MultiObjective Design and Optimization of Turbomachinery: Coupled CFD and FEA

Optimizing the simulation driven design of turbomachinery such as compressors, turbines, pumps, blowers, turbochargers, turbopumps, centrifugal compressors, radial turbines, hydraulic turbines, low speed to transonic fans and torque converters offers enormous potential. Esimlab’s engineering team performs all stages of design and optimization of turbomachinery at the 1D, 2D and 3D levels including 3D blade design, FEA and CFD analysis. Our experience covers all branches of turbomachinery design and related fields of knowledge including: aerodynamics, hydraulics, thermodynamics, structural, Computational Fluid Dynamics and Finite Element Analysis.

Esimlab Engineering Services team is composed of highly skilled turbomachinery design and analysis engineers ready to support and complement your design needs. Whether you need a complete study or are facing challenging multi-point / multi-objective design objectives, our team will be able to support your requirements by application of coupled CFD, FEA and 1D System softwares.

The world class engineering services team at Esimlab possesses a wealth of knowledge in theoretical, academic, and in-the-field experience. This depth of expertise enables us to provide exceptional consulting services for design and optimization in any R&D and Industrial fields.

From the initial concept to the completed 3D model and all the steps in between them, we are here to assist. We Use CFD tools such as Ansys Fluent and Siemens Star-ccm+ and FEA Tools such as Abaqus,  LS-DYNA and MSC Nastran with combination of very experineced engineers to help our customers in:

  • Project Definition and Technical Specifications
  • Preliminary Design & Feasibility Studies
  • Research & Development
  • Analysis of Existing Machines
  • Heat Transfer Simulations
  • Rotor Dynamics
  • Aerodynamic Design
  • Re-design Services
  • CFD Analysis
  • Finite Element Structural Analysis (FEA) for stress and vibration analysis.
  • Aeroacoustic and noise Modelling
  • Aeroelastic Design & Analysis
  • Design of Experiments and Automatic optimization methodology (e.g Simplex, Simulated annealing, Genetic algorithm and Tabu search).

Where Scientific Computing Meets Complicated Industrial Needs

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Turbine, Pump and Compressor (Axial or Centrifugal): Multidisciplinary Turbomachinery Design, Analysis and Optimization

Starting from the preliminary design, our engineers progresses through a 1D inverse task solver optimizer, to continue with meanline (1D) and axisymmetric (2D) analysis, profiling and 3D blade design, 3D finite element analysis (FEA) for structural calculations, secondary air flow hydraulic and thermal calculations (including cooling), rotor design, bearing analysis, rotor dynamics and 3D CFD calculations. We can design axial turbines, Axial Pump, Centrifugal Compressor, Centrifugal Pump and Mixed Flow Compressor/Turbine with or without any pre-loaded profiles, with prismatic (cylindrical) or twisted blades, multiple extractions/injections, inter-stage heat exchangers, Curtis & Rateau stages, impulse & reaction designs, drilled and reamed nozzles, partial admission, etc. Control stages can even be designed with the backpressure optimized for overall machine efficiency.:

  • Analyze existing turbine, pump and Compressor (axial or centrifugal) and their performance at design and off-design conditions
  • Redesign, optimize, rerate and upgrade existing turbine, pump and Compressor (axial or centrifugal)/components
  • Reverse engineer turbine, pump and Compressor (axial or centrifugal) designs
  • Troubleshoot and correct efficiency/reliability issues in existing hardware
  • Optimize cooling configuration and flows for new and existing turbine, pump and Compressor (axial or centrifugal)
  • Aero-thermodynamic calculations of blades and endwalls cooling taking into account the mixing losses and the change of working fluid temperature
  • Determine streamwise and spanwise distribution of kinematics, thermodynamics and loss parameters as well as leakages and secondary air flows (including cooling) for a given set of boundary conditions.
  • Turbine, pump and Compressor (axial or centrifugal) flow optimization calculations including through the use of a DOE approach (Design Of Experiment)
  • Aerodynamic shape optimization of turbomachinery blades to express 3D structural, modal and harmonic analysis using a finite element analysis (FEA) method.
  • Computational Fluid Dynamics (CFD) software used for 3D flow analysis in blade-to-blade channels of  turbine, pump and Compressor (axial or centrifugal), for subsonic, transonic and supersonic flows, using full 3D CFD formulation (Navier-Stokes, viscous with various turbulence models (standard k-e, k-e RNG, k-w, k-w SST models)).
  • Turbine, pump and Compressor (axial or centrifugal) Bearing Analysis and Design
  • Steady-state, transient, and map analysis to calculate the bearings different hydrodynamic and mechanical characteristics
  • Turbine, pump and Compressor (axial or centrifugal) Cooling Flows & Secondary Systems Design and simulation

Our engineering experts have been performing rotor dynamic analysis and working to ensure that no destructive vibrations will occur in the rotor-bearing-support system. We can carry out extremely complicated studies related to unbalanced rotating mass behavior to save you precious time:

  • Calculations of lateral, axial, and torsional vibrations
  • Campbell diagram analysis for damped and undamped systems
  • Unbalance or transient response calculations
  • Computation of rotor system with clearances, full and partial rubbing, external and internal friction, and definition of instability thresholds
  • Computation of rotor system with nonlinear journal/rolling bearings, squeeze-film dampers, and other types of rotor studies

FEA and CFD Analysis for Turbomachinery: Turbine, Pump and Compressor

The range of our analytical capabilities is unmatched in the consulting industry, particularly in the area of Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) analysis. Our engineering team uses the latest FEA and CFD tools and methodologies to determine product configuration and perform optimization, cost and weight reduction, life prediction, system performance evaluation, and failure investigation of mechanical systems. Our engineers are well-versed in many analysis applications, including FEA and CFD.

