Secondary flows and loss caused by blade row interaction in a turbine stage

A study of the three-dimensional stator-rotor interaction in a turbine stage is presented. Experimental data reveal vortices downstream of the rotor which are stationary in the absolute frame - indicating that they are caused by the stator exit flowfield. Evidence of the rotor hub passage vortices is seen, but additional vortical structures away from the endwalls, which would not be present if the rotor were tested in isolation, are also identified. An unsteady computation of the rotor row is performed using the measured stator exit flowfield as the inlet boundary condition. The strength and location of the vortices at rotor exit are predicted. A formation mechanism is proposed whereby stator wake fluid with steep spanwise gradients of absolute total pressure is responsible for all but one of the rotor exit vortices. This mechanism is then verified computationally using a passive-scalar tracking technique. The predicted loss generation through the rotor row is then presented and a comparison made with a steady calculation where the inlet flow has been mixed out to pitchwise uniformity. The loss produced in the steady simulation, even allowing for the mixing loss at inlet, is 10% less than that produced in the unsteady simulation. This difference highlights the importance of the time-accurate calculation as a tool of the turbomachine designer.

The prediction of hot streak migration in a high-pressure turbine

Accurate predictions of combustor hot streak migration enable the turbine designer to identify high-temperature regions that can limit component life. It is therefore important that these predictions are achieved within the short time scales of a design process. This article compares temperature measurements of a circular hot streak through a turning duct and a research turbine with predictions using a three-dimensional Reynolds-averaged Navier-Stokes solver. It was found that the mixing length turbulence model did not predict the hot streak dissipation accurately. However, implementation of a very simple model of the free stream turbulence (FST) significantly improved the exit temperature predictions on both the duct and research turbine. One advantage of the simple FST model described over more complex alternatives is that no additional equations are solved. This makes the method attractive for design purposes, as it is not associated with any increase in computational time.

Analysis of case histories on deep excavations in marine clay

Two case histories on deep excavation of marine clay are used to study the use of a decision-making tool based on a new deign method called the Mobilized Strength Design (MSD) method which allows the designer to use a simple method of predicting ground displacements during deep excavation. This application can approximately satisfy both safety and serviceability requirements by predicting stresses and displacements under working conditions by introducing the concept of "Mobilizable soil strength". The new method accommodates a number of features which are important to design of underground construction between retaining walls, including different deformation mechanism in different stages of excavation. The influence of wall depth, wall flexibility and stratified ground are the major focus of this paper. These developments should make it possible for a design engineer to take informed decisions on the influence of wall stiffness, or on the need for a jet-grouted base slab, for example, without having to conduct project-specific Finite Element Analysis.

Supporting excavations in clay - From analysis to decision-making

Finite Element Analysis (FEA) is used to calibrate a decision-making tool based on an extension of the Mobilized Strength Design (MSD) method which permits the designer an extremely simple method of predicting ground displacements during construction. This newly extended MSD approach accommodates a number of issues which are important in underground construction between in-situ walls, including: alternative base heave mechanisms suitable either for wide excavations in relatively shallow soft clay strata, or narrow excavations in relatively deep soft strata; the influence of support system stiffness in relation to the sequence of propping of the wall; and the capability of dealing with stratified ground. These developments should make it possible for a design engineer to take informed decisions on the relationship between prop spacing and ground movements, or the influence of wall stiffness, or on the need for and influence of a jet-grouted base slab, for example, without having to conduct project-specific FEA. © 2009 Taylor & Francis Group.

Tailored sustainability assessment for urban masterplanning

Tailored sustainability assessment represents one approach to addressing sustainability issues on large-scale urban projects with varying geographical, social and political constraints and diverse incentives among stakeholders. This paper examines the value and limitations of this approach. Three case studies of tailored systems developed by the authors for three unique masterplanning projects are discussed in terms of: contextual sustainability drivers; nature and evolution of systems developed; outcomes of implementation; and overall value delivered. Analysis Leads to conclusions on the key features of effective tailored assessment, the value of tailored sustainability assessment from various perspectives (including client, designer, end-users and the environment), and the limitations of tailored assessment as a tool for comparative analysis between projects. Although systems considered here are specific to individual projects and developed commercially, the challenges and lessons learned are relevant to a range of sustainability assessment approaches developed under different conditions.

