Development of Shape-Optimization Tools for the Aerodynamic Design of Turbomachinery Blades

The aim of this work is to develop an automated tool for the optimization of turbomachinery blades founded on an evolutionary strategy. This optimization scheme will serve to deal with supersonic blades cascades for application to Organic Rankine Cycle (ORC) turbines. The blade geometry is defined using parameterization techniques based on B-Splines curves, that allow to have a local control of the shape. The location in space of the control points of the B-Spline curve define the design variables of the optimization problem. In the present work, the performance of the blade shape is assessed by means of fully-turbulent flow simulations performed with a CFD package, in which a look-up table method is applied to ensure an accurate thermodynamic treatment. The solver is set along with the optimization tool to determine the optimal shape of the blade. As only blade-to-blade effects are of interest in this study, quasi-3D calculations are performed, and a single-objective evolutionary strategy is applied to the optimization. As a result, a non-intrusive tool, with no need for gradients definition, is developed. The computational cost is reduced by the use of surrogate models. A Gaussian interpolation scheme (Kriging model) is applied for the estimated n-dimensional function, and a surrogate-based local optimization strategy is proved to yield an accurate way for optimization. In particular, the present optimization scheme has been applied to the re-design of a supersonic stator cascade of an axial-flow turbine. In this design exercise very strong shock waves are generated in the rear blade suction side and shock-boundary layer interaction mechanisms occur. A significant efficiency improvement as a consequence of a more uniform flow at the blade outlet section of the stator is achieved. This is also expected to provide beneficial effects on the design of a subsequent downstream rotor. The method provides an improvement to gradient-based methods and an optimized blade geometry is easily achieved using the genetic algorithm.

Innovation in industrial turbomachinery

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Diagnóstico de avarias em máquinas rotativas utilizando a análise de órbitas

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica Perfil Manutenção e Produção

Validation of NASA rotor 67 with openFOAM's transonic density-based solver

Dissertação para obtenção do Grau de Mestre em Engenharia Mecânica

A high efficiency microturbine concept

There is a growing trend towards decentralized electricity and heat production throughout the world. Reciprocating engines and gas turbines have an essential role in the global decentralized energy markets and any improvement in their electrical efficiency has a significant impact from the environmental and economic viewpoints. This paper introduces an inter-cooled and recuperated two-shaft microturbine at 500 kW electric output range. The microturbine is optimized for a realistic combination of the turbine inlet temperature, the recuperation rate and the pressure ratio. The new microturbine design aims to achieve significantly increased performance within the range of microturbines and even competing with the efficiencies achieved in large industrial gas turbines. The simulated electrical efficiency is 45%. Improving the efficiency of combined heat and power (CHP) systems will significantly decrease the emissions and operating costs of decentralized heat and electricity production. Cost-effective, compact and environmentally friendly micro-and small-scale CHP turbine systems with high electrical efficiency will have an opportunity to successfully compete against reciprocating engines, which today are used in heat and power generation all over the world and manufactured in large production series. This paper presents a small-scale gas turbine process, capable of competing with reciprocating engine in terms of electrical efficiency.

