Professional Documents
Culture Documents
Introduction
Film cooling is a process that is used to protect turbine vanes in a gas turbine engine from
exposure to hot combustion gases. This tutorial illustrates how to set up and solve a film
cooling problem using a non-conformal mesh. The system that is modeled consists of
three parts: a duct, a hole array, and a plenum. The duct is modeled using a hexahedral
mesh, and the plenum and hole regions are modeled using a tetrahedral mesh. These two
meshes are merged together to form a hybrid mesh, with a non-conformal interface
boundary between them.
Due to the symmetry of the hole array, only a portion of the geometry is modeled in
ANSYS FLUENT, with symmetry applied to the outer boundaries. The duct contains a
high-velocity fluid in streamwise flow (Figure 7.1). An array of holes intersects the duct
at an inclined angle, and a cooler fluid is injected into the holes from a plenum. The
coolant that moves through the holes acts to cool the surface of the duct, downstream of
the injection. Both fluids are air, and the flow is classified as turbulent. The velocity and
temperature of the streamwise and cross-flow fluids are known, and ANSYS FLUENT is
used to predict the flow and temperature fields that result from convective heat transfer.
This tutorial demonstrates how to do the following:
Merge hexahedral and tetrahedral meshes to form a hybrid mesh.
Create a non-conformal mesh interface.
Model heat transfer across a non-conformal interface with specified temperature
and velocity boundary conditions.
Calculate a solution using the pressure-based solver.
Plot temperature profiles on specified isosurfaces.
Prerequisites
This tutorial is written with the assumption that you have completed Tutorial 1, and
that you are familiar with the ANSYS FLUENT navigation pane and menu structure.
Some steps in the setup and solution procedure will not be shown explicitly.
7-1
Problem Description
This problem considers a model of a 3D section of a film cooling test rig. A schematic
of the problem is shown in Figure 7.1. The problem consists of a duct, 49 in long,
with cross-sectional dimensions of 0.75 in 5 in. An array of uniformly spaced holes is
located at the bottom of the duct. Each hole has a diameter of 0.5 inches, is inclined at
35 degrees, and is spaced 1.5 inches apart laterally. Cooler injected air enters the system
through the plenum having cross-sectional dimensions of 3.3 in 1.25 in.
Only a portion of the domain needs to be modeled because of the symmetry of the
geometry. The bulk temperature of the streamwise air (T ) is 450 K, and the velocity
of the air stream is 20 m/s. The bottom wall of the duct that intersects the hole array
is assumed to be a completely insulated (adiabatic) wall. The secondary (injected) air
enters the plenum at a uniform velocity of 0.4559 m/s. The temperature of the injected
air (Tinject ) is 300 K. The properties of air that are used in the model are also mentioned
in Figure 7.1.
0.5 in
0.5 in
9.5 in
24 in
v = 20 m/s
T = 450 K
5 in
y
1.25 in
1.25 in
x
35
Hole1
Hole2
Plenum1
Plenum2
3.3 in
FRONT VIEW
v = 0.4559 m/s
Tinject = 300 K
v = 0.4559 m/s
Tinject = 300 K
z
x
49 in
8
T = 450 K
0.75 in
0.5 in
TOP VIEW
= 0.000017894 kg/ms
Cp = 1006.43 J/kgK
7-2
Step 1: Mesh
1. Read the hex mesh file film hex.msh.
File Read Mesh...
2. Append the tet mesh file film tet.msh.
Mesh Zone Append Case File...
The Append Case File... functionality allows you to combine two mesh files into one
single mesh file.
3. Check the mesh.
General Check
ANSYS FLUENT will perform various checks on the mesh and report the progress
in the console. Make sure that the reported minimum volume is a positive number.
7-3
(a) Make sure that Convert Units is selected in the Scaling group box.
(b) Select in from the Mesh Was Created In drop-down list by first clicking the
down-arrow button and then clicking the in item from the list that appears.
(c) Click Scale to scale the mesh.
Domain Extents will continue to be reported in the default SI unit of meters.
(d) Select in from the View Length Unit In drop-down list to set inches as the
working unit for length.
(e) Close the Scale Mesh dialog box.
5. Check the mesh.
General Check
Note: It is a good idea to check the mesh after you manipulate it (i.e., scale,
convert to polyhedra, merge, separate, fuse, add zones, or smooth and swap.)