Esimlab’s engineering team use CFD software’s  such as Siemens Star-ccm+, Ansys Fluent and Numeca Fine/Turbo in co-simulation with FEA structural solvers, such as Abaqus, Ansys and MSC Nastran. Our team is ready to accept any challenge in fluid dynamics and FEA simulation:

Finite Element Analyses:
  • Linear and Non-Linear
  • Static, Dynamic and Seismic
  • Thermal (Steady-State and Transient)
  • Cyclic Fatigue and Fracture Mechanics
  • Coupled field CFD-Thermo-Structural (Steady State and Transient)
 
CFD/Aero-Thermo Dynamics Analysis:
  • Compressible, incompressible and supersonic flows
  • Laminar and turbulent flows
  • Flows with conjugate heat transfer
  • Multiphase flows
  • Engine installation and ventilation
  • Combustion systems
  • Turbomachinery design
Fatigue/Fracture Mechanics:
  • Hand calculations
  • Goodman assessment
  • Low-Cycle Fatigue (LCF)
  • High-Cycle Fatigue (HCF)
  • Crack growth
  • Residual life
 
Bearings/Seals Simulation:
  • Journal, Thrust Bearings
  • Fixed and Tilting Pad Geometries
  • Ball Bearings
  • Incompressible and Compressible Lubricants
  • Gas Foil Bearings
  • Hydrodynamic, Hydrostatic, or Hybrid
  • Squeeze Film Dampers
  • Annular Seals
Rotor Dynamic Analysis:
  • Drive systems
  • Critical speed
  • Lateral and Torsional Natural Frequency and Corresponding Modes Shape (damped and undamped)
  • Stability Analysis
  • Unbalance Response (variable speed)
  • Time-Transient Response (torsional)
 

Heat Transfer Simulations for Turbomachinery including FSI effect with FEA and CFD

For real world simulation, many elements have to be taken into consideration, in particular, the diversity of flow configurations and applications; the complexity of geometries and physics, the requirements for multidisciplinary analysis and optimization including conjugate heat transfer (CHT) coupling flow and heat transfer: fluid-structure interactions (FSI); fluid-chemistry and multiphase interactions, as in combustion; aero-acoustics coupling flow and noise.

Most machines, such as high-heat turbines (gas and steam), boilers, and combustors for example, require strict control of thermal stresses and expansions. Due to the very particular nature of heat transfer, establishing this control can be both tedious and time consuming.  With using CFD tools such as Numeca Fine/Turbo, Ansys Fluent, Siemens Star-ccm+ and FEA Tools such as Abaqus, Nastran and LS-DYNA with experineced engineers, we can calculate parameters of heat transfer between components and outer and inner gas flow to determine temperatures, relative thermal displacements, and thermal stresses.

We can calculate a wide spectrum of heat-related calculations, including startup and shutdown cycles, thermal warp effects on static elements (casings and exhaust hoods), on shafts, heat transfer analysis, warp and displacement of ceilings. We can also help you calculate predictions of a machine’s behavior on transient operational modes with high-fidelity modeling, closer to the real behavior of products..

Highly complex turbomachinery geometry shape optimization using advanced CFD and FEA tools

Esimlab’s engineering team optimizes complex geometries with respect to given targets, such as total pressure loss and velocity uniformity with use of advanced simulation tools such as Star-ccm+, Ansys Fluent and Numeca Fine/Turbo.  It does so by computing the sensitivities of the geometry itself versus those targets and then modifying it. The sensitivity information comes directly from the flow field so the optimized shape is the one that fits the given flow best. Unlike traditional design methods that rely on trial and error between a given geometry and flow field predicted by CFD codes, we use 3D inverse design method starts by identifying what we want to do to the fluid flow in terms of 3D pressure field and mathematically derives the optimal geometry to achieve that outcome. This significantly reduces the time taken for each design.

  • Complex geometries sensitivity analysis and optimization, providing designs with improved performance.
  • Innovative design
  • Accurate mathematical approach drives the design to the best shape.
  • 3D Inverse Design method that uses fluid dynamics to directly generate optimum blade shape
  • Including secondary flows, corner separations, tip clearance flow, cavitation, and shock in design of turbomachinery
  • Multi-point/multi-disciplinary optimization of all types of turbomachinery
CFD and FEA consultant at ESimLab

We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

Do you need more information or want to discuss your project?

Reach out to us anytime and we’ll happily answer your questions
Contact us