Note

Go to the end to download the full example code.

Inverse-Solving analysis of a rotor fan blade with disk#

This example demonstrates the inverse-solving analysis of a rotor fan blade with disk. The NASA Rotor 67 fan bladed disk is a subsystem of a turbo fan’s compressor set used in aerospace engine applications. This sector model, representing a challenging industrial example for which the detailed geometry and flow information is available in the public domain, consists of a disk and a fan blade with a sector angle of 16.364 degrees. The sector model represents the running condition or hot geometry of the blade. It is already optimized at the running condition under loading. The primary objective is to obtain the cold geometry (for manufacturing) from the given hot geometry using inverse solving.

  • ELEMENTS: SOLID186

  • MATERIAL: Elastic Material

  • CONTACT: MPC bonded contact pair

To highlight Mechanical APDL inverse-solving technology, this example problem does not involve a cyclic symmetry analysis.

Material Properties:

Temperature

Density

Young’s Modulus

Poisson’s Ratio

Coeff of Thermal Expansion

22 deg C

7840

2.2e11 Pa

0.27

1.2e-5

200 deg C

7740

2e11 Pa

0.28

1.3e-5

300 deg C

7640

1.9e11 Pa

0.29

1.4e-5

600 deg C

7540

1.8e11 Pa

0.30

1.5e-5

Following loads are considered:

The rotational velocity (CGOMGA,0,0,1680) is applied along the global Z axis. The reference temperature is maintained at 22°C, and the temperature loading is applied on the blade (BF)

Expected results:

Inverse-Solving Analysis: A nonlinear static analysis using inverse solving (INVOPT,ON) is performed on the hot geometry of the model to obtain the cold geometry (for manufacturing) and the stress/strain results on the hot geometry.

import os

from ansys.mechanical.core import App
from ansys.mechanical.core.examples import delete_downloads, download_file
from matplotlib import image as mpimg
from matplotlib import pyplot as plt

Embed mechanical and set global variables

app = App()
app.update_globals(globals())
print(app)

cwd = os.path.join(os.getcwd(), "out")


def display_image(image_name):
    plt.figure(figsize=(16, 9))
    plt.imshow(mpimg.imread(os.path.join(cwd, image_name)))
    plt.xticks([])
    plt.yticks([])
    plt.axis("off")
    plt.show()

Ansys Mechanical [Ansys Mechanical Enterprise]
Product Version:242
Software build date: 06/03/2024 09:35:09

Download required files#

Download the geometry file

geometry_path = download_file(
    "example_10_td_055_Rotor_Blade_Geom.pmdb", "pymechanical", "embedding"
)

Download the material file

mat_path = download_file(
    "example_10_td_055_Rotor_Blade_Mat_File.xml", "pymechanical", "embedding"
)

Download the CFX pressure data

cfx_data_path = download_file(
    "example_10_CFX_ExportResults_FT_10P_EO2.csv", "pymechanical", "embedding"
)

Download required Temperature file

temp_data_path = download_file(
    "example_10_Temperature_Data.txt", "pymechanical", "embedding"
)

Configure graphics for image export#

cwd = os.path.join(os.getcwd(), "out")
Graphics.Camera.SetSpecificViewOrientation(
    Ansys.Mechanical.DataModel.Enums.ViewOrientationType.Iso
)
Graphics.Camera.SetFit()
image_export_format = Ansys.Mechanical.DataModel.Enums.GraphicsImageExportFormat.PNG
settings_720p = Ansys.Mechanical.Graphics.GraphicsImageExportSettings()
settings_720p.Resolution = (
    Ansys.Mechanical.DataModel.Enums.GraphicsResolutionType.EnhancedResolution
)
settings_720p.Background = Ansys.Mechanical.DataModel.Enums.GraphicsBackgroundType.White
settings_720p.Width = 1280
# settings_720p.Capture = Ansys.Mechanical.DataModel.Enums.GraphicsCaptureType.ImageOnly
settings_720p.Height = 720
settings_720p.CurrentGraphicsDisplay = False