Organisational politics: reconciling leadership's rational-emotional paradox

Purpose – Effective leadership action requires managers to harness power that is intrinsically political. This paper aims to study and characterise the political nature of a manager's behaviour when taking leadership action. Design/methodology/approach – The methodological approach is qualitative and examines three organisations over a three-year period when these entities experienced a major product failure. The paper analyses the actual managerial behaviour of managers and provides insight into the factors that most strongly influence the effectiveness of managers when taking leadership action. Findings – Political behaviour when taking leadership action can be conceptualised in terms of rationality and emotionality. In so doing, it can be clarified how behaviour must be modified to ensure that leadership action is consistently effective. Research limitations/implications – A case study of three multinational engineering companies engaged in the design, development and manufacturing of turbomachinery provides the platform for the research. The concepts presented in the paper will require validating in other organisations of different demographic profiles. Practical implications – The concepts presented and the implications discussed provide insight into the political nature of managerial behaviour when taking leadership action. The paper highlights the practical steps individual managers can embrace to ensure that their behaviour is appropriate to context, even under the most traumatic situations. Thus, the paper provides managers with a model that facilitates effective leadership action. Originality/value – This paper provides insight into how managers behaved in circumstances that mattered to them. Through immersion in events at the time they took place, the authors captured situations in which managers were under real pressure and, in so doing, avoided the bias inherent when interviewing a manager about past events. As such, the paper concludes that the political behaviour in which managers engage when taking leadership action is rooted in the reality of the adversity that the most capable managers have both experienced and overcome. This detailed study reports behaviour in a situation where managers' business and future prospects were in jeopardy. This paper identifies why some managers were able to use the experience positively, helping them to adopt politically intrinsic behaviour to facilitate effective leadership action.

Esforcos hidraulicos dinamicos em turbomaquinas

A measurement device has been developed to measure force and torque components acting on the impeller of a model pump-turbine, which uses crystal quartz load transducers installed on the rotating shaft. These kinds of load transducers allow greater stiffness than arrangements using strain gauges. Therefore, the dynamics behavior of the measurement device has to be taken into account. Some results of measurements are present in the whole operating range of model pump-turbine.

Redução de vibrações de rotores utilizando atuadores magnéticos e sistema de controle feedforward

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Análise do comportamento de grandezas e parâmetros que determinam o dimensionamento de turbomáquinas a vapor

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Modeling of Heat Transfer in Microchannel Gas Flow

Due to the existence of a velocity slip and temperature jump on the solid walls, the heat transfer in microchannels significantly differs from the one in the macroscale. In our research, we have focused on the pressure driven gas flows in a simple finite microchannel geometry, with an entrance and an outlet, for low Reynolds (Re<200) and low Knudsen (Kn<0.01) numbers. For such a regime, the slip induced phenomena are strongly connected with the viscous effects. As a result, heat transfer is also significantly altered. For the optimization of flow conditions, we have investigated various temperature gradient configurations, additionally changing Reynolds and Knudsen numbers. The entrance effects, slip flow, and temperature jump lead to complex relations between flow behavior and heat transfer. We have shown that slip effects are generally insignificant for flow behavior. However, two configuration setups (hot wall cold gas and cold wall hot gas) are affected by slip in distinguishably different ways. For the first one, which concerns turbomachinery, the mass flow rate can increase by about 1% in relation to the no-slip case, depending on the wall-gas temperature difference. Heat transfer is more significantly altered. The Nusselt number between slip and no-slip cases at the outlet of the microchannel is increased by about 10%.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Experimental studies on transitional separated boundary layers

