DSNG algorithm (ref. AIAA-2013-2264)

• Acoustic sources evaluation by means of Lighthill and Lamb formulations

• Coupling with BEM/FEM in presence of interactions with solid bodies

• Orders of magnitude faster than LES/DES approaches

FW-H simulation of

CRORs radiated noise

Automatic import/transformation of harmonic data computed with the NLH method.

Possibility to simulate angle of attack and supersonic tip-speed flow conditions.

Flow-noise

Sound propagation in the nacelle duct and near-field (computed with FINE™/Turbo)

Fan noise -

aero-engine

nacelles

Sound radiation in the far-field (computed

with FINE™/Acoustics) Turbulence noise reconstruction (Flow-Noise simulation of an airfoil with slat deployed) Acoustic pressure

amplitude

NLH analysis of noise source and propagation

Radiation from solid/permeable, fixed/rotating FW-H surfaces

CROR blades

location _radiating FW-H

14 15

Vibro-Acoustic Analysis

Automatic calculation of Transmission Loss of an automotive muffler

Aero-Vibro-Acoustic Analysis

of Exhaust Systems (mufflers)

• FINE™/Acoustics performs fully coupled BEM-FEM vibro-acoustic analysis

• Import of structural modes from main structural solvers (Nastran, Abaqus, Ansys)

• Easy definition of applied forces

• Import of applied pressure fields from any CFD tool

• Acoustic mesh automatically extracted from Structural and CFD meshes

• Surface mesh coarsening

• Automatic Shrink-Wrapping for hole closure and mesh size reduction

• FINE™/Acoustics enables simulation of Pipe-Noise, Shell-Noise and Flow-Noise in muffler applications.

• Automatic calculation of Transmission Loss with different approaches (trans-fer matrix, impedance matrix).

• Multi-domain fully coupled FEM / BEM modules, with structural coupling.

• Sound absorption from bulk reacting materials (e.g. foam, mineral wool, fibers), perforated surfaces, dissipative media.

• Surface impedance boundary condition available.

• Turbomachinery dedicated system

• Preliminary design with AutoDesign™

• Design of Experiment

• Parametric blade modeler with AutoBlade™

• Optimization with genetic and Krylov algorithm

• Artificial neural network model

• Coming soon: user-friendly adjoint based optimization

Transmission Loss

Acoustic pressure distribution over the water pump surface and in the far-field (at BPF and high frequency)

AutoDesign™

The FIRST Totally Integrated

Design and Optimization Software for Turbomachinery

Axial compressor 1.5 stage with fillet on blades AutoDesign™ graphical user interface within OMNIS 1.1

Preliminary and

optimized design

Multidisciplinary

3D blade shape

optimization

From 1D to 3D turbomachinery design and optimization

including flow and mechanical stresses optimization

Centrifugal compressor: Aerodynamic & Acoustic Optimization with FINE™/Design3D

Initial

Optimized

16 17

AutoBlade™ & FINE™/Design3D

3D Design and Optimization

Rotating Machinery

Multipoint and Multi-Objective Optimization

AutoBlade™

AutoBlade™ is an advanced and easy-to-use 3D para-metric modeler dedicated to the design of rotating and turbo-machinery blades including:

• Conversion of CAD models to a fully parametric definition,

• Fitting module to “import” an existing geometry • Interactive graphical edition of the design parameters, • Large variety of turbomachinery parametric models, • Parametric variables for:

• end walls; • non-axisymmetric hub/shroud; • blade profile; • splitter blades; • profile stacking; • technological effects;

• User defined parameters;

• Dependency between parameters decreasing the size of optimization parameters;

• Tool analysis for blade and meridional contour; • Full undo/redo capability;

• And much more!

Blade Re-cut Non-axisymmetric

hub/shroud User-defined parameters AutoBlade Easy-to-Use GUI including: 1. Model editor 2. Interactive 3. Contextual Menus 4. Customizable 3D view 5. View controls 6. Analysis tools 7. Undo / redo functions

Pre-defined parameter templates for various configurations: axial, centrifugal, radial, compressor, fan, turbine, pump,

wind-turbine.

