Results for “blade clearance” — Page 11

NASA NTRS1988

Energy Efficient Engine: High-pressure compressor test hardware detailed design report

The objective of the NASA Energy Efficient Engine program is to identify and verify the technology required to achieve significant reductions in fuel consumption and operating cost for future commercial gas turbine engines. The design and analysis is documented of the high pressure compressor which was tested as part of the Pratt and Whitney effort under the Energy Efficient Engine program. This compressor was designed to produce a 14:1 pressure ratio in ten stages with an adiabatic efficiency of 88.2 percent in the flight propulsion system. The corresponding expected efficiency for the compressor component test rig is 86.5 percent. Other performance goals are a surge margin of 20 percent, a corrected flow rate of 35.2 kg/sec (77.5 lb/sec), and a life of 20,000 missions and 30,000 hours. Low loss, highly loaded airfoils are used to increase efficiency while reducing the parts count. Active clearance control and case trenches in abradable strips over the blade tips are included in the compressor component design to further increase the efficiency potential. The test rig incorporates variable geometry stator vanes in all stages to permit maximum flexibility in developing stage-to-stage matching. This provision precluded active clearance control on the rear case of the test rig. Both the component and rig designs meet or exceed design requirements with the exception of life goals, which will be achievable with planned advances in materials technology.

Howe, David C.↗

NASA NTRS2015

Investigation of Unsteady Tip Clearance Flow in a Low-Speed One and Half Stage Axial Compressor with LES And PIV

The primary focus of this paper is to investigate how a rotor's unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor when the rotor tip gap size is increased from 0.5 mm (0.49% of rotor tip blade chord, 2% of blade span) to 2.4 mm (2.34% chord, 4% span) at the design condition are investigated. The changes in unsteady tip clearance flow with the 0.62 % tip gap as the flow rate is reduced to near stall condition are also investigated. A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at these three flow conditions. Detailed Stereoscopic PIV (SPIV) measurements of the current flow fields were also performed at the Johns Hopkins University in a refractive index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. Unsteady tip clearance flow fields from LES are compared with the PIV measurements and both LES and PIV results are used to study changes in tip clearance flow structures. The current study shows that the tip clearance vortex is not a single structure as traditionally perceived. The tip clearance vortex is formed by multiple interlaced vorticities. Therefore, the tip clearance vortex is inherently unsteady. The multiple interlaced vortices never roll up to form a single structure. When phased-averaged, the tip clearance vortex appears as a single structure. When flow rate is reduced with the same tip gap, the tip clearance vortex rolls further upstream and the tip clearance vortex moves further radially inward and away from the suction side of the blade. When the tip gap size is increased at the design flow condition, the overall tip clearance vortex becomes stronger and it stays closer to the blade suction side and the vortex core extends all the way to the exit of the blade passage. Measured and calculated unsteady flow fields inside the tip gap agree fairly well. Instantaneous velocity vectors inside the tip gap from both the PIV and LES do show flow separation and reattachment at the entrance of tip gap as some earlier studies suggested. This area at the entrance of tip gap flow (the pressure side of the blade) is confined very close to the rotor tip section. With a small tip gap (0.5mm), the gap flow looks like a simple two-dimensional channel flow with larger velocity near the casing for both flow rates. A small area with a sharp velocity gradient is observed just above the rotor tip. This strong shear layer is turned radially inward when it collides with the incoming flow and forms the core structure of the tip clearance vortex. When tip gap size is increased to 2.4 mm at the design operation, the radial profile of the tip gap flow changes drastically. With the large tip gap, the gap flow looks like a two-dimensional channel flow only near the casing. Near the rotor top section, a bigger region with very large shear and reversed flow is observed.

compressor↗

NASA NTRS2015

Investigation of Unsteady Tip Clearance Flow in a Low-Speed One and Half Stage Axial Compressor with LES And PIV

