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At least 307 records · Page 17

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NASA NTRS2009

Design and Testing of Braided Composite Fan Case Materials and Components

Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.

Roberts, Gary D.↗

NASA NTRS2009

Advanced Noise Control Fan Aerodynamic Performance

The Advanced Noise Control Fan at the NASA Glenn Research Center is used to experimentally analyze fan generated acoustics. In order to determine how a proposed noise reduction concept affects fan performance, flow measurements can be used to compute mass flow. Since tedious flow mapping is required to obtain an accurate mass flow, an equation was developed to correlate the mass flow to inlet lip wall static pressure measurements. Once this correlation is obtained, the mass flow for future configurations can be obtained from the nonintrusive wall static pressures. Once the mass flow is known, the thrust and fan performance can be evaluated. This correlation enables fan acoustics and performance to be obtained simultaneously without disturbing the flow.

Bozak, Richard F., Jr.↗

NASA NTRS2010

Regenerative Blower for EVA Suit Ventilation Fan

Portable life support systems in future space suits will include a ventilation subsystem driven by a dedicated fan. This ventilation fan must meet challenging requirements for pressure rise, flow rate, efficiency, size, safety, and reliability. This paper describes research and development that showed the feasibility of a regenerative blower that is uniquely suited to meet these requirements. We proved feasibility through component tests, blower tests, and design analysis. Based on the requirements for the Constellation Space Suit Element (CSSE) Portable Life Support System (PLSS) ventilation fan, we designed the critical elements of the blower. We measured the effects of key design parameters on blower performance using separate effects tests, and used the results of these tests to design a regenerative blower that will meet the ventilation fan requirements. We assembled a proof-of-concept blower and measured its performance at sub-atmospheric pressures that simulate a PLSS ventilation loop environment. Head/flow performance and maximum efficiency point data were used to specify the design and operating conditions for the ventilation fan. We identified materials for the blower that will enhance safety for operation in a lunar environment, and produced a solid model that illustrates the final design. The proof-of-concept blower produced the flow rate and pressure rise needed for the CSSE ventilation subsystem while running at 5400 rpm, consuming only 9 W of electric power using a non-optimized, commercial motor and controller and inefficient bearings. Scaling the test results to a complete design shows that a lightweight, compact, reliable, and low power regenerative blower can meet the performance requirements for future space suit life support systems.

Izenson, Michael G.↗

NASA NTRS2010

Coupled Analysis of an Inlet and Fan for a Quiet Supersonic Jet

A computational analysis of a Gulfstream isentropic external compression supersonic inlet coupled to a Rolls-Royce fan has been completed. The inlet was designed for a small, low sonic boom supersonic vehicle with a design cruise condition of M = 1.6 at 45,000 ft. The inlet design included an annular bypass duct that routed flow subsonically around an engine-mounted gearbox and diverted flow with high shock losses away from the fan tip. Two Reynolds-averaged Navier-Stokes codes were used for the analysis: an axisymmetric code called AVCS for the inlet and a three dimensional (3-D) code called SWIFT for the fan. The codes were coupled at a mixing plane boundary using a separate code for data exchange. The codes were used to determine the performance of the inlet/fan system at the design point and to predict the performance and operability of the system over the flight profile. At the design point the core inlet had a recovery of 96 percent, and the fan operated near its peak efficiency and pressure ratio. A large hub radial distortion generated in the inlet was not eliminated by the fan and could pose a challenge for subsequent booster stages. The system operated stably at all points along the flight profile. Reduced stall margin was seen at low altitude and Mach number where flow separated on the interior lips of the cowl and bypass ducts. The coupled analysis gave consistent solutions at all points on the flight profile that would be difficult or impossible to predict by analysis of isolated components.

