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CFD grid generation and analysis of screw compressor with variable geometry
rotors
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All content following this page was uploaded by Ahmed Kovacevic on 27 March 2018.
Email: sham.rane.1@city.ac.uk
1. INTRODUCTION
Screw compressors are usually manufactured with helical
lobed rotors of uniform lead and a profile optimized for
efficient compression process. It was suggested in open
literature that rotors with variable lead may provide more Figure 1: Oil injected Twin Screw compressor and its
efficient process for high pressure applications. Figure 1 working chamber
shows an example of a CAD model of an oil injected twin Kovacevic et. al. in [5], [6], [7] and [8] have successfully
screw compressor in which the compression process, used algebraic grid generation method with boundary
leakage flows, heat transfer, oil injection and other
1
adaptation to generate numerical mesh for twin screw literature that for the same rotor lengths, diameter, wrap
machines with constant pitch rotors. This has been angles and lobe profiles, variable pitch rotors can be
implemented in the custom made program for the designed to provide higher pressure ratios and larger
calculation of a screw compressor numerical mesh called discharge port opening areas with reduced throttling losses
Screw Compressor Rotor Grid Generator – SCORG©. The when compared to constant pitch rotors [3].
motivation for the present work was to enhance the As confirmed by many authors, screw compressor
functionality of SCORG© to allow grid generation for twin efficiency depends upon the profile of the rotors, number of
screw rotors with variable pitch and variable section profiles lobes on the male and female rotors, the length and
which in turn would allow CFD simulations of these new diameter, the wrap angle and the rotor clearances [2], [4]
types of machines. and [14]. Based on these and the original work of Gardner
Numerical treatment of the CFD models for screw [3] it is suggested that the effects of variable lead rotor
compressors with uniform lead and variable lead rotors designs are as follows;
differs mainly at the grid generation stage. In the grid a) If all other variables are unchanged for a constant lead
generation technique for constant pitch rotors the axial rotor pair and a variable lead rotor pair, the length of the
distance between the grid points is constant. The challenge sealing line will be less for the variable rotor pair as the
in generating a grid for variable lead rotors is in establishing rotor lead reduces from suction to discharge. Since the
the relationship of the axial distance between consecutive leakage loss is directly proportional to the length of the
cross sections and the angular rotation of nodes which sealing line and the sealing line is shorter for the
changes continuously along the rotor axis. To accommodate variable lead rotors in the high pressure regions, the
this change, the grid needs variable spacing in the axial leakage loss will be reduced. This may lead to higher
direction which will still provide a conformal mesh. Figure efficiencies with variable lead rotors.
1 shows the numerical grid in one of the cross-sections. The
topology of the mesh remains same over the entire length of
the rotor but the rotors change their relative position
governed by the variable lead. Still, the grid generator needs
to accommodate the large difference in length scales of the
main domain and the clearances.
2
discharge volume is the size of the compression chamber
at the moment of opening of the discharge port. As
shown in Figure 4, to achieve the same volume index for
variable pitch rotors the discharge port should be opened
earlier which allows it to be bigger than in the constant
lead case. Hence it is possible to have a greater
discharge area at a similar pressure ratio and this will
reduce the throttling losses.
d) If the same size of discharge port is retained for both the
variable and uniform lead rotors, the discharge pressure
of the variable rotors will be higher. This indicates that
variable lead rotors can achieve a higher Vi index.
The advantages and disadvantages identified on the basis of
previous research have not been tested so far on physical Figure 6: Axial spacing difference between uniform pitch
prototypes due to difficulties in producing such rotors with and variable pitch rotor grids
existing manufacturing methods. However, these can be In order to achieve this, the existing structure of the
investigated further in detail by use of CFD analysis if an procedure used in SCORG© has been reformulated to be
appropriate numerical mesh can be generated. adaptable with the variable pitch and variable profile screw
The advantages of the variable lead rotors could be rotors.
enhanced even further by introducing variable rotor profiles The rotor lead variation could be constant, linear or stepped.
which could enhance rate of change of volume in the The former is used in screw vacuum pump technology while
machine and allow for even higher compression ratios and the latter is applied in some car superchargers. The
larger discharge port. Analysis of such machines requires expressions can be specified in the form of equations 1 – 4.
further step in adapting the existing grid generation
technique which requires introduction of a new rotor profile
for each axial cross section. However, if such modifications
are implemented, other positive displacement machines such
as single screw compressor with variable rotor profile along
the axis could also be analyzed.
3
Figure 7: Example of variable pitch grid with uniform
profile: 5/6 ‘N’ rotors
2.2 Approach 2
This approach addresses the more generic requirement for
the rotor pitch variation along with a variable cross section
profile over the length of the rotor. Hence in addition to the
axial variation of cross section in Approach 1, the algorithm
needs to capture the variation of the profile in cross sections.
The grid generation algorithm is represented in a block
diagram in Figure 8 and Figure 9. The foundation of the
approach is that each cross section of the screw compressor
rotor is a conjugate profile pair in which case they can be
calculated independently and the grid generation process
from the splitting of the rotor domain by a rack to the
allocation of 2D vertex coordinate data can be repeated.
2.2.1 Procedure
The process starts with the division of the rotor length
into ‘n’ number of cross sections and proceeds with the Figure 8: Variable Pitch and Variable Profile Grid
generation of 2D vertex data (Nodal x and y coordinates) Generation in 2D
in the first cross section.
4
This involves boundary discretization and adaptation.
Interior nodes at this section are calculated using
Transfinite Interpolation and the vertex data are recorded Discharge End
after grid orthogonalisation and smoothing operations.
This step is labeled as ‘Subroutine Run – 1’ in the block
diagram Figure 8.
