Robert F. Kunz

The Pennsylvania State University, University Park, Pennsylvania

High Fidelity CFD Analysis and Validation of

Rotorcraft Gearbox Aerodynamics Under

Operational and Oil-Out Conditions

Final Report

NASA/CR—2014-216651

July 2014

Notice for Copyrighted Information 

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with the National Aeronautics and Space Administration. The United States Government has a nonexclusive, irrevocable, 

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Robert F. Kunz

The Pennsylvania State University, University Park, Pennsylvania

High Fidelity CFD Analysis and Validation of

Rotorcraft Gearbox Aerodynamics Under

Operational and Oil-Out Conditions

Final Report

NASA/CR—2014-216651

July 2014

Notice for Copyrighted Information 

This manuscript has been authored by employees of The Pennsylvania State University under Contract No. NNC10CA35C 

with the National Aeronautics and Space Administration. The United States Government has a nonexclusive, irrevocable, 

worldwide license to prepare derivative works, publish or reproduce this manuscript, and allow others to do so, for United 

States Government purposes. Any publisher accepting this manuscript for publication acknowledges that the United States 

Government retains such a license in any published form of this manuscript. All other rights are retained by the copyright owner. 

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Executive Summary

	

		



	


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NASA/CR—2014-216651 41
Summary


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NASA/CR—2014-216651 42
Rev. 3.0, 12/28/05

Rev 3.1, 1/27/06

Rev 3.2, 8/11/06

Rev 3.3, 10/7/06

Rev. 3.4, 10/18/06

Rev. 3.5, 10/29/06

Rev. 3.6, 12/8/06

Rev 3.7, 12/15/06

Rev 3.8, 1/11/07

Rev. 3.9, 1/18/07

Rev. 3.10, 3/30/07

Rev. 3.11, 5/12/08

Rev. 3.12, 10/23/08

Rev. 3.13, 5/18/09

Rev. 3.14, 8/10/11

Rev. 3.15, 3/12/13

Rev. 3.16, 5/31/13

N-PHASE-PSU Version 3.16: 

Theory, User’s and Reference Manual 

Robert F. Kunz 

The Pennsylvania State University 

University Park, Pennsylvania 16804

	

NASA/CR—2014-216651 43

1
Table of Contents

	 

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3
Executive Summary 



	
 




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NASA/CR—2014-216651 74

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NPHASE-PSU User’s Manual

Preprocessing

Overview

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NASA/CR—2014-216651 75

33
Input Files

 
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#case title:

#simple nphase.dat file 

iterations to perform 100 

number of fields 1 

time accurate simulation 

temporal discretization momentum 1 

physical timestep in seconds .1 

number of physical timesteps 1 

transient file write frequency 2 

#initialize run with restart file 

produce ensight output 

restart file write frequency 100 

dont perform wall match logic 

inlet patch 1 0 

1. 0. 0. 1. 1. 0.1 0.1 0. 0. 0 0

pressure patch 1 0 

0. 1. 1. 0.1 0.1 0. 0. 

turbulent flow high reynolds number k epsilon 

constant fluid molecular viscosity 1.0e-2 

constant fluid density 1.0 

function entry/exit echo off 

solversweepsforu 3 

solversweepsforv 3 

solversweepsforw 3 

solversweepsfork 3 

solversweepsfore 3 

solver choice for velocity components jacobiuvw 

solver choice for pressure petsc 

parallel strategy for pressure corrector: matrixlevel 

initialize u field 1. 

initialize k field .1

initialize e field .1

Figure 9. Sample nphase.dat file

NASA/CR—2014-216651 76

34


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NASA/CR—2014-216651 77

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NASA/CR—2014-216651 78

36
Boundary Condition Specification

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NASA/CR—2014-216651 79

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NASA/CR—2014-216651 80

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NN NN PPPPPPPP HH HH AAAAAAAAA SSSSSSSSS EEEEEEEEE

 NNN NN PP PPP HH HH AAAAAAAAA SSSSSSSSS EEEEEEEEE 

 NNNN NN PP PP HH HH AA AA SS EE

 NN NN NN PP PPP HH HH AA AA SS EE

 NN NN NN PPPPPPPP HHHHHHHHH AAAAAAAAA SSSSSSSSS EEEE

 NN NN NN PP HH HH AA AA SS EE

 NN NNNN PP HH HH AA AA SS EE

 NN NNN PP HH HH AA AA SSSSSSSSS EEEEEEEEE 

 NN NN PP HH HH AA AA SSSSSSSSS EEEEEEEEE 

 NPHASE: A COMPUTER PROGRAM FOR THE PREDICTION OF MULTIFIELD

FLOWS WITH MASS, MOMENTUM AND ENERGY TRANSFER

Developed by: Rob Kunz

 *** entered pre_author: reading nphase.dat input *** 

 *** exiting pre_author: finished pass 1 on input file *** 

 *** entered pre_author2: reading nphase.dat input *** 

 *** exiting pre_author2: finished pass 1 on input file *** 

 *** entered author: reading nphase.dat input file *** 

iterations to perform 5 

number of fields 1 

time accurate simulation 

temporal discretization momentum 1 

physical timestep in seconds .1 

number of physical timesteps 4 

transient file write frequency 1 

produce ensight output 

dont perform wall match logic 

inlet patch 1 0 

1.0 0. 0. 1. 1. 0.1 0.1 0. 0. 0 0 

pressure patch 1 0 

0. 1. 1. 0.1 0.1 0. 0. 

turbulent flow high reynolds number k epsilon 

constant fluid molecular viscosity 1.e-3 

constant fluid density 1 

function entry/exit echo off 

solver sweeps for u 3 

solver sweeps for v 3 

solver sweeps for w 3 

solver sweeps for p 6 

solver sweeps for k 3 

solver sweeps for e 3 

solver choice for velocity components jacobiuvw 

solver choice for pressure petsc 

parallel strategy for pressure corrector: matrixlevel 

initialize u field 1. 

