Search Results (24)

Adverse pressure gradients are intrinsic to compressor flow behavior and are further intensified by secondary effects associated with rotor tip clearance flow interactions. Tip clearance generates leakage flow, which leads to the formation of tip leakage vortices, a major contributor to aerodynamic losses in axial compressors. These vortices significantly influence both compressor performance and operational stability. Extensive prior research has demonstrated that passive casing treatments, particularly axial slots, can substantially improve the stall margin in axial compressors. In this work, the performance of a new casing treatment geometry is investigated using the concept of recirculating flow within semi-circular axial slots. The proposed casing treatment geometry builds upon recent experimental findings involving single-rotor configurations. It was applied to the first rotor row of a three-and-a-half-stage (3.5-stage) axial compressor comprising an inlet guide vane followed by three rotor–stator stages. The numerical model incorporates axial slots with a novel periodic interface approach implemented in a multistage compressor simulation. Three-dimensional steady-state RANS (Reynolds Average Navier-Stokes) simulations were performed to investigate the aerodynamic effects of the casing treatment across various rotational speeds. The results for the casing treatment configuration were compared with those of a baseline smooth casing. The introduction of the new casing treatment produced noticeable modifications to the internal flow structure, particularly in the tip region, resulting in improved overall compressor stability within the operating range of 85 to 100% of design speed. Full article

Gas turbines in land-based microgrids and shipboard-isolated power grids frequently face operational challenges, such as the startup and shutdown of high-power equipment and sudden load fluctuations, which significantly impact their performance. To examine the dynamic behavior of gas turbines under transitional operating conditions, a three-dimensional computational fluid dynamic simulation is employed to create a model of the gas turbine rotor, incorporating thermal inertia, which is then analyzed in conjunction with three-dimensional finite element methods. The governing equations of the flow field are discretized, providing results for the flow and temperature fields throughout the entire flow path. A hybrid approach, combining temperature differences and heat flux density, is applied to set the thermal boundary conditions for the walls, with the turbine’s operational state determined based on the direction of heat transfer. Additionally, mesh division techniques and turbulence models are selected based on the geometric dimensions and operating conditions of the compressor and turbine. The simulation results reveal that thermal inertia induces a shift in the dynamic characteristics of the rotor components. Under the same heat transfer conditions, variations in rotational speed have a minimal impact on the shift in the characteristic curve. The working fluid temperature inside the compressor components is lower, with a smaller temperature difference from the wall, resulting in less intense heat transfer compared to the turbine components. Overall, heat transfer accounts for only about 0.1% of the total enthalpy at the inlet. When heat exchange occurs between the working fluid and the walls, around 6–15% of the exchanged heat is converted into changes in technical work, with this percentage increasing as the temperature difference rises. Full article

Twist angle errors along the blade radial direction are uncertain and affected by cutting force, tool wear, and other factors. In this paper, the measured twist angle errors of 13 sections of 72 rotor blades were innovatively analyzed to obtain the rational statistical distribution. It is surprisingly found that the under-deflection systematic deviation of twist angle errors shows a gradually increasing W-shaped distribution along the radial direction, while the scatter is nearly linear. Logically, the statistical model is established based on the linear correlation of the scatter by regression analysis to reduce variable dimension from 13 to 1. The influence of the radial non-uniform twist angle errors’ uncertainty on the aerodynamic performance of the three-dimensional compressor rotor is efficiently quantified combining the non-intrusive polynomial chaos method. The results show that the mean values of mass flow rate, total pressure ratio, and isentropic efficiency at the typical operating conditions are lower than the nominal values due to the systematic deviation, indicating that the under-deflection twist angle errors lead to the decrease in compressor thrust. The compressor’s stable operating range is more sensitive to the scatter of twist angle errors, which is up to an order of magnitude greater than that of the total pressure ratio and isentropic efficiency, indicating the compressor’s safe and stable operation risk increases. Additionally, the flow field at the tip region is significantly affected by twist angle errors, especially at the shock wave position of the near-stall condition. Full article

A Lagrangian method is introduced to analyze the tip leakage vortex (TLV) behavior in a low-speed axial compressor rotor. The finite-time Lyapunov exponent (FTLE) fields are calculated based on the delayed detached-eddy simulation (DDES) results and identifying the FTLE ridges as Lagrangian coherent structures (LCSs). The computational method of the FTLE field in three-dimensional unsteady flow fields is discussed and then applied to the instantaneous flow fields at both the design and near-stall conditions. Results show that the accuracy of the particle trajectory and the density of the initial grid of the particle trajectory greatly affect the results of the FTLE field and, thus, the LCSs. Compared to the Eulerian Q method, which is calculated based on the symmetric and anti-symmetric components of the local velocity gradient tensor, the Lagrangian method has great potential in unraveling the mechanism of complex vortex structures. The LCSs show a transport barrier between the TLV and the secondary TLV, indicating two separate vortices. The aLCSs show the bubble-like and bar-like structure in the isosurfaces corresponding to the bubble and spiral breakdown patterns. Full article