Separated transitional boundary layers appear on key aeronautical processes such as the flow around wings or turbomachinery blades. The aim of this thesis is the study of these flows in representative scenarios of technological applications, gaining knowledge about phenomenology and physical processes that occur there and, developing a simple model for scaling them. To achieve this goal, experimental measurements have been carried out in a low speed facility, ensuring the flow homogeneity and a low disturbances level such that unwanted transitional mechanisms are avoided. The studied boundary layers have been developed on a flat plate, by imposing a pressure gradient by means of contoured walls. They generate an initial acceleration region followed by a deceleration zone. The initial region is designed to obtain at the beginning of the deceleration the Blasius profile, characterized by its momentum thickness, and an edge boundary layer velocity, defining the problem characteristic velocity. The deceleration region is designed to obtain a linear evolution of the edge velocity, thereby defining the characteristic length of the problem. Several experimental techniques, both intrusive (hot wire anemometry, total pressure probes) as nonintrusive (PIV and LDV anemometry, high-speed filming), have been used in order to take advantage of each of them and allow cross-validation of the results. Once the boundary layer at the deceleration beginning has been characterized, ensuring the desired integral parameters and level of disturbance, the evolution of the laminar boundary layer up to the point of separation is studied. It has been compared with integral methods, and numerical simulations. In view of the results a new model for this evolution is proposed. Downstream from the separation, the flow near to the wall is configured as a shear layer that encloses low momentum recirculating fluid. The region where the shear layer remains laminar tends to be positioned to compensate the adverse pressure gradient associated with the imposed deceleration. Under these conditions, the momentum thickness remains almost constant. This laminar shear layer region extends up to where transitional phenomena appear, extension that scales with the momentum thickness at separation. These transitional phenomena are of inviscid type, similar to those found in free shear layers. The transitional region analysis begins with a study of the disturbances evolution in the linear growth region and the comparison of experimental results with a numerical model based on Linear Stability Theory for parallel flows and with data from other authors. The results’ coalescence for both the disturbances growth and the excited frequencies is stated. For the transition final stages the vorticity concentration into vortex blobs is found, analogously to what happens in free shear layers. Unlike these, the presence of the wall and the pressure gradient make the large scale structures to move towards the wall and quickly disappear under certain circumstances. In these cases, the recirculating flow is confined into a closed region saying the bubble is closed or the boundary layer reattaches. From the reattachment point, the fluid shows a configuration in the vicinity of the wall traditionally considered as turbulent. It has been observed that existing integral methods for turbulent boundary layers do not fit well to the experimental results, due to these methods being valid only for fully developed turbulent flow. Nevertheless, it has been found that downstream from the reattachment point the velocity profiles are self-similar, and a model has been proposed for the evolution of the integral parameters of the boundary layer in this region. Finally, the phenomenon known as bubble burst is analyzed. It has been checked the validity of existing models in literature and a new one is proposed. This phenomenon is blamed to the inability of the large scale structures formed after the transition to overcome with the adverse pressure gradient, move towards the wall and close the bubble. El estudio de capas límites transicionales con separación es de gran relevancia en distintas aplicaciones tecnológicas. Particularmente, en tecnología aeronáutica, aparecen en procesos claves, tales como el flujo alrededor de alas o álabes de turbomaquinaria. El objetivo de esta tesis es el estudio de estos flujos en situaciones representativas de las aplicaciones tecnológicas, ganando por un lado conocimiento sobre la fenomenología y los procesos físicos que aparecen y, por otra parte, desarrollando un modelo sencillo para el escalado de los mismos. Para conseguir este objetivo se han realizado ensayos en una instalación experimental de baja velocidad específicamente diseñada para asegurar un flujo homogéneo y con bajo nivel de perturbaciones, de modo que se evita el disparo de mecanismos transicionales no deseados. La capa límite bajo estudio se ha desarrollado sobre una placa plana, imponiendo un gradiente de presión a la misma por medio de paredes de geometría especificada. éstas generan una región inicial de aceleración seguida de una zona de deceleración. La región inicial se diseña para tener en al inicio de la deceleración un perfil de capa límite de Blasius, caracterizado por su espesor de cantidad de movimiento, y una cierta velocidad externa a la capa límite que se considera la velocidad característica del problema. La región de deceleración está concebida para que la variación de la velocidad externa a la capa límite sea lineal, definiendo de esta forma una longitud característica del problema. Los ensayos se han realizado explotando varias técnicas experimentales, tanto intrusivas (anemometría de hilo caliente, sondas de presión total) como no intrusivas (anemometrías láser y PIV, filmación de alta velocidad), de cara a aprovechar las ventajas de cada una de ellas y permitir validación cruzada de resultados entre las mismas. Caracterizada la capa límite al comienzo de la deceleración, y garantizados los parámetros integrales y niveles de perturbación deseados se procede al estudio de la zona de deceleración. Se presenta en la tesis un análisis de la evolución de la capa límite laminar desde el inicio de la misma hasta el punto de separación, comparando con métodos integrales, simulaciones numéricas, y proponiendo un nuevo modelo para esta evolución. Aguas abajo de la separación, el flujo en las proximidades de la pared se configura como una capa de cortadura que encierra una región de fluido recirculatorio de baja cantidad de movimiento. Se ha caracterizado la región en que dicha capa de cortadura permanece laminar, encontrando que se posiciona de modo que compensa el gradiente adverso de presión asociado a la deceleración de la corriente. En estas condiciones, el espesor de cantidad de movimiento permanece prácticamente constante y esta capa de cortadura laminar se extiende hasta que los fenómenos transicionales aparecen. Estos fenómenos son de tipo no viscoso, similares a los que aparecen en una capa de cortadura libre. El análisis de la región transicional comienza con un estudio de la evolución de las vii viii RESUMEN perturbaciones en la zona de crecimiento lineal de las mismas y la comparación de los resultados experimentales con un modelo numérico y con datos de otros autores. La coalescencia de los resultados tanto para el crecimiento de las perturbaciones como para las frecuencias excitadas queda demostrada. Para los estadios finales de la transición se observa la concentración de la vorticidad en torbellinos, de modo análogo a lo que ocurre en capas de cortadura libres. A diferencia de estas, la presencia de la pared y del gradiente de presión hace que, bajo ciertas condiciones, la gran escala se desplace hacia la pared y desaparezca rápidamente. En este caso el flujo recirculatorio queda confinado en una región cerrada y se habla de cierre de la burbuja o readherencia de la capa límite. A partir del punto de readherencia se tiene una configuración fluida en las proximidades de la pared que tradicionalmente se ha considerado turbulenta. Se ha observado que los métodos integrales existentes para capas límites turbulentas no ajustan bien a las medidas experimentales realizadas, hecho imputable a que no se obtiene en dicha región un flujo turbulento plenamente desarrollado. Se ha encontrado, sin embargo, que pasado el punto de readherencia los perfiles de velocidad próximos a la pared son autosemejantes entre sí y se ha propuesto un modelo para la evolución de los parámetros integrales de la capa límite en esta región. Finalmente, el fenómeno conocido como “estallido” de la burbuja se ha analizado. Se ha comprobado la validez de los modelos existentes en la literatura y se propone uno nuevo. Este fenómeno se achaca a la incapacidad de la gran estructura formada tras la transición para vencer el gradiente adverso de presión, desplazarse hacia la pared y cerrar la burbuja.

