Splitter Optimization
Splitter Optimization
GT2018-75192
ABSTRACT Nomenclature
In this paper we present and validate a shape optimization c Absolute velocity
framework for the design of splitter blades that extends the
p Static pressure [Pa]
operative range under cavitation while maintaining the wetted
performance of rocket engine turbopumps. For a target P Total pressure [Pa]
turbopump application, the optimization framework allows for Circumferential velocity [m/s]
U
independent changes to the blade angle distributions across the
R Impeller tip radius
span and to the pitchwise position of the splitter blades while
preserving the thickness distributions. W Weighting vector NPR formulation
The optimization is conducted with a surrogate-based X Input sample vector NPR formulation
gradient method. The geometry is optimized at a fixed b Constant NPR formulation
cavitation number corresponding to a 5% head coefficient drop-
off, while constraints are imposed on the wet pump Greek symbols
performance. It is found that this approach, coupled with the φ Flow coefficient
optimal design points distribution provided by the Design of Head coefficient
Experiment method, reduces the computational cost of the ψ
optimization process by minimizing the number of multiphase ρ Density [kg/m3]
calculations. Cavitation number
σ
The numerical results suggest that the optimized splitter
blades successfully increase the pump operative range by 2.2% γ Slip factor
and increase the head coefficient by 5.3% compared to the Subscripts/superscripts
baseline case with non-optimized splitters. These results are
corroborated by experiments conducted in a closed-loop water 2 Tip
test facility. Several pump geometries are tested through rapid cav Cavitation condition
prototyping using additive manufacturing. The experimental
data validate the optimization framework, demonstrating a in Pump inlet
4.7% increase of pump operative range and a 7.6% increase in ind Inducer inlet tip
head coefficient. The calculations are used to gain insight in the
physical mechanisms for the performance improvement. The out Impeller outlet
analysis of the results indicates that the improved performance tip Impeller tip at outlet
is due to the optimized position and shape of the splitter blades vap Vapor
which increase the pump slip factor.
w Wet condition
ideal Ideal condition
0.381
0.380
0 1 2 3 4 5 6 7 8 9
Number of elements (millions)
Figure 6: Mesh convergence study indicates 2.5 million elements are
Figure 5: Test facility at the Osaka Institute of Technology. sufficient to capture pump performance.
Numerical Methodology:
OPTIMIZATION FRAMEWORK
ANSYS CFX 17.1 is used to run steady state, single
passage Reynolds Average Navier-Stokes (RANS) calculations. The optimization is conducted changing the blade
A detailed description of the solver can be found in [19]. The circumferential position, the blade length and the blade angle
computational approach is based on a finite-volume method distribution at the hub and shroud. The design is optimized at
using an implicit incompressible formulation with a second cavitation number corresponding to 5% head drop-off and
order spatial discretization. RANS calculations are closed constraints are imposed to maintain the pump wetted
through the two-equation k-ω shear stress transport turbulence performance. The blade angle distributions at the hub and
model. The total pressure boundary condition is selected at the shroud are parametrized using Bezier curves for the camber line
inlet and the mass flow rate is defined at the outlet. Multiphase as indicated in Figure 7. The blade thickness distribution is
flow simulations are conducted with a Eulerian formulation fixed and selected based on best practices for radial
using a homogenous mixture of water and vapor. The mass turbomachinery design. Six parameters are used: five control
transfer rate due to cavitation is evaluated with the Rayleigh- points define the Bezier curves, of which two control points are
Plesset equation [19]. at the hub and three control points at the shroud. The additional
The computational domain is solved in the relative frame and control point at the shroud defines the position of the leading
comprises three regions: inlet, impeller and outlet/volute. The edge, thus the blade length. One parameter is used to adjust the
impeller mesh is constructed with the adaptive mesh generator circumferential position of the splitter with respect to the main
TurboGrid, allowing for changes of the geometry. The upstream blades as indicated in Figure 8.
influence of the volute on the impeller is carefully assessed
through comparison of the results of calculations with the β
volute
and those conducted without the volute, using simplified outlet.
The computations show no appreciable impact of the volute on
the impeller performance, suggesting that there is no
appreciable effect of the volute on the flow behavior in the
region affected by the splitter blades. The optimizer-based
calculations are therefore conducted without the volute to %M
0 50 100 =
reduce the computational cost of the simulations. hub
The maximum value of the y+ is 30 in all the calculations and shroud
limited to a small area at the impeller leading edge, while on
average y+ is about 10. A mesh convergence study has been Figure 7: Illustration of the Bezier curves parametrization. The blade
conducted to ensure mesh-independent results for the angle distribution is parametrized with three control points of the
Bezier curves.
computations. Figure 6 shows the static head coefficient versus
mesh size. The variation of static head coefficient is below 1%
for the meshes with number of elements above 2 million,
indicating mesh convergence.
𝑀′
𝑃=1
𝜃
Figure 8: The circumferential or pitch position parameter determines
the proximity of the splitter to the suction side (p=1) or to the pressure
side (p=0) of the main blade.
Variation w.r.t.
Parameter
baseline
Circumferential position -5.1%
Hub
Control point 1
+7.68%
(midpoint)
Control point 2 (TE) +65.8%
Shroud
Figure 11: Cavitating performance comparison between experiments
Control point 1 (LE) -6% and computations. Experimental measurements indicate a larger
improvement of operating range than computations.
Control point 2
+14%
(midpoint) 1.5
0.9
0.6
0.3
0.8 2.0 3.2 4.4 5.6
x/xmin,baseline
a)
1.2
Baseline Shroud
1.0 Op0mized Shroud
y/ymin,baseline
0.8
0.6
PTOT/PTOT,max
operative range with cavitation. 0.8
0.5
Splitter LE
0.2
Main Blade LE
Streamwise Loca0on TE
The analysis of the flow field reveals that the circumferential 0.5
position and the blade angle distributions of the splitter have no
beneficial effect on main blade cavitation. The cavitation
volume of the optimized impeller is nearly identical to the Splitter LE
baseline design. The optimized splitter shape removes the 0.2
separation in the hub-region on the main blade pressure side. Main Blade LE
Streamwise Loca0on TE
Flow separation downstream of the cavitating region is
enhanced by the increased pressure gradient due to the cavity Figure 15: Total pressure distribution along a streamline close to hub.
collapse and reduced blockage. The trend is similar to the streamwise averaged of Figure 14.
The streamwise distribution of total pressure is shown in Figure
14. Total pressure losses are larger for the optimized design in 1.1
the first part of the passage and up to about 60% of streamwise
Baseline Shroud
coordinate. However, the optimized splitter blades reduce the
losses due to separation leading to a net increase in total
0.8 Op0mized Shroud
pressure of 5 % at the exit of the component. Figure 15 presents
PTOT/PTOT,max
Figure 17: View from the impeller inlet of the baseline case.
Streamlines departing from the leading edge separate from the wall
after few fractions of the main blade meridional length.