The process is repeated over the second cross section
and additionally this section will receive its axial
position (nodal z-coordinate) from Pitch variation
function. Suction End
The same 2D grid generation process is repeated over all
‘n’ cross sections and then the data are used together to
assemble a set of grid files representing the rotor domain
at every time step.
Discharge End
Suction End
Figure 9: Variable Pitch and Variable Profile Grid Figure 11 shows the 2D cross sections grids for variable
Generation in 3D rotor profile at the suction end, middle of the rotors and the
discharge end.
From each cross section; a block of vertices which
represents the first rotor angular position is collected to 3. CFD ANALYSIS
construct the 3D assembly with correct z coordinate The numerical analysis was carried using ANSYS CFX
variation of the Mesh-0. The process is repeated for all solver with the objective of validating the new grid
sets of data until the Mesh-n is generated. The process is generation procedures and to study the flow behavior in a
graphically shown in Figure 9. variable lead screw compressor with uniform profile. The
2.2.2 Example of application of approach 2 following aspects are considered:
a. Compression characteristics.
An example of variable geometry rotor grid generated using
b. Increase in discharge port area for a given pressure
Approach 2 has been shown in Figure 10. The cross sections
ratio.
changes continuously from suction end to the discharge end
c. Reduction in sealing line length towards the high
of the rotors. As the center distance is fixed, the rotors are of
pressure end of the rotors.
parallel axis and a tapered shape. The outer diameter on the
Three test cases are defined to analyze the above.
main rotor is tapered while the inner diameter is constant
while on the gate rotor, the inner diameter is tapered and the
Case 1. Uniform Pitch rotors and a discharge port opening
outer is constant.
area to give a built in volume index Vi of 1.8.
Case 2. Uniform Pitch rotors and a reduced discharge port
opening area to give built in volume index Vi > 1.8.
In this case, the compression chamber is exposed to
the discharge pressure relatively late in the cycle as
shown in Figure 15. This corresponds to an
additional male rotor rotation of about 6.75° and
5
allows for further pressure build up in the allow positive flow. The lead on the male rotor for the
chambers. uniform pitch rotors was 108.8 mm. For the variable lead
Case 3. Variable Pitch rotors and a discharge port opening cases, the wrap angle on the rotors remains the same while
area same as that of Case 1 with Uniform Pitch the lead was continuously changed from 125.0 mm at the
rotors. Since the wrap angle on both rotors is the suction end to 92.6mm at the discharge end. For all three
same, exposure to the discharge port will take place cases, the rotor grids were generated with the same density.
at the same male rotor rotation angle. The numerical grids for ports were generated externally.
Figure 12 shows the compressor domain decomposed into
three main regions; the Suction Port, the Discharge Port and
the Rotor domains.
6
3.1 Results and Discussion favourable to the reduction of throttling losses in the
compressor.
3.1.1 Compression characteristics
Figure 13 shows the compression characteristic of the three
different cases for one full cycle. Case 3 with the variable
rotor pitch has a steeper rise in pressure than Case 1 and
Case 2 which have constant rotor pitch. At the same time
Case 1, with the same discharge area as that in Case 3,
builds up the least pressure before exposure to the discharge
pressure at about 246° male rotor rotation. Near this region,
Case 2, with a reduced discharge port area, continues to
compress before getting exposed to the discharge pressure.
This lag is about 6.75 ° of male rotor rotation.
7
rotor is 3mm longer but at the discharge end it is 3.5mm
shorter. This helps to reduce leakage as the largest pressure
difference across the sealing line is at the discharge.
Additionally, the total length of the sealing line is reduced
by 2mm in the variable pitch rotors.
4. CONCLUSION
The grid generation for twin screw compressors with
variable pitch rotors was formulated and implemented
successfully in this paper. The framework defined in this
research is suitable for rotors with variable profiles.
Examples of grids with variable lead have been presented
and CFD analysis has shown the flow characteristics in the
machines.
Figure 18: Sealing Line on Variable Pitch Rotor The analysis showed that by varying the rotor lead
continuously from the suction to the discharge, it is possible
Figure 17 shows the sealing line obtained on the uniform to improve compression characteristics with a steeper
pitch rotors (Case 1 and Case 2) and Figure 18 shows the internal pressure build up. The analysis also shows that
sealing line obtained on the variable pitch rotor (Case 3). varying the rotor lead allows a larger size of discharge port
The projection of the sealing line on the rotor normal plane area, thereby reducing throttling losses, and provides
shows the difference more clearly in Figure 19. The sealing increase in volumetric efficiency by reducing the sealing
line on the uniform pitch rotor is of the same length for each line length in the high pressure zone. The latest
interlobe space along the rotor. However, on the variable enhancements in the grid generation open new opportunities
pitch rotors the sealing line is longer at the suction end. It for further investigation of the flow behavior and
decreases towards the discharge end of the rotor. performance predictions for variable lead and variable
profile screw machines by the use of CFD.
NOMENCLATURE
L – Rotor Length
D – Male Rotor Outer Diameter
Φw – Male Rotor Wrap Angle
α – Male rotor rotation angle
Δα – Increment in Male rotor angle
Z – Axial distance along the rotors
ΔZ – Increment in Axial distance
ps – Starting Pitch
pe – Ending Pitch
Figure 19: Comparison of Interlobe Sealing Line Length z1 – Number of lobes on the Male rotor
z2 – Number of lobes on the Female rotor
Table 1 presents the variation in the sealing line lengths r.p.m – Male rotor speed
between the uniform and variable pitch cases at one of the t – Time
rotor positions indicating the magnitude of change along the Vi – Built in Volume Index
rotors. At the suction end the sealing line on variable pitch
8
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