Numerical Model of a Variable-Combined-Cycle Engine for Dual Subsonic and Supersonic Cruise

Efficient high speed propulsion requires exploiting the cooling capability of the cryogenic fuel in the propulsion cycle. This paper presents the numerical model of a combined cycle engine while in air turbo-rocket configuration. Specific models of the various heat exchanger modules and the turbomachinery elements were developed to represent the physical behavior at off-design operation. The dynamic nature of the model allows the introduction of the engine control logic that limits the operation of certain subcomponents and extends the overall engine operational envelope. The specific impulse and uninstalled thrust are detailed while flying a determined trajectory between Mach 2.5 and 5 for varying throttling levels throughout the operational envelope.

Physics of Vibrating Airfoils at Low Reduced Frequency

The unsteady aerodynamics of low pressure turbine vibrating airfoils in flap mode is studied in detail using a frequency domain linearized Navier-Stokes solver. Both the travelling-wave and influence coefficient formulations of the problem are used to highlight key aspects of the physics and understand different trends such as the effect of reduced frequency and Mach number. The study is focused in the low-reduced frequency regime which is of paramount relevance for the design of aeronautical low-pressure turbines and compressors. It is concluded that the effect of the Mach number on the unsteady pressure phase can be neglected in first approximation and that the unsteadiness of the vibrating and adjacent airfoils is driven by vortex shedding mechanisms. Finally a simple model to estimate the work-per-cycle as a function of the reduced frequency and Mach Number is provided. The edge-wise and torsion modes are presented in less detail but it is shown that acoustic waves are essential to explain its behaviour. The non-dimensional work-per-cycle of the edge-wise mode shows a large dependence with the Mach number while in the torsion mode a large number of airfoils is needed to reconstruct the work-per-cycle departing from the influence coefficients.