Ice crystal icing occurs in jet engine compressors, which can severely degrade jet engine performance. In this study, we developed an ice crystal trajectory simulation, considering the state changes of ice crystals with a forced convection model, indicating a significant difference in impinging ice crystal content on the blade for tiny ice crystals. Then, ice crystal trajectory simulations were performed for the rotor blade of an axial fan to investigate the effects of ice crystal size and relative humidity on collision characteristics. The results indicate that the surrounding air affects the composition of tiny ice crystals before collision, and the flight time until impingement on the rotor blade varies significantly depending on the span position. Among them, ice crystals with a diameter of 50 μm impinge with water content that is most likely to adhere to the blade. Three-dimensional simulation results show that many ice crystals impinge not only on the leading edge, where icing occurs as revealed by the two-dimensional simulations but also on the trailing edge of the hub side. This study emphasizes the importance of evaluating the three-dimensional impingement position and water content in the prediction of ice crystal icing. Full article

In this paper, a three-dimensional aerodynamics optimization system is built and applied to optimize a rotor blade to balance the conflicts between stall margin, total pressure ratio, adiabatic efficiency, and mass flow rate for the high-loading and transonic-flow fan. A novel flow diagnostic method based on vorticity dynamics theory is utilized to analyze the reasons for the improvement in aerodynamic performance in the optimized transonic fan. In the established aerodynamic optimization method, use the blade profile camber line curvature and its leading edge metal angle as the optimization variables, which are optimized by modifying the coordinates of their control points and introducing a genetic algorithm. Finally, the vorticity dynamics parameters, such as the boundary vorticity flux (BVF), azimuthal vorticity and skin-friction lines are used to diagnose the key flow features in the optimized and baseline fan passage. The results indicate that, by controlling skillfully the blade camber line curvature in the optimization improves the aerodynamic performance of the fan stage, increasing the total pressure ratio by 1.90% while increasing the mass flow rate and adiabatic efficiency by 5.82% and 4.45%, respectively. The formulas from the vorticity dynamics diagnosis method indicate a close link between the aerodynamic performance and vorticity dynamic parameters for the axial fan/compressor passage flow, and that both azimuthal vorticity and boundary vorticity flux have significant influence on fan stage performance. Moreover, the boundary layer separation flow on the rotor blade surface is accompanied by a spike of entropy and static pressure, and their derivative/gradient also suffer drastic changes under the effect of shock waves. Detailed flow information can be obtained about the on-wall with high accuracy based on the vorticity dynamics diagnosis method, which provides researchers with a novel method for the turbomachinery aerodynamic design and analysis in the aero-engine engineering development field. Full article

Computational fluid dynamics- (CFD-) based component-level numerical simulation technology has been widely used in the design of aeroengines. However, due to the strong coupling effects between components, the numerical simulation of the whole engine considering the full three-dimensional flow and multi-component chemical reaction is still very difficult at present. Aimed at this problem, an efficient implicit solver, ‘sprayDyMFoam’ for an unstructured mesh, is developed in this paper based on the Sunway TaihuLight supercomputer. This sprayDyMFoam solver improves the PIMPLE algorithm in the solution of aerodynamic force and adjusts the existing droplet atomization model in the solution of the combustion process so as to meet the matching situation between components and the combustion chamber in the solution process. Meanwhile, the parallel communication mechanism of AMI boundary processing is optimized based on the hardware environment of the Sunway supercomputer. The sprayDyMFoam solver is used to simulate a typical double-rotor turbofan engine: the calculation capacity and efficiency meet the use requirements, and the obtained compressor performance can form a good match with the test. The research proposed in this paper has strong application value in high-confidence computing, complex phenomenon capturing, and time and cost reduction for aeroengine development. Full article

