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.

Wave propagation in a slowly-varying duct with mean vortical swirling flow

The propagation of unsteady disturbances in a slowlyvarying cylindrical duct carrying mean swirling flow is investigated using a multiple-scales technique. This is applicable to turbomachinery flow behind a rotor stage when the swirl and axial velocities are of the same order. The presence of mean vorticity couples acoustic and vorticity equations which produces an eigenvalue problem that is not self-adjoint unlike that for irrotational mean flow. In order to determine the amplitude variation along the duct, an adjoint solution for the coupled system of equations is derived. The solution breaks down where a mode changes from cut on to cut off. In this region the amplitude is governed by a form of Airy's equation, and the effect of swirl is to introduce a small shift in the origin of the Airy function away from the turning-point location. The variation of axial wavenumber and amplitude along the duct is calculated. In hard-walled ducts mean swirl is shown to produce much larger amplitude variation along the duct compared with a nonswirling flow. Mean swirl also has a large effect in ducts with finite-impedance walls which differs depending on whether modes are co-rotating with the swirl or counter rotating. © 2001 by A.J. Cooper, Published by the American Institute of Aeronautics and Astronautics, Inc.

Development of a turning mid turbine frame with embedded design-part II: Unsteady measurements

© 2014 by ASME. This paper, the second of two parts, presents a new setup for the two-stage two-spool facility located at the Institute for Thermal Turbomachinery and Machine Dynamics (ITTM) of Graz University of Technology. The rig was designed to reproduce the flow behavior of a transonic turbine followed by a counter-rotating low pressure stage such as those in high bypass aero-engines. The meridional flow path of the machine is characterized by a diffusing S-shaped duct between the two rotors. The role of wide chord vanes placed into the mid turbine frame is to lead the flow towards the low pressure (LP) rotor with appropriate swirl. Experimental and numerical investigations performed on this setup showed that the wide chord struts induce large wakes and extended secondary flows at the LP inlet flow. Moreover, large deterministic fluctuations of pressure, which may cause noise and blade vibrations, were observed downstream of the LP rotor. In order to minimize secondary vortices and to damp the unsteady interactions, the mid turbine frame was redesigned to locate two zero-lift splitters into each vane passage. While in the first part of the paper the design process of the splitters and the time-averaged flow field were presented, in this second part the measurements performed by means of a fast response probe will support the explanation of the time-resolved field. The discussion will focus on the comparison between the baseline case (without splitters) and the embedded design.

Development of a turning mid turbine frame with embedded design-part I: Design and steady measurements

© 2014 by ASME. The paper presents a new setup for the two-stage two-spool facility located at the Institute for Thermal Turbomachinery and Machine Dynamics (ITTM) of Graz University of Technology. The rig was designed in order to simulate the flow behavior of a transonic turbine followed by a counter-rotating low pressure (LP) stage like the spools of a modern high bypass aeroengine. The meridional flow path of the machine is characterized by a diffusing S-shaped duct between the two rotors. The role of turning struts placed into the mid turbine frame is to lead the flow towards the LP rotor with appropriate swirl. Experimental and numerical investigations performed on the setup over the last years, which were used as baseline for this paper, showed that wide chord vanes induce large wakes and extended secondary flows at the LP rotor inlet flow. Moreover, unsteady interactions between the two turbines were observed downstream of the LP rotor. In order to increase the uniformity and to decrease the unsteady content of the flow at the inlet of the LP rotor, the mid turbine frame was redesigned with two zero-lifting splitters embedded into the strut passage. In this first part of the paper the design process of the splitters and its critical points are presented, while the time-averaged field is discussed by means of five-hole probe measurements and oil flow visualizations. The comparison between the baseline case and the embedded design configuration shows that the new design is able to reduce the flow gradients downstream of the turning struts, providing a more suitable inlet condition for the low pressure rotor. The improvement in the flow field uniformity is also observed downstream of the turbine and it is, consequently, reflected in an enhancement of the LP turbine performance. In the second part of this paper the influence of the embedded design on the time-resolved field is investigated.

Sound transmission in strongly-curved slowly-varying cylindrical and annular lined ducts with flow

In this paper we consider the propagation of acoustic waves along a curved hollow or annular duct with lined walls. The curvature of the duct centreline and the wall radii vary slowly along the duct, allowing application of an asymptotic multiple scales analysis. This generalises Rienstra's analysis of a straight duct of varying cross-sectional radius. The result of the analysis is that the modal wavenumbers and mode shapes are determined locally as modes of a torus with the same local curvature, while the amplitude of the modes evolves as the mode propagates along the duct. The duct modes are found numerically at each axial location using a pseudo-spectral method. Unlike the case of a straight duct, there is a fundamental asymmetry between upstream and downstream propagating modes, with some mode shapes tending to be concentrated on either the inside or outside of the bend depending on the direction of propagation. The interaction between the presence of wall lining and curvature is investigated in particular; for instance, in a representative case it is found that the curvature causes the first few acoustic modes to be more heavily damped by the duct boundary than would be expected for a straight duct. Analytical progress can be made in the limit of very high mode order, in which case well-known 'whispering gallery' modes, localised close to the wall, can be identified.