Chima, Rodrick V.↗

NASA NTRS2009

Coupled Analysis of an Inlet and Fan for a Quiet Supersonic Aircraft

A computational analysis of a Gulfstream isentropic external compression supersonic inlet coupled to a Rolls-Royce fan was completed. The inlet was designed for a small, low sonic boom supersonic vehicle with a design cruise condition of M = 1.6 at 45,000 feet. The inlet design included an annular bypass duct that routed flow subsonically around an engine-mounted gearbox and diverted flow with high shock losses away from the fan tip. Two Reynolds-averaged Navier-Stokes codes were used for the analysis: an axisymmetric code called AVCS for the inlet and a 3-D code called SWIFT for the fan. The codes were coupled at a mixing plane boundary using a separate code for data exchange. The codes were used to determine the performance of the inlet/fan system at the design point and to predict the performance and operability of the system over the flight profile. At the design point the core inlet had a recovery of 96 percent, and the fan operated near its peak efficiency and pressure ratio. A large hub radial distortion generated in the inlet was not eliminated by the fan and could pose a challenge for subsequent booster stages. The system operated stably at all points along the flight profile. Reduced stall margin was seen at low altitude and Mach number where flow separated on the interior lips of the cowl and bypass ducts. The coupled analysis gave consistent solutions at all points on the flight profile that would be difficult or impossible to predict by analysis of isolated components.

Chima, Rodrick V.↗

NASA NTRS2010

Aerodynamic Design and Computational Analysis of a Spacecraft Cabin Ventilation Fan

Quieter working environments for astronauts are needed if future long-duration space exploration missions are to be safe and productive. Ventilation and payload cooling fans are known to be dominant sources of noise, with the International Space Station being a good case in point. To address this issue in a cost-effective way, early attention to fan design, selection, and installation has been recommended. Toward that end, NASA has begun to investigate the potential for small-fan noise reduction through improvements in fan aerodynamic design. Using tools and methodologies similar to those employed by the aircraft engine industry, most notably computational fluid dynamics (CFD) codes, the aerodynamic design of a new cabin ventilation fan has been developed, and its aerodynamic performance has been predicted and analyzed. The design, intended to serve as a baseline for future work, is discussed along with selected CFD results

Tweedt, Daniel L.↗

NASA NTRS2011

Effects of Inlet Distortion on Aeromechanical Stability of a Forward-Swept High-Speed Fan

Concerns regarding noise, propulsive efficiency, and fuel burn are inspiring aircraft designs wherein the propulsive turbomachines are partially (or fully) embedded within the airframe; such designs present serious concerns with regard to aerodynamic and aeromechanic performance of the compression system in response to inlet distortion. Separately, a forward-swept high-speed fan was developed to address noise concerns of modern podded turbofans; however this fan encounters aeroelastic instability (flutter) as it approaches stall. A three-dimensional, unsteady, Navier-Stokes computational fluid dynamics code is applied to analyze and corroborate fan performance with clean inlet flow. This code, already validated in its application to assess aerodynamic damping of vibrating blades at various flow conditions, is modified and then applied in a computational study to preliminarily assess the effects of inlet distortion on aeroelastic stability of the fan. Computational engineering application and implementation issues are discussed, followed by an investigation into the aeroelastic behavior of the fan with clean and distorted inlets.

Herrick, Gregory P.↗

NASA NTRS2011

Two-Stage Centrifugal Fan

Fan designs are often constrained by envelope, rotational speed, weight, and power. Aerodynamic performance and motor electrical performance are heavily influenced by rotational speed. The fan used in this work is at a practical limit for rotational speed due to motor performance characteristics, and there is no more space available in the packaging for a larger fan. The pressure rise requirements keep growing. The way to ordinarily accommodate a higher DP is to spin faster or grow the fan rotor diameter. The invention is to put two radially oriented stages on a single disk. Flow enters the first stage from the center; energy is imparted to the flow in the first stage blades, the flow is redirected some amount opposite to the direction of rotation in the fixed stators, and more energy is imparted to the flow in the second- stage blades. Without increasing either rotational speed or disk diameter, it is believed that as much as 50 percent more DP can be achieved with this design than with an ordinary, single-stage centrifugal design. This invention is useful primarily for fans having relatively low flow rates with relatively high pressure rise requirements.

