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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan- stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.

Veres, Joseph P.↗
NASA NTRS2018

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes: Public Version

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. In preparation for testing of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The results of those analyses formed the basis of the test matrix. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. Together these comprise a one-dimensional icing tool. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method was enhanced by computing key parameters through the fan-stator at multiple spanwise locations, in order to increase the fidelity with the current mean-line method. In addition, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion near the splitter-lip and shroud. Since there were no thermocouples near the splitter, a simple order of magnitude heat transfer model was implemented to estimate the wall temperature. Future analyses will require a higher fidelity thermal analysis of the compression system metal walls to accurately calculate the total heat flux to the ice particle. For many data points analyzed, there were differences between the thermodynamic system model and the measured test data that may partially be responsible for uncertainties with the results of the current analyses.

Turbomachinery↗
NASA NTRS1985

NASTRAN supplemental documentation for modal forced vibration analysis of aerodynamically excited turbosystems

This report is a supplemental NASTRAN document for a new capability to determine the vibratory response of turbosystems subjected to aerodynamic excitation. Supplements of NASTRAN Theoretical, User's, Programmer's, and Demonstration Manuals are included. Turbosystems such as advanced turbopropellers with highly swept blades, and axial-flow compressors and turbines can be analyzed using this capability, which has been developed and implemented in the April 1984 release of the general purpose finite element program NASTRAN. The dynamic response problem is addressed in terms of the normal modal coordinates of these tuned rotating cyclic structures. Both rigid and flexible hubs/disks are considered. Coriolis and centripetal accelerations, as well as differential stiffness effects are included. Generally nonuniform steady inflow fields and uniform flow fields arbitrarily inclined at small angles with respect to the axis of rotation of the turbosystem are considered as the sources of aerodynamic excitation. The spatial nonuniformities are considered to be small deviations from a principally uniform inflow. Subsonic relative inflows are addressed, with provision for linearly interpolating transonic airloads.

Elchuri, V.↗
NASA NTRS1985

Modal forced vibration analysis of aerodynamically excited turbosystems

Theoretical aspects of a new capability to determine the vibratory response of turbosystems subjected to aerodynamic excitation are presented. Turbosystems such as advanced turbopropellers with highly swept blades, and axial-flow compressors and turbines can be analyzed using this capability. The capability has been developed and implemented in the April 1984 release of the general purpose finite element program NASTRAN. The dynamic response problem is addressed in terms of the normal modal coordinates of these tuned rotating cyclic structures. Both rigid and flexible hubs/disks are considered. Coriolis and centripetal accelerations, as well as differential stiffness effects are included. Generally non-uniform steady inflow fields and uniform flow fields arbitrarily inclined at small angles with respect to the axis of rotation of the turbosystem are considered sources of aerodynamic excitation. The spatial non-uniformities are considered to be small deviations from a principally uniform inflow. Subsonic and supersonic relative inflows are addressed, with provision for linearly interpolating transonic airloads.

Elchuri, V.↗
NASA NTRS1981

Supersonic Stall Flutter of High Speed Fans

An analytical model is developed for predicting the onset of supersonic stall bending flutter in axial flow compressors. The analysis is based on a modified two dimensional, compressible, unsteady actuator disk theory. It is applied to a rotor blade row by considering a cascade of airfoils whose geometry and dynamic response coincide with those of a rotor blade element at 85 percent of the span height (measured from the hub). The rotor blades are assumed to be unshrouded (i.e., free standing) and to vibrate in their first flexural mode. The effects of shock waves and flow separation are included in the model through quasi-steady, empirical, rotor total-pressure-loss and deviation-angle correlations. The actuator disk model predicts the unsteady aerodynamic force acting on the cascade blading as a function of the steady flow field entering the cascade and the geometry and dynamic response of the cascade. Calculations show that the present model predicts the existence of a bending flutter mode at supersonic inlet Mach numbers. This flutter mode is suppressed by increasing the reduced frequency of the system or by reducing the steady state aerodynamic loading on the cascade. The validity of the model for predicting flutter is demonstrated by correlating the measured flutter boundary of a high speed fan stage with its predicted boundary. This correlation uses a level of damping for the blade row (i.e., the log decrement of the rotor system) that is estimated from the experimental flutter data. The predicted flutter boundary is shown to be in good agreement with the measured boundary.