Import geometry#

Reads geometry file and display

geometry_import_group = Model.GeometryImportGroup
geometry_import = geometry_import_group.AddGeometryImport()
geometry_import_format = (
    Ansys.Mechanical.DataModel.Enums.GeometryImportPreference.Format.Automatic
)
geometry_import_preferences = Ansys.ACT.Mechanical.Utilities.GeometryImportPreferences()
geometry_import_preferences.ProcessNamedSelections = True
geometry_import_preferences.NamedSelectionKey = ""
geometry_import_preferences.ProcessMaterialProperties = True
geometry_import_preferences.ProcessCoordinateSystems = True
geometry_import.Import(
    geometry_path, geometry_import_format, geometry_import_preferences
)

app.plot()
Rotor Blade Inverse solve

Assign materials#

Import material from xml file and assign it to bodies

materials = Model.Materials
materials.Import(mat_path)

PRT1 = [x for x in Tree.AllObjects if x.Name == "Component2\Rotor11"][0]
PRT2 = [x for x in Tree.AllObjects if x.Name == "Component3"][0]
PRT2_Blade_1 = PRT2.Children[0]
PRT2_Blade_2 = PRT2.Children[1]
PRT2_Blade_3 = PRT2.Children[2]
PRT1.Material = "MAT1 (Setup, File1)"
PRT2_Blade_1.Material = "MAT1 (Setup, File1)"
PRT2_Blade_2.Material = "MAT1 (Setup, File1)"
PRT2_Blade_3.Material = "MAT1 (Setup, File1)"

Define units system and store variables#

Select MKS units

ExtAPI.Application.ActiveUnitSystem = MechanicalUnitSystem.StandardMKS

# Store all main tree nodes as variables
MODEL = Model
GEOM = Model.Geometry
MESH = Model.Mesh
MAT_GRP = Model.Materials
CS = Model.CoordinateSystems
NS_GRP = Model.NamedSelections

Define named selection#

Create NS for named selection

BLADE_NS = [x for x in Tree.AllObjects if x.Name == "Blade"][0]
BLADE_SURF_NS = [x for x in Tree.AllObjects if x.Name == "Blade_Surf"][0]
FIX_SUPPORT_NS = [x for x in Tree.AllObjects if x.Name == "Fix_Support"][0]
BLADE_HUB_NS = [x for x in Tree.AllObjects if x.Name == "Blade_Hub"][0]
HUB_CONTACT_NS = [x for x in Tree.AllObjects if x.Name == "Hub_Contact"][0]
BLADE_TARGET_NS = [x for x in Tree.AllObjects if x.Name == "Blade_Target"][0]
Hub_Low_NS = [x for x in Tree.AllObjects if x.Name == "Hub_Low"][0]
Hub_High_NS = [x for x in Tree.AllObjects if x.Name == "Hub_High"][0]
BLADE1_NS = [x for x in Tree.AllObjects if x.Name == "Blade1"][0]
BLADE1_Source_NS = [x for x in Tree.AllObjects if x.Name == "Blade1_Source"][0]
BLADE1_TARGET_NS = [x for x in Tree.AllObjects if x.Name == "Blade1_Target"][0]
BLADE2_NS = [x for x in Tree.AllObjects if x.Name == "Blade2"][0]
BLADE2_Source_NS = [x for x in Tree.AllObjects if x.Name == "Blade2_Source"][0]
BLADE2_TARGET_NS = [x for x in Tree.AllObjects if x.Name == "Blade2_Target"][0]
BLADE3_NS = [x for x in Tree.AllObjects if x.Name == "Blade3"][0]
BLADE3_Source_NS = [x for x in Tree.AllObjects if x.Name == "Blade3_Source"][0]
BLADE3_TARGET_NS = [x for x in Tree.AllObjects if x.Name == "Blade3_Target"][0]