Converse, David↗

NASA NTRS2012

Quiet High Speed Fan II (QHSF II): Final Report

This report details the aerodynamic, mechanical, structural design and fabrication of a Honey Engines Quiet High Speed Fan II (lower hub/tip ratio and higher specific flow than the Baseline I fan). This fan/nacelle system incorporates features such as advanced forward sweep and an advanced integrated fan/fan exit guide vane design that provides for the following characteristics: (1) Reduced noise at supersonic tip speeds, in comparison to current state-of-the-art fan technology; (2) Improved aeroelastic stability within the anticipated operating envelope; and (3) Aerodynamic performance consistent with current state-of-the-art fan technology. This fan was fabricated by Honeywell and tested in the NASA Glenn 9- by 15-Ft Low Speed Wind Tunnel for aerodynamic, aeromechanical, and acoustic performance.

Kontos, Karen↗

NASA NTRS2012

Predicting the Inflow Distortion Tone Noise of the NASA Glenn Advanced Noise Control Fan with a Combined Quadrupole-Dipole Model

A combined quadrupole-dipole model of fan inflow distortion tone noise has been extended to calculate tone sound power levels generated by obstructions arranged in circumferentially asymmetric locations upstream of a rotor. Trends in calculated sound power level agreed well with measurements from tests conducted in 2007 in the NASA Glenn Advanced Noise Control Fan. Calculated values of sound power levels radiated upstream were demonstrated to be sensitive to the accuracy of the modeled wakes from the cylindrical rods that were placed upstream of the fan to distort the inflow. Results indicate a continued need to obtain accurate aerodynamic predictions and measurements at the fan inlet plane as engineers work towards developing fan inflow distortion tone noise prediction tools.

Koch, L. Danielle↗

NASA NTRS2012

Predicting the Inflow Distortion Tone Noise of the NASA Glenn Advanced Noise Control Fan with a Combined Quadrupole-Dipole Model

Koch, L. Danielle↗

NASA NTRS2011

Experimental Measurement of Transonic Fan Wake Response to Uniform and Simulated Boundary Layer Ingesting Inlet Flows

BWB Aircraft with embedded engines and BLI inlets offer attractive advantages in terms of reduced noise from engines and increased range and fuel economy. The BLI inlet produces inlet distortion patterns that can reduce fan performance and stall margin, and can produce undesirable forced responses. Knowledge of the dynamic response of fan flow when subjected to flow distortions of the type produced by BLI inlets is important for the design of distortion tolerant fans. This project is investigating fan response to flow distortion by measuring the response of the fan of a JT15D engine to a flow pattern following the results of the NASA Inlet A BLI wind tunnel tests.

O'Brien, Walter F.↗

NASA NTRS2013

Aeromechanics Analysis of a Boundary Layer Ingesting Fan

Boundary layer ingesting propulsion systems have the potential to significantly reduce fuel burn but these systems must overcome the challe nges related to aeromechanics-fan flutter stability and forced response dynamic stresses. High-fidelity computational analysis of the fan a eromechanics is integral to the ongoing effort to design a boundary layer ingesting inlet and fan for fabrication and wind-tunnel test. A t hree-dimensional, time-accurate, Reynolds-averaged Navier Stokes computational fluid dynamics code is used to study aerothermodynamic and a eromechanical behavior of the fan in response to both clean and distorted inflows. The computational aeromechanics analyses performed in th is study show an intermediate design iteration of the fan to be flutter-free at the design conditions analyzed with both clean and distorte d in-flows. Dynamic stresses from forced response have been calculated for the design rotational speed. Additional work is ongoing to expan d the analyses to off-design conditions, and for on-resonance conditions.

Bakhle, Milind A.↗

NASA NTRS2015

On the Crack Bifurcation and Fanning of Crack Growth Data

Crack growth data obtained from ASTM load shedding method for different R values show some fanning especially for aluminum alloys. It is believed by the authors and it has been shown before that the observed fanning is due to the crack bifurcation occurs in the near threshold region which is a function of intrinsic properties of the alloy. Therefore, validity of the ASTM load shedding test procedure and results is confirmed. However, this position has been argued by some experimentalists who believe the fanning is an artifact of the test procedure and thus the obtained results are invalid. It has been shown that using a special test procedure such as using compressively pre-cracked specimens will eliminate the fanning effect. Since not using the fanned data fit can result in a significantly lower calculated cyclic life, design of a component, particularly for rotorcraft and propeller systems will considerably be impacted and therefore this study is of paramount importance. In this effort both test procedures i.e. ASTM load shedding and the proposed compressive pre-cracking have been used to study the fatigue crack growth behavior of compact tension specimens made of aluminum alloy 2524-T3. Fatigue crack growth paths have been closely observed using SEM machines to investigate the effects of compression pre-cracking on the crack bifurcation behavior. The results of this study will shed a light on resolving the existing argument by better understanding of near threshold fatigue crack growth behavior.