initialize k field .1 

initialize e field .1 

 *** exiting author: finished 2nd pass on input file *** 

 about to exit front end 

 1 1 6.498e-02 0.000e+00 0.000e+00 1.515e+01 8.950e-03 5.938e-02 -1.337e+01 

 2 1 1.168e-01 8.494e-02 9.137e-02 3.547e+00 2.788e-03 2.511e-02 -3.696e+00 

 3 1 3.017e-02 2.215e-02 2.427e-02 1.142e+00 2.530e-03 1.011e-02 -1.147e+00 

 4 1 1.281e-02 8.440e-03 9.386e-03 2.657e-01 1.725e-03 3.497e-03 -4.204e-01 

 5 1 7.488e-03 3.947e-03 4.671e-03 1.383e-01 1.132e-03 1.649e-03 -2.265e-01 

Figure 13. Sample nphase.out file

NASA/CR—2014-216651 81

39



	
 

	
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12 processor run 

*** begin execution of nphase ***

unphase.grid files generated by fump version 2.0

nvert=409798 nnode=388114 nfedge=4332994 nface=1102458 

inlet.nbcfedge= 1024, inlet.nbcface= 256, inlet.nbcfaceid= 1 

partition.nbcfedge= 215690, partition.nbcface= 53192, partition.nbcfaceid= 12

pressure.nbcfedge= 2080, pressure.nbcface= 542, pressure.nbcfaceid= 1 

wall.nbcfedge= 116882, wall.nbcface= 32228, wall.nbcfaceid= 5 

finished reading grid in read_grid_unstruct

number of tets in model = 20732

number of hexs in model = 320105

number of prisms in model = 5442 

number of pyramids in model = 29983

number of non-simplicial volume elements in model = 11852 

total mass of ifield = 0 in volume = 5.0867325450934e+04

solidflags: icount10 = 0

Number of internal solid faces = 0

about to exit front end 

************************

time accurate simulation

number of time steps to be run: 4 

number of pseudotimesteps per physical timestep: 5 

time step in seconds : 1.00000000e-01

************************

about to make subdirectory TRANSIN if it does not exist

done with make subdirectory TRANSIN if it does not exist

writing ensight output file(s) for current timestep

finished writing ensight output file(s) for current timestep 

**********************************************

commencing inner iterations for t = 1.00000000e-01

iphystimeglobal = 1

**********************************************

 iter fld ru rv rw rp rk re gmass ws/cif 

1 1 6.498e-02 0.000e+00 0.000e+00 1.515e+01 8.950e-03 5.938e-02 -1.337e+01 3.659e-06 

2 1 1.168e-01 8.494e-02 9.137e-02 3.547e+00 2.788e-03 2.511e-02 -3.696e+00 3.435e-06 

3 1 3.017e-02 2.215e-02 2.427e-02 1.142e+00 2.530e-03 1.011e-02 -1.147e+00 3.455e-06 

4 1 1.281e-02 8.440e-03 9.386e-03 2.657e-01 1.725e-03 3.497e-03 -4.204e-01 3.453e-06 

5 1 7.488e-03 3.947e-03 4.671e-03 1.383e-01 1.132e-03 1.649e-03 -2.265e-01 3.455e-06 

writing ensight output file(s) for current timestep

finished writing ensight output file(s) for current timestep

total mass of ifield = 0 in volume = 5.0867325450934e+04

**********************************************

commencing inner iterations for t = 2.00000000e-01 

iphystimeglobal = 2

**********************************************



Figure 14. Sample n.out file (part 1)

NASA/CR—2014-216651 82

40


	
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commencing inner iterations for t = 4.00000000e-01

iphystimeglobal = 4

**********************************************

iter fld ru rv rw rp rk re gmass ws/cif 

16 1 6.074e-03 3.018e-03 3.006e-03 2.330e-01 3.567e-03 5.877e-03 -2.646e-01 3.485e-06 

17 1 1.721e-03 6.843e-04 6.456e-04 1.321e-01 1.260e-03 3.092e-03 -1.695e-01 3.470e-06 

18 1 1.002e-03 4.132e-04 3.987e-04 5.940e-02 6.373e-04 2.435e-03 -6.422e-02 3.438e-06 

19 1 5.080e-04 2.381e-04 2.078e-04 2.989e-02 3.783e-04 1.976e-03 -4.274e-02 3.469e-06 

20 1 3.505e-04 1.604e-04 1.606e-04 1.385e-02 2.450e-04 1.577e-03 -1.894e-02 3.429e-06 

total mass of ifield = 0 in volume = 5.0867325450934e+04 

writing output restart file(s) at iter = 20

finished writing output restart file(s) at iter = 20 

writing ensight output file(s) for current timestep

finished writing ensight output file(s) for current timestep

total wall secs elapsed = 3.00361910e+01 

total cpu secs used by all processors = 3.29250000e+02 

total elements on all processors = 388114 

cpu secs/element/iteration = 4.24166611e-05

wall secs/element/iteration = 3.86950625e-06

average wall secs/element for each iteration = 3.47251214e-06

ratio of partition faces to elements = 1.37052521e-01

about to enter back end 

writing ensight output file(s) 

finished writing ensight output file(s) 

Number of Inlet Boundaries = 1 

Area and Average Pressure for Inlet Boundary ID 0 = 1024 m**2, 0 Pa 

Mass Flow for Field 0 Through Inlet Boundary ID 0 = -1024 Kg/s 

Mass Flow for Field 0 Through All Inlet Boundaries = -1024 Kg/s 

Number of Pressure Boundaries = 1 

Area and Average Pressure for Pressure Boundary ID 0 = 1024 m**2, 0 Pa 

Mass Flow for Field 0 Through Pressure Boundary ID 0 = 1023.98 Kg/s

Mass Flow for Field 0 Through All Pressure Boundaries = 1023.98 Kg/s

Done with boundary mass flow print

ifield,(massin-massout)/massin: 0 1.8497181118102e-05 

*** ending execution of nphase ***

Figure 15. Sample n.out file (continued)

NASA/CR—2014-216651 83

41





	



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NASA/CR—2014-216651 84

42
emerge and emergetrans 

Once NPHASE-PSU has completed there exist many ENSIGHT files in the 

working directory from which the case is executed. One runs emerge to merge the 

ENSIGHT files generated on the different processors into single ENSIGHT files for each 

variable. One runs emergetrans to merge the ENSIGHT files generated on the different 

processors into single ENSIGHT files for each variable at each timestep that the user has 

selected for outputting these files. emerge and emergetrans are delivered in software 

directory EMERGE. They are written in FORTRAN and some C (I/O functions) and are 

compiled using makefiles (makeem, makeemt) that expect pgf90 and gcc, for which these 

codes are guaranteed to compile and run. Other compilers are untested. 

