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Rotor design to evaluate outer case blowing or bleeding of single stage axial flow compressor
The overall and blade-element performance of a low pressure ratio, low tip speed fan stage at design speed is presented for tow off-design rotor blade angle settings. The rotor design tip speed is 243.8 m/sec and weight flow per unit annulus area is 175.8 kg/sec. Design weight flow and pressure ratio are 29.9 kg/sec and 1.151, respectively.
Axial-flow medium aspect ratio compressor rotor blade rows designed to evaluate use of blade camberline shape to minimize blade element losses at high transonic speed
It is not sufficient to optimize a rotor design in terms of a single noise level calculated for a single flight condition and a single measurement location. The various noise sources, their frequency content, amplitude, and directivity as a function of operating condition must be considered. A summary of the frequency ranges, directivity patterns and the most important operational and design parameters for major rotor noise sources is presented. It is difficult to generalize design requirements for rotor noise because the acoustic output varies so widely depending on the noise source, flight condition, measurement location, and frequency range. However, assuming the rotor must lift a fixed nominal payload and operate over a wide range of flight conditions, three general design guidelines can be stated: (1) minimize tip Mach number; (2) minimize blade thickness in the tip region; and (3) minimize gradients in the spanwise lift distribution in the tip region. Constraints on blade thickness, maximum values for hover tip Mach number, advancing tip Mach number and spanwise lift coefficient gradient will be specified during the aerodynamic, dynamic and structural optimization process. The rotor noise sources to be considered include the low frequency loading and thickness noise, and the higher frequency noise due to blade-vortex interactions (BVI). The analyses to be employed will include the comprehensive rotor analysis and design program CAMRAD and the rotor noise prediction program WOPWOP.
Based on initial results obtained from the performance optimization code, a number of observations can be made regarding the utility of optimization codes in supporting design of rotors for improved performance. (1) The primary objective of improving the productivity and responsiveness of current design methods can be met. (2) The use of optimization allows the designer to consider a wider range of design variables in a greatly compressed time period. (3) Optimization requires the user to carefully define his problem to avoid unproductive use of computer resources. (4) Optimization will increase the burden on the analyst to validate designs and to improve the accuracy of analysis methods. (5) Direct calculation of finite difference derivatives by the optimizer was not prohibitive for this application but was expensive. Approximate analysis in some form would be considered to improve program response time. (6) Program developement is not complete and will continue to evolve to integrate new analysis methods, design problems, and alternate optimizer options.
A genetic algorithm coupled with a simplified acoustic analysis was used to generate low-noise rotor blade designs. The model includes thickness, steady loading and blade-vortex interaction noise estimates. The paper presents solutions for several variations in the fitness function, including thickness noise only, loading noise only, and combinations of the noise types. Preliminary results indicate that the analysis provides reasonable assessments of the noise produced, and that genetic algorithm successfully searches for "good" designs. The results show that, for a given required thrust coefficient, proper blade design can noticeably reduce the noise produced at some expense to the power requirements.
Three helicopter rotor airfoils designed analytically were investigated in a wind tunnel at Mach numbers from about 0.30 to 0.90 and Reynolds from about 0.8 to 2.3 x 10 to the 6th power. The airfoils had thickness-to-chord ratios of 0.08, 0.10, and 0.12 with maximum thickness at 40 percent chord. The camber distribution of each section was the same with maximum camber at 35 percent chord. The 10-percent-thick airfoil was also investigated at Reynolds numbers from 4.8 to 9.4 x 10 to the 6th power. The drag divergence Mach number of the 10-percent-thick airfoil is about 0.83 at a normal-force coefficient of 0 and about 0.72 at a normal-force coefficient of 0.6 at Reynolds numbers near 9 x 10 to the 6th power. The maximum normal-force coefficient is slightly less than that of the NACA 0012 airfoil tested in the same facility. The results indicate that a qualitative evaluation of the drag divergence can be made at normal-force coefficients up to the onset of boundary-layer separation by analytically predicting the onset of sonic flow at the airfoil crest. The qualitative results are conservative with respect to experimental values with the experimental drag divergence Mach number up to 0.05 higher than that indicated by analysis.
