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The applicability of FENSAP-ICE-Unsteady to solve ice accretion on rotating helicopter blades is investigated using a two-bladed rotor and a generic cylinder, to represent a fuselage, for a forward flight test case. The unsteady rime ice accretion is simulated by coupling, at each time step, flow and water drop equations to the Messinger icing model. Mesh displacement effects are taken into account by an Arbitrary Lagrangian-Eulerian method. This new icing model is applied to rotor/fuselage flows by considering two grid domains: the first being fixed around the fuselage, and the second rotating with the blades. The gap region is stitched with tetrahedral elements to fully guarantee flow conservation.

Numerically predicted roughness distributions obtained in in-flight icing simulations with a beading model are used in a quasi-steady manner to compute ice shapes. This approach, called "Multishot," uses a number of steady flow and droplet solutions for computing short intervals (shots) of the total ice accretion time. The iced geometry, the grid, and the surface roughness distribution are updated after each shot, producing a better match with the unsteady ice accretion phenomena. Comparisons to multishot results with uniform roughness show that the evolution of the surface roughness distribution has a strong influence on the final ice shape. The ice horns that form are longer and thinner compared to constant roughness results. The constant roughness approach usually fails to capture the formation of the pressure side horns and under-predicts the thickness of the ice in this region.

The assessment of an unsteady approach for the simulation of in-flight electro-thermal de-icing using a Conjugate Heat Transfer (CHT) technique is presented for a NACA0012 wing and a swept wing. This approach is implemented in the FENSAP-ICE in-flight icing system, and provides simulation capabilities for the heat transfer and ice accretion phenomena occurring during in-flight de-icing with power cycling through several heater pads. At each time step, a thermodynamic balance is established between the water film, the ice layer and the solid domains. The ice shape is then modified according to ice accretion and melting rates. Numerical results show the complex interactions between the water film, the ice layer and the heating system. The NACA0012 validation test case compares well against one of the very few experimental de-icing test cases available in the open literature.

A full-automated CFD mesh generation technique has been developed and implemented for 3-D aircraft icing simulations to permit robust 45-minute ice accretion simulations in support of icing certification campaigns. The changes in the shape of the aircraft surfaces due to accreting ice and their effects on the air and droplet flow are accounted for in a quasi-steady manner by subdividing the total icing time into sequential steps of shorter duration, updating the computational grid at each step. This “multi-shot” ice accretion approach requires robust and accurate grid re-meshing for it to be embedded in engineering design and analysis workflows. ANSYS FENSAP-ICE has been coupled to Fluent Meshing to take advantage of generic and highly automated surface displacement and mesh wrapping tools. A wide spectrum of geometries is supported, ranging from full-size aircraft to air data probes, turbomachinery components, rotors and propellers.

A 3D CFD methodology is presented to simulate ice build-up on propeller blades exposed to known icing conditions in flight, with automatic blade pitch variation at constant RPM to maintain the desired thrust. One blade of a six-blade propeller and a 70-passenger twin-engine turboprop are analyzed as stand-alone components in a multi-shot quasi-steady icing simulation. The thrust that must be generated by the propellers is obtained from the drag computed on the aircraft. The flight conditions are typical for a 70-passenger twin-engine turboprop in a holding pattern in Appendix C icing conditions: 190 kts at an altitude of 6,000 ft. The rotation rate remains constant at 850 rpm, a typical operating condition for this flight envelope.

A CFD simulation methodology for the inclusion of the post-impact trajectories of splashing/bouncing Supercooled Large Droplets (SLDs) and film detachment is introduced and validated. Several scenarios are tested to demonstrate how different parameters affect the simulations. Including re-injecting droplet flows due to splashing/bouncing and film detachment has a significant effect on the accuracy of the validations shown in the article. Validation results demonstrate very good agreement with the experimental data. This approach is then applied to a full-scale twin-engine turboprop to compute water impingement on the wings and the empennage.

A CFD simulation methodology is presented to evaluate the ice that sheds from rotating components. The shedding detection is handled by coupling the ice accretion and stress analysis solvers to periodically check for the propagation of crack fronts and possible detachment. A novel approach for crack propagation is highlighted where no change in mesh topology is required. The entire computation from flow to impingement, ice accretion and crack analysis only requires a single mesh. The accretion and stress module are validated individually with published data. The analysis is extended to demonstrate potential shedding scenarios on three complex industrially-relevant 3D cases: a helicopter blade, an engine fan blade and a turboprop propeller. The largest shed fragment will be analyzed in the context of FOD damage to neighboring aircraft/component surfaces.