Numerical simulation of the fluid-structure interaction

applied to the reed valves of a miniaturized compressor

under high frequency conditions
Celso Kenzo Takemori
Embraco
Presentation topics
Company Overview (2-3 minutes)
Motivation
Methodology
Part I: Modeling and numerical simulation development
Part II: Numerical simulation as a design tool
Conclusion and next steps
COMPANY OVERVIEW
EMBRACO
Embraco - Products
Specialized in cooling solutions, Embraco is the world leader in
the hermetic compressor market for refrigeration.
Embraco
Founded in March 1971
9 thousand employees
30 million compressors per year
80 countries
862 patents granted in the world
3% of annual net revenue in research and development.
Embraco + Multibras = Whirlpool S.A.
Independent operations
Embraco Global Presence
1 Brazil
Plants of compressors,
casting products,
electronic controls,
electric components,
cooling system components
and assembly
2 China
Compressor plant
3 Slovakia
Compressor plant
4 United States
Sales office and
technical assistance
5 Italy
Compressor plant,
Sales office and technical
assistance
6 Mexico
Sales office and technical
assistance
Motivation
Predict the performance before the construction of a physical
prototype
Main features
Oil free
High frequency
Reduced size and weight
1.0 [kg] 7.9 [kg]
110
230
5
0
1
6
5
Modeling and numerical simulation
development
Part I
Method
Numerical solution
3D transient fluid
dynamics
Coupled with structural
valve dynamics
Initial conditions
3D transient flow equations
Transfer loads to structural model
Solve structural dynamics (beam model)
Transfer displacements to fluid domain
Increment time
Time > End time?
End
Yes
No
Fluid domain
Mathematical modeling
Transient 3D Navier-Stokes
Redlich-Kwong equation of state
SST turbulence model
Energy equation with all terms
Numerical solution
Element based finite volume
method
Moving mesh capabilities
Advection schemes
Upwind
High order
Transient schemes
1st Order Backward Euler
2nd Order Backward Euler
Solid domain
Mathematical modeling
Classical pure bending
Euler beammodel
Equivalent material
properties
Numerical solution
Finite element method
Newmark method for
time integration
f
n
, k
E, I, A, f
n
, k
Compressor specifications and operating conditions
R600a
350 [Hz]
0.52 [cm3]
-5C, 1.31 [bar]
+45C, 6.04 [bar]
182 [cm
3
s
-1
] ~ 198 [cm3 s-1]
Numerical parameters for flow simulation
Timesteps per cycle
400 vs. 800
Convergence criteria
1e-3 vs. 1e-4 RMS
Advection Scheme
Upwind vs. High Resolution
Transient Scheme
1
st
vs. 2
nd
Order
Average mass flow rate Suction and discharge losses
pV power Wall clock time
Timesteps per cycle
Timesteps per cycle 400 800
Advection scheme Upwind Upwind
Transient scheme 1st Order 1st Order
Convergence criteria RMS 1.00E-03 1.00E-03
Average mass flow rate [kg h-1] 1.092 1.097
Indicated power [W] 28.7 28.7
Suction losses [W] 2.17 2.19
Discharge losses [W] 2.82 2.87
Efficiency [kg h-1 W-1] 3.81E-02 3.82E-02
Total wall clock time [h] 31 61
Convergence criteria
Timesteps per cycle 800 800
Advection scheme Upwind Upwind
Transient scheme 1st Order 1st Order
Convergence criteria RMS 1.00E-03 1.00E-04
Average mass flow rate [kg h-1] 1.097 1.099
Indicated power [W] 28.7 28.8
Suction losses [W] 2.19 2.17
Discharge losses [W] 2.87 2.88
Efficiency [kg h-1 W-1] 3.82E-02 3.82E-02
Total wall clock time [h] 61 87
Advection scheme
Timesteps per cycle 400 500
Advection scheme Upwind High Resolution
Transient scheme 1st Order 1st Order
Convergence criteria RMS 1.00E-03 1.00E-03
Average mass flow rate [kg h-1] 1.092 1.092
Indicated power [W] 28.7 28.6
Suction losses [W] 2.17 2.17
Discharge losses [W] 2.82 2.78
Efficiency [kg h-1 W-1] 3.81E-02 3.82E-02
Total wall clock time [h] 31 39
Transient scheme
Timesteps per cycle 800 800
Advection scheme Upwind Upwind
Transient scheme 1st Order 2nd Order
Convergence criteria RMS 1.00E-03 1.00E-03
Average mass flow rate [kg h-1] 1.097 1.099
Indicated power [W] 28.7 28.6
Suction losses [W] 2.19 2.2
Discharge losses [W] 2.87 2.87
Efficiency [kg h-1 W-1] 3.82E-02 3.84E-02
Total wall clock time [h] 61 93
1,280
1,285
1,290
1,295
1,300
1,305
1,310
6,0 6,5 7,0 7,5 8,0 8,5 9,0
P
r
e
s
s
u
r
e

