AxSTREAM® Turbomachinery Conceptual Design Suite

AxSTREAM®
Version 3.6

Axial Turbine Flow Path Design,

Analysis and Optimization

2017

AxSTREAM® - SoftInWay Inc. trademark. All rights reserved.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

1 Introduction
The AxSTREAM suite of multidisciplinary turbomachinery design, analysis and optimization software tools
provide a fully integrated and streamlined solution for the complete flow-path design process of both radial and axial
turbomachinery – from preliminary design, initial sizing analysis and optimizations - to profiling, 3D blade design
and 3D CFD analysis. All of this integrated into one software package with a seamless user interface.

Starting from preliminary design (defining basic machine performance from just a few simple parameters –
geometrical constraints, inlet/outlet pressure), AxSTREAM progresses through meanline (1D) and axisymmetric
(2D) analysis, profiling and 3D blade design of the buckets, FEA and 3D CFD analysis and when your project is
finished, easy export of the blade geometry in the most common file formats allows you to continue the design in 3D
CAD.

AxSTREAM provides full design and analysis cycles for axial turbine projects in a flexible and integrated
environment. The tasks user can solve with AxSTREAM are:

• Design new machines from scratch

• Analyze existing machines and their performance

• Redesign, optimize and upgrade existing machines

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 AxSTREAM® Turbomachinery Conceptual Design Suite

2 Turbine Preliminary Design (Axial TURBO Design & Stage License)

Preliminary Design procedure is used to create machine flow path design from scratch from a set of several
boundary conditions, geometrical parameters and taking into account specified constraints.

2.1 Axial Turbine Solution Generator

The Preliminary Design Solution Generator is

used to produce a number of variants (solutions) that
satisfy specified boundary conditions within applied
constraints.

The use of an inverse solver allows the generation of a large

amount of designs in a short span of time (20,000 per min).

AxSTREAM can design machines with multiple

extractions, Curtis stages, partial admission and flow
paths using the unified stages with similar geometry.
Maximum number of stages in machine equals to 50.
Generated set of solution can be explored using Design
Space Explorer.

2.2 Axial Turbine Design Space Explorer

Design Space Explorer allows the user to explore

a set of solution points generated with Solution
Generator.

The Design Space Explorer gives possibility to select

appropriate solutions by specifying different types of
constraints and limitations.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

2.3 Post-design Flow Path Adjustment

Post-design flow path adjustment provides

user with option to adjust separate stages using
changing their geometric parameters, pressure
distribution on Mollier chart or entire machine
endwall contours by spline.

S1/S2 flow path adjustment option enables users to optimize separate

stages

• in pitchwise direction (S1 optimization) taking profile width with regard

to pitch under criteria of loss minimization

• in spanwise direction (S2 optimization) taking geometrical parameters

with regard to outlet capacity and losses within the constraints on reaction,
hub and tip diameters etc.

The optimization is performed using multistage random search with

automatic adjustment of parameter variation intervals at each step of the
search.

3 Streamline Solver (Axial TURBO Meanline Analysis License (1D) & Axial
TURBO Throughflow Analysis License (1D & 2D))
The Streamline solver module
performs meanline (1D) or
axisymmetric (2D) calculation of
machine, taking into account actual
characteristics of the machine geometry
and boundary conditions set.

The system can perform analysis of

stages with full blade rows, with only
rotor or only stator, stages with counter-
rotation, and mixed flow paths with
axial and radial stages.
Additional elements (ducts, diffusers
etc.) can be specified and calculated
In addition to the existing models of
energy loss and seal leakages
calculations, the user can add custom
ones.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

Streamline solver calculates next main

parameters of the flow path:
• Power
• Efficiency
• Mass flow rate, volume flow rate;
• Kinematic, thermodynamic
parameters distribution
• Losses in elements
• Leakages and flow balance;
• Distribution of parameters
spanwise;
• Lean calculation;

2D analysis uses streamline curvature method. This module

performs calculation of radial equilibrium in the gaps between
airfoil rows.
Loss model for profile, secondary losses and leakages losses can
be selected from a few standard ones or customized.
Distribution of parameters can be visualized as colorful gradient.

