2016 Cadfem

Ein Betriebspunkt kommt selten allein
effiziente Kennfeldanalyse mit optiSLang

am Beispiel eines Turboverdichters
Fachkonferenz zur Numerischen Simulation

Winterthur 2016
Dynardo GmbH
Content
1 Introduction of ANSYS optiSLang
2 Aim of the project
3 Method of analyzing performance maps
4 Results of sensitivity analysis
5 Conclusion and outlook
Ein Betriebspunkt kommt selten allein,

2
effiziente Kennfeldanalyse mit optiSLang am Beispiel eines Turboverdichters
Winterthur, 2016
M. Schimmelpfennig, Dynardo GmbH
Dynardo GmbH
Dynardo
Founded: 2001
More than 60 employees,
offices at Weimar and Vienna
Leading technology companies
Daimler, Bosch, E.ON, Nokia,
Siemens, BMW are supported
Software Development CAE-Consulting

Mechanical engineering
Civil engineering &
Dynardo is engineering specialist for Geomechanics

CAE-based sensitivity analysis, Automotive industry
optimization, robustness evaluation Consumer goods industry
and robust design optimization Power generation

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Winterthur, 2016
Dynardo GmbH
optiSLang
is a general purpose tool for variation analysis
using CAE-based design sets (and/or data sets)

for the purpose of
sensitivity analysis
design/data exploration
calibration of virtual models to tests
optimization of product performance
quantification of product robustness and product reliability
Robust Design Optimization (RDO) and Design for Six Sigma (DFSS)
support of process integration

serves arbitrary CAX tools with process automation
workflow generation

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Winterthur, 2016
Dynardo GmbH
SPDM
Input Workflow-Management Output

1 1
with
Process Integration
Input and for Output
2 2
Automatization
Input Output
n m
Excel Add-In ANSYS optiSLang other Solver
Postprocessing

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Winterthur, 2016
Dynardo GmbH
Design Understanding
Investigate parameter sensitivities, Design Improvement
reduce complexity and Optimize design performance
generate best possible meta models
CAE-Data
Robust Design
Measurement
Data
Model Calibration Design Quality

Identify important model parameters
Ensure design robustness
for the best fit between simulation
and reliability
and measurement

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Winterthur, 2016
Dynardo GmbH
CAE-Data
Robust Design
Measurement
Data

and reliability
and measurement

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Winterthur, 2016
Dynardo GmbH
Model Calibration
Model update to increase your simulation quality!
use non scalar values inside ANSYS Workbench

identify where parameters have influence within the curve
match experimental data with simulation

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Winterthur, 2016
Dynardo GmbH
CAE-Data
Robust Design
Measurement
Data

and reliability
and measurement

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Winterthur, 2016
Dynardo GmbH
Sensitivity Analysis
Understand the most important input variables!
Automatic workflow with a minimum of solver runs to:

identify the important parameters for each response
understand and reduce the optimization task
check solver and extraction noise

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Winterthur, 2016
Dynardo GmbH
CAE-Data
Robust Design
Measurement
Data

and reliability
and measurement

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Winterthur, 2016
Dynardo GmbH
Optimization
Optimize your product design!
Optimization
using MOP
Start
User friendly procedure with algorithm to:

work with the reduced subset of only important parameters
pre-optimization on meta model (no solver run)
decision tree for optimization algorithms

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Winterthur, 2016
Dynardo GmbH
CAE-Data
Robust Design
Measurement
Data

and reliability
and measurement

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Winterthur, 2016
Dynardo GmbH
Robustness Evaluation
Ensure your product quality!
Output
parameter variation
Powerful procedure to check design quality:

Latin Hypercube Sampling representing
scattering variables optimally
check variation interval limits and critical responses
Identify the most important scattering variables
and check the solver noise

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Winterthur, 2016
Dynardo GmbH
Content

