Rotating Machinery
Multi-physics solutions for complex rotating machines
Rotating machinery is seen a wide variety of industries ranging from aerospace, automotive, marine, nuclear, energy and other everyday applications.

The complex physics of rotating machinery includes aerodynamics, blade cooling, strength and durability, flutter and noise, resulting in the need for a multi-physics simulation tool to effectively analyze the rotating machinery early in the design phase.

Being one of the most challenging applications of simulation methodologies, STAR-CCM+ naturally offers simulation solutions for various rotating machinery applications such as turbo-machinery and hydropower, compressors, turbines, pumps, impellers, turbochargers, HVAC blowers, under-hood cooling fans, propellers, gas turbines and wind turbines.

Types of machinery and flows that can be handled by STAR-CCM+ include axial/radial, steady/transient/periodic, row/stage/multi-stage and primary/internal/secondary/leakage flows.

The key enabling technology for rotating machinery in STAR-CCM+ is the Harmonic Balance Method, a feature not available in any other commercial simulation package.

The Harmonic Balance method allows for rapid computation of periodic, unsteady rotating machinery flows by recasting the governing equations in the frequency domain.

The advantages of this technology include 10x faster than time-domain solutions, single passage mesh, capture of blade row interaction and computational cost independent of relative blade count.

This method can be successfully used to simulate blade row interaction, single row flutter, multi-stage interaction and flutter. STAR-CCM+ also provides fan models including fan momentum source method and fan interface method. In addition, there are models to reduce computational cost for rotating machinery like Moving Reference Framesand Virtual Blade Model inside STAR-CCM+.

A brief of different rotating machinery objectives that can be achieved using STAR-CCM+ is given below:

Performance mapping

This is the most common application of simulation for rotating machinery. Performance mapping refers to the determination of the efficiency of a machine. STAR-CCM+ provides the cost-effective Harmonic Balance method and capabilities for Efficiency Optimization using Optimate+, an add-on Optimization module with rotating machinery specific post-processing capabilities.

Aeroelastic response

Traditional simulation methods for aeroelastic response present many challenges including long run times, meshing the entire machine, challenges in specifying blade vibration and extracting stability information. The Harmonic Balance Method resolves all these challenges in a cost-effective way.

Conjugate heat transfer (CHT)

STAR-CCM+ offers easy-to-use, automated conformal meshing for CHT analyses with polyhedral cells and automated prism layer generation. Other features like direct CAD import and 3D CAD editing, in addition to a complete suite of thermal simulation models enables CHT simulations in a very efficient manner in housings, casings and internal cooling of blades.

Other application areas include aeroacoustics, aeroelasticity, transitional flows, combustion, fuel injection, casting and blade flutter.

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