CFD meshing on Turbocharger

Aim:

To Check for the geometrical errors, make appropriate volumes of the given model, and perform surface and volumetric mesh.

Given:

1. Blade stage-1 = 1 mm
2. Blade stage-2 = 1 mm
3. Impeller = 2 mm
4. Shaft rotor = 1 mm
5. Turbo casing = 5 mm
6. Compressor casing = 5 mm
7. Inlet casing cover = 5 mm

Procedure:

Step : 1 Topological Clean up of the Model

1. Import CAD model in ANSA. (Open ANSA ⇒File ⇒ Select appropriate CAD Model)
2. To check for Geometrical checks errors like single Cons, Double cons and Surface overlaps.
3. For Checking geometrical errors. (Tools ⇒checks⇒Geometric⇒Select single cons, triple cons, etc and then execute)
4. 
5. Clear error using Modules like Faces (Cut, Delete, Topo, Intersect), Hot Points (Insert, Project, Multi-project), Cons(Fill Hole, Release), and Auxiliaries(Fine).
6. Topo option is used to convert single cons into double cons by combining two single cons.
7. Release option is the opposite function of Topo which is used to convert double cons into single con.
8. Intersect option is used to intersect two faces.

While doing Topological clean up, try to make as a single geometry which is effective in Volumentric mesh.

Step:2 Assign PID

Compression casing:

Turbo casing:

Blades,shaft and Impeller:

Step : 3 Surface Mesh

Compressor casing, Turbo casing, Inlet casing cover - 5mm.

Compressor casing:

Turbo casing:

Inlet casing cover:

Blades and shaft:

Blade stage-1 - 1mm

Blade stage 2 - 1mm

Shaft - 1mm

Impeller - 2mm

Step: 4 - Volumentric Mesh

1. To perform volumetric mesh, surface mesh should be completed.
2. Combining different geometry into single geometry so that less no. of geometry will be auto-detected by ANSA.
3. Delete the thickness of the geometry because the fluid does not flow on the outer surface.

Conclusion:

From the above image, we can observe that the size of the volumetric mesh differs with respect to surface mesh, so indeed surface mesh is mandatory for doing volumetric mesh.