Showing papers on "Tip clearance published in 2016"

Influence of tip clearance on pressure fluctuations in an axial flow pump

Abstract: Rotor-stator interaction in axial pumps can produce pressure fluctuations and further vibrations even damage to the pump system in some extreme case. In this paper, the influence of tip clearance on pressure fluctuations in an axial flow water pump has been investigated by numerical method. Three-dimensional unsteady flow in the axial flow water pump has been simulated with different tip clearances between the impeller blade tip and the casing wall. In addition to monitoring pressure fluctuations at some typical points, a new method based on pressure statistics was proposed to determine pressure fluctuations at all grid nodes inside the whole pump. The comparison shows that the existence of impeller tip clearance magnifies the pressure fluctuations in the impeller region, from the hub to shroud. However, the effect on pressure fluctuation in the diffuser region is not evident. Furthermore, the tip clearance vortex has also been examined under different tip clearances.

Sub-harmonic broadband humps and tip noise in low-speed ring fans

Abstract: A joint experimental and numerical study has been achieved on a low-speed axial ring fan in clean inflow. Experimental evidence shows large periodic broadband humps at lower frequencies than the blade passing frequencies and harmonics even at design conditions. These sub-harmonic humps are also found to be sensitive to the fan process and consequently to its tip geometry. Softer fans yield more intense humps more shifted to lower frequencies with respect to the fan harmonics. Unsteady turbulent flow simulations of this ring fan mounted on a test plenum have been achieved by four different methods that have been validated by comparing with overall performances and detailed hot-wire velocity measurements in the wake. Noise predictions are either obtained directly or are obtained through Ffowcs Williams and Hawkings' analogy, and compared with narrowband and third-octave power spectra. All unsteady simulations correctly capture the low flow rates, the coherent vortex dynamics in the tip clearance and consequently the noise radiation dominated by the tip noise in the low- to mid-frequency range. Yet, only the scale-adaptive simulation and the lattice Boltzmann method simulations which can describe most of the turbulent structures accurately provide the proper spectral shape and levels, and consequently the overall sound power level.

Effects of Double-Leakage Tip Clearance Flow on the Performance of a Compressor Stage With a Large Rotor Tip Gap

Abstract: Effects of a large rotor tip gap on the performance of a one and half stage axial compressor are investigated in detail with a numerical simulation based on LES and available PIV data. The current paper studies the main flow physics, including why and how the loss generation is increased with the large rotor tip gap. The present study reveals that when the tip gap becomes large, tip clearance fluid goes over the tip clearance core vortex and enters into the next blade's tip gap, which is called double-leakage tip clearance flow. As the tip clearance flow enters into the adjacent blade's tip gap, a vortex rope with a lower pressure core is generated. This vortex rope breaks up the tip clearance core vortex of the adjacent blade, resulting in a large additional mixing. This double-leakage tip clearance flow occurs at all operating conditions, from design flow to near stall condition, with the large tip gap for the current compressor stage. The double-leakage tip clearance flow, its interaction with the tip clearance core vortex of the adjacent blade, and the resulting large mixing loss are the main flow mechanism of the large rotor tip gap in the compressor. When the tip clearance is smaller, flow near the end wall follows more closely with the main passage flow and this double-leakage tip clearance flow does not happen near the design flow condition for the current compressor stage. When the compressor with a large tip gap operates at near stall operation, a strong vortex rope is generated near the leading edge due to the double-leakage flow. Part of this vortex separates from the path of the tip clearance core vortex and travels from the suction side of the blade toward the pressure side of the blade. This vortex is generated periodically at near stall operation with a large tip gap. As the vortex travels from the suction side to the pressure side of the blade, a large fluctuation of local pressure forces blade vibration. Nonsynchronous blade vibration occurs due to this vortex as the frequency of this vortex generation is not the same as the rotor. The present investigation confirms that this vortex is a part of separated tip clearance vortex, which is caused by the double-leakage tip clearance flow.