FINE™/Design3D

FINE™/Design3D is highly integrated 3D optimi-zation tool designed to improve the performance of rotating and turbomachinery blades. It allows designers to break the limit of traditional design rules and explore the concept of computer-based 3D innovative design.

FINE™/Design3D integrates in a user-friendly interface, the 3D parametric blade modeler AutoBladeTM_{, genetic}

algorithms artificial intelligence, design of experiments techniques and efficient optimization algorithms.

Turbocharger innovative guide vane profile (“Courtesy BOSCH MAHLE Turbosystems”)

3D turbine multi-points optimization

Torque Converter optimization KAPLAN Turbine optimization 3D Compressor blade multi-points optimization

Mixed flow fan stage optimization

Number of blades and separation zones (red area) are improved Initial Initial Optimized Optimized

Applications

FINE™/Design3D covers a large range of applications including multi-stage axial, radial and mixed-flow compressor, turbine, pumps, fans, wind-turbine

18 19

NUMECA’s Approach to Open CFD

Combine the advantage

of an Open CFD code with

a highly powerful & fully

supported industrial and quality

assured software environment.

To join this program contact

the Numeca Academic Group

at [email protected]

the registration is very simple

and straightforward and

the cost is limited to 500 €

per department.

• OpenLabs™ is a dialogue system with the underlying CFD code FINE™/Open accessing its routines and sources in a Lab in easy text format, allowing unlimited cus-tomization for your own code usage.

• Create or download Labs from the NUMECA library and benefit from a wide community experi-ence through a forum.

• Annual membership

• FINE™/Open with OpenLabs™: as many licenses on as many cores as needed for your department

• Documentation and tutorials included

• Access to online discussion forum

• Possibility for Labs exchange

Unique business model with advantageous cost control for:

• Industrial users benefit from FINE™/Open with OpenLabs™ with unlimited parallel cores capability at the cost of a single seat configuration.

• Academic users benefit from the Academic Membership program with unlimited access to seats and parallel cores.

Examples of applications

• Initial free surface position for a VOF simulation

• Unsteady inlet boundary conditions

• Mass diffusion to track pollutant concentration

• Realizable k-ε model, round/jet anomaly correction

• Generalized transition models

• Time-dependent heat source

• Radiation optical properties, soot formation

• Droplet condensation model, cavitation models

• Heat source term added to a solid block

OpenLabs™

Easy set-up of test case

in FINE™/Open GUI Add/customize physical model in OpenLabs™ GUI Compile with a single click and run Visualize added quantity

Figure 2 Figure 1 OpenLabs™ GUI Example of a Lab to add a Transport equation for the pollutant mass

Fraction. Figure 1:

the Transport equation

Figure 2:

part of the Lab

OpenLabs™ Membership for

Academic Research and Education

NACA0012 α = 2°, static pressure color contour Mach number

2nd _{order upwind}

with mesh adaptation

Actuator disk model of propellers in a duct

Contour of mass fraction Plot: axial velocity at center line

• Open CFD through OpenLabs™

• Automatic full hexa or hex-dominant meshing

(HEXPRESS™ & HEXPRESS™/Hybrid)

• Reduction by one order of magnitude of the CPU time compared to other CFD code, with the CPU-Booster™

• Access to models in combustion, multiphase, radiation…

• Optional extension to FSI (FINE™/Oofelie) on request

• All types of flow and liquids, from low speed to hypersonic regime

KEY FEATURES

20 21

Modal & Flutter Analysis

Modal Approach for Fluid Structure Interaction Prediction

FSI computation with one single code

FINE™/Turbo and FINE™/Open with OpenLabs™ extend their capabilities with the modal approach, an effi-cient method for fluid structure interaction prediction. Only one single integrated code is used: the modal equations of the structure part are solved inside the

fluid flow solver. No additional interpolation is required between fluid and structure data during the FSI compu-tation, reducing the computation time and increasing the accuracy.

Cold-to-hot Analysis

Steady blades’ deformation due to centrifugal and aerodynamic effects.

Right: example of magnitude of deformation (m) for Rotor 67.

Forced Response Analysis

Unsteady blades’ deformation under adjacent blade row passing wake.

