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Vortex generator installation studies on steady state and dynamic inlet distortion

The theoretical and experimental work carried out under the NASA/MOD Joint Aeronautical Program has shown that CFD vortex generator installations designs successfully managed inlet duct flow distortion and that significant benefits in flow unsteadiness at the engine face were also present. The main conclusions to date from the collaborative effort between NASA/Lewis and DRA/Bedford are as follows: (1) vortex generator installations can be designed to be effective over a wide range of inlet operating conditions using Computational Fluid Dynamics and formal optimization procedures, (2) reductions in steady state engine face distortion of up to 80% have been measured in the M2129 inlet S-duct using CFD designed vortex generator installations, (3) reductions in flow unsteadiness of up to 80% have been measured in the W129 inlet S-duct using CFD designed vortex generator installations, and (4) the Reduced Navier-Stokes code RNS3D is a useful tool to design vortex generator installations to manage engine face distortions over a wide range of inlet operating conditions.

Anderson, Bernhard H.

Effects of inlet distortion on a static pressure probe mounted on the engine hub in an F-15 airplane

An inlet static pressure (PS2) probe was mounted on the hub of an F100 engine in an F-15 airplane. Flight test results showed that for low distortion conditions, the ratio of engine-face total pressure to static pressure agreed well with previous altitude facility data. Off-schedule operation of the inlet third ramp angle caused increased distortion of the inlet airflow during steady-state flight conditions. Data are shown for inlet third ramp excursions leading to engine stall. The relationships of inlet face total to static pressure ratio as a function of several distortion descriptors are also described.

Hughes, D. L.

Two-stage fan. 3: Data and performance with rotor tip casing treatment, uniform and distorted inlet flows

A two stage fan with a 1st-stage rotor design tip speed of 1450 ft/sec, a design pressure ratio of 2.8, and corrected flow of 184.2 lbm/sec was tested with axial skewed slots in the casings over the tips of both rotors. The variable stagger stators were set in the nominal positions. Casing treatment improved stall margin by nine percentage points at 70 percent speed but decreased stall margin, efficiency, and flow by small amounts at design speed. Treatment improved first stage performance at low speed only and decreased second stage performance at all operating conditions. Casing treatment did not affect the stall line with tip radially distorted flow but improved stall margin with circumferentially distorted flow. Casing treatment increased the attenuation for both types of inlet flow distortion.

Burger, G. D.

Basic research in fan source noise: Inlet distortion and turbulence noise

A widely recognized problem in jet engine fan noise is the discrepancy between inflight and static tests. This discrepancy consists of blade passing frequency tones, caused by ingested turbulence that appear in the static tests but not in flight. To reduce the ingested distortions and turbulence in an anechoic chamber, a reverse cone inlet is used to guide the air into the fan. This inlet also has provisions for boundary layer suction and is used in conjunction with a turbulence control structure (TCS) to condition the air impinging on the fan. The program was very successful in reducing the ingested turbulence, to the point where reductions in the acoustic power at blade passing frequency are as high as 18 db for subsonic tip speeds. Even with this large subsonic tone suppression, the supersonic tip speed tonal content remains largely unchanged, indicating that the TCS did not appreciably attenuate the noise but effects the generation via turbulence reduction. Turbulence mapping of the inlet confirmed that the tone reductions are due to a reduction in turbulence, as the low frequency power spectra of the streamwise and transverse turbulence were reduced by up to ten times and 100 times, respectively.

Kantola, R. A.