The primary focus of this paper is to investigate how a rotor's unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor when the rotor tip gap size is increased from 0.5 mm (0.49% of rotor tip blade chord, 2% of blade span) to 2.4 mm (2.34% chord, 4% span) at the design condition are investigated. The changes in unsteady tip clearance flow with the 0.62 % tip gap as the flow rate is reduced to near stall condition are also investigated. A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at these three flow conditions. Detailed Stereoscopic PIV (SPIV) measurements of the current flow fields were also performed at the Johns Hopkins University in a refractive index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. Unsteady tip clearance flow fields from LES are compared with the PIV measurements and both LES and PIV results are used to study changes in tip clearance flow structures. The current study shows that the tip clearance vortex is not a single structure as traditionally perceived. The tip clearance vortex is formed by multiple interlaced vorticities. Therefore, the tip clearance vortex is inherently unsteady. The multiple interlaced vortices never roll up to form a single structure. When phased-averaged, the tip clearance vortex appears as a single structure. When flow rate is reduced with the same tip gap, the tip clearance vortex rolls further upstream and the tip clearance vortex moves further radially inward and away from the suction side of the blade. When the tip gap size is increased at the design flow condition, the overall tip clearance vortex becomes stronger and it stays closer to the blade suction side and the vortex core extends all the way to the exit of the blade passage. Measured and calculated unsteady flow fields inside the tip gap agree fairly well. Instantaneous velocity vectors inside the tip gap from both the PIV and LES do show flow separation and reattachment at the entrance of tip gap as some earlier studies suggested. This area at the entrance of tip gap flow (the pressure side of the blade) is confined very close to the rotor tip section. With a small tip gap (0.5mm), the gap flow looks like a simple two-dimensional channel flow with larger velocity near the casing for both flow rates. A small area with a sharp velocity gradient is observed just above the rotor tip. This strong shear layer is turned radially inward when it collides with the incoming flow and forms the core structure of the tip clearance vortex. When tip gap size is increased to 2.4 mm at the design operation, the radial profile of the tip gap flow changes drastically. With the large tip gap, the gap flow looks like a two-dimensional channel flow only near the casing. Near the rotor top section, a bigger region with very large shear and reversed flow is observed.

unsteady↗

NASA NTRS1983

Annulus wall boundary layer development in a compressor stage, including the effects of tip clearance

The end-wall boundary layer development in a compressor stage, including the inlet guide vane (IGV) passage and the rotor passage, was measured. The measurement upstream of the rotor and inside the IGV passage were carried out with a five-hole probe. The data (blade-to-blade) inside the IGV passage were carried out with a five-hole probe. The data (blade-to-blade) inside the rotor passage were measured using a three-sensor rotating hot-wire below the tip clearance region and "V' configuration probe inside the clearance region. The rotor exit measurements (blade-to-blade) were acquired with a laser Doppler velocimeter. The velocity profiles and the integral properties are presented and interpreted. The boundary layer is comparatively well behaved up to the leading edge of the rotor, beyond which complex interactions result in very unconventional profiles. The momentum thicknesses decrease in the leakage flow region of the rotor. The momentum thicknesses and the limiting streamline angles predicted from a momentum integral technique agree well with the data up to the leading edge of the rotor.

Lakshminarayana, B.↗

NASA NTRS2014

Investigation of Unsteady Flow Field in a Low-Speed One and a Half Stage Axial Compressor: Effects of Tip Gap Size On the Tip Clearance Flow Structure at Near Stall Operation - Part 2

The primary focus of this paper is to investigate the effect of rotor tip gap size on how the rotor unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor at near stall operation (for example, where maximum pressure rise is obtained). A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at this flow condition with both a small and a large tip gaps. The numerically obtained flow fields at the small clearance matches fairly well with the available initial measurements obtained at the Johns Hopkins University with 3-D unsteady PIV in an index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. The numerical results are also compared with previously published measurements in a low speed single stage compressor (Maerz et al. [2002]). The current study shows that, with the smaller rotor tip gap, the tip clearance vortex moves to the leading edge plane at near stall operating condition, creating a nearly circumferentially aligned vortex that persists around the entire rotor. On the other hand, with a large tip gap, the clearance vortex stays inside the blade passage at near stall operation. With the large tip gap, flow instability and related large pressure fluctuation at the leading edge are observed in this one and a half stage compressor. Detailed examination of the unsteady flow structure in this compressor stage reveals that the flow instability is due to shed vortices near the leading edge, and not due to a three-dimensional separation vortex originating from the suction side of the blade, which is commonly referred to during a spike-type stall inception. The entire tip clearance flow is highly unsteady. Many vortex structures in the tip clearance flow, including the sheet vortex system near the casing, interact with each other. The core tip clearance vortex, which is formed with the rotor tip gap flows near the leading edge, is also highly unsteady or intermittent due to pressure oscillations near the leading edge and varies from passage to passage. For the current compressor stage, the evidence does not seem to support that a classical vortex breakup occurs in any organized way, even with the large tip gap. Although wakes from the IGV influence the tip clearance flow in the rotor, the major characteristics of rotor tip clearance flows in isolated or single stage rotors are observed in this one and a half stage axial compressor.