RANS-URANS in axial compressor, a design methodology

Turbomachinery flows are inherently unsteady. Until now during the design process, unsteadiness has been neglected, with resort merely to steady numerical simulations. Despite the assumption involved, the results obtained with steady simulations have been used with success. One of the questions arising in recent years is can unsteady simulations be used to improve the design of turbomachines? In this work the numerical simulation of a multi-stage axial compressor is carried out. Comparison of Reynolds averaged Navier-Stokes (RANS) and unsteady Reynolds averaged Navier-Stokes (URANS) calculation shows that the unsteadiness affects pressure losses and the prediction of stall limit. The unsteady inflow due to the wake passing mainly modifies the losses and whirl angle near the endwalls. The computational cost of the fully unsteady compared with a steady simulation is about four times in terms of mesh dimension and two orders of magnitude as number of iterations. A mixed RANS-URANS solution has been proposed to give the designer the possibility to simulate an unsteady stage embedded in a steady-state simulation. This method has been applied to the simulation of a four-stage axial compressor rig. The mixed RANS-URANS approach has been developed using sliding and mixing planes as interface conditions. The rotor-stator interaction has been captured physically while reducing the computational time and mesh size.

Classification and choice in product design

Life is full of difficult choices. Everyone has their own way of dealing with these, some effective, some not. The problem is particularly acute in engineering design because of the vast amount of information designers have to process. This paper deals with a subset of this set of problems: the subset of selecting materials and processes, and their links to the design of products. Even these, though, present many of the generic problems of choice, and the challenges in creating tools to assist the designer in making them. The key elements are those of classification, of indexing, of reaching decisions using incomplete data in many different formats, and of devising effective strategies for selection. This final element - that of selection strategies - poses particular challenges. Product design, as an example, is an intricate blend of the technical and (for want of a better word) the aesthetic. To meet these needs, a tool that allows selection by analysis, by analogy, by association and simply by 'browsing' is necessary. An example of such a tool, its successes and remaining challenges, will be described.

Towards the development of an integrated design framework using the Blackboard model

Current research into the process of engineering design is extending the use of computers towards the acquisition, representation and application of design process knowledge in addition to the existing storage and manipulation of product-based models of design objects. This is a difficult task because the design of mechanical systems is a complex, often unpredictable process involving ill-structured problem solving skills and large amounts of knowledge, some which may be of an incomplete and subjective nature. Design problems require the integration of a variety of modes of working such as numerical, graphical, algorithmic or heuristic and demand products through synthesis, analysis and evaluation activities.

This report presents the results of a feasibility study into the blackboard approach and discusses the development of an initial prototype system that will enable an alphanumeric design dialogue between a designer and an expert to be analysed in a formal way, thus providing real-life protocol data on which to base the blackboard message structures.

Contact and channel modelling using part and function libraries in a function-based design approach

To support the development and analysis of engineering designs at the embodiment stage, designers work iteratively with representations of those designs as they consider the function and form of their constituent parts. Detailed descriptions of "what a machine does" usually include flows of forces and active principles within the technical system, and their localization within parts and across the interfaces between them. This means that a representation should assist a designer in considering form and function at the same time and at different levels of abstraction. This paper describes a design modelling approach that enables designers to break down a system architecture into its subsystems and parts, while assigning functions and flows to parts and the interfaces between them. In turn, this may reveal further requirements to fulfil functions in order to complete the design. The approach is implemented in a software tool which provides a uniform, computable language allowing the user to describe functions and flows as they are iteratively discovered, created and embodied. A database of parts allows the user to search for existing design solutions. The approach is illustrated through an example: modelling the complex mechanisms within a humanoid robot. Copyright © 2010 by ASME.

