Abrasive wear of steel during rolling-sliding contact with rock counterfaces

In many mining operations (e.g. excavation, drilling, tunnelling, rock crushing) metallic components are forced against abrasive rocks in a complex motion. This study examines the relative importance of combined rolling and sliding motion in the two-body abrasive wear of a low carbon tempered martensitic steel against rock counterfaces. A novel wear test rig has been used to vary the amount of rolling and sliding motion between a rotating steel cylinder and a counter-rotating sandstone (highly abrasive) or limestone (much less abrasive) disc. Weight-loss measurements reveal that the wear rate of the steel increases as the amount of motion against the rock counterface is reduced from pure sliding to approximately 50% sliding (and approximately 50% rolling). Scanning electron microscopy shows that when the amount of motion is reduced from pure sliding to approximately 50% sliding the topographical and sub-surface physical properties of the worn steel and rock surfaces are modified.

Stall inception in axial compressors

Detailed measurements have been made of the transient stalling process in an axial compressor stage. The stage is of high hub-casing ratio and stall is initiated in the rotor. If the rotor tip clearance is small stall inception occurs at the hub, but at clearances typical for a multistage compressor the inception is at the tip. The crucial quantity in both cases is the blockage caused by the endwall boundary layer. Prior to stall, disturbances rotate around the inlet flow in sympathy with rotating variations in the endwall blockage.

Three-dimensional interactions in the rotor of an axial turbine

This article presents a study of the development of the three-dimensional flowfield within the rotor blades of a low-speed, large-scale axial flow turbine. Measurements have been performed in the rotating and stationary frames of reference. Time-mean data have been obtained using miniature five-hole pneumatic probes, whereas the unsteady development of the flow has been determined using three-axis subminiature hot-wire anemometers. Additional information is provided by the results of blade-surface flow-visualization experiments and surface-mounted hot-film anemometers. The development of the stator exit flow, as it passes through the rotor blades, is described. Unsteady data suggest that the presence of the rotor secondary and tip leakage flows restricts the region of unsteady interaction to near midspan when the stator wakes and secondary flows are adjacent to the suction surface. Surface-mounted hot-film data show that this affects the suction-side laminar-turbulent transition process.

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.

Vortex Transport and Blade Interactions in High Pressure Turbines

This paper presents a study of the three-dimensional flow field within the blade rows of a high-pressure axial flow steam turbine stage. Half-delta wings were fixed to a rotating hub to simulate an upstream rotor passage vortex. The flow field is investigated in a Low-Speed Research Turbine using pneumatic and hot-wire probes downstream of the blade row. The paper examines the impact of the delta wing vortex transport on the performance of the downstream blade row. Steady and unsteady numerical simulations were performed using structured 3D Navier-Stokes solver to further understand the flow field. The loss measurements at the exit of the stator blade showed an increase in stagnation pressure loss due to the delta wing vortex transport. The increase in loss was 21% of the datum stator loss, demonstrating the importance of this vortex interaction. The transport of the stator viscous flow through the rotor blade row is also described. The rotor exit flow was affected by the interaction between the enhanced stator passage vortex and the rotor blade row. Flow underturning near the hub and overturning towards the mid-span was observed, contrary to the classical model of overturning near the hub and underturning towards the mid-span. The unsteady numerical simulation results were further analysed to identify the entropy producing regions in the unsteady flow field.

The effects of a trip wire and unsteadiness on a high speed highly loaded low-pressure turbine blade

This paper presents the effect of a single spanwise 2D wire upon the downstream position of boundary layer transition under steady and unsteady inflow conditions. The study is carried out on a high turning, high-speed, low pressure turbine (LPT) profile designed to take account of the unsteady flow conditions. The experiments were carried out in a transonic cascade wind tunnel to which a rotating bar system had been added. The range of Reynolds and Mach numbers studied includes realistic LPT engine conditions and extends up to the transonic regime. Losses are measured to quantify the influence of the roughness with and without wake passing. Time resolved measurements such as hot wire boundary layer surveys and surface unsteady pressure are used to explain the state of the boundary layer. The results suggest that the effect of roughness on boundary layer transition is a stability governed phenomena, even at high Mach numbers. The combination of the effect of the roughness elements with the inviscid Kelvin-Helmholtz instability responsible for the rolling up of the separated shear layer (Stieger [1]) is also examined. Wake traverses using pneumatic probes downstream of the cascade reveal that the use of roughness elements reduces the profile losses up to exit Mach numbers of 0.8. This occurs with both steady and unsteady inflow conditions.