To run emerge, simply types “emerge” to the UNIX shell. The user will be 

prompted for the number of processors and the number of fields. Once emerge has 

completed, the following files are resident in the user’s working directory: engold.geo, 

engold.Esca.p00, engold.Esca.unn, engold.Esca.vnn, and engold.Esca.wnn (where nn are 

the fields present (00-99)). Other case specific merged files are also created (e.g., 

engold.Esca.ann, engold.Esca.hnn, engold.Esca.knn, etc...). Finally emerge generates 

velocity vector files: engold.Evec.uvwnn. All files generated appear in the file engold.case, 

an example of which appears in Figure 17. Upon execution of emerge the user needs to 

transfer the case file, and all of the files it points to, to the file system where he will run 

ENSIGHT. To run ENSIGHT, the case file is read in and each of the other files are 

automatically brought in. 

To run emergetrans, simply type “emergetrans” to the UNIX shell. The user will be 

prompted for the number of processors, the number of fields, whether the grid is stationary 

or moving, the first integer timestep counter, the last integer timestep counter and the 

# BOF: engold.case 

FORMAT 

type: ensight gold 

GEOMETRY 

model: engold.geo 

VARIABLE 

scalar per element: Pressure engold.p00.Esca 

scalar per element: X-velocity_00 engold.u00.Esca 

scalar per element: Y-velocity_00 engold.v00.Esca 

scalar per element: Z-velocity_00 engold.w00.Esca 

scalar per element: TKE_00 engold.k00.Esca 

scalar per element: TDS_00 engold.e00.Esca 

scalar per element: Eddy-viscosity_00 engold.m00.Esca 

vector per element: Velocity-vector_00 engold.uvw00.Evec 

# EOF: engold.case 

Figure 17. Example engold.case file

NASA/CR—2014-216651 85

43
interger timestep increment. emergetrans reads all of the transient per-processor files from 

the subdirectory, TRANSIN, and writes all output files to a subdirectory, TRANSOUT. 

Once emergetrans has completed, the following files are resident in TRANSOUT:

engold.geo (or engold.geo.tttttt (if grid is moving), engold.Esca.p00.tttttt,

engold.Esca.unn.tttttt, engold.Esca.vnn.tttttt, and engold.Esca.wnn.tttttt (where nn are the 

fields present (00-99), and tttttt is the integer timestep). Other case specific merged files are 

also created (e.g., engold.Esca.ann.tttttt, engold.Esca.hnn.tttttt, engold.Esca.knn.tttttt,

etc...). Finally emergetrans generates velocity vector files: engold.Evec.uvwnn.tttttt. All 

files generated appear in the file TRANSOUT/engold_transient.case, an example of which 

appears in Figure 18. Upon execution of emerge the user needs to transfer the case file and 

all of the files it points to the file system where he will run ENSIGHT. To run ENSIGHT, 

the case file is read in and each of the other files are automatically brought in. Upon

execution of emergetrans the user needs to transfer the case file, and all of the files it points 

to, to the file system where he will run ENSIGHT. To run ENSIGHT, the case file is read 

in and each of the other files are automatically brought in. 

Tutorials

Four tutorials are provided as of Ver. 3.1, Rev. 1.12. The first is a general 

familiarization case, the second and third are specific to the DARPA FDR program which 

co-funded this documentation. The fourth is a highly compressible case. Each is delivered 

# BOF: engold_transient.case

FORMAT 

type: ensight 

GEOMETRY 

model: engold.geo 

VARIABLE 

scalar per element: Pressure engold.p00.Esca.****** 

scalar per element: X-velocity_00 engold.u00.Esca.****** 

scalar per element: Y-velocity_00 engold.v00.Esca.****** 

scalar per element: Z-velocity_00 engold.w00.Esca.****** 

vector per element: Velocity_00 0 gold.uvw000 vec.****** 

scalar per element: TKE_00 engold0k00.Esca.****** 

scalar per element: TDS_00 engold0e00.Esca.****** 

scalar per element: Mut_00 engold0m00.Esca.****** 

TIME 

time set: 1 

number of steps: 5 

filename numbers: 

0 1 2 3 4 

time values: 

 0.000E+00 0.100E+01 0.200E+01 0.300E+01 0.400E+01 

# EOF: engold_transient.case 

Figure 18. Example engold_transient.case file

NASA/CR—2014-216651 86

44
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Tutorials

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NASA/CR—2014-216651 88

46

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NASA/CR—2014-216651 89

47
emerge

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NASA/CR—2014-216651 90

48

	




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NASA/CR—2014-216651 91

49
) 
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	pp

"""	pp"""

	pp

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	pp

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	pp

""%	pp""%

	pp

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	pp

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	pp

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Figure 25. mrf script

Figure 26. TECPLOT plot of residual history of steady TUTORIAL_1 simulation.

Iteration

RMS(7)

100 200 300 400 500 10-6

10-5

10-4

10-3

10-2

10-1

100

7u

7p

NASA/CR—2014-216651 92

50
Figure 27. ENSIGHT visualization of steady TUTORIAL_1 simulation.

NASA/CR—2014-216651 93

51
Tutorial Case 2: Multiphase HIPLATE Simulation 

This case demonstrates the application of NPHASE-PSU to the HIPLATE 

configuration. The HIPLATE experimental programs were carried out by Ceccio and his 

colleagues at the Universty of Michigan (Sanders et al., 2006) under the DARPA Friction 

Drag Reduction program. Comparison of NPHASE-PSU to and calibration of NPHASEPSU against these data sets were elements of the program (Kunz, et al., 2006, Kunz et al., 

2007). HIPLATE is a very high Reynolds number plate configuration tested in the US 

Navy’s Large Cavitation Channel, using microbubble and polymer drag reduction schemes. 