Define coordinate system#

Create cylindrical coordinate system

coordinate_systems = Model.CoordinateSystems
coord_system = coordinate_systems.AddCoordinateSystem()
coord_system.CoordinateSystemType = (
    Ansys.ACT.Interfaces.Analysis.CoordinateSystemTypeEnum.Cylindrical
)
coord_system.OriginDefineBy = CoordinateSystemAlignmentType.Component
coord_system.OriginDefineBy = CoordinateSystemAlignmentType.Fixed

Define contacts#

# Define connections

CONN_GRP = Model.Connections
CONT_REG1 = CONN_GRP.AddContactRegion()
CONT_REG1.SourceLocation = NS_GRP.Children[6]
CONT_REG1.TargetLocation = NS_GRP.Children[5]
CONT_REG1.Behavior = ContactBehavior.AutoAsymmetric
CONT_REG1.ContactFormulation = ContactFormulation.MPC

Define mesh settings and generate mesh#

MSH = Model.Mesh
MSH.ElementSize = Quantity(0.004, "m")
MSH.UseAdaptiveSizing = False
MSH.MaximumSize = Quantity(0.004, "m")
MSH.ShapeChecking = 0
automatic_method_Hub = MSH.AddAutomaticMethod()
automatic_method_Hub.Location = NS_GRP.Children[0]
automatic_method_Hub.Method = MethodType.Sweep
automatic_method_Hub.SweepNumberDivisions = 6

match_control_Hub = MSH.AddMatchControl()
match_control_Hub.LowNamedSelection = NS_GRP.Children[7]
match_control_Hub.HighNamedSelection = NS_GRP.Children[8]
cyc_coordinate_system = coordinate_systems.Children[1]
match_control_Hub.RotationAxis = cyc_coordinate_system

sizing_Blade = MSH.AddSizing()
selection = NS_GRP.Children[5]
sizing_Blade.Location = selection
# sizing_Blade.ElementSize = Quantity(1e-3, "m")
sizing_Blade.ElementSize = Quantity(1e-2, "m")
sizing_Blade.CaptureCurvature = True
sizing_Blade.CurvatureNormalAngle = Quantity(0.31, "rad")
# sizing_Blade.LocalMinimumSize = Quantity(0.00025, "m")
sizing_Blade.LocalMinimumSize = Quantity(0.0005, "m")

automatic_method_Blade1 = MSH.AddAutomaticMethod()
selection = NS_GRP.Children[9]
automatic_method_Blade1.Location = selection
automatic_method_Blade1.Method = MethodType.Sweep
automatic_method_Blade1.SourceTargetSelection = 2
selection = NS_GRP.Children[10]
automatic_method_Blade1.SourceLocation = selection
selection = NS_GRP.Children[11]
automatic_method_Blade1.TargetLocation = selection
automatic_method_Blade1.SweepNumberDivisions = 5

automatic_method_Blade2 = MSH.AddAutomaticMethod()
selection = NS_GRP.Children[12]
automatic_method_Blade2.Location = selection
automatic_method_Blade2.Method = MethodType.Sweep
automatic_method_Blade2.SourceTargetSelection = 2
selection = NS_GRP.Children[13]
automatic_method_Blade2.SourceLocation = selection
selection = NS_GRP.Children[14]
automatic_method_Blade2.TargetLocation = selection
automatic_method_Blade2.SweepNumberDivisions = 5

automatic_method_Blade3 = MSH.AddAutomaticMethod()
selection = NS_GRP.Children[15]
automatic_method_Blade3.Location = selection
automatic_method_Blade3.Method = MethodType.Sweep
automatic_method_Blade3.SourceTargetSelection = 2
selection = NS_GRP.Children[16]
automatic_method_Blade3.SourceLocation = selection
selection = NS_GRP.Children[17]
automatic_method_Blade3.TargetLocation = selection
automatic_method_Blade3.SweepNumberDivisions = 5