The flexoelectric behaviour of a hypertwisted chiral nematic liquid crystal

The flexoelectric behaviour of a hypertwisted chiral nematic bimesogenic liquid crystal is presented. Through detailed electro-optic measurements, with particular emphasis on the switching properties, we demonstrate remarkably high optical axis tilt angles. The material studied possessed a room temperature nematic phase and aligned easily on cooling under the application of a moderate electric field. Switching times of the order of 500 μs and contrast ratios of 90:1 are readily achieved. The tilt angles, measured using the rotating analyser technique, were found to be practically temperature independent and linear with the applied field. Tilt angles of 22.5° were obtained with moderate applied fields of 9.4 V/μm whilst fields of 25 V/μm yielded tilt angles of 45°. We believe these are the highest tilt angles ever recorded for such fields. © 2001 OPA (Overseas Publishers Association) N.V. Published by license under the Gordon and Breach Science Publishers imprint, a member of the Taylor & Francis Group.

Superconducting micro-bearings

This paper presents research into superconducting Micro-Bearings for MEMS systems. Advanced silicon processing techniques developed for the Very Large Scale Integration (VLSI) industry have been exploited in recent years to enable the production of micro-engineered moving mechanical systems. These devices commonly known as Micro-ElectroMechanical Systems (MEMS) have many potential advantages. In many respects the effect of scaling a machine from macro-sized to micro-sized are either neutral or beneficial. However in one important respect the scaling produces a severely detrimental effect. That respect is in the tribology and the subsequent wear on the high speed rotating machines. This leads to very short device lifetimes. This paper presents results obtained from a MEMS motor supported on superconducting bearings. The bearings are self-positioning, relying on, the Meissner effect to provide a levitation force which moves the rotor into position and flux pinning to provide stability thereafter. The rotor is driven by a simple electrostatic type motor in which photo resist is used to pattern the motor poles directly onto the rotor. © 2005 IEEE.

Vortex filament simulation of trailing vortex merger

Aircraft in high-lift configuration shed multiple vortices. These generally merge to form a downstream wake consisting of two counter-rotating vortices of equal strength. The understanding of the merger of two co-rotating trailing vortices is important in evaluating the separation criteria for different aircraft to prevent wake vortex hazards during landing and take-off. There is no existing theoretical method on the basis of which such norms can be set. The present study is aimed at gaining a better understanding of the behaviour of wake vortices behind the aircraft. Two dimensional studies are carried out using the vortex blob method and compared with Bertenyi's experiment. It is shown that inviscid two dimensional effects are insufficient to explain the observations. Three dimensional studies, using the vortex filament method, are applied to the same test case. Two Lamb-Oseen profile vortices of the same dimensions and initial separation as the experiment are allowed to evolve from a straight starting condition until a converged steady flow is achieved. The results obtained show good agreement with the experimental distance to merger. Core radius and separation behaviour is qualitatively similar to experiment, with the exception of rapid increases at first. This may be partially attributable to the choice of filament-element length, and recommended further work includes a convergence study for this parameter. Copyright © 2005 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Vortex generators near shock/ boundary layer interactions

Experiments have been performed in a blowdown supersonic wind tunnel to investigate the effect of arrays of sub-boundary layer vortex generators placed upstream of a normal shock/ boundary layer interaction. The investigation makes use of a recovery shock wave and the naturally grown turbulent boundary layer on the wind tunnel floor. Experiments were performed at Mach numbers of 1.5 and 1.3 and a freestream Reynolds number of 28 × 106. Two types of vortex generators were investigated - wedge-shaped and arrays of counter-rotating vanes. It was found that at Mach 1.5 the vane-type VGs eliminated and the wedge-type VGs greatly reduced the separation bubble under the shock. When placed in the supersonic part of the flow both VGs caused a wave pattern consisting of a shock, re-expansion and shock. The re-expansion and double shocks are undesirable features since they equate to increased total pressure losses and hence increased -wave drag. Furthermore there are indications that the vortex intensity is reduced by the normal shock/ boundary layer interaction. When the shock was located directly over the VGs there was no re-expansion present, but the 'damping' effect of the shock on the vortex persisted. It appears that the vortices produced by the wedge-shaped VGs lift off the surface more rapidly. Similar results were observed at Mach 1.3, where the flow was unseparated.

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.

