A computational study to define the phenomena that lead to the onset of short length-scale (spike) rotating stall disturbances has been carried out. Based on unsteady simulations, we hypothesize there are two conditions necessary for the formation of spike disturbances, both of which are linked to the tip clearance flow. One is that the interface between the tip clearance and oncoming flows becomes parallel to the leading-edge plane. The second is the initiation of backflow, stemming from the fluid in adjacent passages, at the trailing-edge plane. The two criteria also imply a circumferential length scale for spike disturbances. The hypothesis and scenario developed are consistent with numerical simulations and experimental observations of axial compressor stall inception. A comparison of calculations for multiple blades with those for single passages also allows statements to be made about the utility of single passage computations as a descriptor of compressor stall.

Criteria for Spike Initiated Rotating Stall

This paper presents an assessment of the performance of an embedded propulsion system in the presence of distortion associated with boundary layer ingestion. For fan pressure ratios of interest for civil transports, the benefits of boundary layer ingestion are shown to be very sensitive to the magnitude of fan and duct losses. The distortion transfer across the fan, basically the comparison of the stagnation pressure non-uniformity downstream of the fan to that upstream of the fan, has a major role in determining the impact of boundary layer ingestion on overall fuel burn. This, in turn, puts requirements on the fidelity with which one needs to assess the distortion transfer, and thus the type of models that need to be used in such assessment. For the three-dimensional distortions associated with fuselage boundary layers ingested into a subsonic diffusing inlet, it is found that boundary layer ingestion can provide decreases in fuel burn of several per cent. It is also shown that a promising avenue for mitigating the risks (aerodynamic as well as aeromechanical) in boundary layer ingestion is to mix out the flow before it reaches the engine face.

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Performance of a Boundary Layer Ingesting (BLI) propulsion system

The interaction between an initially laminar boundary layer developing spatially on a flat plate and wakes traversing the inlet periodically has been simulated numerically. The three-dimensional, time-dependent Navier–Stokes equations were solved with 5.24×107 grid points using a message passing interface on a scalable parallel computer. The flow bears a close resemblance to the transitional boundary layer on turbomachinery blades and was designed following, in outline, the experiments by Liu & Rodi (1991). The momentum thickness Reynolds number evolves from Reθ = 80 to 1120. Mean and second-order statistics downstream of Reθ = 800 are of canonical flat-plate turbulent boundary layers and are in good agreement with Spalart (1988).In many important aspects the mechanism leading to the inception of turbulence is in agreement with previous fundamental studies on boundary layer bypass transition, as summarized in Alfredsson & Matsubara (1996). Inlet wake disturbances inside the boundary layer evolve rapidly into longitudinal puffs during an initial receptivity phase. In the absence of strong forcing from free-stream vortices, these structures exhibit streamwise elongation with gradual decay in amplitude. Selective intensification of the puffs occurs when certain types of turbulent eddies from the free-stream wake interact with the boundary layer flow through a localized instability. Breakdown of the puffs into young turbulent spots is preceded by a wavy motion in the velocity field in the outer part of the boundary layer.Properties and streamwise evolution of the turbulent spots following breakdown, as well as the process of completion of transition to turbulence, are in agreement with previous engineering turbomachinery flow studies. The overall geometrical characteristics of the matured turbulent spot are in good agreement with those observed in the experiments of Zhong et al. (1998). When breakdown occurs in the outer layer, where local convection speed is large, as in the present case, the spots broaden downstream, having the vague appearance of an arrowhead pointing upstream.The flow has also been studied statistically. Phase-averaged velocity fields and skin-friction coefficients in the transitional region show similar features to previous cascade experiments. Selected results from additional thought experiments and simulations are also presented to illustrate the effects of streamwise pressure gradient and free-stream turbulence.

Simulation of boundary layer transition induced by periodically passing wakes

The effects of surface roughness on gas turbine performance are reviewed based on publications in the open literature over the past 60 years. Empirical roughness correlations routinely employed for drag and heat transfer estimates are summarized and found wanting. No single correlation appears to capture all of the relevant physics for both engineered and service-related (e.g., wear or environmentally induced) roughness. Roughness influences engine performance by causing earlier boundary layer transition, increased boundary layer momentum loss (i.e., thickness), and/or flow separation. Roughness effects in the compressor and turbine are dependent on Reynolds number, roughness size, and to a lesser extent Mach number. At low Re, roughness can eliminate laminar separation bubbles (thus reducing loss) while at high Re (when the boundary layer is already turbulent), roughness can thicken the boundary layer to the point of separation (thus increasing loss). In the turbine, roughness has the added effect of augmenting convective heat transfer. While this is desirable in an internal turbine coolant channel, it is clearly undesirable on the external turbine surface. Recent advances in roughness modeling for computational fluid dynamics are also reviewed. The conclusion remains that considerable research is yet necessary to fully understand the role of roughness in gas turbines.