MSH.GenerateMesh()

Graphics.Camera.SetFit()
Graphics.ExportImage(
    os.path.join(cwd, "blade_mesh.png"), image_export_format, settings_720p
)
display_image("blade_mesh.png")
Rotor Blade Inverse solve

Define analysis settings#

Setup static structural settings with inverse solve

Model.AddStaticStructuralAnalysis()
STAT_STRUC = Model.Analyses[0]
ANA_SETTINGS = ExtAPI.DataModel.Project.Model.Analyses[0].AnalysisSettings
ANA_SETTINGS.AutomaticTimeStepping = AutomaticTimeStepping.On
ANA_SETTINGS.NumberOfSubSteps = 10

ANA_SETTINGS.Activate()

CMD1 = STAT_STRUC.AddCommandSnippet()
# Add convergence criterion using command snippet.
AWM = """CNVTOL,U,1.0,5e-5,1,,"""
CMD1.AppendText(AWM)

ANA_SETTINGS.InverseOption = True
ANA_SETTINGS.LargeDeflection = True

Define boundary conditions#

Apply rotational velocity

ROT_VEL = STAT_STRUC.AddRotationalVelocity()
ROT_VEL.DefineBy = LoadDefineBy.Components
ROT_VEL.ZComponent.Inputs[0].DiscreteValues = [
    Quantity("0 [s]"),
    Quantity("1 [s]"),
    Quantity("2 [s]"),
]
ROT_VEL.ZComponent.Output.DiscreteValues = [
    Quantity("0 [rad/s]"),
    Quantity("1680 [rad/s]"),
    Quantity("1680 [rad/s]"),
]

# Apply Fixed Support Condition

Fixed_Support = STAT_STRUC.AddFixedSupport()
selection = NS_GRP.Children[3]
Fixed_Support.Location = selection

Import CFX pressure#

Import CFX pressure data and apply it to structural blade surface

Imported_Load_Group = STAT_STRUC.AddImportedLoadExternalData()

external_data_files = Ansys.Mechanical.ExternalData.ExternalDataFileCollection()
external_data_files.SaveFilesWithProject = False
external_data_file_1 = Ansys.Mechanical.ExternalData.ExternalDataFile()
external_data_files.Add(external_data_file_1)
external_data_file_1.Identifier = "File1"
external_data_file_1.Description = ""
external_data_file_1.IsMainFile = False
external_data_file_1.FilePath = cfx_data_path
external_data_file_1.ImportSettings = (
    Ansys.Mechanical.ExternalData.ImportSettingsFactory.GetSettingsForFormat(
        Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.ImportFormat.Delimited
    )
)
import_settings = external_data_file_1.ImportSettings
import_settings.SkipRows = 17
import_settings.SkipFooter = 0
import_settings.Delimiter = ","
import_settings.AverageCornerNodesToMidsideNodes = False
import_settings.UseColumn(
    0,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.XCoordinate,
    "m",
    "X Coordinate@A",
)
import_settings.UseColumn(
    1,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.YCoordinate,
    "m",
    "Y Coordinate@B",
)
import_settings.UseColumn(
    2,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.ZCoordinate,
    "m",
    "Z Coordinate@C",
)
import_settings.UseColumn(
    3,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.Pressure,
    "Pa",
    "Pressure@D",
)

Imported_Load_Group.ImportExternalDataFiles(external_data_files)
Imported_Pressure = Imported_Load_Group.AddImportedPressure()
selection = NS_GRP.Children[2]
Imported_Pressure.Location = selection
Imported_Pressure.AppliedBy = LoadAppliedBy.Direct
Imported_Pressure.ImportLoad()

Tree.Activate([Imported_Pressure])
Graphics.Camera.SetFit()
Graphics.ExportImage(
    os.path.join(cwd, "imported_pressure.png"), image_export_format, settings_720p
)
display_image("imported_pressure.png")
Rotor Blade Inverse solve

