1. Introduction
Abrupt structural failures in aircraft-engine air systems constitute a common class of air-system malfunctions and can escalate to the aviation-engine safety top event known as uncontained high-energy debris fragments [
1]. To mitigate this risk, civil aviation authorities worldwide have promulgated regulations that specify passive-safety design requirements following a range of abrupt structural failure scenarios [
2,
3]. For example, the Federal Aviation Administration (FAA) released Federal Aviation Regulation Part 33 (FAR33). This regulation contains multiple key provisions including 33.19, 33.27, 33.34, and 33.94. These clauses set design-stage requirements for uncontained high-energy debris fragments. The involved contents cover rotor strength, fragment energy, and trajectory prediction. They also specify relevant requirements for casing containment capability [
3]. Shaft fracture is a representative abrupt structural failure mode that can trigger uncontained high-energy debris fragments; accordingly, it has been widely adopted as a canonical case for investigating the fast transient response of the air systems induced by abrupt structural failures, thereby supporting passive safety design for aero-engines [
4,
5,
6].
The prevailing approach for fast transient air-system response research is a whole-engine low-dimensional simulation [
7]. All Secondary Air System (SAS) boundaries lie in the aero-engine main gas path with strong coupling effects. Research under SAS–main gas path interaction captures boundary variations more accurately and improves load evolution prediction in fast transient events [
8]. The SAS has numerous components. Its low-dimensional models are mainly built via the network method, and component model accuracy directly determines simulation reliability. The SAS is treated as a fluid network composed of cavities, pipes, and diverse throttling elements [
9,
10]. Scholars differ in throttling element classification but reach consensus on cavity and pipe classification and modeling assumptions [
11]. For pipes, axial linear parameter distribution is assumed, with cross-sectional non-uniformity ignored and gas velocity considered. For cavities, port area, internal flow velocity, and spatial parameter non-uniformity are generally neglected. The core premise is that a cavity with a far smaller outlet area than its surface area can be simplified as a lumped-parameter control volume. Its pressure response follows mass and energy conservation, independent of geometric parameters. Under the above assumptions, the prediction performance of low-dimensional cavity and pipe models has been experimentally validated in multiple fields [
12,
13].
In practical SAS, compressor and turbine disc cavities have large port areas, which violate the key assumption that port area is far smaller than cavity surface area. Current studies simplify multiple disc cavities into a single unit to meet modeling requirements and establish relevant models [
8]. This simplification has minor impacts on simulations under large time-scale conditions. For engine condition-induced SAS transient responses, boundary variation lasts over 1 s with a 0.1 s time step. In this case, boundary disturbances can fully spread across the whole SAS, and axial distance has little effect on propagation time. However, SAS fast transient processes caused by abrupt structural failures require a time step much smaller than 0.1 s. For typical shaft fracture, boundary adjustment finishes within 10 ms [
14], and the simulation time step can drop to 0.01 ms. Disturbances cannot cover the entire SAS in such a short time step, so the axial distance of cavities must be considered. The total axial dimension of SAS disc cavities accounts for over 40% of engine length. Simplified treatment of disc cavities will directly reduce simulation accuracy.
This issue is characterized by an extremely short boundary variation duration and complex system flow path structure. For long-duration boundary changes, the flow inertial force inside the cavity can be neglected. The cavity can be treated as a lumped-parameter control volume during transient responses [
7]. This treatment is commonly adopted in the research of pressure vessel discharge processes. For flow systems with simple flow paths, three-dimensional simulation can be directly employed. Low-dimensional simulation, which simplifies flows for higher efficiency, is no longer required. A representative case is the investigation of gas explosion shock wave propagation in mine tunnels [
15].
Motivated by this challenge, this work aims to develop a low-dimensional cavity modeling method targeted at the fast transient response of SAS following failures. The proposed method follows a modular paradigm, partitioning the cavity according to geometric and flow features at different locations and then formulating appropriate assumptions and models for each partition. In this way, the approach preserves the computational efficiency of a low-dimensional framework while improving predictive accuracy under fast transient operating conditions.