Forced Response Analysis of a Fan with Boundary Layer Inlet Distortion

Boundary layer ingesting propulsion systems have the potential to significantly reduce fuel burn for future generations of commercial aircraft, but these systems must be designed to overcome the challenge of high dynamic stresses in fan blades due to forced response. High dynamic stresses can lead to high cycle fatigue failures. High-fidelity computational analysis of the fan aeromechanics is integral to an ongoing effort to design a boundary layer ingesting inlet and fan for a wind-tunnel test. An unsteady flow solution from a Reynoldsaveraged Navier Stokes analysis of a coupled inlet-fan system is used to calculate blade unsteady loading and assess forced response of the fan to distorted inflow. Conducted prior to the mechanical design of a fan, the initial forced response analyses performed in this study provide an early look at the levels of dynamic stresses that are likely to be encountered. For the boundary layer ingesting inlet, the distortion contains strong engine order excitations that act simultaneously. The combined effect of these harmonics was considered in the calculation of the forced response stresses. Together, static and dynamic stresses can provide the information necessary to evaluate whether the blades are likely to fail due to high cycle fatigue. Based on the analyses done, the overspeed condition is likely to result in the smallest stress margin in terms of the mean and alternating stresses. Additional work is ongoing to expand the analyses to off-design conditions, on-resonance conditions, and to include more detailed modeling of the blade structure.

Vibrational stress

Computational Evaluation of Inlet Distortion on an Ejector Powered Hybrid Wing Body at Takeoff and Landing Conditions

Due to the aft, upper surface engine location on the Hybrid Wing Body (HWB) planform, there is potential to shed vorticity and separated wakes into the engine when the vehicle is operated at off-design conditions and corners of the envelope required for engine and airplane certification. CFD simulations were performed of the full-scale reference propulsion system, operating at a range of inlet flow rates, flight speeds, altitudes, angles of attack, and angles of sideslip to identify the conditions which produce the largest distortion and lowest pressure recovery. Pretest CFD was performed by NASA and Boeing, using multiple CFD codes, with various turbulence models. These data were used to make decisions regarding model integration, characterize inlet flow distortion patterns, and help define the wind tunnel test matrix. CFD was also performed post-test; when compared with test data, it was possible to make comparisons between measured model-scale and predicted full-scale distortion levels. This paper summarizes these CFD analyses.

Wind Tunnel Testing

Aerodynamic Shape Optimization of the STARC-ABL Concept for Minimal Inlet Distortion

The NASA single-aisle turboelectric aircraft with an aft boundary layer propulsor (STARC-ABL) concept utilizes a novel electrically driven aft fan that ingests the fuselage boundary-layer for increased propulsive efficiency. In this paper we examine how aerodynamic shaping of the fuselage diffuser and nacelle inlet can reduce the flow distortion at the aft fan. Adjoint-based aerodynamic shape optimization with the ARP1420 distortion metric objective is used to automatically determine the optimal shapes for minimal fan-face distortion. Single and multipoint optimizations are carried out for simplified body-duct and wing-body-duct configurations. These two configurations highlight the importance of including the wing downwash effects when designing the propulsor. The optimizations showed the body-duct configuration can obtain cruise distortion values of approximately 1% while the wing-body-duct configuration can obtain distortion values of just over 2%.

Kenway, Gaetan K. W.

Calculations of inlet distortion induced compressor flow field instability

Calculations of the onset of flow instability are carried out for low-speed multistage axial compressors operating with asymmetric inlet flow. The modeling of the fluid dynamic interaction between the spoiled and unspoiled sectors of the compressor is the most important feature of the calculation procedure. The calculations show that annulus average slope of the compressor pressure rise characteristic equal to zero is a useful approximate stability criterion for situations where the dynamics of the compressor flow field do not couple strongly to the compression system or the structure of the imposed distortion is not similar to that of the eigenmodes of the flow in the compressor annulus. This criterion is employed to investigate the relationship between the present model and the 'parallel compressor' model. Calculations are also presented for cases when compressor and compressor system are closely coupled, and situations in which the compressor is subjected to a rotating distortion. These first-of-a-kind computations, and the accompanying description of the physical mechanisms, show that the stability of the flow in the compressor can be adversely affected if the temporal or spatial structure of the distortion is such that resonant type responses can be evoked either from the compressor or from compressor/compression system interactions.

Chue, R.