Forman, Royce G.↗

NASA NTRS2014

Improved Broadband Liner Optimization Applied to the Advanced Noise Control Fan

The broadband component of fan noise has grown in relevance with the utilization of increased bypass ratio and advanced fan designs. Thus, while the attenuation of fan tones remains paramount, the ability to simultaneously reduce broadband fan noise levels has become more desirable. This paper describes improvements to a previously established broadband acoustic liner optimization process using the Advanced Noise Control Fan rig as a demonstrator. Specifically, in-duct attenuation predictions with a statistical source model are used to obtain optimum impedance spectra over the conditions of interest. The predicted optimum impedance information is then used with acoustic liner modeling tools to design liners aimed at producing impedance spectra that most closely match the predicted optimum values. Design selection is based on an acceptance criterion that provides the ability to apply increased weighting to specific frequencies and/or operating conditions. Constant-depth, double-degree of freedom and variable-depth, multi-degree of freedom designs are carried through design, fabrication, and testing to validate the efficacy of the design process. Results illustrate the value of the design process in concurrently evaluating the relative costs/benefits of these liner designs. This study also provides an application for demonstrating the integrated use of duct acoustic propagation/radiation and liner modeling tools in the design and evaluation of novel broadband liner concepts for complex engine configurations.

Nark, Douglas M.↗

NASA NTRS2014

Reverse Flow Engine Core Having a Ducted Fan with Integrated Secondary Flow Blades

Secondary air flow is provided for a ducted fan having a reverse flow turbine engine core driving a fan blisk. The fan blisk incorporates a set of thrust fan blades extending from an outer hub and a set of integral secondary flow blades extending intermediate an inner hub and the outer hub. A nacelle provides an outer flow duct for the thrust fan blades and a secondary flow duct carries flow from the integral secondary flow blades as cooling air for components of the reverse flow turbine engine.

Kisska, Michael K.↗

NASA NTRS2014

Blade Vibration Measurement System for Unducted Fans

With propulsion research programs focused on new levels of efficiency and noise reduction, two avenues for advanced gas turbine technology are emerging: the geared turbofan and ultrahigh bypass ratio fan engines. Both of these candidates are being pursued as collaborative research projects between NASA and the engine manufacturers. The high bypass concept from GE Aviation is an unducted fan that features a bypass ratio of over 30 along with the accompanying benefits in fuel efficiency. This project improved the test and measurement capabilities of the unducted fan blade dynamic response. In the course of this project, Mechanical Solutions, Inc. (MSI) collaborated with GE Aviation to (1) define the requirements for fan blade measurements; (2) leverage MSI's radar-based system for compressor and turbine blade monitoring; and (3) develop, validate, and deliver a noncontacting blade vibration measurement system for unducted fans.

Marscher, William↗

NASA NTRS2015

Investigation of Unsteady Flow Interaction Between an Ultra-Compact Inlet and a Transonic Fan

In the present study, unsteady flow interaction between an ultra-compact inlet and a transonic fan stage is investigated. Future combat aircraft require ultra-compact inlet ducts as part of an integrated, advanced propulsion system to improve air vehicle capability and effectiveness to meet future mission needs. The main purpose of the study is to advance the current understanding of the flow interaction between two different ultra-compact inlets and a transonic fan for future design applications. Both URANS and LES approaches are used to calculate the unsteady flow field and are compared with the available measured data. The present study indicates that stall inception is mildly affected by the distortion pattern generated by the inlet with the current test set-up. The numerical study indicates that the inlet distortion pattern decays significantly before it reaches the fan face for the current configuration. Numerical results with a shorter distance between the inlet and fan show that counter-rotating vortices near the rotor tip due to the serpentine diffuser affects fan characteristics significantly.

Inlet↗