Although NPHASE-PSU was validated against and/or applied to the entire 

spectrum of HIPLATE runs (five gas injection rates, three tunnel speeds, various injector 

port gas flow splits, with vs. without surfactant, two injector geometries, and two water 

tunnel test programs [HIPLATE I, II]), we here demonstrate a coarse grid (fast running) 

application corresponding to the January 2005 program deliverable (validation of code 

against HIPLATE I data). Specifically, a 12 m/s, Qgas=800 scfm case is set up and run. The 

physical model set used here is very close to that used for the January 2006 deliverable to 

DARPA which was a validation study comparing NPHASE-PSU simulations to all 

HIPLATE I data. 

To start the tutorial the user needs to go to the TUTORIAL_HIPLATE directory. 

There are four files there when the software is unpacked: nphase.dat, run.nphase, 

cobalt.inp, and cobalt.bc. The first step is to execute fump (as described in the 

Preprocessing section and Tutorial_1 section above), using (here) 1 domain and a scaling 

factor of 1.0. This step generates a single grid+topology file, unphase.grid000. Figure 28 

shows the file nphase.dat file used for this tutorial. The keywords “employ hiplate 

modeling” are included to instruct nphase to execute the function hiplate_output.c each 

iteration which prints skin friction data (and, if commented in, other data) to standard 

output (redirected to n.out in run.nphase). (See the section entitled Building User 

Specific/Case Specific Postprocessing for details on how to modify or adapt this kind of 

output for different output or simulation case.) 

First the code has to be run in single phase mode to generate the comparison flat 

plate skin friction values at the 6 axial locations on the HIPLATE where shear stress 

measurements were made. To do this, the user needs to modify the green highlighted 

sections in Figure 28 as follows: 1) change number of iterations to 500, 2) change porous 

wall injection velocity from 9.0476 to 0.0000 and the porous wall permeability from 0.7 to 

0.0., 3) comment out the relaxation factor lines (allow for defaults). So the code is being 

run in full 2-phase mode but there is no gas present or injected to it returns a single phase 

convergence and results. 

This single phase job can be run interactively (since its only one processor) or 

submitted to PBS using the qsub command: qsub run.nphase (unless there are other submit

scripts available on the user’s system). This single phase job processor job executes 500

iterations in about 55 wall seconds on a modern LINUX cluster. Figure 29 shows a section 

of the n.out file for this single phase run that includes the computed Cf distribution at the 

six axial HIPLATE stations. To run the microbubble drag reduction case, the nphase.dat 

NASA/CR—2014-216651 94

52
file is used as it appears in Error! Reference source not found.. A total of 20,000 

iterations are selected along with the conservative under-relaxation factors that appear.

iterations to perform 20000 

number of fields 2 

produce ensight output 

restart file write frequency 1000 

dont perform wall match logic 

employ hiplate modeling 

gravity vector 0. 9.81 0. 

employ modified pressure 

reference density for modified pressure 1 

overwrite inlet patch boundary conditions on restart 

overwrite porous wall patch boundary conditions on restart 

overwrite pressure patch boundary conditions on restart 

overwrite_gas_molecular_viscosities 200 1.5e+3 

inlet patch 2 0 

12.0 0. 0. 1000. 0.999999 1.33e-7 1.76e-6 0. 1. 

12.0 0. 0. 1. 0.000001 0. 0. 0. 1. 

porous wall patch 2 0 

9.0476 0. 0. 1000. 0.000001 1.33e-7 1.76e-6 0. 0.7 1. 

9.0476 0. 0. 1. 0.999999 0. 0. 0. 0.7 1. 

pressure patch 2 0 

0.0 1000. 0.999999 1.33e-7 1.76e-6 0. 

0.0 1. 0.000001 0. 0. 0. 

constant fluid density 1000. 1. 

constant fluid molecular viscosity 1.e-3 1.5e-5 

constant fluid surface tension .072 0. 

Turbulence model for each field 1 0 

function entry/exit echo off 

adiabatic flow 

solver sweeps for u 3 

solver sweeps for v 3 

solver sweeps for a 3 

solver sweeps for p 10 

solver sweeps for tke 3 

solver sweeps for tds 3 

solver choice for velocity components jacobiuvw 

solver choice for pressure petsc 

parallel strategy for pressure corrector: matrixlevel 

employ rhie chow for dispersion terms 

relaxation factor for u .05 .05 

relaxation factor for v .05 .05 

relaxation factor for a .05 .05 

initialize u field 12. 12. 

initialize v field 0. 0. 

initialize w field 0. 0. 

initialize a field .999999 0.000001 

initialize tke field 1.33e-7 0. 

initialize tds field 1.76e-6 0. 

NASA/CR—2014-216651 95

53
interfacial area transport model for each field 0 1 

interfacial area coalescence model for each field 0 3 

initialize interfacial area using volume fraction and characteristic length 

interfacial area feeds back into bubble diameter frequency 100 

constant field characteristic diameter 99. .000400 

interfield drag models 1 

1 2 6 .8 

bubble cluster drag modification 

interfield nondrag models 5 

1 2 2 5 50.

1 2 2 7 1. 2. -2.0 0.5 2. 

1 2 3 3 .1 

1 2 1 6 .25 

1 2 5 3 1.

Figure 28. nphase.dat file for HIPLATE tutorial

 iter fld ru rv rw rp ra raint rh rk ... 

1 1 3.580e-03 4.631e-01 0.000e+00 5.767e+03 2.210e-08 0.000e+00 0.000e+00 1.104e-05 ... 

1 2 1.005e+00 1.672e-14 0.000e+00 5.767e+03 2.139e-08 3.208e-04 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 2.57927225e-01 2.57927225e-01 2.57927225e-01 2.57927225e-01 ... 

clipcount0 64 

2 1 7.490e-02 9.948e-02 0.000e+00 1.157e+03 3.543e-08 0.000e+00 0.000e+00 1.324e-03 ... 

2 2 5.775e-01 9.039e-02 0.000e+00 1.157e+03 3.467e-08 5.207e-04 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 4.48393267e+00 5.93114814e+00 6.51944986e+00 6.64137946e+00 ... 

 499 1 8.279e-06 1.624e-07 0.000e+00 3.534e-02 6.881e-06 0.000e+00 0.000e+00 2.490e-06 ... 

 499 2 5.797e-01 4.853e-01 0.000e+00 3.534e-02 4.581e-06 6.947e-02 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 1.59246792e+02 1.49083851e+02 1.39654688e+02 1.36211604e+02 ... 