Tip-Clearance Measurement in the First Stage of the Compressor of an Aircraft Engine

Abstract: In this article, we report the design of a reflective intensity-modulated optical fiber sensor for blade tip-clearance measurement, and the experimental results for the first stage of a compressor of an aircraft engine operating in real conditions. The tests were performed in a ground test cell, where the engine completed four cycles from idling state to takeoff and back to idling state. During these tests, the rotational speed of the compressor ranged between 7000 and 15,600 rpm. The main component of the sensor is a tetrafurcated bundle of optical fibers, with which the resulting precision of the experimental measurements was 12 µm for a measurement range from 2 to 4 mm. To get this precision the effect of temperature on the optoelectronic components of the sensor was compensated by calibrating the sensor in a climate chamber. A custom-designed MATLAB program was employed to simulate the behavior of the sensor prior to its manufacture.

Zonal large-eddy simulation of a tip leakage flow

Abstract: The flow induced by the clearance between the tip of an isolated airfoil and an end-plate is investigated numerically, using a zonal approach with large-eddy simulation in the region of interest. The results are analyzed in comparison with available experimental data, presented in a companion paper. The incoming boundary layer and the pressure distribution around the blade are evaluated. The description of the inflow-jet deviation, with an averaged approach, enables to represent the proper loading on the airfoil. Also, particular attention is paid to the powerful tipleakage vortex. The vortex characteristics are investigated using specific functions to locate its center and quantify its width. Overall, good results are obtained for the flow statistics and spectra. Furthermore, a very good description of the far-field pressure is achieved using the acoustic analogy, and the results confirm that the tip-flow essentially radiates in the central frequency range (0.7 kHz, 7 kHz).

The Effects of Tip Leakage Flow on the Performance of Multistage Compressors Used in Small Core Engine Applications

Abstract: Large rotor tip clearances and the associated tip leakage flows are known to have a significant effect on overall compressor performance. However, detailed experimental data reflecting these effects for a multistage compressor are limited in the open literature. As design trends lead to increased overall compressor pressure ratio for thermal efficiency benefits and increased bypass ratios for propulsive benefits, the rear stages of the high-pressure compressor will become physically small. Because rotor tip clearances cannot scale exactly with blade size due to the margin needed for thermal growth considerations, relatively large tip clearances will be a reality for these rear stages. Experimental data have been collected from a three-stage axial compressor to assess performance with three-tip clearance heights representative of current and future small core machines. Trends of overall pressure rise, stall margin, and efficiency are evaluated using clearance derivatives, and the summarized data presented here begin to narrow the margin of tip clearance sensitivities outlined by previous studies in an effort to inform future compressor designs. Furthermore, interstage measurements show stage matching changes and highlight specific differences in the performance of rotor 1 and stator 2 compared to other blade rows in the machine.

Experimental characterization of tip leakage flow trajectories in a multistage compressor

Abstract: Fast-response pressure measurements collected in a three-stage axial compressor highlight the development of the rotor tip leakage flow. Data collected from an array of high-frequency-response pressure transducers measure time-resolved static pressure over the rotors at several loading conditions for three tip clearance heights. The influence of surrounding vane rows on the rotor tip leakage flow is investigated by adjusting the position of the vanes with respect to fixed sensor positions. One key result is that the wake from the upstream vane creates a modulation of the leakage flow. However, the upstream propagating potential field from the downstream vane row has no measureable impact on the leakage flow trajectory. In some cases, variations of the leakage flow trajectory angle due to these blade row interactions are greater than the differences due to a doubling of the rotor tip clearance height, an important finding not previously reported in the literature. Differences of the leakage flow trajectory...

Study on the performance of a centrifugal compressor considering running tip clearance

Abstract: A series of aero-thermo-mechanical analyses were carried out to predict the running tip clearance and the effects of impeller deformation on the performance using two different centrifugal compressors (blade type A and B). In operation, impeller deformation due to the combination of centrifugal force, aerodynamic pressure and thermal load results in non-uniform tip clearance profile. The results show that the maximum displacement occurs at the leading edge tip of the impeller blade but maximum stress takes place at the blade root of the impeller. A significant reduction of the tip clearance height has occurred at the leading edge and the trailing edge of the impeller. Due to the reduction of the tip clearance, the tip leakage flow has decreased by 19.4% and 16.2% in the blade type A and B, respectively. The polytropic efficiency of blade type A and B at operating condition has increased by 0.72% and 1.81%, respectively.

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

Abstract: Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.