2. Analysis of Existing Low-Dimensional Cavity Models
The experimental and simulation work relevant to this study has been reported in Ref. [
16]. The fast transient experimental platform for the air system employed in this work provides the required geometric step boundary conditions through the rapid motion of the plug in the step boundary simulation device. The configuration of the experimental platform and the operating principle of the step boundary simulation device are illustrated in
Figure 1.
This study employs the three-dimensional simulation model reported in Ref. [
16], which has been subjected to independence analysis and experimentally validated, to conduct the corresponding three-dimensional simulations, as shown in
Figure 2. In all three-dimensional simulations performed in this study, the geometric step boundary is realized through the motion of the plug section. The prescribed motion follows the same law as that used in the experiments, as shown in
Figure 1c, thereby ensuring consistency in the boundary conditions for all datasets used in the study.
The validated three-dimensional model from Ref. [
16] and the low-dimensional model without flow inertial effects are adopted to simulate the fast transient discharge response of the single-port cavity. The purpose is to verify whether existing low-dimensional cavity models can accurately predict pressure variations inside the cavity when key assumptions are violated. Model parameters are listed in
Table 1, where
denotes the port area, and
denotes the cavity volume. The comparison metric is the pressure variation inside the cavity, and the pressure at the cavity midpoint is selected for comparison in the three-dimensional simulation, with the model shown in
Figure 3.
The low-dimensional and three-dimensional simulation results for different values of
are shown in
Figure 4 and
Figure 5. In the three-dimensional simulations, increasing
leads to periodic flow reversal at the cavity outlet, which accelerates the pressure decay within the cavity and induces pronounced pressure oscillations; moreover, the oscillation amplitude increases with
. When
reaches 0.204, the maximum pressure-oscillation amplitude is approximately 3 kPa. By contrast, the low-dimensional simulations capture the effect of increasing
on the pressure-decay rate, but they fail to reproduce the periodic outlet flow reversal and the associated pressure oscillations inside the cavity.
These behaviors can be explained by momentum effects. When a pressure difference exists between the cavity and the surroundings, the gas near the outlet is accelerated outward by the pressure gradient. As the cavity pressure decreases toward the ambient level, the already-accelerated gas cannot be brought to rest instantaneously due to inertia; it continues to discharge, causing the cavity pressure to “overshoot” below the ambient pressure. The pressure difference then reverses sign, driving reverse flow. This alternating process, governed jointly by the pressure difference and inertial forces, manifests as pressure oscillations. A larger implies a higher flow rate and a larger amount of gas participating in momentum exchange within the cavity, making oscillations more likely and increasing their amplitude.
From the perspective of low-dimensional modeling, when , the region over which momentum effects are significant remains confined near the outlet, and the resulting pressure oscillations are negligible; the cavity can then be approximated as a lumped-parameter control volume, and existing low-dimensional cavity models can still predict the fast transient depressurization with reasonable accuracy. As increases, however, the non-uniformity of velocity and thermodynamic states within the cavity becomes more pronounced, and low-dimensional models that neglect internal gas velocity and spatial non-uniformity cannot capture the oscillatory behavior. Therefore, incorporating the effect of inertial forces within the cavity on top of existing volume-based low-dimensional cavity models is expected to improve the fidelity of internal-flow predictions during fast transient responses.
4. Validation of the Modular Low-Dimensional Modeling Method for a Fast Transient Cavity
Using the zonal modular modeling method, low-dimensional cavity models are constructed for both single-port and dual-port cavities. Numerical simulations are then performed to resolve the fast transient response during the cavity discharge process, and the results are compared with the corresponding three-dimensional simulations to validate the predictive accuracy of the low-dimensional models under different port areas
, cavity shapes
, and initial pressure ratios
. This comparison provides a basis for assessing the reliability of the modular modeling method for fast transient cavities. The single-port and dual-port cavity models established using this modeling method are shown in
Figure 17.