This will ensure that the quality of the mesh has not been compromised.
6. Display an outline of the 3D mesh.
General Display...
(a) Retain the default selections in the Surfaces list.
(b) Click Display.
(c) Close the Mesh Display dialog box.
7-4
7. Manipulate the mesh display to obtain a front view as shown in Figure 7.2.
Graphics and Animations Views...
(a) Select front in the Views list.
(b) Click Apply.
(c) Close the Views dialog box.
Y
Z
Mesh
7-5
8. Zoom in using the middle mouse button to view the hole and plenum regions
(Figure 7.3).
In Figure 7.3, you can see the quadrilateral faces of the hexahedral cells that are
used to model the duct region and the triangular faces of the tetrahedral cells that
are used to model the plenum and hole regions, resulting in a hybrid mesh.
Extra: You can use the right mouse button to check which zone number corresponds to each boundary. If you click the right mouse button on one of the
boundaries in the graphics window, its zone number, name, and type will be
printed in the ANSYS FLUENT console. This feature is especially useful when
you have several zones of the same type and you want to distinguish between
them quickly.
7-6
Step 3: Models
Models
1. Enable heat transfer by enabling the energy equation.
Models
Energy Edit...
7-7
Viscous Edit...
7-8
Step 4: Materials
Materials
1. Define the material properties.
Materials
Fluid Create/Edit...
(a) Retain the selection of air from the FLUENT Fluid Materials drop-down list.
(b) Select incompressible-ideal-gas law from the Density drop-down list.
The incompressible ideal gas law is used when pressure variations are small
but temperature variations are large. The incompressible ideal gas option for
density treats the fluid density as a function of temperature only. If the above
condition is satisfied, the incompressible ideal gas law generally gives better
convergence compared to the ideal gas law, without sacrificing accuracy.
(c) Retain the default values for all other properties.
(d) Click Change/Create and close the Create/Edit Materials dialog box.
7-9
7-10
fluid-9 Edit...
fluid-8 Edit...
fluid-9.1 Edit...
7-11
velocity-inlet-1 Edit...
7-12
2. Set the boundary conditions for the first injected stream inlet (velocity-inlet-5).
Boundary Conditions
velocity-inlet-5 Edit...
7-13
3. Copy the boundary conditions set for the first injected stream inlet.
Boundary Conditions
velocity-inlet-plenum1 Copy...
7-14
Copying a boundary condition does not create a link from one zone to
another. If you want to change the boundary conditions on these zones,
you will have to change each one separately.
4. Set the boundary conditions for the second injected stream inlet (velocity-inlet-6).
Boundary Conditions
velocity-inlet-6 Edit...
7-15
pressure-outlet-1 Edit...
7-16
6. Retain the default boundary conditions for the plenum and hole walls (wall-4 and
wall-5).
Boundary Conditions
wall-4 Edit...
7-17
7. Verify that the symmetry planes are set to the correct type in the Boundary Conditions task page.
Boundary Conditions
7-18
7-19
(a) Select wall-1 in the Zone list and select interface as the new Type.
Boundary Conditions
A Question dialog box will open, asking if it is OK to change the type of wall-1
from wall to interface. Click Yes in the Question dialog box.
The Interface dialog box will open and give the default name for the newly
created interface zone.
7-20
When one interface zone is smaller than the other, choose the smaller zone
as Interface Zone 1.
7-21
interface-hole2, and interface-duct boundary zones. They are listed under Boundary Zone 1 in the Create/Edit Mesh Interfaces dialog box. These wall boundaries
are empty, since interface-hole1 and interface-hole2 are completely contained
within the interface-duct boundary.
wall-26 is the non-overlapping region of the interface-duct zone that results from
the intersection of the three interface zones, and is listed under Boundary Zone
2 in the Create/Edit Mesh Interfaces dialog box.
You will not be able to display these walls.
You need to set boundary conditions for wall-26 (since it is not empty). In
this case, the default settings are used.
Step 9: Solution
1. Set the solution parameters.
Solution Methods
(a) Select Second Order Upwind from the Momentum, Turbulent Kinetic Energy, Turbulent Dissipation Rate, and Energy drop-down lists in the Spatial Discretization
group box.
7-22
Residuals Edit...