Cooled Turbine Design and Calculation Features

AxSTREAM can perform calculation of cooled blades

and endwalls, taking into account change of working fluid
temperature and composition due to mixing, mixing losses
from cooling flows. Resulting blade temperature will be
defined basing on cooling flows and heat transfer
coefficients.

In case of preliminary design, user can define

maximal blade temperature and AxSTREAM will
select appropriate cooling flows automatically. They
can be corrected later on manually depending on
actual scheme conditions.
Cooling flows are represented on main balances scheme.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

4 Design of Experiment Optimization (AxPLAN (DoE and optimization)

License)
The AxPLAN module uses streamline solver and
can be run in meanline or axisymmetric task
formulation. It is the main optimization tool at the
last phases of flow path design.

The AxPLAN module allows performing various

design tasks by using design of experiment (DoE)
study methods.

The experiment planning option is fully integrated

into AxSTREAM and is executed in terms of direct
problem formulation of calculation analysis, which
enables the user to make an experiment plan using
familiar formulations.

The use of AxPLAN allows users to see the results

of optimization and to define the cylinder
performance in off-design regimes.

5 Performances Maps Generator (AxMAP License)

The AxMAP module uses a streamline solver and

can be run in meanline or axisymmetric task
formulation. It is developed for automatic generation of
the axial turbine performance maps.

AxMAP makes it possible to study the influence of

operational conditions and geometry variations on the
turbine’s performance.

The maps generation function is integrated into

AxSTREAM and uses current project geometry for
calculations.

AxMAP files can store existing experimental data to

compare them with calculation results.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

6 Profiling and Blade Design (Axial Profiler & 3D Blade Designer License)
Profiling and Blade Design module is
used for creation and editing of 3D airfoils.

Wide range of geometrical tools and

interactive charts allows user to configure
the blades easily and in short time.

Profiling tools provides interactive

mechanism to change profile parameters by
varying with value of inlet and outlet
angles, wedge angles and edge radii.

Profiles can be also manipulated by using the control

points of splines.

Throat (gauging angle) is preserved during profiling

manipulations.

Profiling options offer various methods of profile

optimization.

Automatic profile optimization can be performed basing

on the aerodynamic criteria of profile quality such as
minimum of profile losses.

Potential flow solver in profiling module automatically

calculates the distribution of velocity, pressure,
momentum thickness values and heat transfer
coefficients along the profile outline.

In blade profiling user can take into account thermal

barrier coating thickness, edit its distribution across the
profile and receive final blade with or without coating
depending on task.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

Blade designer is used for 3D blade design, shaping and stacking.

The module has options allowing interactive graphical editing of
blade geometry and twist angles manipulation, changing the
position of profile mass center in separate sections (lean and
sweep.)

In Blade designer user can control blade 3D surface curvature and

displaying blades in rows.

Blade designer helps users to estimate area distribution

and stresses at edges of pressure and suction sides in
real time in order to build 3D blades.

7 Cascade CFD (Cascade CFD license)

The Cascade CFD module is used for 2D
flow analysis in interblade channels on designed
sections.

The analysis is performed using full 2D CFD

formulations (Navier-Stokes, viscous with various
turbulence models (standard k-e, k-e RNG, k-w,
k-w SST models)).

The analysis results are presents as flow charts

with velocity, pressure and other parameters
distribution along the profile outline. You can also
calculate and display heat flux and velocity
vectors in channel.
Cascade CFD is very useful for transonic stages
profiling, where potential flow cannot predict all
effects accurately.

8 AxSLICE Module
(AxSLICE Axial license)
The AxSLICE module is used for the
extraction of profile geometry from a blade’s 3D
models.

AxSLICE uses 3D models in STL, IGES, CURVE

formats.

AxSLICE provides a special option for the

extraction of profiles from a “cloud of points”
obtained by the user with a 3D laser scan.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

Blade model geometry: chords, blade angles, LE/TE diameters are automatically recognized in a specified number
of cross-sections. Recognition results can be immediately loaded into an AxSTREAM project - these results can be
used for automated import and flow path calculations.

9 ATLAS Profile Database (Atlas License)

The Atlas module is a profile database
management system that allows you to save
blade profiles that are standard for to you or
designed in AxSTREAM.

Profiles can be created and edited directly in

ATLAS from XY-points coordinates, arcs
segments or thickness distribution along
camberline.

