Turbine, Pump & Compressor (Axial or Centrifugal): Multidisciplinary Turbomachinery Design, Analysis & Optimization
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
Starting from the preliminary design, our engineers progresses through a 1D inverse task solver optimizer, to continue with meanline (1D) and axisymmetric (2D) analysis, profiling and 3D blade design, 3D finite element analysis (FEA) for structural calculations, secondary air flow hydraulic and thermal calculations (including cooling), rotor design, bearing analysis, rotor dynamics and 3D CFD calculations. We can design axial turbines, Axial Pump, Centrifugal Compressor, Centrifugal Pump and Mixed Flow Compressor/Turbine with or without any pre-loaded profiles, with prismatic (cylindrical) or twisted blades, multiple extractions/injections, inter-stage heat exchangers, Curtis & Rateau stages, impulse & reaction designs, drilled and reamed nozzles, partial admission, etc.
Control Stages can even be designed with the backpressure optimized for overall machine efficiency. Our service for Turbine, Pump & Compressor include:
- Analyze existing turbine, pump and Compressor (axial or centrifugal) and their performance at design and off-design conditions
- Redesign, optimize, rerate and upgrade existing turbine, pump and Compressor (axial or centrifugal)/components
- Reverse engineer turbine, pump and Compressor (axial or centrifugal) designs
- Troubleshoot and correct efficiency/reliability issues in existing hardware
- Optimize cooling configuration and flows for new and existing turbine, pump and Compressor (axial or centrifugal)
- Aero-thermodynamic calculations of blades and endwalls cooling taking into account the mixing losses and the change of working fluid temperature
- Determine streamwise and spanwise distribution of kinematics, thermodynamics and loss parameters as well as leakages and secondary air flows (including cooling) for a given set of boundary conditions.
- Turbine, pump and Compressor (axial or centrifugal) flow optimization calculations including through the use of a DOE approach (Design Of Experiment)
- Aerodynamic shape optimization of turbomachinery blades to express 3D structural, modal and harmonic analysis using a finite element analysis (FEA) method.
- Computational Fluid Dynamics (CFD) software used for 3D flow analysis in blade-to-blade channels of turbine, pump and Compressor (axial or centrifugal), for subsonic, transonic and supersonic flows, using full 3D CFD formulation (Navier-Stokes, viscous with various turbulence models (standard k-e, k-e RNG, k-w, k-w SST models)).
- Turbine, pump and Compressor (axial or centrifugal) Bearing Analysis and Design
- Steady-state, transient, and map analysis to calculate the bearings different hydrodynamic and mechanical characteristics
- Turbine, pump and Compressor (axial or centrifugal) Cooling Flows & Secondary Systems Design and simulation
Our engineering experts have been performing rotor dynamic analysis and working to ensure that no destructive vibrations will occur in the rotor-bearing-support system. We can carry out extremely complicated studies related to unbalanced rotating mass behavior to save you precious time:
- Calculations of lateral, axial, and torsional vibrations
- Campbell diagram analysis for damped and undamped systems
- Unbalance or transient response calculations
- Computation of rotor system with clearances, full and partial rubbing, external and internal friction, and definition of instability thresholds
- Computation of rotor system with nonlinear journal/rolling bearings, squeeze-film dampers, and other types of rotor studies
The range of our analytical capabilities is unmatched in the consulting industry, particularly in the area of Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) analysis. Our engineering team uses the latest FEA and CFD tools and methodologies to determine product configuration and perform optimization, cost and weight reduction, life prediction, system performance evaluation, and failure investigation of mechanical systems. Our engineers are well-versed in many analysis applications, including FEA and CFD.
Enteknograte’s engineering team use CFD software’s such as Siemens Star-ccm+, Ansys Fluent and Numeca Fine/Turbo in co-simulation with FEA structural solvers, such as Abaqus, Ansys and MSC Nastran.