 500 1 8.102e-06 1.540e-07 0.000e+00 3.885e-02 3.922e-06 0.000e+00 0.000e+00 2.440e-06 ... 

 500 2 1.103e-01 1.703e-01 0.000e+00 3.885e-02 3.541e-06 5.406e-02 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 1.59246794e+02 1.49083857e+02 1.39654745e+02 1.36211706e+02 ... 

final cf1,cf2,cf3,cf4,cf5,cf6 1.59246794e+02 1.49083857e+02 1.39654745e+02 ... 

avgcf cf1,cf2,cf3,cf4,cf5,cf6 1.56126868e+02 1.41946021e+02 1.39721464e+02 ... 

stdv cf1,cf2,cf3,cf4,cf5,cf6 1.36051236e+01 1.79146591e+01 1.66518929e+01 ... 

Figure 29. Snippets from standard output (n.out) for single phase TUTORIAL_HIPLATE simulation, 

illustrating case specific skin friction coefficient output.

NASA/CR—2014-216651 96

54
 iter fld ru rv rw rp ra raint rh rk ... 

1 1 2.007e-04 1.944e-02 0.000e+00 7.098e+05 2.068e-03 0.000e+00 0.000e+00 1.102e-05 ...

1 2 7.272e-02 1.021e-02 0.000e+00 7.098e+05 2.067e-03 9.201e+03 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 2.57927225e-01 2.57927225e-01 2.57927225e-01 2.57927225e-01 ... 

clipcount0 85 

2 1 4.648e-01 2.057e-01 0.000e+00 6.805e+05 1.970e-03 0.000e+00 0.000e+00 1.373e-03 ... 

2 2 7.036e-02 3.113e-03 0.000e+00 6.805e+05 1.969e-03 7.497e+03 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 4.53209563e+00 5.96370783e+00 6.54783080e+00 6.66829586e+00 ... 

 19999 1 1.463e-05 4.050e-06 0.000e+00 8.241e-01 3.974e-04 0.000e+00 0.000e+00 1.243e-05 ... 

 19999 2 1.963e-03 1.345e-04 0.000e+00 8.241e-01 3.906e-04 8.455e+01 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 7.61674767e+01 9.95633653e+01 1.12126232e+02 1.20645034e+02 ... 

 20000 1 1.447e-05 4.117e-06 0.000e+00 8.499e-01 3.973e-04 0.000e+00 0.000e+00 1.226e-05 ... 

 20000 2 2.261e-03 1.369e-04 0.000e+00 8.499e-01 3.905e-04 8.445e+01 0.000e+00 0.000e+00 ... 

cf1,cf2,cf3,cf4,cf5,cf6 7.61674747e+01 9.95633580e+01 1.12101175e+02 1.20644965e+02 ... 

final cf1,cf2,cf3,cf4,cf5,cf6 7.61674747e+01 9.95633580e+01 1.12101175e+02 ... 

avgcf cf1,cf2,cf3,cf4,cf5,cf6 7.61676731e+01 9.95634673e+01 1.12181731e+02 ... 

stdv cf1,cf2,cf3,cf4,cf5,cf6 1.64306879e-04 2.11569909e-04 5.42004104e-02 ... 

Figure 30. Snippet from standard output (n.out) for two-phase TUTORIAL_HIPLATE simulation, 

illustrating case specific skin friction coefficient output.

NASA/CR—2014-216651 97

55
The user can then run emerge (1 processor, 2 fields this time) and migrate the 

merged data files (engold.geo, engold.wnn.Esca, engold.vnn.Esca, engold.uvwnn.Evec, 

engold.unn.Esca, engold.ann.Esca, engold.ainn.Esca, engold.rnn.Esca, engold.pnn.Esca, 

engold.mnn.Esca, engold.knn.Esca, engold.enn.Esca , where nn =0 and 1 for the liquid and 

gas fields) and case file (engold.case) to the location he plans on postprocessing using 

ENSIGHT. 

Figure 31. Predicted skin friction coefficient vs. iteration at the six HIPLATE stations for the twophase TUTORIAL_HIPLATE simulation.

Iteration

Cf

0 5000 10000 15000 20000 0

50

100

150

200

250

300 Cf1

Cf2

Cf3

Cf4

Cf5

Cf6

Figure 32. Predicted skin friction coefficient vs. x at the six HIPLATE stations for the two-phase 

TUTORIAL HIPLATE simulation.

x (m)

Drag Reduction

0 2 4 6 8 10 12 0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

NPHASE-PSU

HIPLATE

NASA/CR—2014-216651 98

56
Figure 30 shows a section of the n.out file for the two-phase microbubble drag 

reduction run that includes the computed Cf distribution at the six axial HIPLATE stations. 

Figure 31 shows the computed 2-phase skin friction iteration history. This solution 

converged to the final Cf values in about 5000 iterations. Figure 32 shows the predicted 

drag reduction vs. x for this case. These results are nearly identical to the January 2006 

submission (grid is coarser here). Figure 33 shows contours of predicted gas volume 

fraction with the vertical axis scaled by a factor of 100 in order that the thin microbubble 

layer can be viewed. 

Figure 33. Predicted contours of gas volume fraction for the two-phase TUTORIAL_HIPLATE 

simulation. Vertical axis scaled by a factor of 100.

NASA/CR—2014-216651 99

57
Tutorial Case 3: Multiphase 5415 Simulation 

This case demonstrates the application of NPHASE-PSU to a Navy relevant 

configuration in 1-phase and 2-phase modes. The geometry is the 5415 model, a hull form 

representative of the Arleigh-Burke class destroyer. This model has been extensively tested 

at the Naval Surface Warfare Center Carderock Division (http://www.dt.navy.mil/hyd/surshi-mod/index.html, for example.) The grid was generated using ICEM-CFD and is a

standard tetra+prism mesh. Specifically, the mesh contains 1438852 elements of which 

463837 are prisms extruded in (nominally) five layers from the triangulated hull surface. 

This comparatively coarse mesh is suitable for wall function turbulence modelling. The 

hull surface incorporates a standard solid wall patch and a porous wall patch, aft of the bow 

dome, from which gas is injected. Figure 34 shows two views of the mesh used.