Adamczyk, J. J.↗
NASA NTRS1987

A method for assessing effects of circumferential flow distortion on compressor stability

This paper describes the development of a new analysis to predict the onset of flow instability for an axial compressor operating in a circumferentialy distorted inlet flow. A relatively simple model is used to examine the influence of various distortions in setting this instability point. It is found that the model reproduces known experimental trends for the loss of stability margin with increasing distortion amplitude and with changes in reduced frequency. In particular, there is a recognizable 'critical sector angle' which characterizes loss of stability margin. To the authors' knowledge, this is the first time the effects described herein have been theoretically demonstrated as the direct result of a fluid dynamic stability.

Hynes, T. P.↗
NASA NTRS1961

Experimental Investigation of an Air-Cooled Turbine Operating in a Turbojet Engine at Turbine Inlet Temperatures up to 2500 F

An experimental investigation was made of an air-cooled turbine at average turbine inlet temperatures up to 2500 F. A modified production-model 12-stage axial-flow-compressor turbojet engine operating in a static sea-level stand was used as the test vehicle. The modifications to the engine consisted of the substitution of special combustor and turbine assemblies and double-walled exhaust ducting for the standard parts of the engine. All of these special parts were air-cooled to withstand the high operating temperatures of the investigation. The air-cooled turbine stator and rotor blades were of the corrugated-insert type. Leading-edge tip caps were installed on the rotor blades to improve leading-edge cooling by diverting the discharge of coolant to regions of lower gas pressure toward the trailing edge of the blade tip. Caps varying in length from 0.15- to 0.55-chord length were used in an attempt to determine the optimum cap length for this blade. The engine was operated over a range of average turbine inlet temperatures from about 1600 to about 2500 F, and a range of average coolant-flow ratios of 0.012 to 0.065. Temperatures of the air-cooled turbine rotor blades were measured at all test conditions by the use of thermocouples and temperature-indicating paints. The results of the investigation indicated that this type of blade is feasible for operation in turbojet engines at the average turbine inlet temperatures and stress levels tested(maximums of 2500 F and 24,000 psi, respectively). An average one-third-span blade temperature of 1300 F could be maintained on 0.35-chord tip cap blades with an average coolant-flow ratio of about 0.022 when the average turbine inlet temperature was 2500 F and cooling-air temperature was about 260 F. All of the leading-edge tip cap lengths improved the cooling of the leading-edge region of the blades, particularly at low average coolant-flow ratios. At high gas temperatures, such parts as the turbine stator and the combustor liners are likely to be as critical as the turbine rotor blades.

Cochran, Reeves P.↗
NASA NTRS1976

Numerical solution of periodic transonic flow through a fan stage

A numerical method of solution of the inviscid, compressible, two-dimensional unsteady flow on a blade-to-blade stream surface through a stage (rotor and stator), or a single blade row, of an axial flow compressor or fan is described. A cyclic procedure has been developed for representation of adjacent blade-to-blade passages, which asymptotically achieves the correct phase between all passages of a stage. A shock-capturing finite-difference method is employed in the interior of the passage, and a method-of-characteristics technique is used at the boundaries. The blade slipstreams form two of the passage boundaries, and are treated as moving contact surfaces capable of supporting jumps in entropy and tangential velocity. The Kutta condition is imposed by requiring the slipstreams to originate at the trailing edges, which are assumed to be sharp. Results are presented for several transonic fan rotors, and compared with available experimental data consisting of holographic observations of shock structure and pressure contour maps. A subcritical stator solution is also compared with results from a relaxation method. Finally, a periodic solution for a stage consisting of 44 rotor blades and 46 stator blades is discussed.

Erdos, J. I.↗
NASA NTRS1976

PMR polyimide/graphite fiber composite fan blades

Ultrahigh speed fan blades, designed in accordance with the requirements of an ultrahigh tip speed blade axial flow compressor, were fabricated from a high strength graphite fiber tow and a PMR polyimide resin. The PMR matrix was prepared by combining three monomeric reactants in methyl alcohol, and the solution was applied directly to the reinforcing fiber for subsequent in situ polymerization. Some of the molded blades were completely finished by secondary bonding of root pressure pads and an electroformed nickel leading edge sheath prior to final machining. The results of the spin testing of nine PMR fan blades are given. Prior to blade fabrication, heat resin tensile properties of the PMR resin were examined at four formulated molecular weight levels. Additionally, three formulated molecular weight levels were investigated in composite form with both a high modulus and a high strength fiber, both as-molded and postcured, in room temperature and 232 C transverse tensile, flexure and short beam shear. Mixed fiber orientation panels simulating potential blade constructions were also evaluated. Flexure tests, short beam shear tests, and tensile tests were conducted on these angle-plied laminates.