Shock / boundary-layer interaction control using three-dimensional bumps for transonic wings

Three-dimensional bumps have been developed and investigated, aiming at the two major objectives of shock-wave / boundary-layer interaction control, i.e. drag reduction and suppression of separation, simultaneously. An experimental investigation has been conducted for a default rounded bump in channel now at University of Cambridge and a computational study has been performed for a spanwise series of rounded bumps mounted on a transonic aerofoil at University of Stuttgart. Observed in both cases are wave drag reduction owing to A-shock structures produced by three-dimensional surface bumps and mild control effects on the boundary layer. The effects of rough surface and tall extension have been investigated as well as several geometric variations and multiple bump configurations. A double configuration of narrow rounded bumps has been found to best perform amongst the tested, considerably reducing wave drag through a well-established A-shock structure with little viscous penalty and thus achieving substantial overall drag reduction. Counter-rotating streamwise vortex pairs have been produced by some configurations as a result of local flow separation, but they have been observed to be confined in relatively narrow wake regions, expected to be beneficial in suppressing large-scale separation under off-design condition despite increase of viscous drag. On the whole a large potential of three-dimensional control with discrete rounded bumps has been demonstrated both experimentally and numerically, and experimental investigation of bumps fitted on a transonic aerofoil or wing is suggested toward practical application.

Micro-vortex generator flow control for supersonic engine inlets

To investigate the flow control potential of micro-vortex generators for supersonic mixed-compression inlets, a basic model experiment has been designed which combines a normal shock wave with a subsonic diffuser. The diffuser is formed by a simple expansion corner, with a divergence angle of 6 degrees. The diffuser entry Mach numbers were M=1.3 and M=1.5 and a number of shock locations relative to the corner position were tested. Flow control was applied in the form of counter-rotating micro-vanes with heights of approximately 20% of boundary layer thickness. Furthermore, corner fences where employed to reduce sidewall effects. It was found that micro-vortex generators were able to significantly reduce the extent of flow separation under all conditions, but could not eliminate it altogether. Corner fences also demonstrated potential for improving the flow in rectangular cross section channels and the combination of corner fences with micro-vortex generators was found to give the greatest benefits. At M=1.3 the combination of corner fences and micro-vanes placed close to the diffuser entry could prevent separation for a wide range of conditions. At the higher diffuser entry Mach number the benefits of flow control were less significant although a reduction of separation size and an improved pressure recovery was observed. It is thought that micro-vortex generators can have significant flow control potential if they are placed close to the expected separation onset and when the adverse pressure gradient is not too far above the incipient separation level. The significant beneficial effects of corner fences warrant a more comprehensive further investigation. It is thought that the control methods suggested here are capable of reducing the bleed requirement on an inlet, which could provide significant performance advantages.

Micro-ramp control for oblique shock wave / boundary layer interactions

Supersonic engine intakes operating supercritically feature shock wave / boundary layer interactions (SBLIs), which are conventionally controlled using boundary layer bleed. The momentum loss of bleed flow causes high drag, compromising intake performance. Micro-ramp sub-boundary layer vortex generators (SBVGs) have been proposed as an alternative form of flow control for oblique SBLIs in order to reduce the bleed requirement. Experiments have been conducted at Mach 2.5 to characterise the flow details on such devices and investigate their ability to control the interaction between an oblique shock wave and the naturally grown turbulent boundary layer on the tunnel floor. Micro-ramps of four sizes with heights ranging from 25% to 75% of the uncontrolled boundary layer thickness were tested. The flow over all sizes of microramp was found to be similar, featuring streamwise counter-rotating vortices which entrain high momentum fluid, locally reducing the boundary layer displacement thickness. When installed ahead of the shock interaction it was found that the positioning of the micro-ramps is of limited importance. Micro-ramps did not eliminate flow separation. However, the previously two-dimensional separation was broken up into periodic three-dimensional separation zones. The interaction length was reduced and the pressure gradient across the interaction was increased.

Flow of wet powder in a conical centrifugal filter-an analytical model

A one-dimensional analytical model is developed for the steady state, axisymmetric, slender flow of saturated powder in a rotating perforated cone. Both the powder and the fluid spin with the cone with negligible slip in the hoop direction. They migrate up the wall of the cone along a generator under centrifugal force, which also forces the fluid out of the cone through the powder layer and the porous wall. The flow thus evolves from an over-saturated paste at inlet into a nearly dry powder at outlet. The powder is treated as a Mohr-Coulomb granular solid of constant void fraction and permeability. The shear traction at the wall is assumed to be velocity and pressure dependent. The fluid is treated as Newtonian viscous. The model provides the position of the colour line (the transition from over- to under-saturation) and the flow velocity and thickness profiles over the cone. Surface tension effects are assumed negligible compared to the centrifugal acceleration. Two alternative conditions are considered for the flow structure at inlet: fully settled powder at inlet, and progressive settling of an initially homogeneous slurry. The position of the colour line is found to be similar for these two cases over a wide range of operating conditions. Dominant dimensionless groups are identified which control the position of the colour line in a continuous conical centrifuge. Experimental observations of centrifuges used in the sugar industry provide preliminary validation of the model. © 2011 Elsevier Ltd.