Finite Element Analyses:
- Linear and Non-Linear
- Static, Dynamic and Seismic
- Thermal (Steady-State and Transient)
- Cyclic Fatigue and Fracture Mechanics
- Coupled field CFD-Thermo-Structural (Steady State and Transient)
CFD/Aero-Thermo Dynamics Analysis:
- Compressible, incompressible and supersonic flows
- Laminar and turbulent flows
- Flows with conjugate heat transfer
- Multiphase flows
- Engine installation and ventilation
- Combustion systems
- Turbomachinery design
Fatigue/Fracture Mechanics:
- Hand calculations
- Goodman assessment
- Low-Cycle Fatigue (LCF)
- High-Cycle Fatigue (HCF)
- Crack growth
- Residual life
Bearings/Seals Simulation:
- Journal, Thrust Bearings
- Fixed and Tilting Pad Geometries
- Ball Bearings
- Incompressible and Compressible Lubricants
- Gas Foil Bearings
- Hydrodynamic, Hydrostatic, or Hybrid
- Squeeze Film Dampers
- Annular Seals
Rotor Dynamic Analysis:
- Drive systems
- Critical speed
- Lateral and Torsional Natural Frequency and Corresponding Modes Shape (damped and undamped)
- Stability Analysis
- Unbalance Response (variable speed)
- Time-Transient Response (torsional)
WE WORK WITH YOU
We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.
Enteknograte offers a Virtual Engineering approach with CFD tools such as MSC Cradle, Ansys Fluent, StarCCM+ for flows simulation and FEA based Codes such as MSC Softwrae(Simufact, Digimat, Nastran, Marc, Actran Acoustic solver), ABAQUS, Ansys and LS-Dyna, encompassing the accurate prediction of in-service loads, the performance evaluation, and the integrity assessment including the influence of manufacturing the components.
Finite Element Analysis of Durability and Fatigue Life: Ansys Ncode, Simulia FE-Safe
The demand for simulation of fatigue and durability is especially strong. Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Turbomachinery Generative Design & Optimization
The sensitivity information comes directly from the flow field so the optimized shape is the one that fits the given flow best. Unlike traditional design methods that rely on trial and error between a given geometry and flow field predicted by CFD codes, we use 3D inverse design method starts by identifying what we want to do to the fluid flow in terms of 3D pressure field and mathematically derives the optimal geometry to achieve that outcome. This significantly reduces the time taken for each design.
Read more... Heat Transfer Simulations for Turbomachinery
Including FSI Effect with Coupled FEA & CFD
We can calculate a wide spectrum of heat-related calculations, including startup and shutdown cycles, thermal warp effects on static elements (casings and exhaust hoods), on shafts, heat transfer analysis, warp and displacement of ceilings. We can also help you calculate predictions of a machine’s behavior on transient operational modes with high-fidelity modeling, closer to the real behavior of products..
Read more... Cavitation in Propulsion Systems
CFD Analysis of Propulsion Systems and Cavitation for Marine and Shipbuilding Industry
For water pumps, marine propellers, and other equipment involving hydrofoils, cavitation can cause problems such as vibration, increased hydrodynamic drag, pressure pulsation, noise, and erosion on solid surfaces. Most of these problems are related to the transient behavior of cavitation structures. To better understand these phenomena, unsteady 3D simulations Modeling Cavitation of cavitating flow around single hydrofoils are often performed and the results are compared to experiments.
Read more... 1D/3D Coupled Simulation and Co-Simulation: Detailed Chemistry & Multiphase Flow Modeling with 1D Modeling
Enteknograte engineering team use advantage of CFD solver’s detailed chemistry, multiphase flow modeling, and other powerful features in coupling and co-simulation of CFD (Siemens Star-ccm+, AVL Fire, Ansys Fluent, Converge), 1D systems softwares (Matlab simulink, GT-Suite, Ricardo Wave allowing 1D/3D-coupled analyses to be performed effortlessly) and FEA software (Abaqus, Ansys, Nastran) for engine cylinder coupling, exhaust aftertreatment coupling, and fluid-structure interaction coupling simulation.