Unsteady↗

NASA NTRS1992

Three-dimensional Navier-Stokes heat transfer predictions for turbine blade rows

Results are shown for a three-dimensional Navier-Stokes analysis of both the flow and the surface heat transfer for turbine applications. Heat transfer comparisons are made with the experimental shock-tunnel data of Dunn and Kim, and with the data of Blair for the rotor of the large scale rotating turbine. The analysis was done using the steady-state, three-dimensional, thin-layer Navier-Stokes code developed by Chima, which uses a multistage Runge-Kutta scheme with implicit residual smoothing. An algebraic mixing length turbulence model is used to calculate turbulent eddy viscosity. The variation in heat transfer due to variations in grid parameters is examined. The effects of rotation, tip clearance, and inlet boundary layer thickness variation on the predicted blade and endwall heat transfer are examined.

Boyle, R. J.↗

NASA NTRS1992

Three-dimensional Navier-Stokes heat transfer predictions for turbine blade rows

Results are shown for a three-dimensional Navier-Stokes analysis of both the flow and the surface heat transfer for turbine applications. Heat transfer comparisons are made with the experimental shock-tunnel data of Dunn and Kim, and with the data of Blair for the rotor of the large scale rotating turbine. The analysis was done using the steady-state, three-dimensional, thin-layer Navier-Stokes code developed by Chima, which uses a multistage Runge-Kutta scheme with implicit residual smoothing. An algebraic mixing length turbulence model is used to calculate turbulent eddy viscosity. The variation in heat transfer due to variations in grid parameters is examined. The effects of rotation, tip clearance, and inlet boundary layer thickness variation on the predicted blade and endwall heat transfer are examined.

Boyle, Robert J.↗

NASA NTRS1978

Cold-air performance of a tip turbine designed to drive a lift fan

Performance was obtained over a range of speeds and pressure ratios for a 0.4 linear scale version of the LF460 lift fan turbine with the rotor radial tip clearance reduced to about 2.5 percent of the rotor blade height. These tests covered a range of speeds from 60 to 140 percent of design equivalent speed and a range of scroll inlet total to diffuser exit static pressure ratios from 2.6 to 4.2. Results are presented in terms of equivalent mass flow, equivalent torque, equivalent specific work, and efficiency.

Haas, J. E.↗

NASA NTRS1993

Driven cavity simulation of turbomachine blade flows with vortex control

This paper presents a computational study of the three-dimensional flows in a rotating cavity with clearance between cavity walls and lid wall. The objectives of this study is to understand the interaction mechanism between tip leakage and blade passage flows and to assess the means to control the flow pattern and pressure losses. The classes of problems addressed include: passage geometry, passage loading including lid velocity and anti-vortex strength, and placement necessary to provide flow control. The computational model is first validated on generic flow problems and then applied to a specific blade passage configuration. Results of parametric studies for secondary flow pattern control are analyzed, and practical means of vortex control are discussed.

Athavale, M. M.↗

NASA NTRS1985

End-wall and profile losses in a low-speed axial flow compressor rotor

The blade-to-blade variation of relative stagnation pressure losses in the tip region inside the rotor of a single-stage, axial-flow compressor, is presented and interpreted in this paper. The losses are measured at two flow coefficients (one at the design point and the other at the near peak pressure rise point) to discern the effect of blade loading on the end-wall losses. The tip clearance losses are found to increase with an increase in the pressure rise coefficient. The losses away from the tip region and near the hub regions are measured downstream. The losses are integrated and interpreted in this paper.