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Winterthur, 2016
Dynardo GmbH
2 Aim of project
two main scientific issues are addressed:
Implementation of an automated and

standardized but also adaptive
(in terms of the systems response)
process for numerical
analysis considering all
relevant operating points
(performance maps)
Investigation of usage of
one-dimensional liquid
flow theory for pre-
evaluating design
variants in a sensitivity
study in order to reduce
the numerical effort
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Dynardo GmbH
2 Aim of project
Introduction
Structure and function of an exhaust gas turbocharger

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Winterthur, 2016
Dynardo GmbH
2 Aim of project
Introduction
Performance indicators for characterizing turbochargers:
Pressure ratio
Isentropic
efficiency
polytropic
efficiency
Ein Betriebspunkt kommt selten allein, [4]

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Winterthur, 2016
Dynardo GmbH
2 Aim of project
Introduction
Sensitivity analysis scans the design space and evaluates the variance of the
inputs- (e.g. Geometry) output parameters (e.g. pressure ratio)
1) Design of Experiments within the design space of

the sensitivity analysis
One Design represents

one performance map

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Winterthur, 2016
Dynardo GmbH
2 Aim of project
Introduction
Sensitivity analysis scans the design space and evaluates the variance of the
inputs- (e.g. Geometry) output parameters (e.g. pressure ratio)
2) Usage of regression methods (global and local approach)

3) Evaluate sensitivity of input parameters
One operating point of one design

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Dynardo GmbH
Content

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Winterthur, 2016
Dynardo GmbH

Overview
Design 19, 63, 95 and K:

D19: output parameters E lower than K, calculated with 1D flow theory
D95: sufficient output parameter E, potentially interesting designs,
3D CFD analysis of performance map
D63: best design within design space
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Dynardo GmbH

Overview
Workflow:
Driven by optiSLang
Geometry and the
1D flow computation (CFturbo)
Meshing (TurboGrid)
3D CFD of performance map (CFX)

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Winterthur, 2016
Dynardo GmbH

Geometry (CFturbo)
geometry parameters are determined
to generate a 3D geometry (left)
1D flow computation of output
parameters E (right)

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Dynardo GmbH

Meshing (TurboGrid )
3D Geometry (left)
Meshing of periodic segment
with TurboGrid (right)

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Winterthur, 2016
Dynardo GmbH

3D CFD (CFX)
Calculation of Choke Points through
laws of similarity
Afterwards iterative reduction of the
mass flow until highest poly. efficiency
Ein Betriebspunkt kommt selten allein, [7]

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Winterthur, 2016
Dynardo GmbH

results evaluation
Calculation of correlations
response surfaces (MOP) and
the sensitivity of input parameters
E.g. the objective function (ZF):

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Content

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Winterthur, 2016
Dynardo GmbH

Global analysis
global sensitivity study of performance maps
89% successful design points
1% no geometry generation
9% failed meshing
1% problems with ANSYS CFX Solver
Generation of response surfaces

Approximation accuracy is outweighing good
Dissatisfying quality for polytropic efficiency
Good qualitative agreement of 1D and 3D computation results
Meta-
modell
86 93 64 92 84 50 88
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Winterthur, 2016
Dynardo GmbH

Local analysis
Local analysis (185 Designs), e.g. Design 19
Automated export of meridian view (left),
performance maps of pressure ratio
and polytropic efficiency (right)

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Dynardo GmbH

Local analysis
Reference design (42 OP)
n=150.000 1/min
n=140.000 1/min
n=130.000 1/min
n=120.000 1/min
n=110.000 1/min
n=100.000 1/min
n=90.000 1/min

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Winterthur, 2016
Dynardo GmbH

Local analysis
Design 19 (79 OP)
n=150.000 1/min
n=140.000 1/min
n=130.000 1/min
n=120.000 1/min
n=110.000 1/min
n=100.000 1/min
n=90.000 1/min

