Performance Analysis of Various Rotor Geometries using CFD Simulation Techniques

Recently, CFD has shown it can effectively explore and fine-tune how rotors work under different conditions. Although they are dependable, the old-fashioned experimental methods can be kind of costly and oftentimes, long. Thus, this work involves a comparative CFD study to validate the thermodynamic properties and flow characteristics of various rotor profiles with a constant clearance of 0.15 mm, with a focus on flow dynamics and sealing characteristics. The study examines the variations of temperature, velocity and pressure within the rotor geometry. There are four modified profiles (Profiles 1 - 4) looked at, and the Master Rotor is essentially the reference profile or the baseline. The velocity and temperature readings under very high pressure, velocity, and temperature readings show that Profile 1 performs better than the others, thus indicating better sealing and less restrictive flow passages. Leakage (or a sort of flow separation) occurs in Profiles 2, 3 and 4, with the performance remaining in the middle to poor. Overall, Rotor Profile 1 is the best design that fits within the limits and is a good choice for applications that are more demanding, particularly if the manufacturing tolerances can consistently be maintained to keep this 0.15 mm clearance.