University of Florence

Department of Energy Engineering

Assessment of boundary
conditions for heat transfer and
aeroacoustic analysis
Cosimo Bianchini
HTC group
Energy Engineering Department
Via di S.Marta 3, 50139 Firenze
cosimo.bianchini@htc.de.unifi.it
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Outline
Introduction
Generic grid interface for conjugate heat transfer analysis
Overall effectiveness of effusion cooling plates
Auto-recycling turbulent inlet condition
Heat transfer of axisymmetric impingement jet
Navier-Stokes Characteristic Boundary Conditions
Acoustic response of perforated plates
Conclusions
2/17
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Motivation
3/17
Dome cooling
Impingement arrays
Liner cooling
Effusion systems
Stricter requirements for aero-engine pollutant emission
Lean Partially Premixed technology
Reduced amount of air for cooling purposes
Decreased stability of flames working close to the lean limit
Perforated plates may absorb acoustic fluctuations
Present-day aero-engines combustion chambers cooling is obtained by:
Effusion for the liner
Impingement in the dome
Exploit cooling system as passive dampers
Dual thermal acoustic optimization
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Motivation
4/17
Numerical predictions to reliably help designers needs to
overcome known failures of standard CFD analysis
at a computationally affordable level
Implement methods for
Conjugate Heat Transfer analysis
Large Eddy Simulation
In the context of open-source CFD
OpenFOAM


Increased complexity require adequate boundary treatment
Energy balance on the interface needs to be respected
Grid scale turbulence needs to be specified
DNS
Wall resolved
LES
Far field
LES
Advanced
RANS
RANS
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Objectives
5/17
The aim of the thesis is to
implement, validate and assess boundary conditions for the study of heat transfer
and aero-acoustic phenomena connected with combustor cooling

Technological problems faced
Estimate combined effect of film protection and heat sink in effusion cooling devices
Evaluate the cooling capabilities of impingement jets
Assess the potential of perforated liners as acoustic dampers for the stabilization of
lean flames

Computational aspects
Conjugate interface boundary condition to couple fluid and solid domain
Generation of turbulent fluctuations for inflow boundary
Non-reflecting inflow and outflow boundaries with acoustic forcing



University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Conjugate interface
Energy equation solved in terms of temperature (static or total)

Fluid: convective-diffusive equation
Solid: Fourier equation

Coupled boundary guarantees
Continuity of temperature
Continuity of heat flux: temperature gradient

Different mesh requirements for fluid and solid side
No boundary layer in solid domain
Strictly apply only to Low-Reynolds computations
Non conformal interface treatment



6/17
same matrix for solid
and fluid domain
f w s w
T T
, ,
=
f w
f
s w
s
n
T
k
n
T
k
, ,
|
.
|

\
|
c
c
=
|
.
|

\
|
c
c
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Effusion cooling conjugate analysis
7/17
Conventional (circular hole) and shaped (circular imprint) holes
Same porosity, same slanted angle:17
High temperature rig (Poiters): heat shield, 17-12 rows
3.5 millions cells hybrid mesh for 8 rows
Steady-state RANS analysis: Two-Layer (TL) and anisotropic
Two-Layer (ATL) turbulence models
Conventional Shaped
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Turbulent inlet
8/17
Perfect turbulent inlet should:
look like turbulence
allow easy specification of turbulent
integral properties
easily adjust to new inlet conditions
be computationally cheap

Internal mapping
identify an internal portion of
the domain to apply recycling
methods
Feedback
scaling the mapped field to
satisfy specified integral values
Mapped fluctuation
same procedure applied to
fluctuations
superposed on desired base
profiles
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Axisymmetric Impingement Jet
9/17
Ercoftac database: Re= 23000, H/D=2
Detailed experimental data
hexahedral mesh, 84 blocks, 5.2 millions cells
Incompressible Large Eddy Simulation
Additional equation for temperature
One equation sgs model: transport equation for turbulent
kinetic energy
Convective condition on outlet and top boundaries
Fully developed inlet condition
Mapped and Mapped fluctuation (from pipe simulation)

0 =
c
c
+
c
c
n
U
C
t
U
Mapped
Mapped
fluctuation
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Axisymmetric Impingement Jet
10/17
Mean velocity
Impinging zone






Wall jet zone
R/D = 0
R/D = 0.5
R/D = 1
R/D = 2 R/D = 3
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Axisymmetric Impingement Jet
11/17
Effective fluctuations
Radial fluctuations





Axial fluctuations
' '
r r
U U
R/D = 0.5 R/D = 1 R/D = 2 R/D = 3
' '
z z
U U
R/D = 3 R/D = 2.5 R/D = 1 R/D = 0.5
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Axisymmetric Impingement Jet
12/17
Constant and uniform heat flux: mean Nusselt number
Controversy on stagnation point dip and secondary peak
Secondary peak due to periodical impingement of broken ring vortex
Too low axial fluctuations might have lowered Nu for r/D > 1.5

University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Non reflecting boundaries
13/17
Navier Stokes Characteristic Boundary Conditions (NSCBC)
Characteristic wave analysis on the boundary
NSE are rewritten on the boundary in terms of wave amplitude variations
Entering waves: imposed by means of Linear Relaxation Method

Outgoing waves: extrapolation from internal solution


NSE are integrated on the boundary
Introduction of transverse and diffusive terms
The reflectivity of the boundary is driven by
Acoustic forcing is introduced with variable target value
|
.
|

