Centrifugal Pump Impeller Design with the FRIENDSHIP-Framework

1. Background why using FRIENDSHIP-Framework / Strategy 2. Centrifugal Impeller Design 3. Impeller Modeling within the FRIENDSHIP-Framework 4. Some CFD Results as an Example

Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Why using FRIENDSHIP-Framework?

Background / Strategy
Need of universal optimization tool with variation management for using with CFD and FEM software
Usage in: Preliminary design process Internal CAD System with special parametric modeling techniques

And in daily work

Coupling with external CAD Software planned, no remodeling necessary Meet requirements of industrial standards (ASME Code), CAD data consistency Evaluation process for small and middle sized optimization projects successfully finished Coupled Software today: ICEM CFD, ANSYS CFX Linux Operating System
2 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Centrifugal Pump Impeller

Modeling within Friendship-Framework

Starting as an attempt to check possible limitations of the Framework

Challenge: Great number of possible designing parameters Reducing calculation designs by geometrical evaluation and exclusion Evaluation by experience "Geometric Optimization before Flow Calculation" Start up phase

Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Centrifugal Pump Impeller

Working Principle
Distinction of velocities regarding frame of reference, absolute or relative frame Movement of particles in relative frame along path lines similar to blade shape Absolute movement result of superposition of relative flow and rotating speed of impeller Associated with velocity and pressure changing

Meridian section

Cross section
4 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Meridional Section

Shroud Curve

Relations
m r 2 z 2
m u

Development of cross section area

Radial Pump Impeller Design

m
r

Short Overview
u r

tan

Meridional Section Shaping hub and shroud curves for continuously varying of cross sections Defining leading and trailing edge

Camber line development

z
Hub Curve

m r tan

Camber Line Starting by defining blade angle at trailing edge Step by step development of the camber line along meridian streamlines in circumferential direction Defining blade angle distribution to meet given leading edge 2D description by conformal mapping

Blade angle distribution

Conformal Mapping

3D camber line

m u
L

Blade Profile

Blade Profile Offset mean camber surface

Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Centrifugal Pump Impeller

CFD-Setup
Overview Automatic procedure by bash scripting

Hexahedral mesh ICEM CFD blocking technique Use of replay files

Viscous flow solver ANSYS CFX About 250000 elements Steady state, turbulent Use of sessions files Geometry requirements Rotational periodic Always same labeling of points and curves
6 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Modeling

Meridian Section
Middle Line

Hub and Shroud modeling with Fsplines

Shroud Curve Changing of cross section area

Brent Design Engine for determination of cross section and middle line Determination of shortest distance Meridian variation by modifying area of Fspline Design criteria: Course of cross section area

Hub Curve

Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Modeling
Camber surface Development direction

Camber Line / Surface

Define blade angle distribution in a feature with a Fspline Pointwise development of the camber line in a feature with input of meridional section and angle curve To meet given leading edge position: Find corresponding area below angle distribution Now: Manual Later: Automatic

Conformal Mappings

m 1
mtarget

Lofted surface to generate camber surface

Camber lines
Blade angle distributions

Design criteria: Angle distribution

8 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Definition

Enlarging / Intersection

Blade Surface

Modeling

Blade Profile
Feature for generation profile curves Offset points perpendicular alongside chamber surface Interpolation curve Lofted surface over profile curves Gaps to hub and shroud
Intersection Problem

Enlarging temporary blade profile surface and generating intersection curves with hub and shroud for final blade surface

Sometimes problems with surface intersection curves (each tenth) Depends on interpolated points and start option
9 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Export Curves

Modeling

CFD Domain and Calculation

Additional work for coupling with ICEM CFD Benefit: High quality hexahedral meshes Less time for automatic mesh generation Building CFD Domain with separate curves for IGES export
Export Surfaces

Curve splitting for blocking associations

Optimization process by Generic Integration

Setup of two Computations for mesh generation and CFD Model setup External program start of ICEM CFD in batch mode and execution of bash script for CFX setup Start CFD calculation for different flow rates by Perl script Evaluations of tables and pictures
10 Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Results
Efficiency

Evaluation of Pump Characteristic Curves

Design parameter: Varying of blade angle distribution Variant management within Framework only for single pump operating point (BEP) Data collecting and plotting with bash script Curve plotting with Gnuplot Small influence of blade angle distribution on efficiency, significant influence on pump head

Design Parameter

Head

Flow Rate

Single Pump Operating Point

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Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Results

Example Impeller Flow

Comparison of two blades with different blade angle distribution
Blade to blade view

Meridional view

Post Processing in ANSYS CFD Post Pictures are examples which could be imported into the Framework

To improve
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Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm

Prospect and

Conclusion
Conclusion Modeling of high quality Centrifugal Pump Impellers is possible Finding the solution for defining blade profile most difficult Some problems with Surface Intersection Curves Prospect

Using the Framework

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Centrifugal Pump Impeller Design with the Friendship Framework |Toni Klemm