Unlock the secrets of efficient blade modeling with our step-by-step workflow guide, designed to take you from initial geometry to advanced simulation seamlessly.
Challenges
The process of blade modeling presents several challenges. One of the primary difficulties is capturing the intricate geometry accurately. Blade designs often feature complex curves and fine details that need precise modeling to ensure performance and reliability.
Another significant challenge is transitioning from geometry to a mesh that is suitable for simulation. The meshing process requires careful consideration to balance detail and computational efficiency. Inadequate meshing can lead to inaccurate simulation results, while overly detailed meshes can cause prohibitive computational costs.
Finally, simulating the blade’s performance under various operating conditions is crucial. This stage must account for factors like aerodynamic forces, material stresses, and thermal effects, each requiring specialized simulation approaches and tools.
Engineering Solution
To address these challenges, a structured workflow is essential. Ansys provides all the necessary tools for each step of the workflow shown in Figure 1.
Figure 1. The Blade modeling workflow from the geometry generation to simulation
The corresponding Workbench project may look like this (Figure 2):
Figure 2. The Workbench project of the blade modeling workflow
There are several key actions to be taken in all of these steps.
1. The blade modeling from the initial CAD model requires on working at zx-plane view and creating sketches to describe the flow path.
2. The fillets on the initial CAD model needs to be eliminated while trimming the blade. The fillet will be added in the second geometry session where the new generated blade CAD file will be loaded.
3. The blade design, including the number of blades and blade profiles can be adjusted in the second geometry session (Figure 3).
Figure 3. The blade design modifications
4. The TurboGrid session needs to be "updated" after connected the Design Modeler. This will create an initial mesh structure which can always be modified (Figure 4)
Figure 4. The TurboGrid session
5. The "Turbo Mode" in CFX session creates the turbomachinery model settings seamlessly (Figure 5)
Figure 5. The CFX session
6. The "Turbo" option of CFD-Post helps to generate blade-to-blade views at different spans. Furthermore, additional instants can be added to make the full 3D aspect of the model.
Figure 6. The CFD-Post session
Benefits
Ansys has all the necessary tools of blade modeling!
Implementing a detailed and structured blade modeling workflow offers several benefits. Firstly, it enhances the accuracy of the design, ensuring that the blade meets performance and reliability standards. Accurate modeling and simulation help in predicting real-world behavior, reducing the risk of failure.
Secondly, this workflow improves efficiency. By optimizing the meshing process and using advanced simulation tools, engineers can reduce the time and computational resources required, speeding up the development cycle.
Lastly, a robust blade modeling process supports innovation. With reliable simulation results, engineers can explore new designs and materials with confidence, leading to better-performing blades and competitive advantages in the market.
The details of the workflow can be found in the following YouTube videos:
The YouTube videos can be reached with the following links:
Ozen Engineering Expertise
Ozen Engineering Inc. leverages its extensive consulting expertise in CFD, FEA, optics, photonics, and electromagnetic simulations to achieve exceptional results across various engineering projects, addressing complex challenges like multiphase flows, erosion modeling, and channel flows using Ansys software.
We offer support, mentoring, and consulting services to enhance the performance and reliability of your mining equipment and systems. Trust our proven track record to accelerate projects, optimize performance, and deliver high-quality, cost-effective results for both new and existing systems. For more information, please visit https://ozeninc.com.