Propeller cavitation erosion prediction at an early design stage is becoming more and more important since it is one of the key constraints in the search for maximum propeller efficiency. Despite the experience from model tests, cavitation erosion research on actual ship scale is very limited. In this study, an attempt is made to assess the erosion risk on the blades of a full-scale steerable thruster of a tug boat. Pressure side cavitation was detected on board for three different propeller designs. For the first time, a cavitation erosion analysis is performed on ship-scale, using a rigorous potential energy approach, which accounts for the focusing of the potential energy at the collapse center during the cavity collapse. A full sensitivity study has been performed for the blade surface accumulated energy. The erosion model shows the erosion risk for different propeller designs applied on the vessel, and different operating conditions, by looking at the surface specific energy on the blade. The erosion analysis shows locations of high erosion risk that show a good resemblance with the actual damage locations on the real blades.

Predicting the cavitation impact loads on a propeller surface using numerical tools is becoming essential, as the demand for more efficient designs, stretched to the limit, is increasing. One of the possible design limits is governed by cavitation erosion. The accuracy of estimating such loads, using a URANS approach, has been investigated. We follow the energy balance approach by (Schenke and van Terwisga, 2019), (Schenke et al., 2019), where we take account of the focusing of the potential energy into the collapse center before it is radiated as shock wave energy in the domain. In complex flows, satisfying the total energy balance, when reconstructing the radiated energy, has always been an issue in the past. Therefore, in this study, we investigate different considerations for the vapor reduction rate, in order to minimize the numerical errors, when estimating the local surface impact power. We show that when the vapor volume reduction rate is estimated using the mass transfer source term, then all the energy is conserved and the total energy balance is satisfied. The model is verified on a single cavitating bubble collapse, and it is further validated on a model propeller test case. The obtained surface impact distribution agrees well with the experimental paint test results, illustrating the potential for practical use of our fully conservative method to predict cavitation implosion loads on propeller blades.

A new technique is proposed in this study to assess the erosive aggressiveness of cavitating flows from numerical flow simulations. The technique is based on the cavitation intensity approach by Leclercq et al. (2017), predicting the instantaneous surface impact power of collapsing cavities from the potential energy hypothesis (see Hammitt, 1963; Vogel and Lauterborn, 1988). The cavitation intensity approach by Leclercq et al. (2017) is further developed and the amount of accumulated surface energy caused by the near wall collapse of idealized cavity types is verified against analytical predictions. Furthermore, two different impact power functions are introduced to compute a weighted time average of the impact power distribution caused by the cavity collapses in cavitating flows. The extreme events are emphasized to an extent specified by a single model parameter. Thus, the impact power functions provide a physical measure of the cavitating flow aggressiveness. This approach is applied to four idealized cavities, as well as to the cavitating flow around a NACA0015 hydrofoil. Areas subjected to aggressive cavity collapse events are identified and the results are compared against experimental paint test results by Van Rijsbergen et al. (2012) and the numerical erosion risk assessment by Li et al. (2014). The model is implemented as a runtime post-processing tool in the open source CFD environment OpenFOAM (2018), employing the inviscid Euler equations and mass transfer source terms to model the cavitating flow.

This study presents a novel physical model to convert the potential energy contained in vaporous cavitation into local surface impact power and an acoustic pressure signature caused by the violent collapse of these cavities in a liquid. The model builds on an analytical representation of the solid angle projection approach by Leclercq et al. ["Numerical cavitation intensity on a hydrofoil for 3D homogeneous unsteady viscous flows," Int. J. Fluid Mach. Syst. 10, 254-263 (2017)]. It is applied as a runtime post-processing tool in numerical simulations of cavitating flows. In the present study, the model is inspected in light of the time accurate energy balance during the cavity collapse. Analytical considerations show that the potential cavity energy is first converted into kinetic energy in the surrounding liquid [D. Obreschkow et al., "Cavitation bubble dynamics inside liquid drops in microgravity," Phys. Rev. Lett. 97, 094502 (2006)] and focused in space before the conversion into shock wave energy takes place. To this end, the physical model is complemented by an energy conservative transport function that can focus the potential cavity energy into the collapse center before it is converted into acoustic power. The formulation of the energy focusing equation is based on a Eulerian representation of the flow. The improved model is shown to provide physical results for the acoustic wall pressure obtained from the numerical simulation of a close-wall vapor bubble cloud collapse.