Analytically-based approach to rotor-stator interaction noise in mean swirling flow

A method for modelling and predicting the noise generated by the interaction between the unsteady wake shed from the rotor and a downstream row of stators in a modern ultra-high bypass ducted turbofan engine is described. An analytically-based model is developed to account for three main features of the problem. First, the way in which a typical unsteady wake disturbance from the rotor interacts and is distorted by the mean swirling flow as it propagates downstream. The analysis allows for the inclusion of mean entropy gradients and entropy perturbations. Second, the effects of real stator-blade geometry and proper representation of the genuinely three-dimensional nature of the problem. Third, to model the propagation of the resulting noise back upstream in mean swirling flow. The analytical nature of the problem allows for the inclusion of all wake harmonics and enables the response at all blade passing frequencies to be determined. Example results are presented for an initial wake distribution corresponding to a genuine rotor configuration. Comparisons between numerical data and the asymptotic model for the wake evolution are made. Copyright © 2004 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Generation and scattering of sound in vortical flow

We present solutions to scattering problems for unsteady disturbances to a mean swirling flow in an annular duct with a rigid 'splitter'. This situation has application to rotor-stator interaction noise in aeroengines, where the flow downstream of the fan is swirling and bifurcates into the by-pass duct and the engine core. We also consider the trailing edge extension of this problem. Inviscid mean flow in a cylindrical annulus is considered, with both axial and swirling (azimuthal) velocity components. The presence of vorticity in the mean flow couples the acoustic and vorticity modes of irrotational flow. Instead we have one combined spectrum of acoustic-vorticity waves in which the 'sonic' and 'nearly-convected' modes are fully coupled. In addition to the aeroacoustics application the results offer insight into the behaviour of these acoustic-vorticity waves, and the precise nature of the coupling between the two types of mode. Two regimes are discussed in which progress has been made, one for a specialised mean flow, uniform axial flow and rigid body swirl, and a second regime in which the frequency is assumed large, valid for any axisymmetric mean flow. The Wiener-Hopf technique is used to solve the scattering problems mathematically, and we present numerical evaluations of these solutions. Several new effects are seen to arise due to the mean vorticity, in particular the generation of sound at a trailing edge due to the scattering of a nearly convected disturbance, in contrast to the way a convected gust silently passes a trailing edge in uniform mean flow.

Wake, shock and potential field interactions in a 1.5 stage turbine: Part I: Vane-rotor and rotor-vane interaction

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighboring blade rows was studied, with the individual effects of wake, shock and potential field interaction being determined. Two test geometries were considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were carried out at engine-representative Mach and Reynolds numbers. By comparing the results to time-resolved computational predictions of the flowfield, the accuracy with which the computation predicts blade interaction was determined. It was found that in addition to upstream vane-rotor and rotor-downstream vane interactions, a new interaction mechanism was found resulting from the interaction between the downstream vane's potential field and the upstream vane's trailing edge potential field and shock.

Wake, shock and potential field interactions in a 1.5 stage turbine: Part II: Vane-vane interaction and discussion of results

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighboring blade rows was studied, with the individual effects of wake, shock and potential field interaction being determined. Two test geometries were considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were carried out at engine-representative Mach and Reynolds numbers. By comparing the results to time-resolved computational predictions of the flowfield, the accuracy with which the computation predicts blade interaction was determined. Evidence was obtained that for a large downstream vane, the flow conditions in the rotor passage, at any instant in time, are close to being steady state.

Intermittency transport modeling of separated flow transition

An intermittency transport model is proposed for modeling separated-flow transition. The model is based on earlier work on prediction of attached flow bypass transition and is applied for the first time to model transition in a separation bubble at various degrees of free-stream turbulence. The model has been developed so that it takes into account the entrainment of the surrounding fluid. Experimental investigations suggest that it is this phenomena which ultimately determines the extent of the separation bubble. Transition onset is determined via a boundary layer correlation based on momentum thickness at the point of separation. The intermittent flow characteristic of the transition process is modeled via an intermittency transport equation. This accounts for both normal and streamwise variation of intermittency and hence models the entrainment of surrounding flow in a more accurate manner than alternative prescribed intermittency models. The model has been validated against the well established T3L semicircular leading edge flat plate test case for three different degrees of free-stream turbulence characteristic of turbomachinery blade applications.

