Abstract

High-fidelity simulation of transitional and turbulent flows over multi-scale surface roughness presents several challenges. For instance, the complex and irregular geometrical nature of surface roughness makes it impractical to employ conforming structured grids, commonly adopted in large-scale numerical simulations due to their high computational efficiency. One possible solution to overcome this problem is offered by immersed boundary methods, which allow wall boundary conditions to be enforced on grids that do not conform to the geometry of the solid boundary. To this end, a three-dimensional, second-order accurate boundary data immersion method (BDIM) is adopted. A novel mapping algorithm that can be applied to general three-dimensional surfaces is presented, together with a newly developed data-capturing methodology to extract and analyze on-surface flow quantities of interest. A rigorous procedure to compute gradient quantities such as the wall shear stress and the heat flux on complex non-conforming geometries is also introduced. The new framework is validated by performing a direct numerical simulation (DNS) of fully developed turbulent channel flow over sinusoidal egg-carton roughness in a minimal-span domain. For this canonical case, the averaged streamwise velocity profiles are compared against results from the literature obtained with a body-fitted grid. General guidelines on the BDIM resolution requirements for multi-scale roughness simulation are given. Momentum and energy balance methods are used to validate the calculation of the overall skin friction and heat transfer at the wall. The BDIM is then employed to investigate the effect of irregular homogeneous surface roughness on the performance of an LS-89 high-pressure turbine blade at engine-relevant conditions using DNS. This is the first application of the BDIM to realize multi-scale roughness for transitional flow in transonic conditions in the context of high-pressure turbines. The methodology adopted to generate the desired roughness distribution and to apply it to the reference blade geometry is introduced. The results are compared to the case of an equivalent smooth blade.

1 Introduction

Representing realistic engineering geometries within computational fluid dynamics (CFD) simulations is conventionally achieved by solving the equations of fluid motion on computational grids conforming to the shape of the body, that is, using body-conformal grids. More numerous and finer-scaled geometries demand more grid points to resolve, as will higher Reynolds numbers, which tend to demand ever finer grids near the body’s surface for high-fidelity CFD. Additionally, it is also often not clear a priori what the grid resolution requirements may be, such that generating grids for complex geometries tends to require an iterative approach [1]. Thus in the trend toward realistic geometries and flow conditions, solving for the fluid flow to a high accuracy becomes increasingly challenging with increasing geometrical complexity and increasing Reynolds number as encountered in practical engineering applications. Furthermore, given the prevalence and variety of in-service roughness found on turbomachinery components [2], accurate numerical prediction of blade performance demands faithful representation of this roughness. Adequate resolution of micro-scale features on the surface of a body is especially challenging: compared to smooth-wall or regular roughness studies, a much smaller number of direct numerical simulations (DNS) of realistic, irregular rough surfaces has been attempted [3,4]. Especially in the case of generalized, irregular roughness as introduced in the present work, and further discussed in Part II of this paper [5], it becomes impractical to generate new grids for conventional body-conformal CFD for each roughness topology, especially as different roughness parameters, such as height, or the extent of the roughness, must be varied to gain insight on the effect of the roughness on the fluid field.

Immersed boundary (IB) methods, where wall boundary conditions are enforced on grids that do not conform to the geometry of the body or solid boundary, are a valid alternative. The technique was first introduced in the 1970s to simulate cardiac mechanics with elastic boundaries and the associated blood flow as a fluid–structure interaction problem at low Reynolds number [6]. The technique was subsequently extended to model rigid bodies by the addition of artificial body forces to the fluid equations of motion in an effort to drive the velocity field near the boundary to the desired boundary value. The so-called direct forcing method [7] introduces a force distribution that depends on the velocity field, and it can be seen as an artificial response of the body necessary to directly cancel the error in this boundary value at each time-step. For this reason, an additional set of equations (often in the form of a spring-damper system) needs to be solved at every time-step, increasing the computational cost. Moreover, the numerical stability requirements of these equations often pose strong constraints on time-step size. Another drawback of these direct forcing approaches is that the resulting forcing functions are not designed to satisfy the underlying conservation laws for the cells in the vicinity of the immersed boundary, and such methods are not easily extended to general interfacial conditions such as Neumann boundary conditions [8]. In addition, direct forcing methods are in general first-order accurate in the L norm, and generate spurious pressure fluctuations in the region of the immersed body, resulting from a jump in the velocity across the boundary before the projection step [9]. This is especially problematic for turbomachinery applications where surface pressure on the body is a key quantity of interest. Strict global and local conservation of mass and momentum can only be guaranteed by resorting to a finite-volume approach near the IB, which is the motivation for cut-cell finite-volume IB methods (e.g., for two-dimensional flow [10]). Extending this approach to three dimensions is nontrivial as the cut-cell procedure leads to complex polyhedral cells and discretization of the full Navier–Stokes equations on such polyhedral cells is challenging [1]. Despite the challenges of IB methods, they have been pursued actively in the literature, since, in addition to the complication of grid generation when using body-conformal grids, Cartesian-grid solvers used with IB methods have the potential to generate solutions to complicated problems orders of magnitude faster than conventional body-fitted-grid solvers since, due to grid regularity, solvers can benefit from the use of simple, accurate, and robust numerical methods [8].

