Centrifugal Pump CFD Simulation Training Package: 6 Projects by ANSYS Fluent

Description

Centrifugal Pump CFD Simulation Training Package

Introduction

Centrifugal pumps are among the most common turbomachines used in fluid transportation systems, ranging from water distribution and industrial processes to wastewater treatment and slurry handling. Their efficiency, reliability, and ability to handle a wide range of flow rates make them indispensable in engineering applications. To design and optimize centrifugal pumps, computational fluid dynamics (CFD) plays a crucial role, allowing engineers to investigate internal flow fields, pressure distribution, cavitation regions, and erosion phenomena without excessive reliance on experimental testing. This training package focuses on developing a step-by-step simulation approach for centrifugal pumps using ANSYS Fluent, starting from basic modeling methods to advanced multiphase and fluid-structure interaction (FSI) analyses.

Training Path

The training path is structured as a progressive learning journey. First, a 2D CFD simulation of a centrifugal pump using the Multiple Reference Frame (MRF) approach was developed. This initial project introduces the fundamentals of CFD simulation in rotating machinery by simplifying the geometry to two dimensions, reducing computational cost while teaching the basics of impeller–volute interactions.

Next, the methodology advances to a full 3D centrifugal pump model using the MRF approach, where more realistic flow physics can be captured, including secondary flows and three-dimensional turbulence effects. Building upon this, an additional 3D case using the Mesh Motion approach was carried out, in which the actual rotation of the impeller is modeled to provide a more accurate transient simulation compared to the steady MRF technique.

In the following step, the combination of the MRF approach with advanced analysis and FSI (Fluid–Structure Interaction) was applied. This project focuses on capturing the interaction between the rotating impeller and the surrounding fluid under more realistic conditions, enabling an understanding of structural stresses and potential fatigue.

Finally, two advanced industrial applications were investigated: Sludge Flow in a Centrifugal Pump, which deals with the non-Newtonian behavior of sludge and its effects on pump performance, and Slurry Flow Erosion in a Centrifugal Pump, which simulates particle-laden flows and evaluates erosion patterns on the impeller and casing. These final projects demonstrate how CFD can predict pump lifetime and optimize design for challenging working conditions.