Application Examples

In the design of radial turbomachinery impellers, such as centrifugal compressor or pump impellers, splitter blades are often used to ensure good aerodynamic/ hydrodynamic performance without compromising flow range. In the case of pumps this is necessary to achieve good suction performance.

Nozzle Design

Blade lean is commonly used in the design of axial turbine nozzles to reduce endwall losses and to obtain a more uniform exit flow distribution. Numerical and experimental investigations have shown that the use of blade lean, whether straight or curved, in the conventional design practice merely redistributes the losses in the blade and does not result in a reduction in loss. This is partly because in conventional design the blade profile is kept the same and the stacking line is changed to achieve the blade lean.

The flow in centrifugal compressor impellers is dominated by secondary flows which result in the formation of the impeller exit non-uniformity (the so-called “jet-wake flow” effect). This can be clearly seen in Figure 1, which shows the three-dimensional CFD prediction for a state-of-the-art conventionally designed impeller.

The design of the vaned diffuser of a centrifugal compressor is still based on a considerable amount of empiricism in its design methodology. Parameters such as area ratio and blockage, which are more relevant to conical diffusers, are used in conventional design practice.


Design Target
To develop a high performance 3 stage axial LP turbine in a 6 weeks period time frame to help in a competitive bidding process with other competing aeroengine
manufacturers.

Deliverables
High performance LP turbine developed within 5 weeks.

Impact
The high performance of the turbine enabled the client to beat other major aeroengine manufacturers and win the competitive bid. The turbine has already been manufactured and flown in an aeroengine.

 

Design Targets

  • Optimise aerodynamic efficiency.
  • Achieve desired flow rate and pressure rise.
  • Achieve desired air velocity on the cooling fins.

Deliverables
Impeller geometry.

Impact
High efficiency axial fan designed in two weeks

 

Design Targets
Analysis of an existing double-suction fan stage including inlet ducts, connecting channels, impeller and volute and redesign of fan impeller for improved aerodynamic efficiency.

Deliverables
Redesigned impeller geometry.

Impact
The stage efficiency was improved by up to 4 points.

 

Design Targets

  • Analysis of a complete double-suction pump stage including inlet duct and volute.
  • Redesign the pump impeller to achieve target pump head and efficiency at design and off-design conditions.

Deliverables
Redesigned impeller geometry and pump performance characteristics

Impact
Required stage performance was met with improvement in stage efficiency

TURBOdesign1 has been applied to the design of a three-component automobile torque converter. Due to the strong curvature of the flow passages and high loading, the flow behavior is extremely complex and difficult to optimize using a conventional design approach. Using TURBOdesign1, it is possible to achieve the best matching between the components, control secondary flows, and suppress flow separation.

The design of inducers is critical to achieving high suction performance in industrial pumps and rocket engine turbopumps. However, the conventional design approach, based on blade angles, often causes unstable pump operation. Instabilities such as strong inlet backflow and rotating cavitation in inducers may cause mechanical failures in pumps and the entire pumping system.

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