The boundary data immersion method (BDIM) was first introduced by Weymouth and Yue [8]. Its derivation is based on a general integration kernel formulation allowing the field equations of each domain (i.e., fluid and solid body) and the interfacial conditions to be combined analytically via a meta-equation. The initial formulation of the BDIM is general, therefore it can be applied to a variety of solid/fluid systems including immersed no-slip (such as in the present work) as well as free-slip bodies. By altering the analytic form of the fluid equations, the method ensures exact enforcement of the boundary data and maintains physically consistent behavior near the smoothed interface representing the solid object. Moreover, the BDIM does not incur time-step penalties as other forcing-based methods because it does not require the solution of any additional equations. This is fundamental for high-Re studies, where the time-step is already small and the overall computational cost is high. While the no-slip formulation matches the direct forcing method mentioned above closely, a prominent feature of the BDIM is an additional modification to the pressure term analogous to the discrete operator adjustments of sharp-interface methods (being another class of IB methods where the communication between the moving boundary and the flow solver is accomplished by explicitly modifying the computational stencil near the IB, and both conservation equations are altered). Thus the projection issues for direct forcing methods [9] are avoided. Whereas sharp-interface methods alter the discrete operators, and BDIM alters the analytic equations near the embedded boundary. This allows for simple implementation within existing flow solvers regardless of the geometry being simulated. Building on this initial BDIM formulation, Maertens and Weymouth [11] improved the method’s ability to tackle intermediate Reynolds numbers through the addition of a higher-order term to the integral formulation. The present formulation was extended by Schlanderer et al. [12] to compressible viscous flow.

The present work introduces a framework that exploits an IB method, the BDIM, for high-fidelity simulations of transitional and turbulent flows over multi-scale rough surfaces, with a particular focus on turbomachinery components at engine-relevant conditions. The framework is based on the original mathematical formulation of the BDIM, but includes a new algorithm, here discussed, that extends its applicability to general three-dimensional non-conforming surfaces. This paper also introduces a novel approach to compute and interpret the on-surface data obtained for general non-conforming geometries. In particular, a mathematical approach to derive the wall shear stress and the heat flux on non-smooth walls is introduced. The method is validated in the case of a turbulent channel with egg-carton roughness and on a smooth high-pressure turbine (HPT) blade at engine-relevant conditions. Finally, a new computational setup that exploits the advantages of the BDIM to perform first-of-a-kind high-fidelity simulations of a high-pressure turbine blade with roughness is presented.

2 Three-Dimensional Boundary Data Immersion Method

The generalized mathematical formulation adopted in this work can be found in Refs. [11,12] and will only be summarized here. The algorithm used to discretize the BDIM equations in the case of general three-dimensional surfaces is introduced.

2.1 Mathematical Formulation for Three-Dimensional Geometries.

The idea behind the BDIM is to divide the overall computational domain into two sub-regions, the fluid domain Ωf and the solid body domain Ωb, each characterized by their individual governing equations. The fluid domain is governed by the Navier–Stokes equations, while the solid body is generally characterized by prescribed values of velocity and temperature. The BDIM introduces an interface of finite thickness Ωε between the two domains, with the scope of blending the solutions from the individual sub-domains using some weighting functions. This interface is referred to as smoothing region, and its half-width is indicated with ε. A schematic is shown in Fig. 1. Indicating with Φ(x,t) a generic flow primitive variable (either velocity or temperature) as a function of position and time, x and t, the following second-order accurate meta-equation is solved in the smoothing region:
(1)
Φf, Φb, and Φε are the values of Φ obtained for each sub-domain, fluid, body, and smoothing region, respectively. μ0ε and μ1ε are the weighting functions, also called zeroth and first moment of the BDIM kernel, and their expressions are provided in Ref. [12]. They only depend on the signed distance between the considered point and the solid boundary. ∂/∂n indicates a partial derivative in the direction orthogonal to the solid boundary.
Fig. 1
Domain decomposition and visual representation of the smoothing region Ωε. The values of the zeroth moment μ0ε across the smoothing region are shown.
Fig. 1
Domain decomposition and visual representation of the smoothing region Ωε. The values of the zeroth moment μ0ε across the smoothing region are shown.
Close modal
Equation (1) is discretized by computing the values of μ0ε and μ1ε on the computational grid. This requires mapping the position of the solid boundary with respect to the computational grid, which is achieved by first discretizing the boundary using triangular elements. Each triangular element is characterized by the coordinates of its vertices (nodes) and a connectivity mapping that defines the order in which the nodes are connected. This is necessary to univocally determine the element outward unit normal vector, which allows us to mathematically distinguish the inside and the outside of the solid body. Indicating with v1, v2, and v3 the coordinates of the three nodes that form the triangle, in the order specified by the connectivity, we can define the outward unit normal vector as
(2)
where × indicates the cross product between two vectors and the L2-norm of a vector. A schematic representation of a triangular element is shown in Fig. 2. To determine whether a point x of the fluid domain belongs to the smoothing region Ωε, it is necessary to compute its signed distance dt from the closest triangular element and determine whether (i) its value lies between ε and ε and (ii) its projection on the plane containing the element is inside the triangle. If both conditions are satisfied, x belongs to the smoothing region: Eq. (1) can be solved by computing μ0ε and μ1ε from dt and by using the triangle normal n to compute the partial derivatives. If x satisfies (i) but not (ii), it is necessary to check the signed distance de between x and the closest edge of the triangle. x belongs to the smoothing region if (i) εdeε and (ii) its projection on the line containing the edge of the triangle lies on the segment. If both conditions are satisfied, μ0ε and μ1ε are computed from de, while the partial derivatives are computed along the direction orthogonal to the edge and containing x. Otherwise, the point will not be considered part of the smoothing region.
Fig. 2
Schematic of a triangular surface element. The unit tangential vector t→1, also indicated as t→xy, lies on the intersection between the surface of the triangle and a plane parallel to x − y.
Fig. 2
Schematic of a triangular surface element. The unit tangential vector t→1, also indicated as t→xy, lies on the intersection between the surface of the triangle and a plane parallel to x − y.
Close modal

For static bodies, the weighting functions and the normal unit vectors are computed only once, at the beginning of the simulation. For moving or deformable boundaries, they have to be computed at every time iteration. Equation (1), on the other hand, is enforced at every time iteration, for both static and moving geometries.