[
b
a
r
]
Time [ms]
TS400, Up, 1e-3
TS800, Up, 1e-3
TS800, Up, 1e-4
TS500, HR, 1e-3
Local results Pressure oscillations 1
st
order
Probe
1,280
1,285
1,290
1,295
1,300
1,305
1,310
6,0 6,5 7,0 7,5 8,0 8,5 9,0
P
r
e
s
s
u
r
e

[
b
a
r
]
Time [ms]
TS400, Up, 1e-3, 1st
TS800, Up, 1e-3, 2nd
TS400, Up, 1e-3, 2nd
Local results Pressure oscillations, 1
st
vs. 2
nd
order
Probe
6,025
6,030
6,035
6,040
6,045
6,050
6,055
6,060
6,065
6,0 6,5 7,0 7,5 8,0 8,5 9,0
P
r
e
s
s
u
r
e

[
b
a
r
]
Time [ms]
TS400, Up, 1e-3
TS800, Up, 1e-3
TS800, Up, 1e-4
Local results Pressure oscillations
TS400 vs. TS800, 1st order
Probe
Local results Pressure oscillations
6,025
6,030
6,035
6,040
6,045
6,050
6,055
6,060
6,065
6,0 6,5 7,0 7,5 8,0 8,5 9,0
P
r
e
s
s
u
r
e

[
b
a
r
]
Time [ms]
TS800, Up, 1e-4, 1st
TS800, Up, 1e-3, 2nd
TS400, Up, 1e-3, 2nd
Probe
Numerical simulation as a design
tool
Part II
Newoperating conditions
Replace R600a for R134a as a working fluid
-5C, 1.31 [bar]
+45C, 6.04 [bar]
+15C, 4.88 [bar]
+55C, 14.9 [bar]
Project inside Workbench 12
Geometry
Geometry divided into
subdomains to improve mesh
quality
Valve dynamics
verification MFX setup
(Structural side)
Contact
verification
CFX could
be added
Geometry 99% parameterized
MFX Setup (Structural side)
Usual transient
setup
Fluid solid
interface
MFX Setup (Fluid side)
ANSYS
MultiField
MFX Setup (Fluid side)
ANSYS
MultiField
Discharge valve
Displacement Stress
Suction valve
Displacement Stress
Fluid domain
Real prototype
Results
4,10
4,15
4,20
4,25
4,30
4,35
4,40
4,45
M
a
s
s

f
l
o
w

[
k
g

h
^
-
1
]
Estimated
Measured
Conclusions and next steps
The virtual and the real prototypes works under high
frequency
The analyzed numerical parameters did not show influence on
global results, except wall clock time
In other words, dissipative methods can give good results in
shorter times
High order transient scheme is recommended for high frequency
noise studies
Evaluate the influence of mesh refinement and turbulence
modeling