Nusselt Optimization in Rectangular Ducts with...
Transcript of Nusselt Optimization in Rectangular Ducts with...
Nusselt Optimization in
Rectangular Ducts with
Staggered Arrays of Short Pin
Fins Using STAR-CCM+ and
Optimate+
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Who is MBDA ?
• Created in 2001, MBDA is an industry leader and a
global player in the missile and missile systems sector
• With an unrivalled product portfolio covering the whole
range of land, maritime and airborne requirements
• Prime contractor with more than 45 missile system and
countermeasure programmes in operational service
• Extensive experience of delivering international
programmes including
Meteor, Storm Shadow/SCALP, Aster, Sea Venom,
Taurus
• Supported by three major shareholders:
Airbus Group, BAE Systems, Finmeccanica
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Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Who is MBDA ?
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• Three major multinational programme
families have allowed MBDA entry into
three key market sectors:
- Long-range air-to-air missiles
with the Meteor Programme
- Medium-range surface-to-air
systems with the Aster family
- Deep strike missiles with
Storm Shadow / SCALP and
Taurus
• These three families of programmes are
the core of MBDA’s activity now and in
the future
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Use of STAR-CCM+
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• Thermal analysis team (projects support, multi-physics issues, skill development)
• Using CD-adapco software since 20 years
• Wide panel of multi-physics simulations including :
• Heat flux computation & Conjugate Heat Transfer (Compressive flow, high pressure / high
velocity, plume effect, …)
• , Eulerian-Eulerian, Eulerian-Lagrangian Multiphasic, Multispecies, VOF
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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METZGER validation
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• The METZGER experiment
• Subject
• STAR-CCM+® restitution of Metzger tests
(Metzger, Berry & Bronson Print - ASM
700/Vol104/Nov.1982)
• Modeling heat transfer in rectangular ducts with staggered
arrays of short pin fins.
• Experimental set up
• Air circulating around staggered arrays if short pin fins in
a 5mm high rectangular ducts
• 12 thermally independent arrays of copper blocks with
5mm high pin fins.
• 12 heaters to control cooper block temperature
Flow direction
12 copper blocks arrays with heaters up & down
Staggered arrays of pins fins
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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METZGER validation
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• Modeling description
• 3D steady
• Navier-Stokes + Energy equations
• k-ω turbulence modelling
• Fluid (Air) perfect gas
• Constant thermodynamic & transport properties at standard conditions
• Conjugate heat transfer fluid-solid, solid-solid (with thermal resistance)
• 3D thermal diffusion in the pins and the walls in Copper and in Kapton (Heaters)
• Imposed thermal power on the heaters
• Convective thermal loss on the external sides of the Up. & Low. Heaters
• Adiabatic walls on the Up. & Low. Cu sides elsewhere
• 2 symmetry planes
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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METZGER validation
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• Results example (Tair=300K ; Vref=30m/s ; Power = 2 x 15W per array)
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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METZGER validation
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• Results example (Tair=300K ; Vref=30m/s ; Power = 2 x 15W per array)
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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METZGER validation
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• METZGER validation
• For 2 experiments Reynolds numbers
• Comparison test-simulation on Nusselt numbers sections 2 to 11
• Good overlap for these two Reynolds numbers
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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MBDA & Design optimization
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• Potential value of design optimization
• Collaborative project with CD-adapco® to evaluate the feasibility of
doing design exploration using STAR-CCM+ and Optimate+TM
• On fluid loops using heat exchangers, optimization allows :
• The increasing of thermal exchanges
• The reducing of pressure drop, fluid mass flow, electrical power,
subsystem total mass, …
• In a general way, design exploration technics are motivating for :
• The management of thermal/mechanical/chemical stresses on pieces
• The optimization of trials
• The Improvement of equipment’s performances
Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Optimization Scope
• Pareto optimization of Metzger design
• Parameterize pin geometry from Metzger experiments
• Due to simple geometry STAR-CCM+ 3D-CAD modeler was used
• Identify Pareto front between pressure drop and Nusselt number
• Identify designs that have both lower pressure drop and higher average
Nusselt number
• Single objective optimization of novel pin design concept
• Design concept chosen to include a larger number of parameters
• Evaluate capability to include native CAD parameters in the optimization
workflow
• Select a problem statement that is representative of the kind of design
problems likely to be faced in a production environment
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Metzger Pareto Optimization
• Parameters (6)
• Number of stream wise
pins
• Number of transverse
pins
• Pin diameter
• Ratio of heat exchanger
occupied by pins
• Objectives
• Maximize heat
exchanger average Nu
• Average taken over
entire wetted surface
• Characteristic length
set to hydraulic
diameter
• Minimize pressure drop
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Metzger Pareto Optimization
• 250 designs evaluated
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0
2
4
6
8
10
12
14
16
18
20
250 300 350 400 450 500
Pre
ssu
re D
rop
(kP
a)
Average Nusselt Number
All Designs
Baseline
Better Than Baseline
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Metzger Pareto Optimization
• Possible 2.7% increase in
average Nu for no additional
pressure drop
• Possible 27% reduction in
pressure drop for no loss in
average Nu
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Metzger Exp. Highest Average Nu
Lowest Pressure Drop
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Metzger Pareto Optimization - Conclusions
• Pareto front between pressure drop and average Nu identified
• Identified designs with improvement in either objective
without degradation in the other, particularly effective at
reducing pressure drop
• Room for additional resolution of the Pareto front near the
Metzger design
• Average Nu may not best represent the heat transfer objective
of an industrial design problem
• Apply constraints to objectives in order to focus Pareto
optimization
• STAR-CCM+ optimization was robust and efficient with 3D-
CAD
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Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Novel Pin Design Optimization – Design Concept
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• Parameters (11)
• Number of stream wise
pins
• Number of transverse pins
• Pin length
• Pin width
• Pin height
• Pin angle
• Pin fillets (top, sides,
bottom)
• Pin draft angle
• Heater power output
• Design Considerations
• Heater max temp < 85 C
• Minimize pressure drop
• Maximize heater output
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Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Novel Pin Design Optimization – Background and Methodology
• CATIA V5 used to generate
parametric model
• Mesh
• 1.3 ~ 4.0 M polyhedral cells
• Physics
• Metzger experiments
• Reporting
• 750 iteration moving averages of
pressure drop and max
temperature
• Convergence
• 30 Pa 750 iteration asymptotic
stopping criteria for pressure
drop
• 12000 max iterations
• flags design as error due to lack
of convergence if reached
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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• sdfds
Novel Pin Design Optimization - Results
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Ce document est la propriété de MBDA. Il ne peut être communiqué à des tiers et /ou reproduit sans l’autorisation préalable écrite de MBDA et son contenu ne peut être divulgué. © MBDA 2015.
This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Novel Pin Design Optimization - Results
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All Designs < 86.5 C < 85.25 C Best Design
Temp Pressure Angle Draft Height Nx Ny Length Fillet Radii Width
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This document and the information contained herein is proprietary information of MBDA and shall not be disclosed or reproduced without the prior authorization of MBDA. © MBDA 2015.
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Novel Pin Design Optimization – Results and Future Work
• Successfully incorporated native CAD parameters into an
Optimate+ workflow
• Total study turn around time was < 2 weeks
• Heater max temp yielded results that more closely matched
common design goals than average Nu
• Optimate+ obtained design meeting max temperature
constraint
• Expect continued improvements in pressure drop with
additional runs
• Potential improvements to the geometry
• Increase robustness of CAD parameters (~25% failure rate observed)
• Allow rows of pins to be staggered similar to the Metzger geometry
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