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.

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.

Design support for turbomachinery

From the steam turbines which provide most of our electricity to the jet engines which have shrunk our World, turbomachines undoubtedly play a major role in life today. Competition in the turbomachinery industry is fiercely strong [Wisler, 1998], hence good aerodynamic design is vital. However, with efficiency levels already close to their theoretical maxima, companies are increasingly looking to reduce costs and increase reliability through improved design practice. Computational Fluid Dynamics (CFD) can make a strong contribution to assisting this process as it has the potential to increase performance while reducing cost. The situation is, however, complicated by an ever decreasing number of engineers with sufficient design experience to reap the full benefits offered by CFD. With the large risks involved, novice designers of today are increasingly confined to refining old designs rather than gaining experience, like their forebears, through 'clean sheet' exercises. Hence it is desirable to capture the knowledge and experience of older designers, before it is lost, to assist the engineers of tomorrow. It is therefore the aim of this project to produce a design support tool which will not only store the appropriate CFD codes, but also provide a dynamic signpost (based on elicited knowledge and experience) to advise the engineer in their use. The signposting methodology developed for the aerospace industry [Clarkson and Hamilton, 1997] will provide the basic framework for the tool. This paper reviews current turbomachinery design practice (including an examination of the relevant CFD) in order to establish the important issues which a support tool must address. Current design support methodologies and their propriety are then reviewed, followed by a detailed description of the signposting concept. It then sets out a clear statement of the objectives for the research and the methods proposed to meet them. The paper concludes with a timetable of the work.

Landing gear for a 'silent' aircraft

The Silent Aircraft Initiative aims to provide a conceptual design for a large passenger aircraft whose noise would be imperceptible above the background level outside an urban airfield. Landing gear noise presents a significant challenge to such an aircraft. 1/10th scale models have been examined with the aim of establishing a lower noise limit for large aircraft landing gear. Additionally, the landing gear has been included in an integrated design concept for the 'Silent' Aircraft. This work demonstrates the capabilities of the closed-section Markham wind tunnel and the installed phased microphone arrays for aerodynamic and acoustic measurements. Interpretation of acoustic data has been enhanced by use of the CLEAN algorithm to quantify noise levels in a repeatable way and to eliminate side lobes which result from the microphone array geometry. Results suggest that highly simplified landing gears containing only the main struts offer a 12dBA reduction from modern gear noise. Noise treatment of simplified landing gear with fairings offers a further reduction which appears to be limited by noise from the lower parts of the wheels. The importance of fine details and surface discontinuities for low noise design are also underlined.

Articulated wooden blades for a horizontal-axis wind turbine. Design, construction and testing.

A pair of blades were constructed following a Tapered Chord, Zero Twist pattern after Anderson. The construction uses the Wood Epoxy Saturation Technique, with a solid Beech main spar and leading edge joined together with laminated veneers of beech forming a D-section; the trailing edge is formed from millimetre ply skins, foam filled to resist compressive loads. This construction leads to an extremely light, flexible blade, with the centres of gravity and torsion well forward, giving good stability. Each blade has three built-in strain gauges, alowing flapwise bending to be measured. Stiffness, and natural frequencies, were measured, to input to a numerical computer model to calculate blade deformation during operation, and to determine stability boundaries of the blade. Preliminary aerodynamic performance measurements are presented and close agreement is found with theory.

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.

The effect of an upstream turbine on a low-aspect ratio vane

The interaction between a high-pressure rotor and a downstream vane is dominated by vortex-blade interaction. Each rotor blade passing period two co-rotating vortex pairs, the tip-leakage and upper passage vortex and the lower passage and trailing shed vortex, impinge on, and are cut by, the vane leading edge. In addition to the streamwise vortex the tip-leakage flow also contains a large velocity deficit. This causes the interaction of the tip-leakage flow with a downstream vane to differ from typical vortex blade interaction. This paper investigates the effect these interaction mechanisms have on a downstream vane. The test geometry considered was a low aspect ratio second stage vane located within a S-shaped diffuser with large radius change mounted downstream of a shroudless high-pressure turbine stage. Experimental measurements were conducted at engine-representative Mach and Reynolds numbers, and data was acquired using a fast-response aerodynamic probe upstream and downstream of the vane. Time-resolved numerical simulations were undertaken with and without a rotor tip gap in order to investigate the relative magnitude of the interaction mechanisms. The presence of the upstream stage is shown to significantly change the structure of the secondary flow in the vane and to cause a small drop in its performance.

Heat transfer and aerodynamics of turbine blade tips in a linear cascade

Local measurements of the heat transfer coefficient and pressure coefficient were conducted on the tip and near tip region of a generic turbine blade in a five-blade linear cascade. Two tip clearance gaps were used: 1.6% and 2.8% chord. Data was obtained at a Reynolds number of 2.3 × 10 5 based on exit velocity and chord. Three different tip geometries were investigated: a flat (plain) tip, a suction-side squealer, and a cavity squealer. The experiments reveal that the flow through the plain gap is dominated by flow separation at the pressure-side edge and that the highest levels of heat transfer are located where the flow reattaches on the tip surface. High heat transfer is also measured at locations where the tip-leakage vortex has impinged onto the suction surface of the aerofoil. The experiments are supported by flow visualisation computed using the CFX CFD code which has provided insight into the fluid dynamics within the gap. The suction-side and cavity squealers are shown to reduce the heat transfer in the gap but high levels of heat transfer are associated with locations of impingement, identified using the flow visualisation and aerodynamic data. Film cooling is introduced on the plain tip at locations near the pressure-side edge within the separated region and a net heat flux reduction analysis is used to quantify the performance of the successful cooling design. copyright © 2005 by ASME.

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.

The low Reynolds number aerodynamics of leading edge flaps

Within the low Reynolds number regime at which birds and small air vehicles operate (Re=15,000-500,000), flow is beset with laminar separation bubbles and bubble burst which can lead to loss of lift and early onset of stall. Recent video footage of an eagle's wings in flight reveals an inconspicuous wing feature: the sudden deployment of a row of feathers from the lower surface of the wing to create a leading edge flap. An understanding of the aerodynamic function of this flap has been developed through a series of low speed wind tunnel tests performed on an Eppler E423 aerofoil. Experiments took place at Reynolds numbers ranging from 40000 to 140000 and angles of attack up to 30°. In the lower range of tested Reynolds numbers, application of the flap was found to substantially enhance aerofoil performance by augmenting the lift and limiting the drag at certain incidences. The leading edge flap was determined to act as a transition device at low Reynolds numbers, preventing the formation of separation bubbles and consequently decreasing the speed at which stall occurs during landing and manoeuvring.