2.2 Surface Data-Capturing and Analysis.

On-surface data provide direct quantitative information on the effect of the flow on an immersed body or a rough surface on the flow. For this reason, instantaneous on-surface data are collected at regular intervals during run-time. The data collection procedure is composed of three steps, which can be summarized as follows:

  • A series of on-surface data collection points based on the BDIM geometry is defined.

  • The location of the collection points, due to the non-conforming nature of the solid boundary, is mapped onto the computational grid. In the case of non-moving solid bodies, as in the present work, these preliminary steps are performed once per simulation, in the pre-processing stage. For moving or deforming geometries, the computation of the collection points and the location mapping have to be repeated at every collection time-step.

  • The desired flow variables of interest are then computed at the collection points at each capturing time interval by means of interpolation.

As introduced in Sec. 1, one of the key aspects of the BDIM is the presence of a smoothing region at the interface between the fluid domain and the solid body, where the velocity and the temperature of the fluid are modified according to Eq. (1) to simulate the effect of the solid body. For this reason, the values of the flow variables in this region are considered non-physical, as they are not a result of the direct numerical solution of the Navier–Stokes equation. Following Schlanderer et al. [12], flow quantities are thus collected outside of the smoothing region, at a distance of ε from the body surface. Due to this offset, it has been shown that the wall-normal gradients can sometimes be slightly under-predicted with respect to those computed on an equivalent body-fitted grid [12]. This is not a specific problem related to the BDIM, but occurs in other immersed boundary approaches as well [13].

Given the generic flow variable ψ(x,t) (either a scalar or the scalar component of a vector or a tensor), we indicate with ψi the value of ψ corresponding to the ith triangular surface element. ψi can be extracted from the flow computational grid by interpolating its value at the centroid of the triangle, or by interpolating at its nodes and then computing its surface average. Both methods are presented.

2.2.1 Data Collection at the Centroids.

Surface data collection points can be defined by offsetting the location of each triangular element centroid by ε along the outward normal. The collection point xc,i of the ith element can therefore be defined as follows:
(3)
with xb,i=(vi,1+vi,2+vi,3)/3 being the coordinates of the centroid determined from the nodes of the element. This results in one collection point per element. A search algorithm is then employed to map the location of xc,i onto the three-dimensional, structured fluid grid. This is achieved by identifying the indices of the eight grid points forming the cubic cell that encloses xc,i. The distance of each of these grid points from xc,i is computed. Subsequently, the flow variables of interest at the neighboring grid points are interpolated at xc,i by means of a trilinear method.

2.2.2 Data Collection at the Nodes.

In this case, the collection points are defined with respect to the nodes of each triangle, such that
(4)
where j = 1, 3 is the index of the three nodes that form the ith triangle, vi,j are the coordinates of the nodes, and ni,j* is the unit normal vector of each node. ni,j* is defined as the average of the normals of the triangles that share the considered node. At this point, the required variables are collected at each capturing point using the interpolation method previously introduced. The value of the generic variable ψi for the ith element is then obtained by averaging the values collected at the nodes ψi,j as follows:
(5)
A simplified two-dimensional example to explain the difference between the two approaches is shown in Fig. 3. The contours indicate the instantaneous spanwise vorticity field of a two-dimensional plane extracted from the suction side of a high-pressure turbine blade flow with surface roughness. The figure shows details of the flow over a single small-scale roughness element. It can be observed that due to the nature of the geometry and because of the discretization by means of planar triangular elements, the largest gradients are localized in the vicinity of the element nodes. For this reason, given the same number of elements, collecting the flow variables at the nodes often yields more accurate results. This can help limiting the size of the surface discretization, especially when dealing with micro-scale roughness. By increasing the number of elements, the two methods converge to the same result. In this work, all the on-surface data-capturing is performed at the element nodes.
Fig. 3
Comparison between the data collection approaches: (a) at the centroids and (b) at the nodes. Capturing at the nodes often yields more accurate results because the largest gradients are localized at the interface between elements.
Fig. 3
Comparison between the data collection approaches: (a) at the centroids and (b) at the nodes. Capturing at the nodes often yields more accurate results because the largest gradients are localized at the interface between elements.
Close modal

2.2.3 Wall Shear Stress and Heat Flux.

The Navier–Stokes equations are numerically solved on the flow computational grid. Hence, some variables such as the wall shear stress and the heat flux, because of their dependence on the local orientation of each surface element, require an additional step to be computed.

The wall shear stress is defined as the wall-normal derivative of the velocity tangential to the wall. As shown in Fig. 2, for each triangular element, we can univocally define a unit tangential vector t1 from the intersection between the plane containing the element and the xy plane and such that t1i>0. Because of its definition, we will also refer to this vector as txy. In the case that the triangular element lies on the xy plane, we assume t1=i. From n and t1, we can then define t2 as
(6)
At this point, the following expression for the wall shear stress vector can be introduced:
(7)
where
(8)
Here, μ indicates the molecular viscosity of the fluid and VT the gradient of the velocity vector, transposed. The wall shear stress τw,i for the ith triangular element can thus be computed by first interpolating the values of Vi and μi following one of the two procedures previously introduced, and then applying Eq. (7).
Similar considerations apply to the evaluation of the heat flux Q, defined as
(9)
Here, Pr is the Prandtl number, γ is the heat capacity ratio, Mref is the reference Mach number, and T is the flow temperature. In this case, μi and Ti are extracted first, then Qi is computed.

2.2.4 Normalization by Reference Area.

Since roughness increases the surface area exposed to the flow with respect to an equivalent smooth geometry, it can be useful to introduce a normalization based on a reference smooth area. This is achieved by mapping each triangular element of the rough surface onto an equivalent element of the reference smooth surface by projecting its nodes, as shown in Fig. 4. Indicating with A the area of an element of the rough blade, we can therefore compute its reference area As obtained from the projection. Similarly, we can compute a reference tangential direction t1s defined with respect to the reference element.

