Welcome again to Ansys Simulation World my

name is Sunil

Patil and I'm an industry leader for

turbomachinery and propulsion

and I'm going to present our solution for gas

turbines

The exist significant challenges for gas

turbine design and development such

as environmental regulations covering

emissions and noise a race to

increase the performance at the same time

maintaining or increasing durability life and

safety of the engine

and there is always pressure to reduce the

cost and

time to market

The first four of these challenges are

typically addressed during

the design phase

But we also want to make sure the engines

performed

well during the operation phase with the

minimal downtime possibly

with predictive maintenance rather than

traditional preventive maintenance

Over the years simulations have made a

significant impact on

gas turbine design and development

Companies have used simulation to increase

the performance by reducing

fuel burn up to 15%

Simulations have been used to reduce the

design cycle time

up to 33%

And simulations have been used also for cost

reduction

by 30% by reducing physical testing

There are many real life stories on how

simulations have

impacted gas turbine design and development

Ansys provides a range of capabilities to

realize the benefits mentioned

in previous video and slides

Some of these capabilities related to gas

turbines are digitalization

industrial Internet of Things materials

additive manufacturing aerodynamic performance

aerothermal

acoustics combustion

structural durability and reliability process

compression robust design and optimization

foreign object damage and icing

Ansys capabilities for digitalization and

IoT address the engineering

challenge to reduce the unplanned downtime

through simulation based

digital twin

In the video being played at the right bottom

you

will see the simulation based digital twin of

a turbomachinery

system where the critical components of the

system such as

electric motor compressor drive and control

systems are represented through

a reduced order model

and these ROMs are connected intelligently to

represent the system

performance

Further it is connected to an IoT platform

which is SAP

in this case to provide real time engineering

insights on

health and condition of the machine

For gas turbine this means prediction of the

engine maintenance

improvement of engine lifetime and efficiency

improvement of overall system

performance and reliability

Ansys provides comprehensive simulation

platform for additive manufacturing

Topology optimization in Ansys Aechanical or

Discovery helps lightweighting parts

We have workflow to generate geometry and

physics based supports

which really helps to reduce the build time

and also

reduce the support cost

Also we can do print process simulations

while accounting for

residual stresses which really helps in getting

the build right

the first time itself

Structural and aero analysis are so critical

and fundamental in

gas turbine design and development so I'm

going to talk

about this in more detail

in next few slides Ansys Mechanical enables

you to work

with multidimensional geometries to reduce

the simulation time

For example you can extract in a semi

automated manner

an axisymmetric model for the whole engine

to perform lots of analysis in early design

stages calculations

such as the duty cycle analysis then you can

transition

to 3D but with cyclic symmetry for a single

row

or multiple stages

and then transition to full 3D model as

needed

Ansys Workbench also provides streamlined

workflows for couple thermomechanical analysis

as you can see in this image on the top

right

It can also include 1D network to represent

fluid flows

within turbine and that is important for

doing something like

whole engine modeling

And these workflows I'm talking

can be used for the steady as well as

transient

analysis

Ansys Mechanical provides advanced solver

capabilities

required to understand the structural

behavior of turbines such as

highly accurate contact analysis to capture

fine interaction between the

parts complex nonlinear material to capture

thermo mechanical fatigue effects

inverse analysis for hot to cold geometry

analysis rotordynamics fracture

analysis including crack propagation

vibration for force response analysis for

a tuned or even a mistuned system to account

for manufacturing

imperfections

Some of the critical or catastrophic events

for aircraft engines

can be foreign object damage or both strike

and fan

blade out

These critical events can be modelled using

Ansys explicit dynamic

solutions

It can couple multiple physics using

different approaches like Lagrangian

ALE SPH and these methods are highly

scalable to provide

a fast turn around

Now switch to aero Ansys provides core

technologies such as

turbulence modeling scalable high performance

computing fast and parallel meshing

as well as tools such as Ansys CFX for

compressor and turbine aerodynamics

Ansys Fluent for combustion and emission

calculations and these core

technologies and tools enables you to go from

anywhere like

the individual blade design to account for

interaction also the

interactions between the edges and blade rows

or interaction between

the adjacent components or to do complex

multiphysics simulations such

as aeromechanics and hot streak migration

One of the core technologies for aerodynamics

aerothermal

or aeromechanics analysis is blade row methods

Ansys CFX provides

wide range of blade row methods for steady as

well as

transient analysis

Steady methods can be used for individual

blade aero design

It can also be used with mixing plane to get

the performance of a stage or the whole

module such

as compressor or turbine

Steady methods can fall short for off design

conditions and

some phenomena like flutter are inherently

unsteady for which we

provide transient or harmonic method with

appropriate big change approach

