Aeroacoustic Evaluation of an Axial Fan using CFD Methods Frederik Folke, Martin Hildenbrand (ITB Ingenieure GmbH)
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1 Aeroacoustic Evaluation of an Axial Fan using CFD Methods Frederik Folke, Martin Hildenbrand (ITB Ingenieure GmbH) ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 1
2 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 2 ITB Ingenieure GmbH engineering since 1998 Introduction FEM Thermo-Mechanical Fatigue Digital Development CFD (1D/3D) Process Automatization / Programming
3 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 3 ITB Ingenieure GmbH engineering since 1998 Introduction Engine Development Exhaust After-Treatment Turbomachinery Production Processes
4 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 4 Motivation Introduction Aeroacoustic evaluation of an axial blower Blower is used in urban environments Statutory limitations of noise pollution Test case geometry Straightforward numerical approach for aeroacoustic evaluation CFD-Simulation (aerodynamics) model adjustments + simulation time Aeroacoustic results
5 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 5 Contents ITB Ingenieure GmbH Motivation INTRODUCTION BASICS Aeroacoustic Basics TEST CASE Computational Model Results Summary and Conclusion
6 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 6 AEROACOUSTIC BASICS What is "Aeroacoustic Noise"? Numerical Simulation of Aeroacoustic Noise Numerical Challenge in Time Estimation of Discretization
7 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 7 What is "Aeroacoustic Noise"? Aeroacoustic Basics Flow induced (fluctuating) pressure waves in audible frequency range. Small magnitudes compared to flow field Wide frequency range ( depends on the receiver, e.g. human) Sound sources monopole-sources interaction of flow and solid structures (dipoles) turbulence noise sources (quadrupoles) Sound propagation propagation from sources to far field damping interaction with solid structures (reflection, adsorption)
8 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 8 Numerical Simulation of Aeroacoustic Noise Aeroacoustic Basics Sound sources resolution of the aerodynamical flow field resolution / modelling of all relevant mechanisms in space and time (e.g. blade passing, turbulence) Sound propagation Resolution of the propagating pressure wave Elimination of boundary effects Propagation to locations outside of the computational field Mesh boundary layer resolution local mesh size moving mesh Physics turbulence models (resolution) time-step Mesh Physics sufficient mesh size in far-field resolving propagating pressure waves time-step boundary treatment (non-reflecting boundaries)
9 Sound Pressure ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 9 Numerical Challenge in Time Aeroacoustic Basics Frequency Low frequencies long-time events in time-domain physical time of event has to be captured τ total 1 High frequencies short time events (turbulence) time-step has to capture event Δt 1 τ total n Δt Large number of time-steps necessary
10 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 10 TEST CASE Computational Domain Physics and Solver
11 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 11 Computational Domain Test Case FW-H = Ffowcs Williams - Hawkings Stator Rotor FW-H Surface Pressure outlet Sound propagation model Freestream boundary conditions
12 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 12 Physics and Solver Test Case Preconditions rotational speed 16'000 min -1 frequency range Hz Numeric Setup solver turbulence time step size boundary conditions total number of cells CD-adapco STAR-CCM+ k-w SST (urans) 1e -5 s freestream / pressure outlet ~ 10 million
13 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 13 RESULTS Flow field Sound pressure level
14 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 14 Flow Field (Aerodynamic) Results MEAN FLOW (macroscopic) TURBULENCE (microscopic)
15 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 15 Aeroacoustics Results Volume sound Surface sound Main sound sources in region of rotor and stator
16 [db] Simulated physical time ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 16 Sound Spectrum BPF 2 x BPF x R1 Results Broadband noise sources insufficiently captured by urans! x R2 Receiver 1 (close) Receiver 2 (far away)
17 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 17 SUMMARY AND CONCLUSION Summary and Conclusion Outlook
18 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 18 Summary & Conclusion Summary Successful aerodynamic simulation of axial fan (very good agreement with measurement) Successful aeroacoustical simulation of an axial fan (academic test case) based on a well-resolved transient urans simulation Conclusion Ability to identify noise sources (dipoles, quadrupoles) Ability to resolve tonal noise (blade passing frequency) Ability to evaluate the sound pressure level By an adequate numerical effort!
19 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 19 Outlook Special thanks to CD-adapco for support! Hildenbrand (2014), Aeroacoustic simulation of rotating parts, ITB GmbH / Uni Stuttgart Mir (2016), Aeroacoustic simulation of an axial fan, ITB GmbH / Uni Stuttgart (in progress) Ongoing study Outlook Improvement of boundary treatment (non-reflecting boundaries, minimization of disturbing noise) Higher resolution of boundary layer (shear flow) Turbulence Validation by experimental data (not measured yet)
20 ITB Innovative Technische Berechnungen GmbH Deckerstr. 37 D Stuttgart ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 20
21 APPENDIX ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 21
22 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx 22 Noise Sources p x, t = f t x c x Monopole Radial radiation Noise in jet stream Cavitation bubbles p x, t = x 1 f t x x c Dipole Directed radiation Two contrary monopoles Surface noise (separations) Turbulence-Structure interaction Quadrupole Longitudinal / Transverse / arbitrary Free turbulence / shear flow p x, t = 2 x 1 x 1 f t x x c p x, t = 2 x 1 x 2 f t x x c
23 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 23 Classification of Noise Sources Acoustic Analogy Physical Phenomenon Numerical Treatment Monopoles Dipoles Quadrupoles Jet stream, cavitation bubbles Interaction of flow with solid structures Blade Passing Separation Stagnation Points Turbulence Noise Shear flow Not relevant in this case Sufficient resolution of the boundary layer Flow-Structure Interaction Resolution of turbulent structures. Scale resolving methods
24 ITB_SGC_AeroacousticEvaluationOfAnAxialFanUsingCFDMethods_ pptx ITB GmbH, Folke, Hildenbrand 24 Estimation of Discretization Spatial Discretization Time Discretization STAR-CCM+ Best Practice 20 cells per acoustic wavelength are recommended STAR-CCM+ Best Practice Approx. 1 rotation per time-step or at least 15 time-steps per blade passage Example: f = 3000 Hz Max. mesh size < 5.7 mm Example: ω = /min Time step size = 1e -5 s
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