The overall flow-path structure is shown in
Figure 18. To represent the influence of the local high-pressure region near the outlet reported in Ref. [
16], an element characterizing this local high-pressure region is introduced between the test cavity and the ambient-pressure boundary. Based on the geometric data provided in Ref. [
16], this element has a length of 80 mm and a diameter of 80 mm. A corresponding model is established with reference to the single-port cavity model, as shown in
Figure 19. Interpolation of the data in
Figure 14 gives the corresponding
value as 1.89. The mass flow rate from the test cavity to the ambient environment is selected as the comparison metric, and the simulation accuracy of the low-dimensional model is assessed by comparing the duration of the cavity charge and discharge processes and the total transported mass.
Following the cases listed in
Table 2, three-dimensional simulations and low-dimensional simulations were performed for the fast transient discharge response of both a single-port cavity and a dual-port cavity. The simulation accuracy of the low-dimensional model under different
conditions was evaluated by comparison, and the results are shown in
Figure 20. Quantitative comparisons of discharge-process duration
, discharged-gas mass
, charge-process duration
, and charged-gas mass
under different
conditions are reported in
Table 3,
Table 4 and
Table 5.
Based on the preceding analysis, under different length-to-diameter ratios, the low-dimensional and three-dimensional simulations of the fast transient discharge response in single-port and dual-port cavities exhibit certain discrepancies yet show good overall consistency. Both approaches accurately capture the dynamic evolution of the outlet flow rate from the cavity.
Under different length-to-diameter ratios, the maximum error in during the discharge process is 16.6%, while that in is 7.1%. During the charge process, the maximum error in is 24.0%, and that in is 22.8%. Overall, the errors of the main parameters remain within 10% for most operating conditions. The simulation accuracy for the discharge process is generally higher than that for the charge process, and the errors under single-port conditions are consistently smaller than those under dual-port conditions. The largest discrepancy occurs under condition , where the error in the total inflow during the charge process of the dual-port cavity reaches 24.0%.
Using the operating conditions listed in
Table 6, we perform three-dimensional and low-dimensional simulations of the discharge fast transient response for both single-port and dual-port cavities to evaluate the prediction accuracy of the low-dimensional model under different
conditions. The comparisons are summarized in
Figure 21. Quantitative results for discharge duration
, total discharged mass
, charge duration
, and total charged mass
under different
conditions are reported in
Table 7,
Table 8,
Table 9 and
Table 10. The simulation results for
have already been presented in
Figure 20c,d as well as in
Table 4 and are therefore not repeated here.
Under different pressure-ratio conditions, the low-dimensional and three-dimensional simulation models show good overall consistency in predicting the fast transient discharge response of single-port and dual-port cavities, although certain discrepancies remain across individual operating conditions. The low-dimensional approach effectively reproduces the key dynamic features of the cavity during both discharge and charge stages under varying pressure ratios.
From the perspective of the error distribution, the overall simulation accuracy during the discharge process is superior to that during the charge process. The errors for case are generally below 10.1%, whereas the maximum error for case reaches 24.2%. By contrast, the charge process exhibits larger errors overall, with the maximum error in case reaching 16.9% and the error in case increasing to as high as 39.0%. In addition, the error level under single-port conditions is generally lower than that under dual-port conditions. As the pressure ratio increases, the error under dual-port conditions shows a pronounced upward trend. Among all cases, the most significant deviation occurs in the dual-port cavity condition at pressure ratio , where the error in the total mass of inflowing gas during the charge process reaches 39.0%.
Using the operating conditions listed in
Table 11, we conduct three-dimensional and low-dimensional simulations of the discharge fast transient response for both single-port and dual-port cavities to further assess the predictive accuracy of the low-dimensional model under different
conditions. The comparison is summarized in
Figure 22. Quantitative comparisons of discharge duration
, total discharged mass
, charge duration
, and total charged mass
under different
conditions are reported in
Table 12 and
Table 13. The simulation results for
have already been presented in
Figure 20c,d as well as in
Table 4 and are therefore not repeated here.
Figure 22.
Comparison of cavity outlet flow rate variations under different values of A/V2/3. (a) A/V2/3 = 0.074, Single-Port; (b) A/V2/3 = 0.074, Dual-Port; (c) A/V2/3 = 0.131, Single-Port; (d) A/V2/3 = 0.131, Dual-Port.
Figure 22.