An investigation was conducted in the NASA Langley Transonic Dynamics Tunnel to evaluate an advanced main rotor designed for use on a utility class helicopter, specifically the U.S. Army UH-60A Blackhawk. This rotor design incorporated advanced twist, airfoil cross sections, and geometric planform. For evaluation purposes, the current UH-60A main rotor was also tested and is referred to as the baseline blade set. A total of four blade sets were tested. One set of both the baseline and the advanced rotors were dynamically scaled to represent a full scale helicopter rotor blade design. The remaining advanced and baseline blade sets were not dynamically scaled so as to isolate the effects of structural elasticity. The investigation was conducted in hover and at rotor advance ratios ranging from 0.15 to 0.4 at a range of nominal test medium densities from 0.00238 to 0.009 slugs/cu ft. This range of densities, coupled with varying rotor lift and propulsive force, allowed for the simulation of several vehicle gross weight and density altitude combinations. Performance data are presented for all blade sets without analysis; however, cross referencing of data with flight condition may be useful to the analyst for validating aeroelastic theories and design methodologies as well as for evaluating advanced design parameters.
A method for selecting rotor suspension design criteria that allow rotors with internal friction to negotiate critical speeds and avoid subsynchronous internal friction instabilities is described. A rotor model of a test rotor with internal friction is created and used to calculate the test rotor’s critical speeds, mode shapes, Campbell plots, and the rotational speed corresponding to the stability boundary for a nominal set of suspension parameters. The test rotor model is then used to demonstrate the suspension design criteria selection method.
The rotor dynamic design considerations are essentially limitations on the vibratory response of the blades which in turn limit the dynamic excitation of the fuselage by forces and moments transmitted to the hub. Quantities which are associated with the blade response and which are subject to design constraints are discussed. These include blade frequencies, vertical and inplane hub shear, rolling and pitching moments, and aeroelastic stability margin.
The importance of blade design parameters in rotor vibratory response and the design of a minimum vibration blade based upon this understanding are examined. Various design approaches are examined for a 4 bladed articulated rotor operating at a high speed flight condition. Blade modal shaping, frequency placement, structural and aerodynamic coupling, and intermodal cancellation are investigated to systematically identify and evaluate blade design parameters that influence blade airloads, blade modal response, hub loads, and fuselage vibration. The relative contributions of the various components of blade force excitation and response to the vibratory hub loads transmitted to the fuselage are determined in order to isolate primary candidates for vibration alleviation. A blade design is achieved which reduces the predicted fuselage vibration from the baseline blade by approximately one half. Blade designs are developed that offer significant reductions in vibration (and fatigue stresses) without resorting to special vibration alleviation devices, radical blade geometries, or weight penalties.
An analytical formulation of optimum rotor interdisciplinary design is presented. A finite-state aeroelastic rotor model, coupling generalized dynamic wake with blade finite elements, is applied to perform the optimum rotor blade design for improved aerodynamic performance and vehicle vibration, while a feasible direction nonlinear optimizer, CONMIN, provides the optimization algorithm. The approach features a systematic rotor aeroelastic model which offers an efficient analytical tool, and retains necessary aerodynamic and blade dynamic building blocks for a sufficient rotor dynamic response analysis. The formulation is well suited for an efficient design sensitivity computation without resorting to finite difference, and thus provides a practical design tool. The results show improved rotor aerodynamic performance and reduced hub vibratory loads for the optimized blade as compared to the advanced rotor of reference design.
Design tools have been developed for ultra-low Reynolds number rotors, combining enhanced actuator-ring / blade-element theory with airfoil section data based on two-dimensional Navier-Stokes calculations. This performance prediction method is coupled with an optimizer for both design and analysis applications. Performance predictions from these tools have been compared with three-dimensional Navier Stokes analyses and experimental data for a 2.5 cm diameter rotor with chord Reynolds numbers below 10,000. Comparisons among the analyses and experimental data show reasonable agreement both in the global thrust and power required, but the spanwise distributions of these quantities exhibit significant deviations. The study also reveals that three-dimensional and rotational effects significantly change local airfoil section performance. The magnitude of this issue, unique to this operating regime, may limit the applicability of blade-element type methods for detailed rotor design at ultra-low Reynolds numbers, but these methods are still useful for evaluating concept feasibility and rapidly generating initial designs for further analysis and optimization using more advanced tools.