Fig. 4
Projection of a triangular element from a rough geometry (top triangle) on a reference smooth surface (bottom triangle)
Fig. 4
Projection of a triangular element from a rough geometry (top triangle) on a reference smooth surface (bottom triangle)
Close modal

2.2.5 Spanwise Averaging.

For cases in which both the geometry and the flow are homogeneous in one direction, it might be of interest to perform a spatial averaging. Since the surface triangular elements form an unstructured grid, it is necessary to separate the elements into groups, here referred to as bins. For the present work, spatial averaging will always be performed in the spanwise direction. For this reason, we can use the x coordinates to create the averaging bins. Indicating with x1 and x2 the boundaries of the jth bin, we consider as belonging to that bin the Nbin elements for which the x coordinate of their centroid xb lies within the boundaries. The bin is identified by the coordinate xj = (x1 + x2)/2. The spanwise averaging for the generic variable ψ can therefore be expressed as follows:
(10)
The spanwise averaging of surface data will be used to compare surface data between a turbine blade with roughness and an equivalent smooth blade in Sec. 3.2.5.

3 Results

The BDIM has been extensively validated in the context of two-dimensional simulations over a range of test cases of different complexity including the flow around a cylinder, turbulent boundary layers, and airfoil trailing edge noise [12]. The purpose of this work is to provide a numerical framework to investigate transitional and turbulent flows over multi-scale roughness. Hence, the validations discussed here serve to demonstrate that the numerical method is able to accurately predict the various flow mechanisms that are relevant to the topic. Schlanderer et al. [12] already demonstrated the capabilities of the BDIM to correctly simulate the transient growth of oblique instabilities in a supersonic flat plat boundary layer. The framework not only accurately captured the amplitude of the velocity, temperature, and density perturbations but also the growth rate, which is a strong endorsement for the method’s suitability for compressible transitional flow. The accuracy has been demonstrated also in the case of a plate not aligned with (and hence not conforming to) the underlying fluid computational grid. It is worth repeating that the numerical formulation of the BDIM has not changed in this work, we only propose a new point-mapping algorithm that can extend the current capabilities to simulate general complex three-dimensional geometries.

In the context of transitional and turbulent flows over complex surfaces, it is worth mentioning the recent work of Ananth et al. [14], in which the BDIM is successfully applied to assess the performance of riblets with different shapes. In this case, the BDIM has also been shown to be able to simulate the effect of a roughness element to trigger the boundary layer transition.

Here, we present a validation of the BDIM applied to two different cases: a three-dimensional channel with egg-carton roughness and a smooth HPT blade at engine-relevant conditions. In the case of the channel, we will see that the BDIM is able to correctly represent the effect of surface roughness on the boundary layer velocity profile and higher-order statistics, provided the grid in the vicinity of the wall is sufficiently refined to accurately resolve the interface between flow and solid body. This test case is also employed to validate the data-capturing framework. The smooth HPT case will serve to assess the capability of the framework to capture complex aero-thermal features such as strong pressure gradients, boundary layer transition, shock waves, and strong turbulent mixing processes. All the simulations are carried out using HiPSTAR, a well-validated in-house numerical solver for compressible flow [15].

3.1 Channel Flow With Egg-Carton Roughness

3.1.1 Computational Setup.

DNS of a turbulent channel flow with roughness are performed to validate the performance of the present three-dimensional BDIM. Since the main focus of the validation is on the near-wall region, the minimal-span channel with roughness used by Macdonald et al. [16] is adopted. It has in fact been shown that the minimal-span channel can accurately capture the turbulent near-wall flow using a reduced spanwise domain size with respect to a full-span simulation, hence significantly reducing the computational cost. A schematic of the computational setup for a rough channel and a reference smooth channel is shown in Fig. 5. The dimensions of the reference smooth channel, normalized with respect to the channel half-height h, are Lx = 2258/Reτ, Ly = 360/Reτ, and Lz = 113/Reτ, where x, y, and z are the streamwise, wall-normal, and spanwise directions, respectively. Reτ is the friction Reynolds number based on the reference channel half-height h. Simulations are carried out at Reτ = 180. The domain is periodic in the x and z directions and it is discretized using a body-fitted Cartesian grid, with a number of grid points Nx = 1130, Ny = 169, and Nz = 56. The spacing in the streamwise and spanwise directions is constant and it is equal to Δx+ = 2.0 and Δz+ = 2.0, respectively. The superscript + is employed to indicate lengths expressed in viscous units. The grid in the wall-normal direction is refined in the near-wall region, with a minimum spacing of Δyw+=0.40 at the wall and a maximum spacing of Δyc+=6.1 at the channel centerline. The flow is driven by a pressure gradient Px = −1 acting in the streamwise direction, constant both in time and space, and it is an input to the simulation. A uniform heat sink Hs = −20 is applied to the flow, while both smooth and rough walls are iso-thermal, with a uniform temperature T = 1. The values of Px, Hs, and T are normalized using reference primitive variables or a combination of thereof. The reference Mach number is set to M = 0.018, small enough to ensure that any compressibility effect is negligible.

Fig. 5
Domain dimensions for the smooth (left) and the rough channel (right)
Fig. 5
Domain dimensions for the smooth (left) and the rough channel (right)
Close modal
For the rough channel, the top and bottom walls have an egg-carton shape prescribed according to the following equation:
(11)
with k = h/18 (equivalent to k+ = 10) being the roughness mean height and λ = 113/Reτ the wavelength. Following Eq. (11), the coordinates of the bottom and top walls can be expressed as yb(x, z) = −h + hr(x, z) and yt(x, z) = +h + hr(x, z), respectively. Both walls are simulated using the BDIM, which implies that the overall computational domain, discretized using a Cartesian grid, must be larger than the reference smooth channel in the wall-normal direction in order to accommodate the rough walls. For the rough channel, we have Lyr=Ly+2(k+δε). δε is a small gap (2 to 6 grid points) between the boundaries of the domain in the wall-normal direction and the troughs of the egg-carton roughness, introduced to avoid numerical instabilities arising from the intersection of the BDIM smoothing region with the domain boundary. The rough channel domain is discretized using Nx = 1130, Ny = 251, and Nz = 56 grid points, resulting in Δx+ = Δz+ = 2.0 (both uniform in the entire domain), Δyw+=0.40, and Δyc+=6.0. The spacing in the wall-normal direction is uniform in the rough region.