Later on they can be inserted to AxSTREAM

and used for blade design purposes.

In ATLAS user can work with a number of independent

profiles databases at the same time.

Standard profiles (e.g. NACA series) can be inserted

into the Atlas module and then used in projects.

10 Import of Profiles (Import Profile License)

You can import profiles created using XY point
coordinates with the help of the Import Profile
module in AxSTREAM.

AxSTREAM allows importing of separate profiles

and a series of profiles in blade airfoil. The data can
be imported from a file or copied from EXCEL
tables.

AxSTREAM provides interactive adjustment of

imported points with fully and semi-automatic
determination of edges and blade angles.

An imported profile can be inserted into the cascade

in the position it was imported, scaled to fit chord
and inserted into the cascade, retaining the throat and stagger angle.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

11 Structural and Modal Analysis (AxSTRESS License)

The AxSTRESS module is used for express 3D
structural, modal and harmonic analysis of the blades using
the finite element method. The module has tools for
automated mesh generation and results post-processing.
Boundary conditions (pressures, temperatures before and
after element, rotation speed etc.) are automatically taken
from an AxSTREAM project.
Hub cap and shroud cap can be added to the airfoil 3D
shape ipso facto providing the opportunity of analyzing the
complete 3D model without leaving AxSTREAM.

AxSTRESS also has a library of attachments possible to

manage and use throughout projects. Lashing wires can also
be accounted for in the calculations.

Geometry can be defined for symmetric and asymmetric

root or disk profiles. In the same way the shroud
platform can be added and edit.
AxSTRESS can calculate and display Campbell and
interference diagrams for a single element or groups of
blades.

AxSTRESS has options to perform:

• “hot-to-cold” state calculation to determine
appropriate manufacturing conditions before profile
export
• “cold-to-hot” state calculations. Their results
can be used for scanned blades to receive them in “hot”
working state for calculation in AxSTREAM

12 3D CFD Analysis (AxCFD License)

The AxCFD module is used
for 3D flow analysis in blade-to-
blade channels.

The analysis is performed using

full 3D CFD formulation
(Navier-Stokes, viscous with
various turbulence models
(standard k-e, k-e RNG, k-w, k-
w SST models)).

All of the geometry data is

transferred from AxSTREAM
project to AxCFD automatically.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

In preprocessor, you can setup the distribution of

boundary conditions both before and after domain,
mesh quality for automated generation and solver
settings. CFD can be calculated for individual rows,
for a stage, or for the entire machine.
The analysis results are the values of flow rate,
efficiency, kinematic and thermodynamic parameters
distribution.
The system post-processing can visualize the
distribution of parameters in any section of the
channel in pitchwise direction and the distribution of
parameters in the section along the profile outline.
Depending on blade temperature specified and
conditions of flow in channel, heat transfer
coefficient and its vectors will be calculated.

CFD calculation results can be saved for later review

or compared with other calculations and experiments
data in main program project.

The AxCFD solver includes the functionality to

calculate the quasi-2D flow for each separate
geometric section of the blade.

The mesh is automatically created in the course of the

calculation according to the defined parameters.

The solver enables the user to analyze the subsonic or

supersonic flow for each airfoil and optimize it.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

13 Export of Geometry (Export License)

The Export module allows you to export 3D blade geometry as
IGES, STL, IBL files to use them in numerous CAD systems.

Blade 3D geometry can also be exported in specialized formats to

different commercial CFD and CAE software systems for further 3D
aerodynamic and structural analysis (CFX, FLUENT, NUMECA,
ANSYS).

Additional customized export formats can be added on demand.

14 AxSTREAM Database (Project (database) License)

The Project Base license is a
mandatory software element for use on each
workstation and is required to start working
with AxSTREAM in either single user or
floating license. The Project license is used
as base system element managing the
available set of network licenses.

AxSTREAM database allows integration of

the turbomachinery projects, giving access
to project data for viewing and editing,
consistency management and data recovery,
project data loading and saving.

You can modify the number of blades, profiling

modes, structural properties used in different
elements of the turbine, define methods of energy
loss calculations, select different units in measuring
system settings used during the data output and
change the graphical user interface language
(English, Russian).

