ECCOMAS 2024

High-Fidelity Film-Cooled Rotor High Pressure Turbine Simulation using Metric-Based Anisotropic Mesh Adaptation

  • Alauzet, Frédéric (Inria)
  • Parente, Enza (Safran Tech)
  • Remigi, Alberto (Safran Tech)

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Film cooled turbines are one of the main technologies necessary to achieve the emission reduction. This is done by increasing the operating temperature. Consequently, high-fidelity simulations are required to better predict the flow features. RANS simulations are nowadays the main tool used for performance prediction of turbines and aerodynamic components. Film cooled turbines geometries are extremely complex as they are composed of many different-shaped film-cooling holes and contains an internal complex cooling circuit. This makes almost impossible to mesh them with classical multi-block hexahedral meshing methods. For this reason, tetrahedral meshes are preferable, thanks to the extreme flexibility of the elements. On the other hand, thanks to a sustained effort on anisotropic mesh adaptation methods, they have been extended successfully to turbulent flows modeled by the RANS equations. We proved that it is possible to achieve very accurate predictions on fully-unstructured adapted meshes composed only of tetrahedra. Moreover, we showed that the same accuracy can be obtained with a reduction of the mesh size by a factor of between 20 and 100 with respect to the best-practice expert-created meshes. One other important result is that we are now able to achieve mesh-convergence even on complex 3D geometries. In this presentation, we will develop all the technical points that are required to apply anisotropic mesh adaptation in such context. First, the mesh adaptation is extended to periodic domain. To adapt the periodic mesh surface, a two-step process is proposed where the mesh is first adapted without modifying the periodic surface, and then, the periodic surface is adapted after moving layers of elements on either side of the periodic surface such that it becomes internal. Second, film-cooled vanes involve at the same time aerodynamics and thermal features. Adapting the mesh only to the aerodynamics is not sufficient to capture accurately the cooling of the blade. To this end, we combine the local Mach number and the temperature fields in the error estimate to perform an adaptation on both dynamics. Finally, the cooling of such cases is very dependent on the free stream turbulence, coming from the combustion chamber, impacting the blade. We will show how free-stream turbulence impact the cooling.