Using CFD to enable better decisions early in the design process leads to lower lifecycle costs. Products: HEEDS, Simcenter Products, Simcenter STAR-CCM+
Industry Sector: Marine

Vision of Precision: -

Founded in 1974, Teignbridge Propellers International (Teignbridge) is a leading designer and manufacturer of marine propulsion and stern gear products. With over 65,000 square feet of floor space and more than 100 employees at its headquarters in Southwest England, it is the largest producer of its kind in Europe. Teignbridge is renowned for optimizing the performance of ships of all sizes, from yachts and patrol boats to tankers and military vessels. The company manages everything from the engine and gearbox to the back of the vessel, including couplings, shafts, bearings, seals, stern tubes, brackets, propellers, and rudders. Regardless of the size of a propeller, which can be up to 8 meters in diameter, altering the design by just one millimetre can significantly impact efficiency and performance. Therefore, Teignbridge uses computational fluid dynamics (CFD) simulations to develop the best possible designs and ensure the highest level of manufacturing precision. "With the latest significant investment in enhancing production precision, we’re able to manufacture the propeller to within the accuracy of a hair," says Mark Phare, Group Managing Director at Teignbridge. "Now, whatever the engineers design, we can replicate it perfectly in the finished product." Ensuring design and production accuracy is paramount for Teignbridge's global operations, as they need to get it right the first time, every time, without the ability to frequently send parts to fix potential issues.

Stricter Maritime Regulations: -

The International Maritime Organization (IMO) and the Marine Environment Protection Committee (MEPC) set regulations for the maritime industry. Historically, their requirements have been guidelines, but they are now being strictly enforced. The IMO has implemented a strict emissions mandate to reduce carbon dioxide (CO2) output by 50% by 2050 and introduced an energy efficiency index for new designs and existing ships. Achieving this significant reduction necessitates innovation. Therefore, Teignbridge must utilize the latest technology to stay ahead of the competition, comply with industry regulations, and build leading-edge components that deliver optimum performance.

"It is important for us to be at the top of our game and design products that improve efficiency and reduce emissions," says Saeed Javdani, Innovation and Technology Manager at Teignbridge.

Harnessing the Power of CFD Simulations: -

To meet these challenges and optimize designs, Teignbridge uses Simcenter™ STAR-CCM+™ software to run fast and accurate CFD simulations. These simulations help designers understand the interaction between propulsion systems and the high-velocity water flowing across their surfaces. With the support of Maya HTT, a Siemens Digital Industries Software solution partner, Teignbridge conducts these activities. Understanding cavitation—where vapor bubbles in a fluid grow and collapse due to local pressure fluctuations—allows engineers to predict its impact on propulsion performance, durability, and noise. The simulations help predict the location, extent, and type of cavitation and modify designs to minimize it. Engineers also use Simcenter STAR-CCM+ to optimize components for the entire propulsion system, ensuring their influence on water flow complements the propeller’s design. For instance, they identified areas of low pressure on the leading edge of a rudder that could cause cavitation and noise. By redesigning the rudder and aligning its leading edge to the downstream rotational flow from the propeller blades, they increased the vessel’s top speed

CFD result: The graph shows the dynamic thrust loading during one revolution and the mapped pressure distribution on the surface of the reference blade.

FEA result: The graph shows the dynamic stress during one revolution and the mapped stress distribution on the surface of the reference blade.

Using computer-aided engineering (CAE) and Simcenter simulation tools, these performance improvements are made before any components are manufactured. This allows for crucial decisions to be made much earlier in the design process, leading to increased efficiency, reduced costs, and improved products. "With CFD simulation, we can predict the wake field coming into the propeller and how the flow can be affected by the bracket in front and the rudder behind. This means we can evaluate the system rather than individual parts," says Phare. Javdani adds, "Simcenter STAR-CCM+ is vital to our development processes. Simulation makes it possible to explore many more iterations in less time, so we can come up with the optimal design."

Reducing Noise Pollution: -

Protecting the environment involves more than designing propulsion systems that use less or cleaner fuel. Noise pollution can significantly impact marine life. "If you want to save the planet, save the oceans," remarks Javdani. Simcenter STAR-CCM+ is critical for analyzing noise generation and adapting designs to reduce it. "Every vessel has a unique acoustic signature. The simulations help us reduce the amplitude and mask the signature as much as possible." Javdani explains why Teignbridge selected Simcenter as their analysis tool: "We don’t have to combine Simcenter STAR-CCM+ with another software package because everything is in one place. The procedures, tools, and techniques are all intuitive and well-documented, making life easier for us."

Optimizing Performance: -

When designing new components, it is crucial for Teignbridge to provide customers with accurate predictions of efficiency and performance improvements. Using Simcenter STAR-CCM+ numerical simulations and CFD analysis allows engineers to predict the effects of design changes. For example, a customer with a boat achieving 31.8 knots but aiming for 34 knots was able to reach the target speed by adding a velocity-aligned rudder. In another case, CFD helped achieve about a 15-decibel reduction in radiated noise below 1 kHz, exceeding a customer's requirement. Using HEEDS™ software, Teignbridge can explore up to 500 design iterations in 48 hours to find the most optimal design. "Running so many iterations is simply not possible without HEEDS," says Javdani. "We’re also designing new devices that reduce the energy efficiency index of propulsion systems, such as propeller boss cap fins (PBCFs), which recover energy from the rotating flow of the blades."

CFD as a Common Language: -

Teignbridge also needs to demonstrate to classification societies that new components meet safety requirements. "Simcenter STAR-CCM+ enables us to show relevant authorities that new designs will meet their standards before they are built," says Javdani. "Using CFD as a common language makes it easier to show classification societies that all requirements are being met early in the development process."

Seeking to Be the Best: -

Phare is clear on his vision for the future: "We want to be the world-leading designer and manufacturer of propulsion equipment. To do that, we need to produce the best components and deliver the best customer service." Javdani adds, "Simcenter STAR-CCM+ has sparked a great deal of innovation at Teignbridge. It helps us to better understand exactly what customers need and solve problems they didn’t know they had. We can now design and supply products that open up new markets and establish us as the go-to company in the industry." By incorporating advanced simulation tools, Teignbridge Propellers International continues to lead in innovation, precision, and performance in marine propulsion, ensuring a sustainable and efficient future for the maritime industry.