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 AxSTREAM® Turbomachinery Conceptual Design Suite

AxSTREAM viewer helps to explore axial turbine flow path (both meridional view and 3D blade geometry),
velocity triangles, HS-diagram, flow balance diagram, distribution of kinematic and thermodynamic parameters of
machine.

AxSTREAM allows the copying and pasting of machine or

stage objects from one project to another. This option gives
you the capability to store industry approved types of stages
in the libraries and quickly assemble them into new flow path
designs.

AxSTREAM supports data exchange with Microsoft

EXCEL tables. This allows users to prepare the initial
data without using an AxSTREAM workstation, and
after that quickly import the data to the system

AxSTREAM allows the

management of the structural
materials database. Material
mechanical properties are defined
in AxSTREAM within the
temperature range. It gives the
capability of accurately estimating
the values of stresses in turbine
elements. (Structural materials
database can be easily customized
by the user.)

AxSTREAM allows the user to

generate customized reports
including all project data. Users can
select their own list of elements and
properties that should be displayed in each report.

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 AxSTREAM® Turbomachinery Conceptual Design Suite

15 AxSTREAM Licensing

Flexible licensing systems allow you to

choose the appropriate set of modules.
AxSTREAM comes with personal
(attached to defined PC) or floating
(allowing AxSTREAM to run on multiple
computers connected to your network).

If there are multiple Project licenses

installed, then other licenses can be split
and used on different workstations at the
same time.

Below is a table with all available modules

for axial turbine design.

Module/License Description
Workplace base license. Project database
Project (database)
management
Machine preliminary design and optimization,
Axial TURBO Design Stage design and optimization, Design Space
Explorer
Axial TURBO Meanline Analysis Meanline (1D) with meanline solver
Axial TURBO Throughflow (1D Meanline (1D) and axisymmetric 2D analysis
and 2D) Analysis with streamline solver
Axial Profiler & 3D Blade Plane cascades profiling, 3D blade design
Designer (stacking)
3D FEA analysis, Hot to Cold and Cold to Hot
AxSTRESS
calculation, shroud and attachment design
2D CFD solution built in the profiling (if AxCFD
Cascade CFD
is purchased, then Cascade CFD is included)
AxCFD 3D CFD solver
Import Profile Import blade profile geometry
Export of blade geometry to CAD/CAE
Export
commercial packages
Storage for designed and standard company
Atlas
profiles
AxPLAN (DoE and optimization) Design of experiment and optimization engine
Turbomachinery performances maps
AxMAP
generator
Including Fluid Designer based on NIST
AxSTREAM Fluid Tool Box Refprop, Fluid designer for Combustion
Process and Fluid Calculator
Extraction of profile’s geometry from blade’s
AxSLICE Axial
3D CAD models or cloud of scanning points

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 AxSTREAM® Turbomachinery Conceptual Design Suite

16 AxSTREAM Tutorials, Documentation and Technical Support

A full set of AxSTREAM Tutorials are available to ensure a quick mastering of the software suite. SoftInWay
also offers best-in-class technical support for our current clients (requires active support agreement). Our
experienced turbomachinery support engineers have a deep understanding of all types of turbomachinery and can
assist you with all your questions.

17 Turbomachinery & AxSTREAM Training

To fully master all the features of the AxSTREAM suite, we highly recommend that you attend one of our
training classes.

AxSTREAM offers both classroom and online training. The online training class makes it possible for you to attend
the training from your office. Our best-in-class classroom training offers both advanced and fundamental training
on turbomachinery design and analysis, as well as hands-on AxSTREAM workshops. Please see
www.softinway.com for a training schedule or contact your AxSTREAM representative.

18 About SoftInWay
SoftInWay provides high quality engineering services and software products in the area of research, design and
digital prototyping of turbo-, thermo- and rotating machinery. AxSTREAM’s software suite combines more than
600 years of in-house turbomachinery engineering expertise to help you reach optimal performance. SoftInWay is
headquartered in Burlington, MA, USA.

HQ Contact Info:
1500 District Avenue
Burlington, MA 01803, USA
Main Number: 1-781-685-4942
Sales Number: 1-347-580-1459
Technical Support Number: 1-781-682-7867
FAX: 1-781-685-4601
For product information or assistance: Sales@SoftInWay.com
For technical support: Tech_Support@SoftInWay.com

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