The extra resolution with respect to the smooth channel is required to adequately represent the effect of the rough walls using the BDIM. In fact, the grid should offer enough resolution in the streamwise, spanwise, and wall-normal directions to resolve the BDIM smoothing region. The grid requirements therefore highly depend on the solid body geometry (in particular the local orientation of its surface with respect to the Cartesian axis) and on the characteristics of the flow. The ideal case is obviously a grid with equal uniform spacing in all directions, such that Δx = Δy = Δz, to guarantee the best representation of the soothing region. However, this is generally impractical from a computational perspective, because the resulting overall point count is often prohibitive. It is therefore necessary to find a trade-off between accuracy and number of points. Some general guidelines can be given for the specific case of wall-bounded flows, for which the direction that requires the largest resolution is the wall-normal, due to the large velocity gradients. For wall-bounded flows, ε should be prescribed as a multiple of the wall-normal spacing Δymin (uniform within the BDIM smoothing region), such that ε=αΔymin and 2.0 ≤ α ≤ 2.5. This ensures that the smoothing region contains a minimum of four grid points in the wall-normal direction. For the present case, we have chosen α = 2.0. For the streamwise and spanwise directions, a convergence study should be performed to ensure that the smoothing region is represented by at least two grid points. This preliminary study can be performed just by observing the resolution of the smoothing region on the grid, without performing the simulation. This approach performed in the xy plane for the rough channel is presented in Fig. 6 by showing the values of the first weighting function μ0 for different streamwise resolutions. The grid resolution is progressively increased, as summarized in Table 1. By visual inspection, the coarsest grid has been discarded due to the inadequate aspect ratio of the cells at the wall. A canonical grid convergence study has then been performed on grids (c) and (d) from Fig. 6 to assess their accuracy in capturing the relevant fluid dynamics. Grid (c) with Nx = 1130 has been preferred because it ensures adequate accuracy at a lower computational cost.

Fig. 6
Effect of a progressive grid refinement in the streamwise direction on the discretization of the weighting function μ0ε. Visualization of the location and extent of the smoothing region (a) and detail views of the grid refinement in the x direction for (b) Nx = 5650, (c) Nx = 1130, (d) Nx = 2828, and (e) Nx = 5655. The grid characteristics are listed in Table 1. Simulations are carried out with a number of streamwise points Nx = 1130, corresponding to the grid shown in (c).
Fig. 6
Effect of a progressive grid refinement in the streamwise direction on the discretization of the weighting function μ0ε. Visualization of the location and extent of the smoothing region (a) and detail views of the grid refinement in the x direction for (b) Nx = 5650, (c) Nx = 1130, (d) Nx = 2828, and (e) Nx = 5655. The grid characteristics are listed in Table 1. Simulations are carried out with a number of streamwise points Nx = 1130, corresponding to the grid shown in (c).
Close modal
Table 1

Streamwise grid refinement for the rough channel

NxΔxΔxy
5650.022310.0
11300.01115.0
28280.004442.0
56550.002221.0
NxΔxΔxy
5650.022310.0
11300.01115.0
28280.004442.0
56550.002221.0

Due to the higher resolution required in the near-wall region, the grid used for the rough channel simulation is 1.5 times larger than the equivalent smooth case. In terms of computational requirements, owing to the additional operations required to enforce the boundary conditions using the BDIM, the cost for the rough channel simulation was 1.64 times higher than the smooth simulation.

3.1.2 Validation of the Results.

The results for the wall-normal mean streamwise velocity profile u¯+ and for the root mean square of the velocity fluctuations urms+, vrms+ and wrms+ are shown in Fig. 7 as a function of the wall-normal viscous coordinate y+. The velocity profiles for both the smooth and the rough channels have been averaged in time, as well as in the streamwise direction. The averaging is performed on an interval of 100 flow-through units, corresponding to the time it takes for flow to convect through the channel 100 times. The results from the current simulations agree well with the reference data obtained from body-fitted simulations by Macdonald et al. [16]. The minor differences observed fall within the accuracy range that is expected when comparing BDIM against body-fitted data and they can also be attributed to differences in the numerical solver, the grid resolution, and the simulation parameters. Similar trends have been observed in Ref. [14] for the same validation. It is also important to remember that the minimal-span channel can adequately capture only the near-wall turbulent structures up to a distance of 0.4Lz from the wall. Hence the comparison of the present method with respect to the reference is restricted to that region.