Import Temperature#

Import temperature data and apply it to structural blade

Imported_Load_Group = STAT_STRUC.AddImportedLoadExternalData()

external_data_files = Ansys.Mechanical.ExternalData.ExternalDataFileCollection()
external_data_files.SaveFilesWithProject = False
external_data_file_1 = Ansys.Mechanical.ExternalData.ExternalDataFile()
external_data_files.Add(external_data_file_1)
external_data_file_1.Identifier = "File1"
external_data_file_1.Description = ""
external_data_file_1.IsMainFile = False
external_data_file_1.FilePath = temp_data_path

external_data_file_1.ImportSettings = (
    Ansys.Mechanical.ExternalData.ImportSettingsFactory.GetSettingsForFormat(
        Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.ImportFormat.Delimited
    )
)
import_settings = external_data_file_1.ImportSettings
import_settings.SkipRows = 0
import_settings.SkipFooter = 0
import_settings.Delimiter = ","
import_settings.AverageCornerNodesToMidsideNodes = False
import_settings.UseColumn(
    0,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.XCoordinate,
    "m",
    "X Coordinate@A",
)
import_settings.UseColumn(
    1,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.YCoordinate,
    "m",
    "Y Coordinate@B",
)
import_settings.UseColumn(
    2,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.ZCoordinate,
    "m",
    "Z Coordinate@C",
)
import_settings.UseColumn(
    3,
    Ansys.Mechanical.DataModel.MechanicalEnums.ExternalData.VariableType.Temperature,
    "C",
    "Temperature@D",
)

Imported_Load_Group.ImportExternalDataFiles(external_data_files)
imported_body_temperature = Imported_Load_Group.AddImportedBodyTemperature()

selection = NS_GRP.Children[1]
imported_body_temperature.Location = selection
imported_body_temperature.ImportLoad()

Tree.Activate([imported_body_temperature])
Graphics.Camera.SetFit()
Graphics.ExportImage(
    os.path.join(cwd, "imported_temperature.png"), image_export_format, settings_720p
)
display_image("imported_temperature.png")
Rotor Blade Inverse solve

Postprocessing#

Insert results

SOLN = STAT_STRUC.Solution

TOT_DEF1 = SOLN.AddTotalDeformation()
TOT_DEF1.DisplayTime = Quantity("1 [s]")

EQV_STRS1 = SOLN.AddEquivalentStress()
EQV_STRS1.DisplayTime = Quantity("1 [s]")

EQV_TOT_STRN1 = SOLN.AddEquivalentTotalStrain()
EQV_TOT_STRN1.DisplayTime = Quantity("1 [s]")

THERM_STRN1 = SOLN.AddThermalStrain()
THERM_STRN1.DisplayTime = Quantity("1 [s]")

Run Solution#

Solve inverse analysis on blade model

SOLN.Solve(True)
STAT_STRUC_SS = SOLN.Status

Postprocessing#

Evaluate results and export screenshots

Total deformation

Tree.Activate([TOT_DEF1])
Graphics.ViewOptions.ResultPreference.ExtraModelDisplay = (
    Ansys.Mechanical.DataModel.MechanicalEnums.Graphics.ExtraModelDisplay.NoWireframe
)
Graphics.ExportImage(
    os.path.join(cwd, "deformation.png"), image_export_format, settings_720p
)
display_image("deformation.png")
Rotor Blade Inverse solve

Equivalent stress

Tree.Activate([THERM_STRN1])
Graphics.ExportImage(
    os.path.join(cwd, "thermal_strain.png"), image_export_format, settings_720p
)
display_image("thermal_strain.png")
Rotor Blade Inverse solve

Cleanup#

Save project

app.save(os.path.join(cwd, "blade_inverse.mechdat"))
app.new()

Delete example file

delete_downloads()

True

Total running time of the script: (1 minutes 45.247 seconds)

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