To start the tutorial the user needs to go to the TUTORIAL_5415 directory. There 

are five files there when the software is unpacked: nphase.dat, run.nphase, cobalt.inp, 

cobalt.bc and mrf. The first step is to execute fump (as described in the Preprocessing

section and Tutorial_1 section above), using (here) 32 domains and a scaling factor of .001 

(to convert the grid from mm to m.) This step generates the 32 files unphase.grid000, 

unphase.grid001, ...., unphase.grid0031. Figure 35 shows the file nphase.dat. The 

keywords “employ model 5415 modeling” are included to instruct nphase to execute the 

function model5415_output.c each iteration which generates a wetted area and a net vehicle 

drag coefficient printout to standard output (redirected to n.out in run.nphase). (See the 

section entitled Building User Specific/Case Specific Postprocessing for details on how to 

modify or adapt this kind of output for different output or simulation case.) A freestream 

velocity of 2.2134 m/s is specified (model scale) and the k-model is selected. 

First the user should run the code to generate a single phase solution for comparison 

to multiphase runs to be made later. To do this, the user needs to modify the green 

highlighted sections in Figure 35 as follows: 1) change number of iterations to 2500, 2) 

change porous wall injection velocity from 0.3000 to 0.0000 and the porous wall 

permeability from 0.7 to 0.0. So the code is being run in full 2-phase mode but there is no 

gas present. The job is submitted to PBS using the qsub command: qsub run.nphase (unless 

there are other submit scripts available on the user’s system). This 32 processor job 

Figure 34. Views of mesh employed for 5415 tutorial

waterline

porous injection patch

prism layer

hull boundary

NASA/CR—2014-216651 100

58
-
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0 
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02""06 
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#case title:

#5415

iterations to perform 10000

employ model 5415 modeling

number of fields 2

#initialize run with restart file

produce ensight output

restart file write frequency 100

dont perform wall match logic

read wall proximity from file

gravity vector 0. 0. -9.81

employ modified pressure

reference density for modified pressure 1000.

#simple hydrostatic pressure treatment

overwrite inlet patch boundary conditions on restart

overwrite porous wall patch boundary conditions on restart

overwrite pressure patch boundary conditions on restart

#overwrite_gas_molecular_viscosities 200 1.5e+3

inlet patch 2 0

2.2134 0. 0. 1000. .99999999999 .002939 .02618 0. 0.

2.2134 0. 0. 1. .00000000001 .0 .0 0. 0.

pressure patch 2 0

0.0 1000. .99999999999 .002939 .02618 0. 0.

0.0 1. .00000000001 .0 .0 0. 0.

porous wall patch 2 0

0.3000 0. 0. 1000. .00000000001 .002939 .02618 0. 0.7 1.

0.3000 0. 0. 1. .99999999999 .0 .0 0. 0.7 1.

turbulence model for each field 1 0

constant fluid molecular viscosity 1.e-3 1.5e-5 

constant fluid density 1000. 1.

constant fluid surface tension .072 0.

spatial discretization momentum 2

function entry/exit echo off

adiabatic flow

solversweepsforu 3 3

solversweepsforv 3 3

solversweepsforw 3 3

solversweepsfora 3 3

solversweepsfork 3 3

solversweepsfore 3 3

NASA/CR—2014-216651 101

59
) 
%@
2
 

 	0



 2


2C



0

:@""1 4.207e-06 2.098e-06 8.752e-07 1.029e-03 2.231e-11 0.000e+00 1.127e-06 2.070e-04

...

2500 2 1.480e-01 2.008e-01 6.633e-02 1.029e-03 2.395e-11 0.000e+00 0.000e+00 0.000e+00

...

Awetted dot i: 2.2368721880023e-05 m^2 

Viscous drag force: 3.3070651056143e+01

Pressure drag force: 1.0161932291489e+01

Total drag force: 4.3232583347632e+01

) 
%9
2

0

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solver choice for velocity components jacobiuvw

solver choice for pressure petsc

parallel strategy for pressure corrector: matrixlevel

petscprintnorm

employ rhie chow for dispersion terms

#relaxation factor for u .2 .2

#relaxation factor for v .2 .2

#relaxation factor for w .2 .2

#relaxation factor for a .2 .2

#relaxation factor for k .2 .2

#relaxation factor for e .2 .2

# 

initialize u field 2.2134 2.2134

initialize v field 0. 0.

initialize w field 0. 0.

initialize a field .99999999999 .00000000001

initialize k field .002939 .0

initialize e field .02618 .0

clips_on_velocity -5. 10. -5. 5. -5. 5.

#interfacial area transport model for each field 0 1

#interfacial area coalescence model for each field 0 3

#initialize interfacial area using volume fraction and characteristic length

#interfacial area feeds back into bubble diameter frequency 100

constant field characteristic diameter 99. .000400

interfield drag models 1

1 2 6 0.8

bubble cluster drag modification

interfield nondrag models 5

1 2 2 5 50.

1 2 2 7 1. 2. -2.0 0.5 2.

1 2 3 3 .1

1 2 1 6 .25

1 2 5 3 1.

Figure 35. nphase.dat file for TUTORIAL_5415.

NASA/CR—2014-216651 102

60

50





02
	
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Figure 36. TECPLOT plot of residual history of single phase TUTORIAL 5145 simulation.

Iteration

RMS(

7q)

0 500 1000 1500 2000 2500 10-8

10-7

10-6

10-5

10-4

10-3

10-2

10-1

100

101

U-velocity

Pressure

TKE

iter fld ru rv rw rp ra rh rk re ...

. 

. 

. 

. 

2500 1 4.207e-06 2.098e-06 8.752e-07 1.029e-03 2.231e-11 0.000e+00 1.127e-06 2.070e-04 ...

2500 2 1.480e-01 2.008e-01 6.633e-02 1.029e-03 2.395e-11 0.000e+00 0.000e+00 0.000e+00 ...

Awetted dot i: 2.2368721880023e-05 m^2 

Viscous drag force: 3.3070651056143e+01

Pressure drag force: 1.0161932291489e+01

Total drag force: 4.3232583347632e+01

Figure 37. Snippets from standard output (n.out) for single phase TUTORIAL_5145 simulation, illustrating 

case specific drag output.

