Toward the use of LES for industrial complex geometries. Part I: automatic mesh definition

With the constant increase of computational power for the past years, Computational Fluid Dynamics (CFD) has become an essential part of the design in complex industrial processes. In this context, among the scale resolving numerical methods, Large-Eddy Simulation (LES) has become a valuable tool for the simulation of complex unsteady flows. To generalise the industrial use of LES, two main limitations are identified. First, the generation of a proper mesh can be a difficult task, which often relies on user-experience. Secondly, the ‘time-to-solution’ associated with the LES approach can be prohibitive in an industrial context. In this work, these two challenges are addressed in two parts. In this Part I, an automatic procedure for mesh definition is proposed, whereas the Part II is devoted to numerical technique to reduce the LES ‘time-to-solution’. The main goal of these works is then to develop an accurate LES strategy at an optimised computational cost. Concerning the mesh definition, because LES is based on separation between resolved and modelled subgrid-scales, the quality of the computed solution is then directly linked to the quality of the mesh. However, the definition of an adequate mesh is still an issue when LES is used to predict the flow in an industrial complex geometry without a priori knowledge of the flow dynamics. This first part presents a user-independent approach for both the generation of an initial mesh and the convergence of the mesh in the LES framework. An automatic mesh convergence strategy is proposed to ensure LES accuracy. This strategy is built to guarantee a mesh-independent mean field kinetic energy budget. The mean field kinetic energy is indeed expected to be mesh independent since only turbulent scales should be unresolved in LES. The approach is validated on canonical cases, a turbulent round jet and a turbulent pipe flow. Finally, the PRECCINSTA swirl burner is considered as a representative case of complex geometry. First, an algorithm for the generation of an unstructured mesh from a STL file is proposed to generate a coarse initial mesh, before applying the mesh convergence procedure. The overall strategy including automatic first mesh generation and its automatic adaptation paves the way to use LES approach as a decision support tool for various applications, provided that the ‘time-to-solution’ is compatible with the applications constraint. A second paper, referred as Part II, is devoted to the reduction of this time.