Highly three–dimensional and complex flow structures are closely related to the aerodynamic losses occurring in the transonic axial–flow compressor. The large eddy simulation (LES) approach was adopted to study the aerodynamic performance of the NASA rotor 37 for the cases at the design, the near stall (NS), and the near choke (NC) flow rate. The internal flow vortex topology was analyzed by the Q–criterion method, the omega (Ω) vortex identification method, and the Liutex identification method. It was observed that the Q–criterion method was vulnerable to being influenced by the flow with high–shear deformation rate, especially near the end–wall regions. The Ω method was adopted to recognize the three–dimensional vortex structure with a higher precision than that of the Q–criterion method. Meanwhile, the Liutex vortex identification method showed a good performance in vortex identification, and the corresponding contribution of Liutex components in the vortex topology was analyzed. The results show that the high–vortex fields around the separation line and reattachment line had high vortex components in the x–axis, the tip clearance vortices presented a high–vortex component in the y–axis, and the suction side corner vortex possessed high–vortex components in the y– and z–axes. Full article

As an important component of hydrogen fuel cell vehicles, the air compressor with an air foil bearing rotates at tens of thousands of revolutions per minute. The heat generation concentration problem caused by the high-speed motor loss seriously affects the safe and normal operation of the motor, so it is very important to clarify the loss distribution of the high-speed motor and adopt a targeted loss reduction design for air compressor heat dissipation. In this paper, for an air compressor with a foil bearing with a rated speed of 80,000 rpm, an empirical formula and a three-dimensional transient magnetic field finite element model are used to model and calculate the air friction loss, stator core loss, winding loss and permanent magnet eddy current loss. The accuracy of the analytical calculation method is verified by torque test experiments under different revolutions, and the average simulation accuracy can reach 91.1%. Then, the distribution of the air friction loss, stator core loss, winding loss and eddy current loss of the air compressor motor at different revolutions is obtained by using this method. The results show that the proposed method can effectively calculate the motor rotor loss of a high-speed air compressor with air foil bearing. Although the motor efficiency increases with the increase in motor speed, the absolute value of loss also increases with the increase in motor speed. Stator core loss and air friction loss are the main sources of loss, accounting for 55.64% and 29% of the total motor loss, respectively. The electromagnetic loss of winding, the eddy current and other alloys account for a relatively small proportion, which is 15% in total. The conclusions obtained in this paper can effectively guide calculations of motor loss the motor heat dissipation design of a high-speed air compressor with an air foil bearing. Full article

In order to prolong the service life of multistage axial compressors, it is increasingly important to study the influence of blade surface roughness on the compressor performance. In this paper, a five-stage axial compressor of a real aero-engine was selected as the research object, and an equivalent gravel roughness model was used to model the roughness based on measured blade surface roughness data. Furthermore, the impact of blade surface roughness on the performance at design rotational speed was studied by full three-dimensional numerical simulation, and the mechanism of performance variation caused by the roughness was discussed combined with quantitative and flow field analyses. The results show that, when the blade surface roughness of all blades increases, the peak total efficiency decreases by approximately 0.4%, the blocking mass-flow decreases by approximately 0.3%, and the stable working range changes little. When the surface roughness of all rotor blades increases, the performance decline is close to that of all rotor and stator blades, and the variation in stator blade roughness has little effect on the compressor performance. Regarding the variation in roughness, the performance of the latter stage is more sensitive than that of the previous stage, and the decline in the performance of the fifth stage contributes the most to the total performance degradation of the compressor. Once the surface roughness of the fifth-stage rotor blade increases, the flow in the middle of the rotor blade deteriorates and the stage performance decreases obviously, which is the main reason for the decline in the overall performance. Full article

The onset of rotating stall and surge in compressors limits the operating range of aero-engines. Accurately predicting the key features during these events is critical in the engine design process. In this paper, a three-dimensional computational model for transient simulation of multi-stage axial compressors during stall is proposed. The kinetic equations describing the dynamic process of the compression system are constructed, with a 3D through-flow model for the compression part and a 1D gas collector model for the outlet part. The calculation of the source term is performed using the developed body-force model, which realizes the correlation between the deviation angle and the loss coefficient with the inlet parameters in various flow regions. Validated on a single-stage compressor and a single-rotor fan, the results show that the method is capable of capturing the stall and surge features correctly and that the three-dimensional structure of the stall cell can be captured. In addition, this model could be used for the analysis of the surge load, which is significant for the structural integrity of the compressor. Full article

