Research Papers

Rapid Prototyping Design Optimization Using Flow Sculpting

[+] Author and Article Information
W. N. Dawes

CFD Laboratory, Department of Engineering, University of Cambridge, Cambridge CB2 1PZ, UK

J. Turbomach 130(3), 031012 (May 05, 2008) (6 pages) doi:10.1115/1.2777178 History: Received January 15, 2007; Revised January 16, 2007; Published May 05, 2008

Computational fluid dynamics has become a mature art form and its use in turbomachinery design has become commonplace. Simple blade-blade simulations run at near interactive rates but anything involving complex geometry—such as turbine cooling—turns around too slowly to participate in realistic design cycles; this is mostly due to the difficulty of modifying and meshing the geometry. Simulations for complex geometries are run afterwards as a check—rather than at the critical conceptual design phase. There is a clear opportunity for some sort of rapid prototyping but fully 3D simulation to remedy this. This paper reports work exploring the relationship between solid modeling, mesh generating, and flow solving in the general context of design optimization but with the emphasis on rapid prototyping. In particular, the work is interested in the opportunities derived by tightly integrating these traditionally separate activities together within one piece of software. The near term aim is to ask the question: how might a truly virtual, rapid prototyping design system, with a tactile response such as sculpting in clay, be constructed? This paper reports the building blocks supporting that ambition.

Copyright © 2008 by American Society of Mechanical Engineers
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Figure 1

Typical tessellated surface extracted by CAPRI (Haimes and Follen (10)) from a Parasolid solid model of a turbine

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Figure 2

Basic head (left) sculpted simply via CSG Boolean operations enacted via a spatial occupancy solid model of tool and workpiece; the head right results from much more complex tool/workpiece interactions (from Baerentzen (16))

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Figure 3

Scanned spatial density variation (black is high density, white is low) stored on a Cartesian grid; a “voxel raster” (left), which can be rendered (right) by extracting various isosurfaces (Jones and Satherley (13))

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Figure 4

The basic flow of activities within BOXER

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Figure 5

The capture of a generic turbocharger housing

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Figure 6

Viscous layers can be inserted between cut cells and the body—above is such a layer near the LE of an airfoil: this creates a new, quadrilateral surface definition illustrated by showing the midsection of an F18 geometry originally imported as a tessellated surface

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Figure 7

Stages in the capture of a generic film cooled turbine blade: top left, the tessellated geometry; top right, the octree mesh, bottom left, the flow mesh; bottom right, the clipped distance field

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Figure 8

Sculpting a new film cooling passage through the distance field (the zero isosurface, the blade, is rendered green) with a cutting tool (blue)

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Figure 9

The newly sculpted mesh and examples of the current distance field

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Figure 10

Two snapshots of the new flow solution; total temperature (left) and Mach number (right)



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