NASA/CR—2014-216651 103

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NASA/CR—2014-216651 104

62
Figure 38. TECPLOT plot of residual history for two-phase TUTORIAL_5145 simulation.

V1

V3, V4, V5, V6, V7, V8, V9, V10, V11

0 500 1000 1500 2000 10-5

10-4

10-3

10-2

10-1

100

101

102

Figure 39. TECPLOT plot of drag force history for two-phase TUTORIAL_5145 simulation.

Iteration

Axial Force (N)

0 500 1000 1500 2000 0

10

20

30

40

50 Viscous

Pressure

Total

G


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NASA/CR—2014-216651 105

63
iter fld ru rv rw rp ra rh rk re ...

. 

. 

. 

. 

10000 1 5.809e-03 2.045e-03 2.639e-03 6.509e-01 1.482e-02 0.000e+00 6.091e-04 2.577e-02 ...

10000 2 3.713e-01 4.032e-01 1.596e-01 6.509e-01 1.099e-02 0.000e+00 0.000e+00 0.000e+00 ...

Awetted dot i: 2.2368721880023e-05 m^2

Viscous drag force: 2.7868256856116e+01

Pressure drag force: 1.2050646663068e+01

Total drag force: 3.9918903519184e+01

Figure 40. Snippets from standard output (n.out) for two phase TUTORIAL_5145 simulation, illustrating case 

specific drag output.

Figure 41. Surface pressure contours and gas=0.5 isosurface for Uinj=0.3 m/s TUTORIAL_5145 

simulation.

NASA/CR—2014-216651 106

64
Figure 42. Predicted Total Hull Drag vs. Non-Dimensional Gas Injection for 5415 Simulations

Qa/(Qa+Qw)

Drag (N)

0 0.1 0.2 0.3 0.4 0.5 0

5

10

15

20

25

30

35

40

45

50

Viscous

Pressure

Total

Figure 43. Predicted Total Drag Reduction vs. Non-Dimensional Gas Injection for 5415 

Simulations

Qa/(Qa+Qw)

Drag Reduction

0 0.1 0.2 0.3 0.4 0.5 0

0.02

0.04

0.06

0.08

0.1

NASA/CR—2014-216651 107

65
Tutorial Case 4: Compressible Flow over a Bump


		

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NASA/CR—2014-216651 108

66
#case title:

#INVISCID BUMP

iterations to perform 2500

number of fields 1

#initialize run with restart file

produce ensight output

restart file iteration write frequency 1000

dont perform wall match logic

#pamb=101325 Pa, Tamb=293.15 K

inlet patch 1 0

240.24145833 0. 0. 1.204328093 1. 0. 0. 0. 323327.154 0 0 #stagnation enthalpy

pressure patch 1 0

101325. 1.204328093 1. 0. 0. 323327.154 0. #stagnation enthalpy

constant fluid molecular viscosity 1.0e-15

use stagnation enthalpy as primitive energy transport variable 0

strongly coupled compressibility

perfect gas compressibility parameters 0

287. 1.4

single phase heating on

continuity error treatment for enthalpy

print umin and umax

print tmin and tmax

#clips on velocity -500. 500. -500. 500. -500. 500.

spatialdiscretizationmomentum 2

spatialdiscretizationenthalpy 2

function entry/exit echo off

#relaxation factor for p .3

relaxation factor for u 0.7

relaxation factor for v 0.7

solver choice for velocity components jacobiuvw

solver choice for pressure petsc

#solver choice for pressure jacobi

parallel strategy for pressure corrector: matrixlevel

initialize u field 240.24145833

initialize p field 101325.

initialize h field 323327.154 #stagnation enthalpy

Figure 44. nphase.dat file for TUTORIAL_MACH_BUMP.

NASA/CR—2014-216651 109

67
Figure 45. Predicted Mach number contours for TUTORIAL_MACH_BUMP.

NASA/CR—2014-216651 110

68
Tutorial Case 5: Flow around a Shrouded Gear 

To demonstrate application of NPHASE-PSU to gear windage simulation, we have 

provided a tutorial case of a 72-tooth shrouded spur gear investigated by Diab et al. (2004).

Considering the symmetry of the problem, only one side of a single tooth sector is 

simulated, decreasing simulation size substantially. The simulation is performed in a 

reference frame rotating with the gear, so that a stationary mesh can be used with a moving 

wall boundary condition applied on the shroud. Figure 46 shows the nphase.dat file used 

for this case. Because the simulated flow is incompressible and there are no inlets or 

outlets, pressure must be set to a reference value (0) somewhere within the domain for the 

equations of motion to remain well-posed. We have chosen to anchor the pressure value 

implicitly (appearing in the pressure equation matrix). This is specified through inclusion 

of the line, anchor pressure implicitly.

Attributes specific to gear windage simulation are specified in the line 

employ diab gear modeling 1000.0 2 72 0. The first argument is the gear rotation

speed in radians per second. The second argument is an integer denoting the strategy used 

for the rotation. 0 is a stationary grid with a stationary reference frame, and implicit wall 

motion, but is applicable only to cylinders. 1 is for a stationary grid in the relative reference 

frame with absolute velocities. 2 is a stationary grid in the relative frame with relative 

velocities. 3 is a rotating grid in the absolute reference frame with absolute velocities. Here, 

we have chosen to use option 2, for a stationary grid in the relative frame with relative 

velocities. The third argument is the number of teeth. The fourth argument is a Boolean 

toggle denoting whether the output should be made relative to the first time-step. As this is 

a steady state simulation, this parameter is irrelevant and is set to zero. Due to the lack of 

inlets and outlets, the cyclic boundary conditions, and the manner in which flow is driven, 

this simulation takes many iterations to converge. To maintain numerical stability, it is best 

to run it with first order discretization for the first 50,000 iterations, then uncomment the 

second order discretization commands in nphase.dat, and run it again, re-initializing from 

restart files. 