Right: example of deformation field on stator blade of a compressor stage (Courtesy of TU Darmstadt)

Flutter Analysis

Unique on the market: Flutter Analysis of turbo machinery now affordable at industrial level with the coupling of Modal Approach and the NLH method. The blades’ aerodamping can be derived from the unsteady flow response by computing only one passage per blade row at whatever IBPA!

NASA LSCC - Blade deformation - IBPA 90°

St

ability par

amen

ter

Aerodamping versus IBPA

IBPA (deg)

CPU-Booster™

Drastically reduce your computation time

CPU-Booster™  fits into  NUMECA’s  objective to keep reducing computation time. Most importantly, this time reduction is made without compromising the accuracy of the flow solution.

CPU-Booster™ reduces the computation time by up to one order of magnitude with an optimum efficiency on large mesh size.

CPU-Booster™  is available with FINE™/Turbo and FINE™/Open with OpenLabs™ and can be applied to various turbomachinery and external flow configura-tions.

Unique

convergence

acceleration

technique

• Impressive gain in convergence speed, up to 1 order of magnitude

• Automatic settings for the flow solver when activating the CPU-Booster™

• This new method allows users to increase the CFL number up to 1,000

• The CPU-Booster™ is compatible with the main features of FINE™/Turbo and FINE™/Open with OpenLabs™

Re=3.106, Angle of Attack: 3 degrees Geometrical uncertainties: • Uncertain relative thickness, • Uncertain camberline.

Output: The airfoil pres-sure coefficient

& its standard deviation.

NACA0012 Airfoil

Non-Deterministic Simulations

22 23

Managing Uncertainties and Risks

within NUMECA’s CFD

Simulation Process

Operational and geometrical uncertainties in the CFD simulation: • Tolerances of manufacturing

• Uncertainties on inlet and boundary conditions • Model uncertainties

• ‘Incompressible’ numerical errors • etc.

NASA Rotor 37

Operational uncertainty: Uncertain Inlet Total Pressure profile.

Pressure distribution around mid-span blade profile. Node locations (left).

Shock locations are observed with larger uncertainty(right). Error bars represent variation of standard deviation σ.

Operational uncertainty: Uncertain Outlet Static Pressure. Pitch-wise averaged pressure ratio radial distribution. Larger uncertainty near tip.

Courtesy TU DELFT

Uncertainty Quantification

Enhance the reliability of your CFD simulations

Quantify the effect of input parameters’ uncertainty on CFD solutions.

Actual operating conditions of industrial systems are a combination of numerous operational and geometrical uncertainties.

This is a major source of risk in the design process.

• Non-deterministic specific menu

• Different probability density function can be set for each uncertainty

• Pre-defined or user-defined probability density functions can be used

• Turbomachinery performance map with error bars

New methodologies are required to incorporate the presence of uncertainties at the level of the simulation tools in order to improve the predictive reliability. This means that the simulations tools become non-deterministic.

With NUMECA’s Uncertainty Quantification module, designers now have the capability to easily quantify uncertainty and produce a range of confidence in their performance prediction. Through an intuitive interface, the UQ module allows users to set input parameters’ uncertainty gaussians, combine them to get the effect on the solution.

FINE™/Open with OpenLabs™

for Combustion & Radiation Modeling

Robust, Accurate and Reliable Modules for All Types of Combustion

Simulation of the Reactive Flow in a Combustion Chamber

Automatically Generated full-Hex Mesh

RANS

Flamelet FGM Progress Variable

TU Darmstadt’s Generic Gas Turbine Combustor

>

_{Non-Premixed Combustion Modeling:}

• Mixture fraction approach • Tabulated chemistry method

• Enthalpy defect method for simulation of non-adi-abatic flames (radiative heat loss)

• Spray combustion

>

_{Partially Premixed Combustion Modeling:}

• Mixture fraction/progress variable approach • Two modeling methods available:

• Flamelet Generated Manifold technique

• Hybrid BML/Flamelet model

>

_{Premixed Combustion Modeling:}

• Progress variable approach for flame front tracking • Zimonts‘ Turbulent Flame Speed Closure

Modeling the Combustion Process

and the Radiative Heat Transfer

in Furnaces

Full Hex HEXPRESS™ Mesh of an Aero Engine Combustor

Easy to Use GUI

for Combustion

and Radiation

Modelling

Non-premixed

Combustion GUI Partially-premixed Combustion GUI

Accurate and Reliable Predictions with the FGM Method

Sydney/Sandia Bluff-body Stabilized Flame (Experiment and simulated flow fields)

