Three-dimensional Navier-Stokes simulations of turbine rotor-stator interaction. I - Methodology
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A numerical study of the aerodynamic and thermal environment associated with axial turbine stages is presented. Computations were performed using a modification of the unsteady viscous code, ROTORI, and an improved version of the steady inviscid cascade system, MERIDL-TSONIC, coupled with boundary layer codes, BLAYER and STAN5. Two different turbine stages were analyzed: the first stage of the United Technologies Research Center Large Scale Rotating Rig (LSRR) and the first stage of the Space Shuttle Main Engine (SSME) high pressure fuel turbopump turbine. The time-averaged airfoil midspan pressure and heat transfer profiles were predicted for numerous thermal boundary conditions including adiabatic wall, prescribed surface temperature, and prescribed heat flux. Computed solutions are compared with each other and with experimental data in the case of the LSRR calculations. Modified ROTORI predictions of unsteady pressure envelopes and instantaneous contour plots are also presented. Relative merits of the two computational approaches are discussed.
Local Stanton numbers were experimentally determined for the endwall surface of a turbine vane possage. A six vane linear cascade having vanes with an axial chord of 13.81 cm was used. Resutls were obtained for Reynolds numbers based on inlet velocity and axial chord between 75,000 and 495,000. The test section was connected to a low pressure exhaust system. Ambient air was drawn into the test section, inlet velocity was controlled up to a maximum of 59.4 m/sec. The effect of the inlet boundary layer thickness on the endwall heat transfer was determined for a range of test section flow rates. The liquid crystal measurement technique was used to measure heat transfer. Endwall heat transfer was determined by applying electrical power to a foil heater attached to the cascade endwall. The temperature at which the liquid crystal exhibited a specific color was known from a calibration test. Lines showing this specific color were isotherms, and because of uniform heat generation they were also lines of nearly constant heat transfer. Endwall static pressures were measured, along with surveys of total pressure and flow angles at the inlet and exit of the cascade.
A description of the Axial Flow Turbine Research Facility (AFTRF) being built at the Turbomachinery Laboratory of the Pennsylvania State University is presented. The purpose of the research to be performed in this facility is to obtain a better understanding of the rotor/stator interaction, three dimensional viscous flow field in nozzle and rotor blade passages, spanwise mixing and losses in these blade rows, transport of wake through rotor passage, and unsteady aerodynamics and heat transfer of rotor blade row. The experimental results will directly feed and support the analytical and the computational tool development. This large scale low speed facility is heavily instrumented with pressure and temperature probes and has provision for flow visualization and laser Doppler anemometer measurement. The facility design permits extensive use of the high frequency response instrumentation on the stationary vanes and more importantly on the rotating blades. Furthermore it facilitates detailed nozzle wake, rotor wake, and boundary layer surveys. The large size of the rig also has the advantage of operating at Reynolds numbers representative of the engine environment.
Results from experimental and analytical studies on rotor to stationary element partial rubbings at several locations and their effects on rotor dynamic responses are presented. The mathematical model of a rubbing rotor is given. The computer program provides numerical results which agree with experimentally obtained rotor responses.
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