An approach to multi-fidelity optimization of aeroengine compression systems

The aerodynamic design of turbomachinery presents the design optimisation community with a number of exquisite challenges. Chief among these are the size of the design space and the extent of discontinuity therein. This discontinuity can serve to limit the full exploitation of high-fidelity computational fluid dynamics (CFD): such codes require detailed geometric information often available only sometime after the basic configuration of the machine has been set by other means. The premise of this paper is that it should be possible to produce higher performing designs in less time by exploiting multi-fidelity techniques to effectively harness CFD earlier in the design process, specifically by facilitating its participation in configuration selection. The adopted strategy of local multi-fidelity correction, generated on demand, combined with a global search algorithm via an adaptive trust region is first tested on a modest, smooth external aerodynamic problem. Speed-up of an order of magnitude is demonstrated, comparable to established techniques applied to smooth problems. A number of enhancements aimed principally at effectively evaluating a wide range of configurations quickly is then applied to the basic strategy, and the emerging technique is tested on a generic aeroengine core compression system. A similar order of magnitude speed-up is achieved on this relatively large and highly discontinuous problem. A five-fold increase in the number of configurations assessed with CFD is observed. As the technique places constraints neither on the underlying physical modelling of the constituent analysis codes nor on first-order agreement between those codes, it has potential applicability to a range of multidisciplinary design challenges. © 2012 by Jerome Jarrett and Tiziano Ghisu.

Parallel coordinates in computational engineering design

Modern Engineering Design involves the deployment of many computational tools. Re- search on challenging real-world design problems is focused on developing improvements for the engineering design process through the integration and application of advanced com- putational search/optimization and analysis tools. Successful application of these methods generates vast quantities of data on potential optimum designs. To gain maximum value from the optimization process, designers need to visualise and interpret this information leading to better understanding of the complex and multimodal relations between param- eters, objectives and decision-making of multiple and strongly conflicting criteria. Initial work by the authors has identified that the Parallel Coordinates interactive visualisation method has considerable potential in this regard. This methodology involves significant levels of user-interaction, making the engineering designer central to the process, rather than the passive recipient of a deluge of pre-formatted information. In the present work we have applied and demonstrated this methodology in two differ- ent aerodynamic turbomachinery design cases; a detailed 3D shape design for compressor blades, and a preliminary mean-line design for the whole compressor core. The first case comprises 26 design parameters for the parameterisation of the blade geometry, and we analysed the data produced from a three-objective optimization study, thus describing a design space with 29 dimensions. The latter case comprises 45 design parameters and two objective functions, hence developing a design space with 47 dimensions. In both cases the dimensionality can be managed quite easily in Parallel Coordinates space, and most importantly, we are able to identify interesting and crucial aspects of the relationships between the design parameters and optimum level of the objective functions under con- sideration. These findings guide the human designer to find answers to questions that could not even be addressed before. In this way, understanding the design leads to more intelligent decision-making and design space exploration. © 2012 AIAA.

Computational engineering design for micro-scale combustors

At present, optimisation is an enabling technology in innovation. Multi-objective and multi-disciplinary design tools are essential in the engineering design process, and have been applied successfully in aerospace and turbomachinery applications extensively. These approaches give insight into the design space and identify the trade-offs between the competing performance measures satisfying a number of constraints at the same time. It is anticipated here that the same benefits can be obtained for the design of micro-scale combustors. In this paper, a multi-disciplinary automated design optimisation system was developed for this purpose, which comprises a commercial computational fluid dynamics package and a multi-objective variant of the Tabu Search optimisation algorithm. The main objectives that are considered in this study are to optimise the main micro-scale combustor design characteristics and to satisfy manufacturability considerations from the very beginning of the whole design operation. Hydrogen-air combustion as well as 14 geometrical and 2 operational parameters are used to describe and model the design problem. Two illustrative test cases will be presented, in which the most important device operational requirements are optimised, and the efficiency of the developed optimisation system is demonstrated. The identification, assessment and suitability of the optimum design configurations are discussed in detail. Copyright © 2012 by ASME.

