Modeling of Roughness Effects on Generic Gas Turbine Swirler via a Detached Eddy Simulation Low-y+ Approach

The use of additive manufacturing (AM) has seen increased utilization over the last decade, thanks to well-documented advantages such as lower startup costs, reduced wastage, and the ability to rapidly prototype. The poor surface finish of unprocessed AM components is one of the major drawbacks of this technology, with the research literature suggesting a measurable impact on flow characteristics and burner operability. For instance, surface roughness has been shown to potentially increase resistance to boundary layer flashback—an area of high concern, particularly when utilizing fuels with high hydrogen content. A more detailed understanding of the underlying thermophysical mechanisms is, therefore, required. Computational fluid dynamics can help elucidate the impact of these roughness effects by enabling detailed data interrogation in locations not easily accessible experimentally. In this study, roughness effects on a generic gas turbine swirler were numerically modeled using a low-y+ detached eddy simulation (DES) approach. Three DES models were investigated utilizing a smooth reference case and two rough cases, the latter employing a literature-based and novel equivalent sand-grain roughness (ks) correlation developed for this work. Existing experimental isothermal and CH4 data were used to validate the numerical simulations. Detailed investigations into the effects of roughness on flow characteristics, such as swirl number and recirculation zone position, were subsequently performed. The results show that literature-based ks correlations are unsuitable for the current application. The novel correlation yields more promising outcomes, though its effectiveness depends on the chosen turbulence model. Moreover, it was demonstrated that, for identical ks values, while trends remained consistent, the extent to which they manifested differed under reacting and isothermal conditions.