To run this case, NPHASE requires that the high and low cyclic boundary faces be 

sorted. First, sort_cyclic is run, which generates cobalt.inp.sort. Next, this file must be renamed cobalt.inp. From here, fump is run. The current case is decomposed for 12 

processors using METIS and a scale of 1. The sector angle for cyclic simulation is 5 

degrees for a 72-tooth gear, so this is input when prompted. After running fump to generate 

unphase.grid000 – unphase.grid011, the run script can be appropriately modified for the 

batch scheduling system and mpiexec used, and then submitted to the queue. After running 

with first order accuracy, nphase.dat should be modified for second order accuracy and 

initializing from restart files. To move the nphase_restart_out### files to 

nphase_restart_in###, run mrf. The run script can then be re-submitted to the queue to 

achieve a second order accurate solution. Figure 47 shows streamlines colored by pressure 

for this simulation. The streamlines were created in EnSight by applying computational 

symmetry to the solution as a post-processing step.

NASA/CR—2014-216651 111

69
# Case title 

# Diab gear windage tutorial 

iterations to perform 50000 

restart file iteration write frequency 5000 

#initialize run with restart file 

number of fields 1 

produce ensight output 

employ diab gear modeling 1000.0 2 72 0 

#spatial discretization momentum 2 

#spatial discretization turbulence 2

dont perform wall match logic 

anchor pressure implicitly 

pressure gradient at walls extrapolation 

constant fluid molecular viscosity 1.e-5 

constant fluid density 1. 

turbulence model for each field 1 

turbulence model reynolds number regime for each field 0 

production destruction ratio clip 500 

solver choice for velocity components jacobiuvw 

solver choice for pressure petsc 

parallel strategy for pressure corrector: matrixlevel 

#relaxation factor for u .7 

relaxation factor for k 0.7 

relaxation factor for e 0.7 

initialize u field 0. 

initialize p field 0. 

initialize k field 0.015 

initialize e field 5.0 

Figure 46. nphase.dat file for TUTORIAL_GEAR.

Figure 47. Streamlines colored by pressure from shrouded gear tutorial.

NASA/CR—2014-216651 112

70
Other Items of Interest

Running Two-Dimensional Problems

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NASA/CR—2014-216651 114

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#include "nphase_struct.h"

#include "mpi.h"

#include <math.h>

#include <stdio.h>

extern struct boundary_patch wall;

extern struct boundary_patch porwall;

extern struct data var;

extern int myid;

int model5415_output()

{ 

/*---------------------------------------------------

called from:

nphase

V2.0 baseline code

initials comment

rfk

---------------------------------------------------*/

int *nfield=var.nfield;

int *nnode=var.nnode;

int ibf,nstride,inode,fstride,ifield;

real sumforce,sumforce0,sumflux,sumflux0;

real awetted,awetted0;

real rinf,uinf,cd;

real *a=var.a;

real *u=var.u;

entered("model5415_output") ;

uinf=2.2134;

rinf=1000;

// wetted area

awetted=0.;

for(ibf=0;ibf<=wall.nbcface-1;++ibf){

inode=wall.bcface_n[ibf];

awetted+=wall.bamag[ibf];

} 

for(ibf=0;ibf<=porwall.nbcface-1;++ibf){

inode=porwall.bcface_n[ibf];

awetted+=porwall.bamag[ibf];

} 

MPI_Reduce(&awetted,&awetted0,1,mpireal,MPI_SUM,0,MPI_COMM_WORLD);

if(myid==0)printf("Awetted: %20.13e m^2\n",awetted0);

// drag force on boat

sumforce=0.;

for(ifield=0;ifield<=*nfield-1;++ifield){

fstride=ifield*wall.nbcface ;

nstride=ifield* *nnode;

for(ibf=0;ibf<=wall.nbcface-1;++ibf){

inode=wall.bcface_n[ibf] ;

sumforce+=wall.tmlt[ibf+fstride]* *(a+inode+nstride) * wall.bamag[ibf]* *(u+inode+nstride);

} 

for(ibf=0;ibf<=porwall.nbcface-1;++ibf){

inode=porwall.bcface_n[ibf] ;

sumforce+=porwall.tmlt[ibf+fstride]* *(a+inode+nstride) * porwall.bamag[ibf]* *(u+inode+nstride);

} 

} 

MPI_Reduce(&sumforce,&sumforce0,1,mpireal,MPI_SUM,0,MPI_COMM_WORLD);

if(myid==0)printf("Drag force: %20.13e\n",sumforce0);

if(myid==0)cd=sumforce0/(.5*rinf*uinf*uinf*awetted0);

if(myid==0)printf("CD=: %20.13e\n",cd);

exiting("model5415_output") ; 

return 0 ;

} 

Figure 48. model5415_output.c

NASA/CR—2014-216651 115

73
Turbomachinery

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Homogeneous Multiphase Flow

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NASA/CR—2014-216651 116

74
NPHASE-PSU Reference Manual 

Control Commands



	



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NASA/CR—2014-216651 117

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NASA/CR—2014-216651 118

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NASA/CR—2014-216651 119

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NASA/CR—2014-216651 120

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NASA/CR—2014-216651 121

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1.4.5. Porous Boundary

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1.5.5. Initial Pressure Field


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1.6.1. Environmental Properties

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1.6.3.3.Turbulent Flow Low Reynolds Number k-' Turbulence model


	


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1.6.5.3.Mass Diffusion Coefficient Laminar 




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Software Delivery and Installation Summary

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Installing NPHASE-PSU software and Running Tutorials

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References 

40 $

 
(

 



 

4W@90

:0  080 *0 *2 )0 $

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	8
 


$
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/	 )
2 

  
 	1 International Journal of

Multiphase Flow+
0:@4WWW		0:@#/%"@0

%0 00)
00'
/
/8



G
	 /
C 6?

1 G
 A

 
 


8
)
+
04E4WW&		0::W/:@90

&0 


 

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/?
*	
1Chemical Engineering Science+
0%:4W##

	0 4:EW0

@0 *080'$
 ,D 23 40

+
 
 :"/4"""//* $
1 Journal of Geophyscial Research -

Oceans+
0W9
0@4WW4	0EW"40

90 *U0+ )0+- 0  0 :""& 'D  
 ( 

	,|6-	 

1ASME Journal

of Mechanical Design4:9;@5		0W"%^W"E0

#0 *
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  D

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)

1Theoretical and Computational Fluid Dynamics+
0%4WW4		04/4%0

E0 6G,(



	3>>2220 0
> 0:""90

W0 )06 
0'.8
* 



	 *
	  

 $

   2 8

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