to account for unsteady interaction between

the edges and blade rows

These methods require only a sector for

unsteady harmonic

analysis

which increase the solution speed up

dramatically while maintaining the

same fidelity as traditional full 360 or full

view methods

These methods can be used for a wide range of

applications such as multistage CFD analysis

flutter calculations inlet distortion

analysis or hot streak migration analysis

Aeromechanics is an important area from

fatigue and durability perspective

Ansys provide streamlined workflows for two

important aeromechanics problems

1st I'm going to talk about blade flutter

workflow where

you can first perform a modal analysis in

Ansys Mechanical

bring in the mode shape of interest and carry

out

aero damping calculation in answer CFX for

a range of nodal

diameters

We also enabled the fast fourier

transformation method

to work either in time domain or in frequency

domain

to do do this tons of calculations for

different frequencies

for range of nodal diameters really fast

which is critical

to get to know whether there will be a

flutter

or not for a given system and to get the

flutter map for the individual components

right

The other important aspect of

aeromechanics is force response

analysis

for which Ansys mechanical provides two

important core technologies

cyclic symmetry and mode superposition which really

enables the force response

analysis really fast

Now this workflow starts on the CFD side

where one

of these transient blade row methods I mentioned

can be used

to capture the unsteady interaction between

the blade rows and

that EO forcing can be used in Ansys

Mechanical

to do a cyclic symmetry mode superposition

harmonic response analysis

to compute the response of the blade for

given forcing

We also introduced an ACT app in Workbench for

force

response analysis which really automates this

analysis from set up

to get all the way detail post processing

results which

are important for fatigue and lifing

calculations

For cooled turbine heat transfer analysis

Ansys CFX provides two

different approaches

The film cooling approach can be used in

early design

iteration to optimize the film cooling holes

while the high fidelity conjugate heat

transfer approach can be

used with panel meshing an fast solid

numerics to gain

further insights and perform validations

Ansys provides also best in class tools for

modeling flow

turbulence and combustion

We provide all necessary tools to model any

fuel our

model fuel library contains more than 60

validated fuel

models and tools like Chemkin-pro can be used

for

mechanism reduction flame speed calculations

and fuel characterization

Ansys Fluent has advanced VOF to DPM

model for accurate spray characterization

in Fluent you can also simulate

complex phenomena such as the flame

propagation as shown in

this multi burner case and perform combustion

dynamics calculations to

get accurate pressure signature and the

frequency spectrum

Ansys Fluent also provides sophisticated models

for emissions

For example you can see good soot predictions

using method

of moments model for Young's flame and also

good prediction

of trends for CO and NOx on different

cases using

FGM and flame generated combustion

model

Icing is another critical area for aircraft

engines

and we provide solutions to not only model

ice accretion

but we can also model the impact of it on

the aerodynamic performance degradations we

provide this automated workflows which

avoids any manual user intervention and

meshing of complex

ice shapes

We also provide fast ice shedding modeling

for gas turbines

which predicts the shedding frequency total

shed mass and the

max size of the shed pieces

We also provide the integrated stress

analysis and accretion analysis

workflows which really enables simulated

complex phenomena such as cracking

in the ice sheet shown here in this animation

which

is really impressive anti-icing and deicing

systems are very

critical for aircraft engines Ansys provides

a workflow for the

assessment of both hot air anti icing and

electrothermal deicing

systems you can simulate ice buildup if the

water runs

past the protected zone and also more

importantly visualize the

ice buildup as you can see in this animation

or

melting as shown here in the animation below

And one last capability I'm going to cover

is process

compression robust design and optimization

which addresses an important initiative

to get faster to market and optimize the

product performance

We offer scripting at the tool as well as the

workflow level to fully automate the design

processes

Ansys optiSLang has advanced optimization

and robust design

capabilities

We offer the reduced order model generation

at various levels

from a simple response surface ROM to

detailed 3D ROM

or even dynamic ROM which can be used for the

transient phenomenon

I would like to wrap my

talk by repeating that Ansys

is providing a proven solution for gas

turbines

and among the organazations use simulation based

digital twin and

field meta models for predictive maintenance

of their fleet

a gas turbine OEM leverage simulation to

excellent product development

improve product quality and reduce testing

time

And many companies use simulations

to increase performance by increasing the

turbine inlet temperature

These stories you can read in more details

the links

to these stories are provided in the gas

turbine collateral

which is part of this booth

If you have any questions on what I presented

or

anything else relevant to gas turbines please

let us know

through the chat or Q&A window after this

presentation you

can also use the chat function of the booth

and either me or one of my many colleagues

which

are subject matter expert for gas turbines

around the world

will reply to you live

Finally enjoy the rest of your time at this

booth

and Simulation World we are here to chat with

you