Boundary-layer flow separation is a common flow feature in many engineering applications. The consequences of flow separation in turbomachinery can be disastrous in terms of performance, stability and noise. In this context, flow separation is particularly difficult to understand because of its three-dimensional and confined aspects. Analyzing the skin friction lines is one key point to understanding and controlling this phenomenon. In the case of separation, the flow at the wall agglutinates around a manifold while the fluid from the boundary layer is ejected toward the flow away from the wall. The analysis of a three-dimensional separation zone based on topology is well addressed for a simple geometry. This paper aims at providing simple rules and methods, with a clear vocabulary based on mathematical background, to conduct a similar analysis with complex turbomachinery geometry (to understand a surface with a high genus). Such an analysis relies on physical principles that help in understanding the mechanisms of flow separation on complex geometries. This paper includes numerous typical turbomachinery surfaces: the stator row, vaneless diffuser, vaned diffuser, axial rotor and shrouded and unshrouded centrifugal impeller. Thanks to surface homeomorphisms, the generic examples presented can easily be converted into realistic shapes. Furthermore, classical turbomachinery problems are also addressed, such as periodicity or rotor clearance. In the last section, the proposed methodology is conducted on a radial diffuser of an industrial compressor. The flow at the wall is extracted from LES computations. This study presents the different closed separation zones in a high-efficiency operating condition. Full article

This paper researches the parametric optimization of a two-stage transonic compressor having a large air bypass at partial rotating speed according to flow analysis for a turbine-based combined cycle engine (TBCC). To obtain adequate thrust, the inlet transonic compressor of the turbofan part of the TBCC is required to have a wider frequently used corrected rotating speed range and a larger mass-flow rate at low rotating speed, which is different from a typical transonic compressor. The one-dimensional blade design parameters and flow path of the baseline two-stage transonic compressor are introduced. With the widely used CFD software Numeca, the three-dimensional flow fields of the baseline transonic compressor and effects of the flow path between Stage 1 and Stage 2 on the inlet mass flow rate are analyzed for indicating the further improvement direction. For design speed (N_C = 1.0), to improve the efficiency at the design point, parametric research is carried out on Rotor 2 to optimize the shock structure and strength, resulting in enhanced efficiency at the design point due to reduced shock loss of Rotor 2. For partial speed (N_C = 0.8 and 0.7), since the flow field analysis indicates that the flow blockage in S1 limits the entire mass flow rate, the parametric redesign of stator S1 aims at obtaining an increased blade throat width to enhance the flow capacity of S1. Simulation confirms the increase in the mass-flow rate and efficiency at partial speed due to the reduction in flow blockage and related viscous losses. Aerodynamic analysis at representative operation points indicates that the modifications of R2 and S1 lead to obvious aerodynamic improvement at all rotating speeds (N_C = 1.0 to 0.7), while maintaining sufficient stall margin. Full article

Based on the COMSOL software, body forces substituted into the Reynolds-averaged Navier–Stokes (RANS) equations as the source terms instead of the actual blade rows were improved to better predict the compressor performance. Improvements in parallel body force modeling were implemented, central to which were the local flow quantities. This ensured accurate and reliable off-design performance prediction. The parallel force magnitude mainly depended on the meridional entropy gradient extracted from three-dimensional (3D) steady single-passage RANS solutions. The COMSOL software could easily and accurately translate the pitchwise-averaged entropy into the grid points of the body force domain. A NASA Rotor 37 was used to quantify the improved body force model to represent the compressor. Compared with the previous model, the improved body force model was more efficient for the numerical calculations, and it agreed well with the experimental data and computational fluid dynamics (CFD) results. The results indicate that the improved body force model could quickly and efficiently capture the flow field through a turbomachinery blade row. Full article

The seal cavity leakage flow has a considerable impact on the performance of the aeroengine, especially on the multistage compressor. Thus, a quasi-three-dimensional simulation program named CAM is developed basing on circumferentially averaged throughflow method. The program enables a rapid diagnosis for the performance degradation of multistage compressor caused by labyrinth wear. The coupling flow field between the seal cavity leakage flow and the main flow field at the root of the shrouded stator of a high-loading three-stage compressor with inlet guide vanes (IGV) was simulated by CAM and the results indicate that seal cavity leakage flow has a significant impact on the overall performance of the compressor. That is, for a 1% increase in the seal-tooth clearance-to-span ratio, the decrease in total pressure ratio was 2.6%, and the reduction in efficiency was 0.6%. Stage performance shows that the seal cavity leakage flow reduces the pressurization capacity of the current stator and the work capacity of the downstream rotor, but has little effect on the upstream blade row. Spanwise distribution of blade element performance shows that the leakage flow leads to an increased flow blockage near the hub, resulting in spanwise migration. The incidence of the stator and rear rotor then change through the entire span. The leakage flow leads to the flow blockage and migration and hence changes the incidence angle, which results in the deterioration of compressor performance. Full article