Analysis of dynamic inlet distortion applied to a parallel compressor model

An investigation of surge was conducted by using a parallel compressor model of the J85-13 compressor implement on an analog computer. Surges were initiated by various types of dynamic disturbances in inlet pressure. The compressor model was less sensitive to disturbances of short duration, high frequency, and long duration where the compressor discharge pressure could react. Adding steady distortion to dynamic disturbances reduced the amount of dynamic disturbance required to effect surge. Steady and unsteady distortions combined linearly to reduce surge margin.

Wenzel, L. M.

Effects of inlet distortion on a static pressure probe mounted on the engine hub in an F-15 airplane

Problems encountered in obtaining good engine face pressure data were studied. A single static measurement located upstream of the engine hub in the stream flow was found to provide a pressure signal suitable for engine control. Two identical probes for measuring fan inlet static (PS2) pressure were designed and mounted on the hub of the left F100-PW-100 turbofan engine installed in the F-15 test aircraft for flight evaluation. The probe is used as a static pressure sensor for a digital engine control system.

Hughes, D. L.

Analytical prediction of the performance and stability of a J85-13 compressor with distorted inlet flow

The parallel compressor concept was studied using a compressor model based on the overall clean-inlet performance map obtained from experimental tests in an altitude chamber using a General Electric J85-13 turbojet engine. The model, which includes a static-pressure balance calculation at compressor discharge, was exercised at conditions corresponding to 10 different screen-induced distortion patterns included in the experimental data base. The spoiled area of these patterns ranged from 30 deg to 180 deg, and the distortion screen density, or the area blocked by the screen wire per unit area of screen, varied from 26 to 69 percent. The study indicates that at the higher corrected speeds, the analytical surge lines obtained are good representations of the corresponding experimental surge lines and are independent of distortion angle or distortion angle or distortion level.

Milner, E. J.

Experimental Evaluation of Inlet Distortion on an Ejector Powered Hybrid Wing Body at Take-off and Landing Conditions

As part of the NASA Environmentally Responsible Aircraft project, an ultra high bypass ratio engine integration on a hybrid wing body demonstration was planned. The goal was to include engine and airframe integration concepts that reduced fuel consumption by at least 50% while still reducing noise 42 db cumulative on the ground. Since the engines would be mounted on the upper surface of the aft body of the aircraft, the inlets may be susceptible to vortex ingestion from the wing leading edge at high angles of attack and sideslip, and separated wing/body flow. Consequently, experimental and computational studies were conducted to collect flow surveys useful for characterizing engine operability. The wind tunnel tests were conducted at two NASA facilities, the 14- by 22-foot at NASA Langley and the 40- by 80-foot at NASA Ames Research Center. The test results included in this paper show that the distortion and pressure recovery levels were acceptable for engine operability. The CFD studies conducted to compare to experimental data showed excellent agreement for the angle of attacks examined, although failed to match the low speed experimental data at high sideslip angles.

Carter, Melissa B.

Application of computational fluid dynamics to the study of vortex flow control for the management of inlet distortion

A study is presented to demonstrate that the Reduced Navier-Stokes code RNS3D can be employed effectively to develop a vortex generator installation that minimizes engine face circumferential distortion by controlling the development of secondary flow. The necessary computing times are small enough to show that similar studies are feasible within an analysis-design environment with all its constraints of costs and time. This study establishes the nature of the performance enhancements that can be realized with vortex flow control, and indicates a set of aerodynamic properties that can be utilized to arrive at a successful vortex generator installation design.

Anderson, Bernhard H.

Mitigation of Engine Inlet Distortion Through Adjoint-Based Design

The adjoint-based design capability in FUN3D is extended to allow efficient gradient- based optimization and design of concepts with highly integrated aero-propulsive systems. A circumferential distortion calculation, along with the derivatives needed to perform adjoint-based design, have been implemented in FUN3D. This newly implemented distortion calculation can be used not only for design but also to drive the existing mesh adaptation process and reduce the error associated with the fan distortion calculation. The design capability is demonstrated by the shape optimization of an in-house aircraft concept equipped with an aft fuselage propulsor. The optimization objective is the minimization of flow distortion at the aerodynamic interface plane of this aft fuselage propulsor.

Ordaz, Irian