The development of turbine exit flow in a swan-necked inter-stage diffuser

This paper describes both the migration and dissipation of flow phenomena downstream of a transonic high-pressure turbine stage. The geometry of the HP stage exit duct considered is a swan-necked diffuser similar to those likely to be used in future engine designs. The paper contains results both from an experimental programme in a turbine test facility and from numerical predictions. Experimental data was acquired using three fast-response aerodynamic probes capable of measuring Mach number, whirl angle, pitch angle, total pressure and static pressure. The probes were used to make time-resolved area traverses at two axial locations downstream of the rotor trailing edge. A 3D time-unsteady viscous Navier-Stokes solver was used for the numerical predictions. The unsteady exit flow from a turbine stage is formed from rotordependent phenomena (such as the rotor wake, the rotor trailing edge recompression shock, the tip-leakage flow and the hub secondary flow) and vane-rotor interaction dependant phenomena. This paper describes the time-resolved behaviour and three-dimensional migration paths of both of these phenomena as they convect downstream. It is shown that the inlet flow to a downstream vane is dominated by two corotating vortices, the first caused by the rotor tip-leakage flow and the second by the rotor hub secondary flow. At the inlet plane of the downstream vane the wake is extremely weak and the radial pressure gradient is shown to have caused the majority of the high loss wake fluid to be located between the mid-height of the passage and the casing wall. The structure of the flow indicates that between a high pressure stage and a downstream vane simple two-dimensional blade row interaction does not occur. The results presented in this paper indicate that the presence of an upstream stage is likely to significantly alter the structure of the secondary flow within a downstream vane. The paper also shows that vane-rotor interaction within the upstream stage causes a 10° circumferential variation in the inlet flow angle of the 2nd stage vane.

Deposition of small particles from turbulent flows

This paper deals with particle deposition onto solid walls from turbulent flows. The aim of the study is to model particle deposition in industrial flows, such as the one in gas turbines. The numerical study has been carried out with a two fluid approach. The possible contribution to the deposition from Brownian diffusion, turbulent diffusion and shear-induced lift force are considered in the study. Three types of turbulent two-phase flows have been studied: turbulent channel flow, turbulent flow in a bent duct and turbulent flow in a turbine blade cascade. In the turbulent channel flow case, the numerical results from a two-dimensional code show good agreement with numerical and experimental results from other resources. Deposition problem in a bent duct flow is introduced to study the effect of curvature. Finally, the deposition of small particles on a cascade of turbine blades is simulated. The results show that the current two fluid models are capable of predicting particle deposition rates in complex industrial flows.

Movement of deposited water on turbomachinery rotor blade surfaces

A theoretical approach for calculating the movement of liquid water following deposition onto a turbomachine rotor blade is described. Such a situation can occur during operation of an aero-engine in rain. The equation of motion of the deposited water is developed on an arbitrarily oriented plane triangular surface facet. By dividing the blade surface into a large number of facets and calculating the water trajectory over each one crossed in turn, the overall trajectory can be constructed. Apart from the centrifugal and Coriolis inertia effects, the forces acting on the water arise from the blade surface friction, and the aerodynamic shear and pressure gradient. Non- dimensionalisation of the equations of motion provides considerable insight and a detailed study of water flow on a flat rotating plate set at different stagger angles demonstrates the paramount importance of blade surface friction. The extreme cases of low and high blade friction are examined and it is concluded that the latter (which allows considerable mathematical generalisation) is the most likely in practice. It is also shown that the aerodynamic shear force, but not the pressure force, may influence the water motion. Calculations of water movement on a low-speed compressor blade and the fan blade of a high bypass ratio aero-engine suggest that in low rotational speed situations most of the deposited water is centrifuged rapidly to the blade tip region. Copyright © 2006 by ASME.

Performance of a Boundary Layer Ingesting (BLI) propulsion system

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.

An experimental study of unsteady separated shock wave boundary layer interactions

An experimental investigation of the unsteady interaction between a turbulent boundary layer and a normal shock wave of strength M∞ = 1.4 subject to periodic forcing in a parallel walled duct has been conducted. Emphasis has been placed on the mechanism by which changes in the global flow field influence the local interaction structure. Static pressure measurements and high speed Schlieren images of the unsteady interaction have been obtained. The pressure rise across the interaction and the appearance of the local SBLI structure have been observed to vary during the cycle of periodic shock wave motion. The magnitude of the pressure rise across the interaction is found to be related to the relative Mach number of the unsteady shock wave as it undergoes periodic motion. Variations in the upstream Influence of the interaction are sensitive to the magnitude and direction of shock wave velocity and acceleration and it is proposed that a viscous lag exists between the point of boundary layer separation and the shock wave position. Further work exploring the implications of these findings is proposed, including studies of the variation in position of the points of boundary layer separation and reattachment.