FGM - Flamelet Generated Manifold Approach:

NUMECA ’s Unique Feature for Improved Modelling

25 24

>

Applications

• Simulation of furnaces • General non-premixed

or partially premixed gaseous combustion processes

• Aero-engine combustors • Gas turbine combustors

Attached Flame

Lifted Flame

>

_{Multi-species framework for general}

reactive flow simulations

• Finite rate chemistry

• Eddy dissipation modeling approach

>

_{Radiation Modeling:}

• First Order Spherical Harmonics Method (P1) • Emission Model for optically thin media

• Finite Volume Method (FVM) for radiative heat transfer • Weighted-Sum-of-Grey-Gases (WSGG) method for

the determination of optical properties

>

_{Modeling Pollutant Formation:}

• NOx postprocessing module (thermal)

• Soot models: • One equation model of Greeves & Khan

• Two equation model of Moss & Lindstedt

Combustion Look-up Table

FGM table created with TABGEN/Chemistry, NUMECA’s combustion table generation tool. The plot shows the temperature manifold in dependence of the mixture fraction

and the progress variable

z r z r z r FGM: Flamelet Generated Manifold

Experiment Temperature OH Velocity magn.

This shows the streamlines coloured with the temperature of the simulated flow field in DLR Stuttgart’s model combustor. The computation was carried out using Zimont’s modeling approach for premixed combustion processes.

Simulated temperature field in the IFRF glass melting furnace. The temperature field was obtained using a non-premixed flamlelet method coupled with the P1 radiation model

Modeling of the Reactive Flow

in Premixed Combustors

26 27

Multifluid & Multiphase Flows

TABGEN: User Generated

Thermodynamic Table

for Multiphase & Multifluid Thermodynamic

& Transport Properties

• TABGEN, Thermodynamic table generation tool for complex real Fluids and mixture definition based on the NIST-REFPROP database.

• 84 pure fluids & mixtures with up to 20 components: typical natural gas constituents, hydrocarbons, main air constituents, water, refrigerants, noble elements

User Defined

Fluid Properties

Lagrangian Particle Tracking for Separators

Lagrangian particle tracking in

turbo-machines

Multiphase flow – Lagrangian particle tracking approach one or two way

coupling Streamlines of relative

particle velocities in a turbine (stator-rotor-stator configuration)

Perfect Gas, Ideal gas with Cp(T), Real fluid modeling

Modeling of Evaporating Sprays

Broken Dam Problem with the free surface VOF model. Evolution of the wave shape with time

VOF Model for Free Surface flow

Volumic Heat Sources for FIRE Simulation

Barotropic Model for Cavitating Flow

DELFT Hydrofoil Cavitating flow showing bubble detachment captured by FINE™/Turbo barotropic cavitation law. Courtesy TU Delft.

Cavitating flow on marine propeller. The wake is well captured by FINE™/Turbo barotropic cavitation law. Experimental results courtesy INSEAN Italy.

Compressible Cavitating Flows

Fire simulation with FINETM_{/Open with}

OpenLabsTM _volumic

heat source model

Cavitating flow of R114 liquid on 4° Venturi (Thermo table approach). Compressibility effects are well taken into account here. Sharp discontinuity captured at the bubble frontier. Particle velocity streamlines

with fluid axial velocity con-tour field and iso-lines of

par-ticle diameter at location of complete evaporation.

Mean number diameter of initially mono-dispersed

evapo-rating droplet spray.

A Large Range of Models to Cover

all CFD Applications and Physics

Porous Media

29

Unsteady Phenomena Predicted in Hours,

Superior Solutions

with Nonlinear Harmonic Approach (NLH)

2 Orders of Magnitude Gain

in CFD Turn-Around Time

NLH Method for Large Scale Multi-Stage Turbomachinery Unsteady Flow

One passage mesh only: less memory and affordable CPU time

NLH Method for Casing Treatment

(Courtesy LFA TU-München).