Read more... Hydrodynamics CFD simulation, Coupled with FEA for FSI Analysis of Marine and offshore structures
Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, Cavitation, Vibration and Fatigue
Hydrodynamics is a common application of CFD and a main core of Enteknograte expertise for ship, boat, yacht, marine and offshore structures simulation based design. Coupling Hydrodynamic CFD Simulation in Ansys Fluent, Siemens Star-ccm+ and MSC Cradle with structural finite element solver such as Abaqus and Ansys, enable us to Simulate most complicated industrial problem such as Cavitation, Vibration and Fatigue induced by hydrodynamics fluctuation, Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, considering two way FSI (Fluid Structure Interaction) coupling technology.
Read more... Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation
Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.
Read more... Turbine, Pump & Compressor (Axial or Centrifugal)
Multidisciplinary Turbomachinery Design, Analysis & Optimization
We can design axial turbines, Axial Pump, Centrifugal Compressor, Centrifugal Pump and Mixed Flow Compressor/Turbine with or without any pre-loaded profiles, with prismatic (cylindrical) or twisted blades, multiple extractions/injections, inter-stage heat exchangers, Curtis & Rateau stages, impulse & reaction designs, drilled and reamed nozzles, partial admission, etc. Enteknograte’s engineering team use CFD software’s such as Siemens Star-ccm+, Ansys Fluent and Numeca Fine/Turbo in co-simulation with FEA structural solvers, such as Abaqus, Ansys and MSC Nastran.
Read more... Electromagnetic Multiphysics
FEA & CFD Based Simulation Including Thermal Stress, Fatigue, and Noise, Vibration & Harshness – NVH for Electric Motors
Enteknograte Finite Element Electromagnetic Field simulation solution which uses the highly accurate finite element solvers and methods such as Ansys Maxwell, Simulia Opera, Simulia CST, JMAG, Cedrat FLUX, Siemens MAGNET and COMSOL to solve static, frequency-domain, and time-varying electromagnetic and electric fields includes a wide range of solution types for a complete design flow for your electromagnetic and electromechanical devices in different industries.
Read more... Aerodynamics Simulation: Coupling CFD with MBD, FEA and 1D-System Simulation
Aerodynamics studies can cover the full speed range of low speed, transonic, supersonic and hypersonic flows as well as turbulence and flow control. System properties such as mass flow rates and pressure drops and fluid dynamic forces such as lift, drag and pitching moment can be readily calculated in addition to the wake effects. This data can be used directly for design purposes or as in input to a detailed stress analysis. Aerodynamics CFD simulation with sophisticated tools such as MSC Cradle, Ansys Fluent and Siemens Star-ccm+ allows the steady-state and transient aerodynamics of heating ventilation & air conditioning (HVAC) systems, vehicles, aircraft, structures, wings and rotors to be computed with extremely high levels of accuracy.
Read more... Aerodynamic Noise Simulation
Sound caused by pressure oscillation of fluid, such as wind noise, and sound caused by resonance can be predicted using Large Eddy Simulation (LES) and a weak compressible flow model. A Fast Fourier Transform calculation can be used within the CFD software to predict the frequency of noise. Predicting the noise generated by complex flows from steady CFD solutions allows us to study the noise generated by turbulent flows from CFD solutions.
Read more... Creep and Creep-Fatigue Interactions
considering Creep-Fatigue interaction in high temperature simulations identifies whether fatigue and/or creep are the dominant damaging mechanisms, thus allowing re-design to focus on the relevant damage mechanisms and significantly reduce pre-service component testing.
Read more... Vibration Fatigue Finite Element Simulation: Time & Frequency Domain
Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.
Read more... Finite Element Analysis of Durability and Fatigue Life
Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Read more... Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation
We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.
Read more... Acoustics and Vibration: FEA and CFD for AeroAcoustics, VibroAcoustics and NVH Analysis
Noise and vibration analysis is becoming increasingly important in virtually every industry. The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.
Read more... Multi-objective Design & Optimization of Turbomachinery: Coupled CFD & FEA
Optimizing the simulation driven design of turbomachinery such as compressors, turbines, pumps, blowers, turbochargers, turbopumps, centrifugal compressors, radial turbines, hydraulic turbines, low speed to transonic fans and torque converters offers enormous potential. . Our experience covers all branches of turbomachinery design and related fields of knowledge including: aerodynamics, hydraulics, thermodynamics, Acoustics, structural, Computational Fluid Dynamics and Finite Element Analysis.
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