Cavano, P. J.↗
NASA NTRS1977

Computation of unsteady transonic flows through rotating and stationary cascades. 1: Method of analysis

A numerical method of solution of the inviscid, compressible, two-dimensional unsteady flow on a blade-to-blade stream surface through a stage (rotor and stator) or a single blade row of an axial flow compressor or fan is described. A cyclic procedure has been developed for representation of adjacent blade-to-blade passages which asymptotically achieves the correct phase between all passages of a stage. A shock-capturing finite difference method is employed in the interior of the passage, and a method of characteristics technique is used at the boundaries. The blade slipstreams form two of the passage boundaries and are treated as moving contact surfaces capable of supporting jumps in entropy and tangential velocity. The Kutta condition is imposed by requiring the slipstreams to originate at the trailing edges, which are assumed to be sharp. Results are presented for several transonic fan rotors and compared with available experimental data, consisting of holographic observations of shock structure and pressure contour maps. A subcritical stator solution is also compared with results from a relaxation method. Finally, a periodic solution for a stage consisting of 44 rotor blades and 46 stator blades is discussed.

Erdos, J. I.↗
NASA NTRS1978

A new blade element method for calculating the performance of high and intermediate solidity axial flow fans

A method is presented to design and predict the performance of axial flow rotors operating in a duct. The same method is suitable for the design of ducted fans and open propellers. The unified method is based on the blade element approach and the vortex theory for determining the three dimensional effects, so that two dimensional airfoil data can be used for determining the resultant force on each blade element. Resolution of this force in the thrust and torque planes and integration allows the total performance of the rotor, fan or propeller to be predicted. Three different methods of analysis, one based on a momentum flow theory; another on the vortex theory of propellers; and a third based on the theory of ducted fans, agree and reduce cascade airfoil data to single line as a function of the loading and induced angle of attack at values of constant inflow angle. The theory applies for any solidity from .01 to over 1 and any blade section camber. The effects of the duct and blade number can be determined so that the procedure applies over the entire range from two blade open propellers, to ducted helicopter tail rotors, to axial flow compressors with or without guide vanes, and to wind tunnel drive fans.

Borst, H. V.↗
NASA NTRS1980

Distribution analysis for F100(3) engine

The F100(3) compression system response to inlet circumferential distortion was investigated using an analytical compressor flow model. Compression system response to several types of distortion, including pressure, temperature, and combined pressure/temperature distortions, was investigated. The predicted response trends were used in planning future F100(3) distortion tests. Results show that compression system response to combined temperature and pressure distortions depends upon the relative orientation, as well as the individual amplitudes and circumferential extents of the distortions. Also the usefulness of the analytical predictions in planning engine distortion tests is indicated.

Walter, W. A.↗
NASA NTRS1982

High-speed laser anemometer system for intrarotor flow mapping in turbomachinery

A fringe-type laser anemometer with innovative features is described. The innovative features include: (1) rapid, efficient data acquisition processes, (2) detailed graphic display of data being accumulated, and (3) input laser-beam positioning that allows greater optical access to the intrarotor region. Results are presented that demonstrate the anemometer's capability in flow mapping within a transonic axial-flow compressor rotor.

Powell, J. A.↗
NASA NTRS1982

Fringe localization requirements for three-dimensional flow visualization of shock waves in diffuse-illumination double-pulse holographic interferometry

A theory of fringe localization in rapid-double-exposure, diffuse-illumination holographic interferometry was developed. The theory was then applied to compare holographic measurements with laser anemometer measurements of shock locations in a transonic axial-flow compressor rotor. The computed fringe localization error was found to agree well with the measured localization error. It is shown how the view orientation and the curvature and positional variation of the strength of a shock wave are used to determine the localization error and to minimize it. In particular, it is suggested that the view direction not deviate from tangency at the shock surface by more than 30 degrees.

Decker, A. J.↗
NASA NTRS1982

Gas turbine rotor/case structural response to rotating stall: Experimental documentation and analytical approach

The forcing functions and structural responses characterizing gas turbine rotor/case system vibration due to rotating stall in an axial flow compressor are described. Two data sets with fundamentally different response characteristics are presented; one is supersynchronous and the other subsynchronous. Conventional beam element rotor dynamics analysis is shown to be severely limited in its ability to predict these responses. A new analytical approach, which significantly increases structural response predictive capability for these phenomena, is briefly discussed.

Haley, P. J.↗