Fig. 7
Streamwise-averaged velocity profiles for the smooth and the rough channel (a), velocity deficit caused by the wall roughness (b) and root mean square of the velocity fluctuations for the smooth (c) and the rough channel (d). The results are compared to the study of Macdonald et al. [16]. The vertical dotted line is located at y+=0.4Lz+ and it marks the upper limit of the near-wall region where the minimal-channel approximation holds.
Fig. 7
Streamwise-averaged velocity profiles for the smooth and the rough channel (a), velocity deficit caused by the wall roughness (b) and root mean square of the velocity fluctuations for the smooth (c) and the rough channel (d). The results are compared to the study of Macdonald et al. [16]. The vertical dotted line is located at y+=0.4Lz+ and it marks the upper limit of the near-wall region where the minimal-channel approximation holds.
Close modal
The flow is driven by a uniform streamwise pressure gradient Px. Exploiting the periodic boundary conditions in the x and z directions of the computational domain, from the time-averaged Navier–Stokes momentum equation in the streamwise direction, it follows that the volume integral of Px is equal to the sum of the streamwise forces acting at the walls, such that
(12)
with
Σf indicates the surface area of the channel walls. The overbar indicates time-averaged quantities. From Eq. (12), it follows that for the smooth channel, where the wall-normal vector n is always orthogonal to the streamwise direction (in other words, ni=0), the mean flow driving force is balanced by the mean wall shear stress integrated over the surface area of the top and bottom walls. This is not the case for the rough channel, for which the contribution of the pressure component at the wall to the overall streamwise force is not necessarily zero, due to the fact that n is in general not aligned with i. Equation (12) can be used to validate the BDIM data-capturing framework, since the right-hand side (RHS) can be directly computed from the variables collected at each surface triangular element as
(13)
with Nt being the total number of surface triangles and Ai the area of the ith element. Following Eq. (12), a similar relationship can be obtained for the heat sink Hs and the total heat flux at the wall from the energy equation:
(14)
The contribution to the energy equation of the product between the pressure gradient Px and the average streamwise velocity u¯ is added to the term Hs and the result is indicated with Hs*. A comparison between the left-hand side (LHS) of Eqs. (12) and (14), evaluated analytically, and the respective RHSs, computed numerically from the BDIM surface data, can be found in Table 2. As mentioned in Sec. 2.2, the BDIM slightly under-predicts the gradients at the wall due to the presence of the smoothing region. It is also worth mentioning that Eqs. (12) and (14) hold when the flow is in equilibrium. For this channel flow, we have observed that the turbulent structures cause long-period fluctuations in the mass flowrate as well as in the wall shear stress and heat flux, due to a continuous exchange of momentum. This can contribute to the percentage difference observed in the results shown in Table 2.
Table 2

Validation of the BDIM surface data-capturing using the conservation of streamwise momentum and total energy

LHSRHSRHS − LHS
ΩfPxdVi=0Nt(p¯inii+τ¯w,x,i)AiΔ
15.7915.094.43%
ΩfHs*dVi=0NtQ¯iAiΔ
106.4111.7+4.97%
LHSRHSRHS − LHS
ΩfPxdVi=0Nt(p¯inii+τ¯w,x,i)AiΔ
15.7915.094.43%
ΩfHs*dVi=0NtQ¯iAiΔ
106.4111.7+4.97%

3.2 High-Pressure Turbine Blade With Roughness

3.2.1 Computational Setup.

The challenges of simulating surface roughness and its effects on the performance of a turbine blade are investigated and discussed in the case of a VKI LS-89 HPT blade [17] in a linear cascade using DNS. This configuration without surface roughness has already been explored in previous studies in the context of high-fidelity simulations, thus offering a well-established reference [1820]. Simulations are carried out at engine-relevant conditions, with a Reynolds number of Re = 590, 000 based on the axial chord Cax, the outlet flow velocity, and an exit Mach number M = 0.9. The spanwise extent of the HPT blade is set to 0.4Cax, which is wide enough to ensure the correct development of the largest inflow turbulence structures [20]. All quantities are presented in non-dimensional form, with lengths normalized by Cax and flow quantities such as velocities, density, and temperature normalized by reference inlet conditions. At the inlet, synthetic turbulence is introduced in the domain employing a compressible version of the digital filter [21] method. The turbulence intensity Tk, obtained from the three components of the velocity fluctuations as u′, v′, and w′, is defined as Tk=1/3(urms2+vrms2+wrms2) and is equal to 8% of the axial inlet velocity Uin. The integral length scale is Lx/Cax=8%. At the outlet, a non-reflective characteristics boundary condition [22] is enforced in combination with a stretching of the grid in the streamwise direction to introduce numerical dissipation and to avoid non-physical reflections of the acoustic waves.

A schematic of the computational domain in the xy plane is shown in Fig. 8. The computational grid is composed of three blocks with different topologies interfaced using an overset method [23], which allows the exchange of information between blocks by means of interpolation in the overlapping regions. This allows to locally optimize the grid topology and resolution to suit the needs of regions of the domain subjected to different physical dynamics and different computational requirements. As shown in Fig. 8, the blade passage is discretized using an H-type Cartesian background grid, indicated as block 1. This grid contains the inlet and the outlet of the simulation and it is subjected to periodic boundary conditions in the pitchwise direction. Block 1 is discretized using Nx × Ny × Nz = 1470 × 716 × 576 grid points in the axial, pitchwise, and spanwise directions, respectively. Two O-type grids are employed to discretize the flow region around the blade. These grids are arranged in two layers, an outer (block 2) and an inner one (block 3), and their topology follows the mean blade geometry. Block 2 has a resolution of Ns × Nn × Nz = 8165 × 239 × 576 points, where the subscript s denotes the blade tangential direction and n the wall-normal direction. Block 3 has been introduced to provide additional resolution in the near-wall region, necessary to accurately resolve the interactions between roughness and turbulent eddies using the BDIM. The grid count for block 3 is Ns × Nn × Nz = 35,595 × 110 × 1200 points for the rough blade and Ns × Nn × Nz = 35,595 × 100 × 576 points for the smooth blade. Introducing a normalization based on the local viscous length scale obtained from the reference smooth blade, the grid spacing is such that Δs+ ≤ 3.0, Δn+ ≤ 0.9 and Δz+ ≤ 6.5, resulting in a much higher resolution with respect to previous high-fidelity simulation studies [18,24].