A Review of Surface Roughness Effects in Gas Turbines

A major issue in surrogate model-based design optimization is the modeling fidelity. An effective approach is to employ multiple surrogates based on the same training data to offer approximations from alternative modeling viewpoints. This approach is employed in a compressor blade shape optimization using the NASA rotor 37 as the case study. The surrogate models considered include polynomial response surface approximation, Kriging, and radial basis neural network. In addition, a weighted average model based on global error measures is constructed. Sequential quadratic programming is used to search the optimal point based on these alternative surrogates. Three design variables characterizing the blade regarding sweep, lean, and skew are selected along with the three-level full factorial approach for design of experiment. The optimization is guided by three objectives aimed at maximizing the adiabatic efficiency, as well as the total pressure and total temperature ratios. The optimized compressor blades yield lower losses by moving the separation line toward the downstream direction. The optima for total pressure and total temperature ratios are similar, but the optimum for adiabatic efficiency is located far from them. It is found that the most accurate surrogate did not always lead to the best design. This demonstrated that using multiple surrogates can improve the robustness of the optimization at a minimal computational cost.

Multiple surrogate modeling for axial compressor blade shape optimization

Flow separations in the corner regions of blade passages are common. The separations are three dimensional and have quite different properties from the two-dimensional separations that are considered in elementary courses of fluid mechanics. In particular the consequences for the flow may be less severe than the two-dimensional separation. This paper describes the nature of three-dimensional separation and addresses the way in which topological rules, based on a linear treatment of the Navier-Stokes equations, can predict properties of the limiting streamlines, including the singularities which form. The paper shows measurements of the flow field in a linear cascade of compressor blades and compares these with the results of 3D CFD. For corners without tip clearance, the presence of three-dimensional separation appears to be universal and the challenge for the designer is to limit the loss and blockage produced. The CFD appears capable of predicting this.Copyright © 2004 by ASME

Three-Dimensional Separations in Axial Compressors

This paper presents a new methodology for quantifying compressor endwall blockage and an approach, using this quantification, for defining the links between design parameters, flow conditions, and the growth of blockage due to tip clearance flow. Numerical simulations, measurements in a low-speed compressor, and measurements in a wind tunnel designed to simulate a compressor clearance flow are used to assess the approach. The analysis thus developed allows predictions of endwall blockage associated with variations in tip clearance, blade stagger angle, inlet boundary layer thickness, loading level, loading profile, solidity, and clearance jet total pressure. The estimates provided by this simplified method capture the trends in blockage with changes in design parameters to within 10 percent. More importantly, however, the method provides physical insight into, and thus guidance for control of, the flow features and phenomena responsible for compressor endwall blockage generation.

Endwall Blockage in Axial Compressors

This paper describes the introduction of 3D blade designs into the core compressors for the Rolls-Royce Trent engine with particular emphasis on the use of sweep and dihedral in the rotor designs. It follows the development of the basic ideas in a university research project, through multistage low-speed model testing, to the application to high pressure engine compressors. An essential element of the project was the use of multistage CFD and some of the development of the method to allow the designs to take place is also discussed. The first part of the paper concentrates on the university-based research and the methods development. The second part describes additional low-speed multistage design and testing and the high-speed engine compressor design and test.Copyright © 2002 by ASME

The Use of Sweep and Dihedral in Multistage Axial Flow Compressor Blading—Part I: University Research and Methods Development

Averaging non-uniform flow is important for the analysis of measurements in turbomachinery and gas turbines; more recently an important need for averaging arises with results of CFD. In this paper we show that there is a method for averaging which is “correct”, in the sense of preserving the essential features of the non-uniform flow, but that the type of averaging which is appropriate depends on the application considered. The crucial feature is the decision to retain or conserve those quantities which are most important in the case considered. Examples are given to demonstrate the appropriate methods to average non-uniform flows in the accounting for turbomachinery blade row performance, production of thrust in a nozzle, and mass flow capacity in a choked turbine. It is also shown that the numerical differences for different types of averaging are, in many cases, remarkably small.Copyright © 2005 by ASME

Averaging Nonuniform Flow for a Purpose

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics, 2000.

Nicholas Cumpsty

Papers

Three-Dimensional Separations in Axial Compressors

Endwall Blockage in Axial Compressors

The Use of Sweep and Dihedral in Multistage Axial Flow Compressor Blading—Part I: University Research and Methods Development

Averaging Nonuniform Flow for a Purpose

Impeller–Diffuser Interaction in a Centrifugal Compressor