Comparison of cavity outlet flow rate variations under different values of A/V2/3. (a) A/V2/3 = 0.074, Single-Port; (b) A/V2/3 = 0.074, Dual-Port; (c) A/V2/3 = 0.131, Single-Port; (d) A/V2/3 = 0.131, Dual-Port.
Based on the above analysis, under different conditions, the low-dimensional simulation and the three-dimensional simulation exhibit certain discrepancies in predicting the fast transient response of discharge in single-port and dual-port cavities, yet their overall agreement remains strong. Both methods accurately capture the periodic flow-reversal characteristics at the cavity outlet. Under different conditions, the maximum error for during the discharge process is 3.9%, and that for is 3.8%; the maximum error for is 25.9%, while that for is 9.6%. Overall, the errors in the principal parameters remain within 10% for most operating conditions. The largest deviation occurs under condition , where the error in the total inflow during the charge process of the dual-port cavity reaches 25.9%.
For cavities with different inlet/outlet configurations, the charged mass during the charging process increases gradually with . As increases from 0.074 to 0.208:
- (1)
For the single-inlet/outlet cavity, increases from 1.87 × 10−5 kg to 2.72 × 10−5 kg, with a growth rate of 45.5%;
- (2)
For the dual-inlet/outlet cavity, increases from 2.31 × 10−5 kg to 4.39 × 10−5 kg, with a growth rate of 90.0%.
This trend aligns with the law describing how
affects the flow inertia inside the cavity, as reported in Ref. [
16]. Meanwhile, it reflects the compatibility with existing low-dimensional cavity models: as
decreases, mcharge also decreases, and the difference between the simulation results of the two low-dimensional models gradually reduces. The predictions become nearly consistent when
.
From the above comparison results, the cavity discharge model established by the modular modeling method for rapidly transient cavities can satisfactorily reproduce the three-dimensional simulation results under various working conditions, including different inlet/outlet area ratios , cavity shape ratios , and initial pressure ratios . In most conditions, the errors of key parameters can be controlled within 10%, showing good overall consistency and meeting the basic accuracy requirements of the research.
The error distribution reveals clear trends in model performance. The simulation accuracy for the discharge process is generally higher than that for the charge process, and the error level under single-port conditions is overall lower than that under dual-port conditions. Across different parameter settings, relatively large errors tend to occur near the boundaries of the parameter range. The maximum error appears under the dual-port cavity condition with a high initial pressure ratio, where the error in the total gas mass during the charge process reaches 39.0%. The principal causes of these errors can be attributed to the following four aspects.
- (1)
Influence of simplified assumptions in zonal modeling. The modular modeling method for fast transient cavities discretizes the cavity into multiple zones and assumes one-dimensional flow within each zone. Interactions with other zones or components are considered only at the flow inlet and outlet of each zone, while the complex coupling and mutual influence among zones during internal flow evolution are neglected.
- (2)
Influence of simplified complex flow structures. This modeling approach represents the three-dimensional complex flow inside the cavity as a superposition of one-dimensional flows in different directions. As a result, it is difficult to accurately reproduce the spatial distributions of pressure and velocity within the cavity. In particular, non-unidirectional flow structures that may exist inside the cavity, such as vortices and recirculation, cannot be effectively captured, leading to the loss of detailed flow information.
- (3)
Influence of the mapping relationship between cavity geometry and zonal range. In the zonal-range quantification method, the mapping relationship between cavity geometric parameters and zonal ranges is derived from processed three-dimensional simulation data. During data processing, temporal and spatial averaging is applied to the three-dimensional simulation results. This treatment introduces discrepancies between the flow state represented in the model and the actual three-dimensional flow, thereby affecting the accuracy of the simulation results.
- (4)
Influence of simplified ambient pressure distribution. Although the low-dimensional model represents the local non-uniform distribution of ambient pressure near the cavity outlet by introducing a local high-pressure region, this treatment remains simplified relative to the three-dimensional model. Consequently, the suppression of outflow by the local high-pressure region during discharge, as well as its promotion of inflow during charge, cannot be fully represented in the low-dimensional simulation, which in turn affects the simulation results.