Investigations of rotating instability and fluctuating tip clearance flow in a low-speed axial compressor:

Abstract: To investigate the relationship between rotating instability and fluctuating tip clearance flow, experimental tests as well as numerical studies are conducted on a 1.5 stage low-speed axial compressor rig. The rotating instability is detected through casing mounted dynamic pressure sensors. The phase-locked and root-mean-square pressure contours show that the interaction of tip clearance flow with the neighboring blade is the most likely cause of casing flow field fluctuation. From the calculated results of entire-annulus cascade, it is found that the tip clearance vortex structures oscillate periodically at low flow rate conditions. That leads to intense fluctuation of the casing flow field. Further, phase lag of pressure fluctuations exists between two neighboring passages, which induces a rotating pressure pattern of multiple frequencies. The frequency characteristics of this rotating pressure pattern caused by fluctuating tip clearance flow is coincident with the frequency of rotating instability. Thi...

Heat Transfer and Secondary Flow with a Multicavity Gas Turbine Blade Tip

Abstract: Multicavity gas turbine blade tips were formed by adding ribs in the blade tip cavities of squealer tips, and the effects of the tip clearance size, the number and the installation angle of the ribs on the tip heat transfer, and the blade passage total pressure loss were investigated experimentally. Tests were conducted in a low-speed linear cascade. The transient liquid crystal technique and a seven-hole probe were used to measure the heat transfer and flowfield, respectively. Results showed that a multicavity tip was able to reduce the total pressure loss coefficient, and the total pressure loss coefficients decreased as the number of ribs increased. Additional ribs on the tip cavity reduced the heat transfer coefficients on the cavity surface near the leading edge, but induced an additional high heat transfer coefficient region downstream from the rib due to the flow reattachment.

Method to improve the blade tip-timing accuracy of fiber bundle sensor under varying tip clearance

Abstract: Blade vibration measurement based on the blade tip-timing method has become an industry-standard procedure. Fiber bundle sensors are widely used for tip-timing measurement. However, the variation of clearance between the sensor and the blade will bring a tip-timing error to fiber bundle sensors due to the change in signal amplitude. This article presents methods based on software and hardware to reduce the error caused by the tip clearance change. The software method utilizes both the rising and falling edges of the tip-timing signal to determine the blade arrival time, and a calibration process suitable for asymmetric tip-timing signals is presented. The hardware method uses an automatic gain control circuit to stabilize the signal amplitude. Experiments are conducted and the results prove that both methods can effectively reduce the impact of tip clearance variation on the blade tip-timing and improve the accuracy of measurements.

Dynamic measurement system for blade tip clearance

Abstract: The invention discloses a dynamic measurement system for the blade tip clearance and relates to the technical field of engines. The dynamic measurement system for the blade tip clearance comprises a capacitive sensor and a capacitive sensor signal-processing structure. The capacitance sensor is arranged on the casing of an engine. The induction terminal of the capacitive sensor is lower than the inner surface of the casing of the engine. A to-be-measured blade tip clearance is formed between the inner surface of the casing of the engine and a blade tip. The rotor of the engine is in normal operation. The to-be-measured blade tip clearance is dynamically changing. The capacitive sensor transmits an induction signal to the capacitive sensor signal-processing structure. The capacitive sensor signal-processing structure is used for processing the signal transmitted from the capacitive sensor. The system is simple and compact in structure, and the measurement of the system is realized in the non-contact mode. Therefore, the interference of the system on the jet flow field of the engine is reduced. The requirement of the on-line dynamic measurement on the blade tip clearance of the engine can be met.

On the development of a magnetoresistive sensor for blade tip timing and blade tip clearance measurement systems.

Abstract: A simultaneous blade tip timing (BTT) and blade tip clearance (BTC) measurement system enables the determination of turbomachinery blade vibrations and ensures the monitoring of the existing running gaps between the blade tip and the casing. This contactless instrumentation presents several advantages compared to the well-known telemetry system with strain gauges, at the cost of a more complex data processing procedure. The probes used can be optical, capacitive, eddy current as well as microwaves, everyone with its dedicated electronics and many existing different signal processing algorithms. Every company working in this field has developed its own processing method and sensor technology. Hence, repeating the same test with different instrumentations, the answer is often different. Moreover, rarely it is possible to achieve reliability for in-service measurements. Developments are focused on innovative instrumentations and a common standard. This paper focuses on the results achieved using a novel magnetoresistive sensor for simultaneous tip timing and tip clearance measurements. The sensor measurement principle is described. The sensitivity to gap variation is investigated. In terms of measurement of vibrations, experimental investigations were performed at the Air Force Institute of Technology (ITWL, Warsaw, Poland) in a real aeroengine and in the von Karman Institute (VKI) R2 compressor rig. The advantages and limitations of the magnetoresistive probe for turbomachinery testing are highlighted.