Lakshminarayana, B.↗

NASA NTRS1989

An interactive grid generation procedure for axial and radial flow turbomachinery

A combination algebraic/elliptic technique is presented for the generation of three dimensional grids about turbo-machinery blade rows for both axial and radial flow machinery. The technique is built around use of an advanced engineering workstation to construct several two dimensional grids interactively on predetermined blade-to-blade surfaces. A three dimensional grid is generated by interpolating these surface grids onto an axisymmetric grid. On each blade-to-blade surface, a grid is created using algebraic techniques near the blade to control orthogonality within the boundary layer region and elliptic techniques in the mid-passage to achieve smoothness. The interactive definition of bezier curves as internal boundaries is the key to simple construction. This procedure lends itself well to zonal grid construction, an important example being the tip clearance region. Calculations done to date include a space shuttle main engine turbopump blade, a radial inflow turbine blade, and the first stator of the United Technologies Research Center large scale rotating rig. A finite Navier-Stokes solver was used in each case.

Beach, Timothy A.↗

NASA NTRS1990

An interactive grid generation procedure for axial and radial flow turbomachinery

A combination algebraic/elliptic technique is presented for the generation of three dimensional grids about turbo-machinery blade rows for both axial and radial flow machinery. The technique is built around use of an advanced engineering workstation to construct several two dimensional grids interactively on predetermined blade-to-blade surfaces. A three dimensional grid is generated by interpolating these surface grids onto an axisymmetric grid. On each blade-to-blade surface, a grid is created using algebraic techniques near the blade to control orthogonality within the boundary layer region and elliptic techniques in the mid-passage to achieve smoothness. The interactive definition of bezier curves as internal boundaries is the key to simple construction. This procedure lends itself well to zonal grid construction, an important example being the tip clearance region. Calculations done to date include a space shuttle main engine turbopump blade, a radial inflow turbine blade, and the first stator of the United Technologies Research Center large scale rotating rig. A finite Navier-Stokes solver was used in each case.

Beach, T. A.↗

NASA NTRS1980

CF6 fan performance improvement

A significant portion of the NASA-sponsored Performance Improvement Program for the CF6 engine was the development of an improved fan concept. This involved aerodynamic redesign of the CF6 fan blade to increase fan efficiency while retaining the mechanical integrity, operability, and acoustic characteristics of the existing blade. A further improvement in performance was obtained by adding a fan case stiffener ring to decouple blade-case vibrational characteristics, permitting a significant reduction in running tip clearance. Engine testing was performed to establish the performance, mechanical and acoustic properties of the new design relative to the current fan, and to establish power management characteristics for the CF6-50C2/E2 engine. A significant improvement in cruise power SFC of 1.8 percent was demonstrated in Sea Level testing projected to altitude flight conditions.

Patt, R. F.↗

NASA NTRS2012

Rotary-Wing Relevant Compressor Aero Research and Technology Development Activities at Glenn Research Center

Technical challenges of compressors for future rotorcraft engines are driven by engine-level and component-level requirements. Cycle analyses are used to highlight the engine-level challenges for 3000, 7500, and 12000 SHP-class engines, which include retention of performance and stability margin at low corrected flows, and matching compressor type, axial-flow or centrifugal, to the low corrected flows and high temperatures in the aft stages. At the component level: power-to-weight and efficiency requirements impel designs with lower inherent aerodynamic stability margin; and, optimum engine overall pressure ratios lead to small blade heights and the associated challenges of scale, particularly increased clearance-to-span ratios. The technical challenges associated with the aerodynamics of low corrected flows and stability management impel the compressor aero research and development efforts reviewed herein. These activities include development of simple models for clearance sensitivities to improve cycle calculations, full-annulus, unsteady Navier-Stokes simulations used to elucidate stall, its inception, and the physics of stall control by discrete tip-injection, development of an actuator-duct-based model for rapid simulation of nonaxisymmetric flow fields (e.g., due inlet circumferential distortion), advanced centrifugal compressor stage development and experimentation, and application of stall control in a T700 engine.

Welch, Gerard E.↗

NASA NTRS1983

Investigation of the tip clearance flow inside and at the exit of a compressor rotor passage. II - Turbulence properties

The flow in the tip clearance region of a compressor rotor is highly turbulent due to the strong interaction of the leakage flow with the annulus wall boundary layer. This paper deals with the turbulence properties of the flow in the tip clearance region of a moderately loaded compressor rotor. The experimental results reported in this paper were obtained using a two-sensor hot-wire probe in combination with an ensemble averaging technique. Blade-to-blade distribution of the axial and tangential turbulence intensities at various radial locations and ten axial locations (four inside the blade passage and the remaining six outside the passage) were derived from this data. Isointensity contours in the clearance region at various radial locations were also obtained from the experimental data. A region of very high turbulence intensities was indicated at the half-chord location from these results. The turbulence intensity profiles also indicated that the leakage flow travels toward the midpassage before rolling up. The turbulence is almost isotropic beyond three-quarter chord downstream of the trailing edge.