NLH for Flutter Analysis

NASA LSCC - Blade deformation - IBPA 90°

Fan stage acoustic pressure wave

28

NLH for Flow Distortion

Flow distortion in external and internal flow

NLH Method for Clocking Analysis

Only one run for the whole clocking spectrum

Nonlinear Harmonic Method in FINE™/Open with OpenLabs™

Stator 1 and Stator 2 are aligned

Blade-to-blade cut at mid-span Distortion effects on 360°

3 harmonics per perturbation One blade passage computed

Solution after rotation of the stator 1 by 80% of its pitch. Efficiency is better at this clocking angle.

Nonlinear Harmonic (NLH)

CPU Time – 3D Radial Turbine

2 orders of magnitude gain in CPU time. NLH compared to full unsteady with reference to quasi-steady mixing plane in logarithmic scale.

NLH for Aero-Acoustics

Fluctuation of Static Pressure [Pa] in the volute due to the relative motion of the impeller. Reconstruction in CFView™.

30 31

Cooling Flow and Thermal Effects

in Turbomachinery

FINE™/Turbo, FINE™/Open with

OpenLabs™ & AutoMesh™ Offer

Flexibility in Handling Cooled Turbine

& Conjugate Heat Transfer (CHT)

Flows

Full meshing flexibility in AutoMesh™ by: • Parametric design and meshing in AutoGrid5TM_;

• Fully hexahedral unstructured meshing in HEXPRESSTM_;

• Extremely complex configuration meshing in HEXPRESSTM_/

Hybrid.

Rich options for solving Turbine Conjugate Heat Transfer by meshing real geometry or by source/sink terms without channel meshing.

Internal cooling passages, solid body and external blade main channel meshing (AutoGrid5™)

All Hexahedral Cooled Channel

Structured Mesh

CHT

30

_{Conjugate Heat Transfer simulation is made “simple” with non-matching interfaces between solid-fluid and fluid-fluid blocks for higher quality of mesh}

31

Streamline and temperature in fluid and solid body. 1 stage (IGV + Rotor), 20 million cells on 45-core cluster. CHT simulation compared to test result.

Blade surface temperature. Mark II turbine test case

Local Source & Sink Terms

for Film Cooling

No meshing of the channels is required

Fully Hexahedral Unstructured Mesh

(HEXPRESS™)

Cooling Module Full Mesh

Full Mesh

Cooling Module

Increasing blowing ratio Experiment : red dots

Cooling/Bleed : blue continuous line Full mesh : blue dotted line

FINE™/Open with OpenLabs™ with HEXPRESS™ provide high quality full hexa unstructured resolution of

cooled turbine phenomena.

Cooling Module and Full mesh flow configurations give similar

results. (Case Duden, 1999)

AutoGrid5™ allows easy positioning of local source & sink locations: single hole, line of holes or slots

Cooled Turbine Parametric Design and

Automatic Meshing in AutoGrid5™

Interactive and easy-to-use graphical user interface.

Extremely Complex Configuration

NUMECA CFD Solutions

for Aerospace Applications

Broad Range of Applications:

External, Internal, Low Speed, High Speed,

Thermal, Fluid Structure Interaction, Acoustics

HEXPRESS™/Hybrid Hex Dominant

Parallel Meshing of Hyper-Complex

Full Aircraft Configuration in Hours

Extended Range of Capabilities

for Aircraft Installation and Integration

Aircraft configuration study: Open Rotor-Fuselage interaction (top left), Pylon-Open rotor interaction (top right), Ground effect at take-off (bottom left),

Wing-body interaction (bottom right)

32

High-Lift Device Design

Alpha=31° High-lift devices performance at low speed configuration

Fast and Accurate Prediction of Aerodynamics of Passenger Airliner

HVAC in an aircraft cabin

Passenger

Comfort

Analysis

Flutter Analysis

Flutter Analysis:

FSI coupling of FINE™/Open with OpenLabs™ and an FEA code through MPCCI

Lift vs.angle of attack Alpha=10°

Automated Full-Hex Mesh for

Quick CFD Turn Around & Accurate

Refueling Simulation

HEXPRESS™ full-Hex mesh of a wing-box fuel tank for refueling simulation

Hypersonic Flow

Very fast accurate aerodynamic performance of transonic, supersonic & hypersonic flows with CPU-BoosterTM