Centrifugal compressor tip clearance and impeller flow

Abstract: Compressors consume a considerable portion of the electricity used in the industrial sector. Hence, improvements in compressor efficiency lead to energy savings and reduce environmental impacts. The efficiency of an unshrouded centrifugal compressor suffers from leakage flow over the blade tips. The effect of tip leakage flow on the passage flow differs between the full and splitter blade passages. In this study, the differences in the flow fields between the full and splitter blade passages were studied numerically in detail. An industrial high-speed compressor with a design pressure ratio of 1.78 was modelled. Numerical studies were conducted with six different tip clearances and three different diffuser widths. The results show that increasing tip clearance considerably increases the reversed flow into the impeller with an unpinched diffuser. The reversed flow then partly mixes into the flow in the same blade passage it entered the impeller and the rest migrates over the blade, mixing with the tip clearance flow. Furthermore, as the reversed and clearance flow mix into the wake, the wake is weakened. As pinch reduces both the reversed flow and clearance flow, the passage wakes are stronger with pinches. However, the pinch is beneficial as the losses at the impeller outlet decrease.

Analyzing the shape parameter effects on the performance of the mixed-flow fan using CFD & Factorial design

Abstract: Fans are representative turbo-machinery widely used for ventilation throughout the industrial world. Recently, as the importance of energy saving has been magnified with the fans, the demand for the fans with high efficiency and performance has been increasing. The representative method for enhancing the performance includes design optimization; in practice, fan performance can be improved by changing the shape parameters such as those of meridional plane, impeller, and diffuser. Before optimizing the efficient design, a process of screening to select important design parameters is essential. The present study aimed to analyze the effects of mixed-flow fans’ shape parameters on fan performance (static pressure and fan static efficiency) and derive optimum models based on the results. In this study, the shape parameters considered in the impeller domain are as follows: tip clearance, number of blades, beta angle of Leading edge (LE) in the blade, and beta angle of Trailing edge (TE) in the blade. The shape parameters considered in the diffuser domain are as follows: meridional length of the Guide vane (GV), number of GV, beta angle of LE in the GV and beta angle of TE in the GV. The effects of individual shape parameters were analyzed using the CFD (Computational fluid dynamic) and DOE (Design of experiments) methods. The reliability of CFD was verified through the comparison between preliminary fan model’s experiment results and CFD results, and screening processes were implemented through 24-1 fractional factorial design. From the analysis of DOE results, it could be seen that the tip clearance and the number of blades in the impeller domain greatly affected the fan performance, and the beta angle of TE at the GV in the diffuser domain greatly affected the fan performance. Finally, the optimum models with improved fan performance were created using linear regression equations derived from 24-1 fractional factorial design.

Tip clearance effects on loads and performances of semi-open impeller centrifugal pumps at different specific speeds

Abstract: Relevant industrial standards or customer's specifications could strictly forbid any device adjusting the axial rotor/stator position, so that tip clearance between semi-open impeller and casing might become a result of the pump machining tolerances and assembling process, leading to big tip clearance variations compared to its nominal value. Consequently, large disparities of global performances (head, power, efficiency) and axial loads are observed with high risk of both specifications noncompliance and bearing damages. This work aims at quantifying these variations by taking into account tip clearance value and pump specific speed. Computational Fluid Dynamics is used to investigate this phenomenon by means of steady simulations led on a semi-open centrifugal pump numerical model including secondary flows, based on a k-omega SST turbulence model. Four different specific speed pump sizes are simulated (from 8 to 50, SI units), with three tip clearances for each size on a wide flow range (from 40% to 120% of the best efficiency point). The numerical results clearly show that head, power and efficiency increase as the tip clearance decreases for the whole flow range. This effect is more significant when the specific speed is low. Meanwhile, the resulting axial thrust on the impeller is very sensitive to the tip clearance and can even lead to direction inversion.