Strength mobilization in clays and silts

A large database of 115 triaxial, direct simple shear, and cyclic tests on 19 clays and silts is presented and analysed to develop an empirical framework for the prediction of the mobilization of the undrained shear strength, cu, of natural clays tested from an initially isotropic state of stress. The strain at half the peak undrained strength (γM=2) is used to normalize the shear strain data between mobilized strengths of 0.2cu and 0.8cu. A power law with an exponent of 0.6 is found to describe all the normalized data within a strain factor of 1.75 when a representative sample provides a value for γM=2. Multi-linear regression analysis shows that γM=2 is a function of cu, plasticity index Ip, and initial mean effective stress p′0. Of the 97 stress-strain curves for which cu, Ip, and p′0 were available, the observed values of γM=2 fell within a factor of three of the regression; this additional uncertainty should be acknowledged if a designer wished to limit immediate foundation settlements on the basis of an undrained strength profile and the plasticity index of the clay. The influence of stress history is also discussed. The application of these stress-strain relations to serviceability design calculations is portrayed through a worked example. The implications for geotechnical decision-making and codes of practice are considered.

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 (α), compound angle (β ), 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 α and β but with the same angle between the mainstream and coolant flow directions (angle κ). This relationship is assessed through experiments by testing two sets of cylindrical holes with different α and β : one set with κ = 35°, another set with κ = 60°. The data confirm the stated relationship between α, β, κ and the aerodynamic mixing loss. The results show that the designer should minimise κ to obtain the lowest loss, but maximise β to achieve the best heat transfer performance. A suggestion on improving the loss model is also given. Five different hole geometries (α =35.0°, β =0°) 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. Copyright © 2011 by ASME.

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.

Multi-objective shape optimisation for horizontal-axis wind turbine blades

We are developing a wind turbine blade optimisation package CoBOLDT (COmputa- tional Blade Optimisation and Load De ation Tool) for the optimisation of large horizontal- axis wind turbines. The core consists of the Multi-Objective Tabu Search (MOTS), which controls a spline parameterisation module, a fast geometry generation and a stationary Blade Element Momentum (BEM) code to optimise an initial wind turbine blade design. The objective functions we investigate are the Annual Energy Production (AEP) and the fl apwise blade root bending moment (MY0) for a stationary wind speed of 50 m/s. For this task we use nine parameters which define the blade chord, the blade twist (4 parameters each) and the blade radius. Throughout the optimisation a number of binary constraints are defined to limit the noise emission, to allow for transportation on land and to control the aerodynamic conditions during all phases of turbine operation. The test case shows that MOTS is capable to find enhanced designs very fast and eficiently and will provide a rich and well explored Pareto front for the designer to chose from. The optimised blade de- sign could improve the AEP of the initial blade by 5% with the same flapwise root bending moment or reduce MY0 by 7.5% with the original energy yield. Due to the fast runtime of order 10 seconds per design, a huge number of optimisation iterations is possible without the need for a large computing cluster. This also allows for increased design flexibility through the introduction of more parameters per blade function or parameterisation of the airfoils in future. © 2012 by Nordex Energy GmbH.

Multi-objective shape optimisation for horizontal-axis wind turbine blades

We are developing a wind turbine blade optimisation package CoBOLDT (COmputa- tional Blade Optimisation and Load Deation Tool) for the optimisation of large horizontal- axis wind turbines. The core consists of the Multi-Objective Tabu Search (MOTS), which controls a spline parameterisation module, a fast geometry generation and a stationary Blade Element Momentum (BEM) code to optimise an initial wind turbine blade design. The objective functions we investigate are the Annual Energy Production (AEP) and the apwise blade root bending moment (MY0) for a stationary wind speed of 50 m/s. For this task we use nine parameters which define the blade chord, the blade twist (4 parameters each) and the blade radius. Throughout the optimisation a number of binary constraints are defined to limit the noise emission, to allow for transportation on land and to control the aerodynamic conditions during all phases of turbine operation. The test case shows that MOTS is capable to find enhanced designs very fast and efficiently and will provide a rich and well explored Pareto front for the designer to chose from. The optimised blade de- sign could improve the AEP of the initial blade by 5% with the same apwise root bending moment or reduce MY0 by 7.5% with the original energy yield. Due to the fast runtime of order 10 seconds per design, a huge number of optimisation iterations is possible without the need for a large computing cluster. This also allows for increased design flexibility through the introduction of more parameters per blade function or parameterisation of the airfoils in future. © 2012 AIAA.