33

35

NUMECA CFD Solutions

for the Automotive Industry

Hydroplaning

Hydroplaning simulation of a tyre, employing free-sur-face and splash, plus particle tracking within the grooves

External Aerodynamics

Thermal Flow in a Cabin

Heat

Transfer

Flow over a motor bloc

Breakthrough in CFD Solution

with FINE™/Open with OpenLabs™

• Full Second Order Accurate solution • Agglomeration multigrid

• CPU-BoosterTM

Breakthrough in Full Automatic

Meshing with HEXPRESS™/Hybrid

F1 (40 million cells)

NO CAD Cleaning - NO Surface Mesh

Hyper-Complex Configuration Meshing

34

HEXPRESS™/Hybrid allows meshing of complete car configurations ...

Standard Approach:

NUMECA’s solution:

Days / weeks of engineering time

Hours with HEXPRESSTM_/Hybrid

Increase Your Productivity

by at Least One Order of Magnitude

NUMECA CPU-Booster

TM

_{combined with the agglomeration multigrid allows for running}

with CFL 1000 in around 50 cycles for complete car geometries!

Simulation of Terrain Effects

on Wind Farm Energy Production

with FINE

TM

_{/Open with OpenLabs}

TM

NUMECA Solutions

for the Wind Turbine Industry

Breakthrough in

3D Wind Turbine Meshing:

Full automatic all hexahedra cells

meshing in minutes with AutoGrid5™

Advanced Applications: • Complex configuration

• Cross wind in single blade passage • Unsteady flow simulation • Vibration

• Flow generated noise

Breakthrough in Flow Simulation

Computing Time:

Fully accurate solution in about 50 cycles with CPU-BoosterTM_.

• Multi-point and multi-objective optimization • Fully automatic process with no user intervention • Optimization featuring Design of Experiments,

Artificial Neural Network and Genetic Algorithms • Powered by AutoBlade™, 3D parametric blade modeler

with pre-defined template for Wind Turbine

3D flow features at high wind speed

Black: Optimized Blade

Red: Initial Blade

2.5 MW twist distribution optimized blade with a gain in annual energy production between 5 and 10%.

Fluid Structure Interactions

• Strong fluid/structure interaction with FINETM_/FSI-Oofelie

• Modal approach in FINETM_/Turbo

• Coupling to FEA commercial or in-house tools through MPCCI

FSI - Enhancing the torsional flexibility of the blade by

optimal selection of the composite fiber orientation

Wind speed prediction for wind turbine placement in urban environment

36 37

Breakthrough in Full 3D

Wind Turbine Blade Optimization

with FINE™/Design3D

Nonlinear Harmonic Method:

A Major Breakthrough

in Unsteady CFD Simulations

• Accurate Rotor/Stator interactions • Single passage mesh simulations

• Accurate unsteady solution with low number of harmonics (Blade Passing Frequencies)

• Reconstruction in time of the solution

Advanced CFD and Optimization Solutions

for Hydro Engineering

High Quality all Hexahedra Cells Meshing

with AutoGrid5™ and HEXPRESS™

Structured mesh for Francis Turbine stay vane, guide vane and runner (AutoGrid5™ - mesh generated in a few minutes on a standard PC)

Unstructured mesh for spiral casing and distributor (HEXPRESS™ - < 1 hour CPU time for 1 million cells)

Before After

Full 3D Blade Optimization

with FINE™/Design3D

Optimized blade and comparison of Blade Sections (initial in red & optimized in green)

Advanced Cavitation Modelling

Comparison of Non-Linear harmonic and sliding grid simulation: instantaneous Blade pressure distribution and pressure fluctuation amplitude through FFT

39 38

CPU cost comparison for Nonlinear Harmonic and Sliding Grid simulation with reference to Steady Mixing Plane simulation.

Nonlinear

Harmonic Sliding Grid Mesh size 900,000 15,000,000 RAM 1.5 Gb 7.5 Gb Iterations 500 40,000 CPU Time w.r.t. Steady Mixing Plane 5 > 1000

Centrifugal Pump - Cavitation increase on suction side of the impeller with decreasing NPSH

NUMECA International

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Tel: +32.2.647.83.11 - Fax: +32.2.647.93.98 email: [email protected] - http://www.numeca.com

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