The acoustic analogy in an annular duct with swirling mean flow

This paper is concerned with modelling the effects of swirling flow on turbomachinery noise. We develop an acoustic analogy to predict sound generation in a swirling and sheared base flow in an annular duct, including the presence of moving solid surfaces to account for blade rows. In so doing we have extended a number of classical earlier results, including Ffowcs Williams & Hawkings' equation in a medium at rest with moving surfaces, and Lilley's equation for a sheared but non-swirling jet. By rearranging the Navier-Stokes equations we find a single equation, in the form of a sixth-order differential operator acting on the fluctuating pressure field on the left-hand side and a series of volume and surface source terms on the right-hand side; the form of these source terms depends strongly on the presence of swirl and radial shear. The integral form of this equation is then derived, using the Green's function tailored to the base flow in the (rigid) duct. As is often the case in duct acoustics, it is then convenient to move into temporal, axial and azimuthal Fourier space, where the Green's function is computed numerically. This formulation can then be applied to a number of turbomachinery noise sources. For definiteness here we consider the noise produced downstream when a steady distortion flow is incident on the fan from upstream, and compare our results with those obtained using a simplistic but commonly used Doppler correction method. We show that in all but the simplest case the full inclusion of swirl within an acoustic analogy, as described in this paper, is required. © 2013 Cambridge University Press.

Models for acoustic propagation through turbofan exhaust flows

Turbomachinery noise radiating into the rearward arc is an important problem. This noise is scattered by the trailing edges of the nacelle and the jet exhaust, and interacts with the shear layers between the external flow, bypass stream and jet, en route to the far field. In the past a range of relevant model problems involving semi-infinite cylinders have been solved. However, one limitation of previous solutions is that they do not allow for the jet nozzle to protrude a finite distance beyond the end of the nacelle (or in certain configurations being buried a finite distance upstream). In this paper we use the matrix Wiener-Hopf technique, which will allow precisely the finite nacelle-jet nozzle separation to be included. The crucial step in our work is to factorise a certain matrix as a product of terms analytic and invertible in the upper/lower halves of the complex plane. The way we do this matrix factorisation is quite different in the buried and protruding nozzle cases. In the buried case our solution method is the so-called pole-removal technique. In the technically more demanding protruding case, however, we must first use Pade approximants to generate a uniformly-valid, meromorphic representation of a certain function, before the same pole-removal method can be applied. Sample results are presented, investigating in particular the effects of exit plane stagger. © 2007 by B Veitch and N Peake.

Aerodynamic design of high end wall angle turbine stages-part I: Methodology development

A design methodology is presented for turbines in an annulus with high end wall angles. Such stages occur where large radial offsets between the stage inlet and stage outlet are required, for example in the first stage of modern low pressure turbines, and are becoming more prevalent as bypass ratios increase. The turbine vanes operate within s-shaped ducts which result in meridional curvature being of a similar magnitude to the bladeto-blade curvature. Through a systematic series of idealized computational cases, the importance of two aspects of vane design are shown. First, the region of peak end wall meridional curvature is best located within the vane row. Second, the vane should be leant so as to minimize spanwise variations in surface pressure-this condition is termed "ideal lean." This design philosophy is applied to the first stage of a low pressure turbine with high end wall angles. © 2014 by ASME.

Improving intermediate pressure turbine performance by using a nonorthogonal stator

Intermediate pressure (IP) turbines in high bypass ratio civil aeroengines are characterized by a significant increase in radius and a low aspect ratio stator. Conventional aerodynamic designs for the IP turbine stator have had leading and trailing edges orthogonal to the hub and casing end walls. The IP turbine rotor, however, is stacked radially due to stress limits. These choices inevitably lead to a substantial gap between the IP stator and rotor at the outer diameter in a duct that is generally diffusing the flow due to the increasing radius. In this low Mach number study, the IP stator is redesigned, incorporating compound sweep so that the leading and trailing edges are no longer orthogonal to the end walls. Computational investigations showed that the nonorthogonal stator reduces the flow diffusion between the stator and rotor, which yields two benefits: The stator trailing edge velocity was reduced, as was the boundary layer growth on the casing end wall within the gap. Experimental measurements confirm that the turbine with the nonorthogonal stator has an increased efficiency by 0.49%, while also increasing the work output by 4.6%, at the design point. © 2014 by ASME.