\
|
c
c
c
c
=
u
c , , ,
n
p
,
n
u
f L
|
) (
T
L u u =
u u
o
u
L
u
o
) cos( e + = u t A
T
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Acoustic response of perforated plates
Bellucci test
14/17
Periodic circular hole at 90 deg with bias flow
Pulsed pressure outflow and fully reflecting inlet with NSCBC
Wall Adaptive Local Eddy (WALE) viscosity model
Estimate reflection coefficient of perforated plate with bias flow

Multimicrophone (4 stations) post processing technique
Reconstruction of progressive and regressive wave
+
I

I
+

I
I
= R
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Acoustic response of perforated plates
Bellucci test
15/17
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Acoustic response of perforated plates
KIAI test
16/17
Same set up more realistic geometry and flow conditions
Multifrequency excitation







Effect of stagger studied with different cyclic boundary arrangement at 1000 Hz

=
i
i i
T
t A p ) cos(e
in line
staggered rhomboidal staggered rectangular
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Conclusions
17/17
Three boundary conditions were implemented in an open-source CFD code
A conjugate interface with implicit non-conformal coupling
An internal mapping turbulent inlet generator
Non and partially reflecting inflow and outflow conditions
Accuracy of prediction was tested under conditions relevant for combustor liners
cooling system design
An effusion cooling plate at engine like condition
An axisymmetric impingement jet with heat transfer
The acoustic response of perforated liners with bias flow
The implemented conditions showed results aligned with state of the art
computations
Further work should be addressed towards:
Improving efficiency, robustness and stability
Development of homogeneous model for thermal and acoustic behavior of
perforated plates
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Publications
Bianchini, Da Soghe, Facchini, Innocenti, Micio, Bozzi, Traverso, Development of numerical tools for stator-rotor
cavities calculation in heavy-duty gas turbines", 2008, ASME PAPER GT2008-51266, Asme Turbo Expo, Berlin
Bianchini, Facchini, Mangani, Conjugate heat transfer analysis of an internally cooled turbine blades with an
object oriented cfd code", 2009, European Turbomachinery Congress, Graz
Andreini, Bianchini, Ceccherini, Facchini, Mangani, Cinque, Colantuoni, Investigation of circular and shaped
effusion cooling arrays for combustor liner application Part II: Numerical analysis", 2009, ASME PAPER GT2009-
60038, Asme Turbo Expo, Orlando
Boust, Lalizel, Bianchini, Facchini, Cinque, Colantuoni, Dual investigations on the improvement of effusion
cooling by shaped holes", 2009, 7th World Conference on Experimental Heat transfer Fluid mechanics Thermodynamics, Krakow
Bianchini, Simonetti, Zecchi, Numerical and experimental investigation of turning flow effects on innovative pin fin
arrangements for trailing edge cooling configurations, 2010, ASME PAPER GT2010-23536, Asme Turbo Expo, Glasgow to
appear on Journal of Turbomachinery
Bianchini, Mangani, Maritano, Heat transfer performance of fan-shaped film cooling holes. Part II Numerical
analysis, 2010, ASME PAPER GT2010-22809, Asme Turbo Expo, Glasgow
Bianchini, Bonanni, Carcasci, Facchini, Tarchi, Experimental survey on heat transfer in an internal channel of a
trailing edge cooling system, 2010, 65ATI conference
Bianchini, Andreini, Facchini, Numerical analysis of the heat transfer in a trailing edge cooling duct in stationary
and rotating conditions, 2011,9th European Turbomachinery Congress, Istanbul
Andreini, Bianchini, Armellini, Casarsa, Flow field analysis of a trailing edge internal cooling channel, 2011, ASME
PAPER GT2011-45724, Asme Turbo Expo, Vancouver, Accepted for publication
Simonetti, Andreini, Bianchini, Assessment of numerical tools for the evaluation of the acoustic impedance of
multi-perforated plates, 2011, ASME PAPER GT2011- 46303, Asme Turbo Expo, Vancouver, Accepted for publication



University of Florence
Department of Energy Engineering
Assessment of boundary
conditions for heat transfer and
aeroacoustic analysis
Cosimo Bianchini
HTC group
Energy Engineering Department
Via di S.Marta 3, 50139 Firenze
cosimo.bianchini@htc.de.unifi.it
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
Multiple implicit coupling - ghost cell mechanism
Contribution of ghost cell calculated via cell-to-cell addressing and
weighting factors
i


Weighting factors based on face overlapping areas
Algorithm for overlapping area based on surface integral of the product of
the winding number of the two polygons
Applies to every non self-intersecting polygon, positively oriented: all types
of meshes can be used (tetra,hexa,poly,etc..)
( )
,
1
f p p p i n i
i
w w | | o| = +

, i o i fp
A A o =
, n i n i
C C o =
Domain 1
Domain 2
p
n1 n2
Non conformal interface
Generic grid interface
20/20
University of Florence
Department of Energy Engineering
Cosimo Bianchini PhD thesis dissertation 13/04/2011
DNS near wall LES far field LES Advanced RANS RANS
Effusion cooling Effusion acoustic Impingement jet
KIAI test Flow field analysis
21/20
Instantaneous axial velocity show typical
turbulent behaviour
Modal analysis performed with Proper
Orthogonal Decomposition technique
Equivalent but symmetric modes at 3 and 5
Mode 2: vortex rings aligned with hole axis
Mode 4: vortex rings misaligned with hole axis
POD pressure modes