Design Process with AxSTREAM

Step 1: Basic inputs

– Input a set of boundary conditions, geometrical parameters and constraints that are known to the user.

Step 2: Design space generation

– Thousands of machine flow path designs can be generated from scratch
–  Explore a set of design solution points using the Design Space Explorer
–  Adjusting geometric parameters while retaining the desired boundary conditions is also possible

Preliminary Design
Figure 1: Design space
Post design geo modification B
Figure 2:  Post design geometry modification

Step 3: Streamline solver

– Determine streamwise and spanwise distribution of kinematics, thermodynamics and loss parameters as well as leakages and secondary air flows (including bleed) for a given set of boundary conditions.

Figure 3: Throughflow analysis window

Step 4: Optimization and performance maps generation

– Optimize the design using a DOE approach (Design of Experiment)
– Generate performance maps (and compare against previous results or experimental data) for any number of variables with AxMAP.

 

Figure 4: 3D Optimization Surface (DoE approach)
Figure 5: 2D map curves for off-design performance analysis

Step 5: 3D profiling

– Profiling of the 3D blades is done through inlet and outlet geometric parameters, beta, theta and channel thickness distributions for each of up to 49 spanwise sections while providing interactive and automatic visualization of the changes on the blade geometry while recalculating the outlet flow angle.
– Different profiling modes are available to ensure flexibility of the geometry editing for 3D blades, with interactive displays of the blade curvature which ensures a smooth surface therefore helping prevent flow separation and minimize losses.
– Blade re-staggering can also be performed to study how the throat area gets affected to allow for more or less flow rate. This re-staggering can even be optimized based on the rotation speed using user-defined rotation schedules.

Figure 6: 3D profiling
Figure 7: 3D geometry

Step 6: CFD and FEA

– An automated turbomachinery-specific, structured hexagonal meshing by customizable blocks is available for computational domain division.
– Select the problem formulation depending on whether you desire to calculate a pressure value (inlet or outlet) or the machine mass flow rate. Viscosity and different turbulence models (including k-ε, k-ω, k-ε RNG, k-ω SST) can be used for new calculations or to resume existing ones.
– Export of CFD results allows comparisons at design and off-design conditions between different calculations using the same or different solvers (1D, 2D, 3D) as well as experimental results.
– Import CFD loads for structural calculations and centrifugal, pressure and thermal loads can also be accounted for at design and off-design conditions.
– Perform static, modal, harmonic, “hot-to-cold” and “cold-to-hot” analysis, as well as Campbell and interference diagrams with AxSTRESS.

Figure 8: CFD
Figure 9: Structural analysis results

And this is just the beginning. Users can export flow path and stress analysis results and design the shaft of the machine with RotorDesigner module. Then, lateral and torsional analysis of the shaft can be performed including bearings properties with the use of Rotordynamics and Bearings modules. In addition, for cooling flows, secondary systems and hydraulics, AxSTREAM NET can be employed and with the use of our ION module, all the modules (as well as external software) can be wrapped under the same optimization/project scenario. If this is not complete, then what is? Ask a member of our team to demonstrate the capabilities of AxSTREAM live!

Figure 10: Rotordynamics analysis
Figure 11: Cooling scheme of entire gas turbine
Figure 12: Off design calculation of cooled gas turbine engine made in AxSTREAM ION

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