Fig. 8
Three-block domain discretization using an overset method (a). Insets show details of block 2 (b) and block 3 (c), including a two-dimensional slice of the rough blade. The resolution of the grids has been reduced in the figures by skipping points for the sake of clarity.
Fig. 8
Three-block domain discretization using an overset method (a). Insets show details of block 2 (b) and block 3 (c), including a two-dimensional slice of the rough blade. The resolution of the grids has been reduced in the figures by skipping points for the sake of clarity.
Close modal

3.2.2 Roughness Generation.

The roughness distribution is generated using the multi-scale anisotropic rough surface (MARS) algorithm introduced by Jelly and Busse [25,26]. The MARS algorithm generates a planar surface distribution hr(x′, z′) with prescribed statistical characteristics and double periodic boundary conditions. In order to apply the roughness distribution to the blade surface, it is necessary to introduce a curvilinear coordinate system (s, z) associated with the smooth blade, in which s is the curvilinear abscissa in the tangential direction. Indicating with xs the coordinates of a generic point on the surface of the smooth blade and with ns the corresponding outward normal unit vector, the coordinates of a point of the rough blade xr can be expressed as
(15)
In Eq. (15), a coordinate transformation from (x′, z′) to (s, z) has been applied, such that x′ = s and z′ = z. When generating the roughness distribution, it is therefore important to ensure that the extent of the planar domain in the x′ direction is equal to the length of the blade cross section in the streamwise direction, formally:
(16)
where As indicates the surface of the smooth blade. Similar considerations also apply to the spanwise direction, with Lz = 0.4Cax.

In the present work, the roughness that characterizes the surface of the blade is irregular and three-dimensional and it has a spatial statistical distribution that is near Gaussian. This type of roughness has been shown to well represent the surface characteristics of real-life blades subjected to operational metal erosion [27]. The key topographical parameters of the current distribution are shown in Table 3. The root mean square roughness height krms of the selected distribution is krms = 0.0004 Cax, corresponding to an equivalent value of Nikuradse sand grain roughness of ks = 0.002 Cax (ks = 5.0krms). For a blade with an axial chord of 50 mm, this is equivalent to a surface roughness distribution with ks = 100 μm (and krms = 20 μm). The value of ks normalized with respect to the local averaged viscous length scale on the suction side of the reference smooth blade, indicated as ks+, is shown in Fig. 9. Both the skewness and the excess kurtosis of the distribution are approximately 0. The streamwise effective slope, ESs=As1As|hr(s,z)/s|dAs, and the spanwise effective slope, ESz=As1As|h(s,z)/z|dAs, are 0.16 and 0.17, respectively.

Fig. 9
ks normalized with respect to the local viscous length scale obtained from the reference smooth blade
Fig. 9
ks normalized with respect to the local viscous length scale obtained from the reference smooth blade
Close modal
Table 3

Key topological parameters of the roughness distribution

kskrmsSkewkurt − 3.0ESsESz
0.0020.00040.00+0.010.160.17
kskrmsSkewkurt − 3.0ESsESz
0.0020.00040.00+0.010.160.17

A comparison of the blade surface at the trailing edge between the smooth and the rough blade is shown in Fig. 10.

Fig. 10
Comparison of the blade surface at the trailing edge between (a) the smooth and (b) the rough blade
Fig. 10
Comparison of the blade surface at the trailing edge between (a) the smooth and (b) the rough blade
Close modal

3.2.3 Validation of the Reference Smooth Blade.

Validation of the reference smooth blade in terms of surface pressure coefficient, skin-friction coefficient, and wall-normal heat flux are carried out by comparing the BDIM results against the numerical simulations of Pichler et al. [20] and Zhao and Sandberg [28]. Validation of the reference results against experiments is included in the original papers.

Figure 11(a) shows the spanwise and time-averaged pressure coefficient C¯p on the blade surface, exhibiting excellent agreement with the reference. The skin-friction coefficient C¯f is shown in Fig. 11(b), demonstrating that the present method is able to correctly simulate the boundary layer transition location and evolution in the vicinity of the blade trailing edge. The BDIM data show a slight under-prediction of C¯f at x = 0.25 on the suction side (10%). The agreement of the overall C¯f trend with the reference is, however, excellent. A more detailed discussion of the computation of the skin-friction coefficient C¯f is presented in the next section. Finally, the heat flux Q¯ is compared in Fig. 11, again showing good agreement of the overall trend, despite some discrepancies that are slightly larger, especially on the suction side, with respect to the previously discussed quantities.

Fig. 11
Validation of the pressure coefficient C¯p (a), the skin-friction coefficient C¯f (b), and the heat flux Q¯ (c) against the numerical results of Pichler et al. [20] () and Zhao and Sandberg [28] ( and ). Results for the current method are plotted with a solid black line.
Fig. 11
Validation of the pressure coefficient C¯p (a), the skin-friction coefficient C¯f (b), and the heat flux Q¯ (c) against the numerical results of Pichler et al. [20] () and Zhao and Sandberg [28] ( and ). Results for the current method are plotted with a solid black line.
Close modal

3.2.4 Flow Overview.

The instantaneous snapshots of the flow field around the smooth and the rough blades shown in Fig. 12 provide a visual representation of some of the complex physics that characterize HPT flows. Iso-volumes obtained from the Q-criterion offer qualitative information on the turbulent structures present in the boundary layers and in the wake region, highlighting the differences between the two blade configurations. For the smooth blade, on-surface turbulent eddies can only be observed in the trailing edge region, suggesting that the boundary layer behavior is predominantly laminar. This is not the case for the rough blade. The surface roughness acts as a trip and has the effect of promoting a much earlier transition. As a result, the boundary layer on the suction side is predominantly in a fully turbulent state. In Part II, where additional roughness amplitudes and distributions are also presented, we will see that this has direct implications on the loss and on the overall performance of the blade. The instantaneous velocity divergence field collected at mid-span and displayed in Fig. 12 highlights a series of normal shocks on the blade suction side, suggesting that the flow is subjected to a strong acceleration in the HPT blade, reaching transonic conditions. The two flow snapshots suggest that the surface roughness has an impact on the location and the strength of the shock waves. For the rough blade, the shocks are shifted upstream and their intensity seems to reduce with respect to the smooth blade. Further analysis is necessary to fully quantify and characterize this behavior. It is interesting to observe that the normal shocks interact not only with the boundary layers but also with the wakes of the other blades present in the linear cascade, once again an indication of the complex dynamics observed in HPT flows.