Pandya, A.↗

NASA NTRS1995

Enhanced analysis and users manual for radial-inflow turbine conceptual design code RTD

Modeling enhancements made to a radial-inflow turbine conceptual design code are documented in this report. A stator-endwall clearance-flow model was added for use with pivoting vanes. The rotor calculations were modified to account for swept blades and splitter blades. Stator and rotor trailing-edge losses and a vaneless-space loss were added to the loss model. Changes were made to the disk-friction and rotor-clearance loss calculations. The loss model was then calibrated based on experimental turbine performance. A complete description of code input and output along with sample cases are included in the report.

Glassman, Arthur J.↗

NASA NTRS2011

Study of Near-Stall Flow Behavior in a Modern Transonic Fan with Composite Sweep

Detailed flow behavior in a modern transonic fan with a composite sweep is investigated in this paper. Both unsteady Reynolds-averaged Navier-Stokes (URANS) and Large Eddy Simulation (LES) methods are applied to investigate the flow field over a wide operating range. The calculated flow fields are compared with the data from an array of high-frequency response pressure transducers embedded in the fan casing. The current study shows that a relatively fine computational grid is required to resolve the flow field adequately and to calculate the pressure rise across the fan correctly. The calculated flow field shows detailed flow structure near the fan rotor tip region. Due to the introduction of composite sweep toward the rotor tip, the flow structure at the rotor tip is much more stable compared to that of the conventional blade design. The passage shock stays very close to the leading edge at the rotor tip even at the throttle limit. On the other hand, the passage shock becomes stronger and detaches earlier from the blade passage at the radius where the blade sweep is in the opposite direction. The interaction between the tip clearance vortex and the passage shock becomes intense as the fan operates toward the stall limit, and tip clearance vortex breakdown occurs at near-stall operation. URANS calculates the time-averaged flow field fairly well. Details of measured RMS static pressure are not calculated with sufficient accuracy with URANS. On the other hand, LES calculates details of the measured unsteady flow features in the current transonic fan with composite sweep fairly well and reveals the flow mechanism behind the measured unsteady flow field.

Hah, Chunill↗

NASA NTRS2017

Progress of High Efficiency Centrifugal Compressor Simulations Using TURBO

Three-dimensional, time-accurate, and phase-lagged computational fluid dynamics (CFD) simulations of the High Efficiency Centrifugal Compressor (HECC) stage were generated using the TURBO solver. Changes to the TURBO Parallel Version 4 source code were made in order to properly model the no-slip boundary condition along the spinning hub region for centrifugal impellers. A startup procedure was developed to generate a converged flow field in TURBO. This procedure initialized computations on a coarsened mesh generated by the Turbomachinery Gridding System (TGS) and relied on a method of systematically increasing wheel speed and backpressure. Baseline design-speed TURBO results generally overpredicted total pressure ratio, adiabatic efficiency, and the choking flow rate of the HECC stage as compared with the design-intent CFD results of Code Leo. Including diffuser fillet geometry in the TURBO computation resulted in a 0.6 percent reduction in the choking flow rate and led to a better match with design-intent CFD. Diffuser fillets reduced annulus cross-sectional area but also reduced corner separation, and thus blockage, in the diffuser passage. It was found that the TURBO computations are somewhat insensitive to inlet total pressure changing from the TURBO default inlet pressure of 14.7 pounds per square inch (101.35 kilopascals) down to 11.0 pounds per square inch (75.83 kilopascals), the inlet pressure of the component test. Off-design tip clearance was modeled in TURBO in two computations: one in which the blade tip geometry was trimmed by 12 mils (0.3048 millimeters), and another in which the hub flow path was moved to reflect a 12-mil axial shift in the impeller hub, creating a step at the hub. The one-dimensional results of these two computations indicate non-negligible differences between the two modeling approaches.

turbomachinery↗