Aerodynamic design of high end wall angle turbine stages- part II: Experimental verification

An experimental investigation of a turbine stage featuring very high end wall angles is presented. The initial turbine design did not achieve a satisfactory performance and the difference between the design predictions and the test results was traced to a large separated region on the rear suction-surface. To improve the agreement between computational fluid dynamics (CFD) and experiment, it was found necessary to modify the turbulence modeling employed. The modified CFD code was then used to redesign the vane, and the changes made are described. When tested, the performance of the redesigned vane was found to have much closer agreement with the predictions than the initial vane. Finally, the flowfield and performance of the redesigned stage are compared to a similar turbine, designed to perform the same duty, which lies in an annulus of moderate end wall angles. A reduction in stage efficiency of at least 2.4% was estimated for the very high end wall angle design. © 2014 by ASME.

Influence of film cooling hole angles and geometries on aerodynamic loss and net heat flux reduction

Turbine design engineers have to ensure that film cooling can provide sufficient protection to turbine blades from the hot mainstream gas, while keeping the losses low. Film cooling hole design parameters include inclination angle (a), compound angle (b), hole inlet geometry, and hole exit geometry. The influence of these parameters on aerodynamic loss and net heat flux reduction is investigated, with loss being the primary focus. Low-speed flat plate experiments have been conducted at momentum flux ratios of IR=0.16, 0.64, and 1.44. The film cooling aerodynamic mixing loss, generated by the mixing of mainstream and coolant, can be quantified using a three-dimensional analytical model that has been previously reported by the authors. The model suggests that for the same flow conditions, the aerodynamic mixing loss is the same for holes with different a and b but with the same angle between the mainstream and coolant flow directions (angle k). This relationship is assessed through experiments by testing two sets of cylindrical holes with different a and b: one set with k=35 deg, and another set with k=60 deg. The data confirm the stated relationship between α, β, k and the aerodynamic mixing loss. The results show that the designer should minimize k to obtain the lowest loss, but maximize b to achieve the best heat transfer performance. A suggestion on improving the loss model is also given. Five different hole geometries (α=35.0 deg, β=0 deg) were also tested: cylindrical hole, trenched hole, fan-shaped hole, D-Fan, and SD-Fan. The D-Fan and the SD-Fan have similar hole exits to the fan-shaped hole but their hole inlets are laterally expanded. The external mixing loss and the loss generated inside the hole are compared. It was found that the D-Fan and the SD-Fan have the lowest loss. This is attributed to their laterally expanded hole inlets, which lead to significant reduction in the loss generated inside the holes. As a result, the loss of these geometries is≈50% of the loss of the fan-shaped hole at IR=0.64 and 1.44. © 2013 by ASME.

The effect of clearance on shrouded and unshrouded turbines at two levels of reaction

In this paper, the effect of seal clearance on the efficiency of a turbine with a shrouded rotor is compared with the effect of the tip clearance when the same turbine has an unshrouded rotor. The shrouded versus unshrouded comparison was undertaken for two turbine stage designs one having 50% reaction, the other having 24% reaction. Measurements for a range of clearances, including very small clearances, showed three important phenomena. Firstly, as the clearance is reduced, there is a "break-even clearance" at which both the shrouded turbine and the unshrouded turbine have the same efficiency. If the clearance is reduced further, the unshrouded turbine performs better than the shrouded turbine, with the difference at zero clearance termed the "offset loss." This is contrary to the traditional assumption that both shrouded and unshrouded turbines have the same efficiency at zero clearance. The physics of the break-even clearance and the offset loss are discussed. Secondly, the use of a lower reaction had the effect of reducing the tip leakage efficiency penalty for both the shrouded and the unshrouded turbines. In order to understand the effect of reaction on the tip leakage, an analytical model was used and it was found that the tip leakage efficiency penalty should be understood as the dissipated kinetic energy rather than either the tip leakage mass flow rate or the tip leakage loss coefficient. Thirdly, it was also observed that, at a fixed flow coefficient, the fractional change in the output power with clearance was approximately twice the fractional change in efficiency with clearance. This was explained by using an analytical model. © 2014 by ASME.