Fig. 12
Comparison between the characteristics of the instantaneous flow around (a) the smooth blade and (b) the rough blade. Iso-volumes obtained from the Q-criterion and colored according to the spanwise vorticity provide qualitative information on the boundary layer state. In the background, a two-dimensional slice containing the divergence of the velocity vector indicates the presence of normal shocks on the suction side of each blade.
Fig. 12
Comparison between the characteristics of the instantaneous flow around (a) the smooth blade and (b) the rough blade. Iso-volumes obtained from the Q-criterion and colored according to the spanwise vorticity provide qualitative information on the boundary layer state. In the background, a two-dimensional slice containing the divergence of the velocity vector indicates the presence of normal shocks on the suction side of each blade.
Close modal

3.2.5 On-Blade Data Analysis: The Skin Friction Coefficient.

The skin-friction coefficient Cf is defined as the tangential force per unit area acting on the blade surface, normalized by a reference dynamic pressure. For a rigorous comparison of Cf between the smooth and the rough blade, it is necessary to use the same reference to determine the tangential direction along which to compute the tangential force. Indicating with txys (or t1s) the tangential unit vector in the xy for the smooth blade, here taken as reference, we therefore have
(17)
where p is the surface pressure and ρin and Uin are the inlet density and velocity, respectively. For a smooth blade Cf=Cf*, since ntxys=0. This is not the case for the rough blade, for which we need to take into account the additional contribution to the tangential force given by the surface pressure, also known as form drag.

A comparison of the skin-friction coefficient averaged in time and in the spanwise direction can be found in Fig. 13. For the spanwise averaging (see Sec. 2.2.5), in the calculation of Cf*, the pressure term has been replaced by pip¯bin, where p¯bin is the pressure averaged in each bin. This is necessary to reduce the noise present in the curve of Cf* due to the fact that p is several orders of magnitude larger than τw. This is justified by the fact that what contributes to the pressure drag is not the absolute value of p, but the pressure variations in the tangential direction. From Fig. 13, we can see that in the case of the rough blade, C¯f only accounts for about 50% of the overall skin-friction coefficient C¯f*. Roughness has the effect of increasing the overall skin-friction coefficient on both the suction and the pressure side, promoting the transition of the boundary layer from laminar to turbulent, as already inferred from Fig. 12. We refer to Part II for a more detailed discussion on the effect of roughness on skin friction and heat flux.

Fig. 13
Time and spanwise averaged distributions of the skin-friction coefficient Cf (transparent) and Cf* (solid) for the smooth blade (black) and the rough blade (gray). Positive values of x refer to the blade suction side and negative values to the pressure side.
Fig. 13
Time and spanwise averaged distributions of the skin-friction coefficient Cf (transparent) and Cf* (solid) for the smooth blade (black) and the rough blade (gray). Positive values of x refer to the blade suction side and negative values to the pressure side.
Close modal

4 Conclusion

A framework for high-fidelity simulation of transitional and turbulent flows over multi-scale roughness has been presented. The backbone of the framework is a three-dimensional, second-order accurate BDIM that allows us to simulate complex three-dimensional geometries on non-conforming structured grids, hence retaining high computational efficiency. The general formulation of the BDIM has been presented, with a particular focus on the procedure used to map the surface of the solid body, discretized with triangular elements, onto the computational grid. The effect of a solid boundary on the flow is obtained by directly enforcing local velocity and temperature values to those grid points located in the vicinity of the boundary. A BDIM data-capturing method used for on-surface data collection and analysis has also been introduced. It has been shown that collecting on-surface data at the element nodes generally yields more accurate results, due to the presence of larger gradients in these regions.

The BDIM and the surface data-capturing have been validated on fully developed turbulent channel flow over sinusoidal egg-carton roughness in a minimal-span domain simulated by means of DNS. The boundary layer profiles have been compared to reference data present in the literature, showing good agreement. The integral streamwise force and the total heat flux, computed numerically using the BDIM data-capturing method, have been validated using momentum and energy conservation principles. The rough channel case also served to discuss the BDIM grid resolution requirements.

The BDIM has then been employed to investigate the effect of irregular homogeneous surface roughness on the performance of a high-pressure turbine blade at engine-relevant conditions using DNS. The resolution required to accurately resolve the interaction between the flow and the surface roughness has been achieved by an overset three-block grid, in which two overset o-grids with different resolutions—a refined inner layer for the near-wall region and a coarser outer layer for the external boundary layer—have been employed to resolve the blade, while a Cartesian background grid has been used to resolve the incident turbulence and the far wake. Flow visualizations have shown that the surface roughness promotes the boundary layer transitions on the suction side, shifting the transition region upstream with respect to a reference smooth blade. This has also been confirmed by comparing the time-averaged and the spanwise averaged skin-friction coefficient. We have seen that when comparing on-surface data between rough and smooth blades, the results should refer to the geometry of the smooth blade: in particular, surface quantities should be normalized by the same reference area and the same tangential direction should be considered when comparing the skin-friction coefficient. As a consequence, in the case of a rough blade, the skin-friction coefficient does not only depend on the wall shear stress but also on the tangential component of the pressure force, which accounts for about 50% of the total coefficient.

Acknowledgment

Support from the ARC is acknowledged. This research used data generated on the Oak Ridge Leadership Computing Facility, which is a DOE Office of Science User Facility supported under Contract DE-AC05-00OR2272.

Conflict of Interest

There are no conflicts of interest.

Data Availability Statement

The datasets generated and supporting the findings of this article are obtainable from the corresponding author upon reasonable request.

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