7-23
7-24
7-25
(a) Click Default in the Actions group box and close the Views dialog box.
2. Display filled contours of static pressure (Figure 7.5).
Graphics and Animations
7-26
1.69e+02
1.57e+02
1.45e+02
1.33e+02
1.21e+02
1.09e+02
9.72e+01
8.53e+01
7.33e+01
6.13e+01
4.93e+01
3.73e+01
2.54e+01
1.34e+01
1.40e+00
-1.06e+0
-2.26e+0
-3.45e+0
-4.65e+0
-5.85e+0
-7.05e+0
Y
Z
7-27
7-28
(a) Select Temperature... and Static Temperature from the Contours of drop-down
lists.
(b) Disable Auto Range in the Options group box so that you can change the
maximum and minimum temperature gradient values to be plotted.
(c) Enter 300 for Min and 450 for Max.
(d) Disable Clip to Range in the Options group box.
(e) Make sure that, interface-duct, interface-hole1, interface-hole2, symmetry-1, symmetrytet1, symmetry-tet2, wall-4, and wall-5, are selected from the Surfaces selection
list.
(f) Click Display and close the Contours dialog box.
(g) Zoom in on the view to get the display shown in Figure 7.9.
Figures 7.8 and 7.9 clearly show how the coolant flow insulates the bottom of
the duct from the higher-temperature primary flow.
7-29
7-30
(a) Make sure Velocity... and Velocity Magnitude are selected from the Color by
drop-down lists.
(b) Enable Auto Range in the Options group box
(c) Enter 2 for the Scale.
This enlarges the displayed vectors, making it easier to view the flow patterns.
(d) Make sure that, interface-duct, interface-hole1, interface-hole2, symmetry-1, symmetrytet1, symmetry-tet2, wall-4, and wall-5, are selected from the Surfaces selection
list.
Use the scroll bar to access the surfaces that are not initially visible in the
dialog box.
(e) Click Display and close the Vectors dialog box.
(f) Zoom in on the view to get the display shown in Figure 7.10.
In Figure 7.10, the flow pattern in the vicinity of the coolant hole shows the level of
penetration of the coolant jet into the main flow. Note that the velocity field varies
smoothly across the non-conformal interface.
7-31
5. Create an isosurface along a horizontal cross-section of the duct, 0.1 inches above
the bottom, at y = 0.1 in.
Surface Iso-Surface...
7-32
(a) Select Mesh... and Y-Coordinate from the Surface of Constant drop-down lists.
(b) Enter 0.1 for Iso-Values.
(c) Enter y=0.1in for New Surface Name.
(d) Click Create.
(e) Close the Iso-Surface dialog box.
6. Create an XY plot of static temperature on the isosurface created (Figure 7.11).
Plots
(a) Retain the default values in the Plot Direction group box.
(b) Select Temperature... and Static Temperature from the Y-Axis Function dropdown lists.
(c) Select y=0.1in in the Surfaces selection list.
Scroll down using the scroll bar to access y=0.1in.
(d) Click Plot.
In Figure 7.11, you can see how the temperature of the fluid changes as the
cool air from the injection holes mixes with the primary flow. The temperature
is coolest just downstream of the holes. You can also make a similar plot on
the lower wall to examine the wall surface temperature.
(e) Close the Solution XY Plot dialog box.
7-33
Summary
This tutorial demonstrated how the non-conformal mesh interface capability in ANSYS
FLUENT can be used to handle hybrid meshes for complex geometries, such as the film
cooling hole configuration examined here. One of the principal advantages of this approach is that it allows you to merge existing component meshes together to create a
larger, more complex mesh system, without requiring that the different components have
the same node locations on their shared boundaries. Thus, you can perform parametric studies by merging the desired meshes, creating the non-conformal interface(s), and
solving the model. For example, in the present case, you can do the following:
Use a different hole/plenum mesh.
Reposition the existing hole/plenum mesh.
Add additional hole/plenum meshes to create aligned or staggered multiple hole
arrays.
Further Improvements
This tutorial guides you through the steps to reach an initial solution. You may be able
to obtain a more accurate solution by using an appropriate higher-order discretization
scheme and by adapting the mesh. Mesh adaption can also ensure that the solution is
independent of the mesh. These steps are demonstrated in Tutorial 1.
7-34