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Dynardo GmbH

Local analysis
Comparison reference design vs. design 19

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Winterthur, 2016
Dynardo GmbH

1D and 3D flow computation
Metamodell
Measurement
confidence interval
prediction
1D
Metamodell
CFturbo
3D CFD
What's the accuracy of every Modell?
o
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Winterthur, 2016
Dynardo GmbH

1D and 3D flow computation

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Dynardo GmbH
Content

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Winterthur, 2016
Dynardo GmbH

Methodology of adaptive analysis of perfomance maps:
In Sensitivity successful applied for 90% of the designs
Important Parameters for 1D and 3D analysis agree well
Not universal applicable for all turbomachines
improves method for performance maps in 3D-CFD

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Winterthur, 2016
Dynardo GmbH

Result validation through experiments
Geometry (CFturbo):
Access to all parameters (speed, pressure ratio, mass flow)
and systematic analysis of deviations in the performance map
3D CFD (CFX):
Full model and numerical prediction of surge line
Apply methodology to other turbo machines (turbine, pump)
Stochastic evaluation (optiSLang)

Calculate speed lines and designs in parallel
Optimization of performance maps
Answering some question will rise up many new questions.

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Winterthur, 2016
Dynardo GmbH
Thank you for

your attention!
For more information
please visit our homepage:
www.dynardo.com

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Winterthur, 2016

2016 Cadfem

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Ein Betriebspunkt kommt selten allein

effiziente Kennfeldanalyse mit optiSLang

Fachkonferenz zur Numerischen Simulation

1 Introduction of ANSYS optiSLang

2 Aim of the project

3 Method of analyzing performance maps

4 Results of sensitivity analysis

5 Conclusion and outlook

Ein Betriebspunkt kommt selten allein,

Software Development CAE-Consulting

Dynardo is engineering specialist for Geomechanics

Ein Betriebspunkt kommt selten allein,

using CAE-based design sets (and/or data sets)

support of process integration

Ein Betriebspunkt kommt selten allein,

Input Workflow-Management Output

Excel Add-In ANSYS optiSLang other Solver

Ein Betriebspunkt kommt selten allein,

Model Calibration Design Quality

Ein Betriebspunkt kommt selten allein,

Model Calibration Design Quality

Ein Betriebspunkt kommt selten allein,

use non scalar values inside ANSYS Workbench

Ein Betriebspunkt kommt selten allein,

Model Calibration Design Quality

Ein Betriebspunkt kommt selten allein,

Automatic workflow with a minimum of solver runs to:

Ein Betriebspunkt kommt selten allein,

Model Calibration Design Quality

Ein Betriebspunkt kommt selten allein,

User friendly procedure with algorithm to:

Ein Betriebspunkt kommt selten allein,

Model Calibration Design Quality

Ein Betriebspunkt kommt selten allein,

Powerful procedure to check design quality:

Ein Betriebspunkt kommt selten allein,

1 Introduction of ANSYS optiSLang

2 Aim of the project

3 Method of analyzing performance maps

4 Results of sensitivity analysis

5 Conclusion and outlook

Ein Betriebspunkt kommt selten allein,

Implementation of an automated and

Ein Betriebspunkt kommt selten allein,

Ein Betriebspunkt kommt selten allein, [4]

1) Design of Experiments within the design space of

One Design represents

Ein Betriebspunkt kommt selten allein,

2) Usage of regression methods (global and local approach)

One operating point of one design

Ein Betriebspunkt kommt selten allein,

1 Introduction of ANSYS optiSLang

2 Aim of the project

3 Method of analyzing performance maps

4 Results of sensitivity analysis

5 Conclusion and outlook

Ein Betriebspunkt kommt selten allein,

3 Method of analyzing performance maps

Design 19, 63, 95 and K:

3 Method of analyzing performance maps

Ein Betriebspunkt kommt selten allein,

3 Method of analyzing performance maps

Ein Betriebspunkt kommt selten allein,