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NASA NTRS1994

An Overview of Unsteady Three-Dimensional Navier-Stokes Simulations of Multistage Turbomachinery Flows

Fluid dynamics of turbomachines are complicated by inherently three dimensional structures such as endwall boundary layers, hub corner separation bubbles and tip-leakage flows. In addition, the relative motion between rotors and stators causes unsteady aerodynamic interactions to occur between blade rows. It is necessary to understand the aerodynamics associated with these interactions in order to design turbomachines that are both light and compact as well as reliable and efficient. An unsteady, three-dimensional, thin-layer, Navier-Stokes zonal algorithm is used to investigate the unsteady aerodynamics of multi-stage turbines and compressors. Relative motion between rotors and stators is made possible by the use of systems of patched and overlaid grids. Time-averaged pressures and pressure envelopes have been computed for several two- and three-dimensional single- and multi-stage configurations. Flow visualizations and computed results are in good agreement with experimental data.

Gundy-Burlet, Karen L.↗

NASA NTRS1999

Inlet Flow Distortion and Unsteady Blade Response in a Transonic Axial-Compressor Rotor

This paper describes the unsteady blade surface pressures on the first-stage rotor blades of a two-stage transonic axial flow compressor experiencing inlet flow distortion. This study was conducted to demonstrate the ability of a full annulus unsteady Reynolds-averaged Navier-Stokes numerical technique to predict unsteady pressures on the rotor blades operating in a distorted inflow. A total pressure distortion produced by a variable mesh screen mounted near the inlet was used to excite the unsteady blade loading on the rotor. On-blade pressure transducers were used to measure the unsteady blade surface pressure. These pressures and the resulting transient load on the rotor blades were compared to the numerical prediction. It is important to develop numerical techniques to predict these transient loads to better understand the response of compressor blades to forcing functions. With this enhanced understanding and ability to predict these transient forces, more robust compressors can be developed. In the study, a high definition of the inlet flow distortion was achieved by rotating the distortion screens. In this manner the inlet flow distortion and the distortion at the first stage stator leading edge were measured at approximately every 0.7 degrees. This full annulus high definition of the inlet flow distortion was used as the inlet boundary condition for the numerical technique. The experimental measurements and numerical analyses are highly complementary in this study. Detailed comparisons between the measurements and the numerical analyses indicate that the current numerical procedure calculates the unsteady aerodynamic pressure on the blade surfaces reasonably well. Further, the agreement of the measured and predicted rotor exit flow distortion at the first stage stator leading edge provides verification of the numerical technique.

Rabe, D. C.↗

NASA NTRS1999

Development of Hub Corner Stall and Its Influence on the Performance of Axial Compressor Blade Rows

A detailed investigation has been performed to study hub corner stall phenomena in compressor blade rows. Three-dimensional flows in a subsonic annular compressor stator and in a transonic compressor rotor have been analyzed numerically by solving the Reynolds-averaged Navier-Stokes equations. The numerical results and the existing experimental data are interrogated to understand the mechanism of compressor hub comer stall. Both the measurements and the numerical solutions for the stator indicate that a strong twister-like vortex is formed near the rear part of the blade suction surface. Low-momentum fluid inside the hub boundary layer is transported toward the suction side of the blade by this vortex. On the blade suction surface near the hub, this vortex forces fluid to move against the main flow direction and a limiting stream surface is formed near the hub. The formation of this vortex is the main mechanism of hub corner stall. When the aerodynamic loading is increased, the vortex initiates further upstream, which results in a larger corner stall region. For the transonic compressor rotor studied in this paper, the numerical solution indicates that a mild hub corner stall exists at 100 percent rotor speed. The hub corner stall, however, disappears at the reduced blade loading, which occurs at 60 percent rotor design speed. The present study demonstrates that hub comer stall is caused by a three-dimensional vortex system and that it does not seem to be correlated with a simple diffusion factor for the blade row.

Hah, C.↗

NASA NTRS2003

Blade Row Interaction Effects on the Performance of a Moderately Loaded NASA Transonic Compressor Stage

Blade row interaction effects on loss generation in compressors have received increased attention as compressor work-per-stage and blade loading have increased. Two dimensional Laser Doppler Velocimeter measurements of the velocity field in a NASA transonic compressor stage show the magnitude of interactions in the velocity field at the peak efficiency and near stall operating conditions. The experimental data are presented along with an assessment of the velocity field interactions. In the present study the experimental data are used to confirm the fidelity of a three-dimensional, time-accurate, Navier Stokes calculation of the stage using the MSU-TURBO code at the peak efficiency and near stall operating conditions. The simulations are used to quantify the loss generation associated with interaction phenomena. At the design point the stator pressure field has minimal effect on the rotor performance. The rotor wakes do have an impact on loss production in the stator passage at both operating conditions. A method for determining the potential importance of blade row interactions on performance is presented.

VanZante, Dale E.↗

NASA NTRS2003

Task I: A Computational Model for Short Wavelength Stall Inception and Development In Multi-Stage Compressors

A computational model is presented for simulating axial compressor stall inception and development via disturbances with length scales on the order of several (typically about three) blade pitches. The model was designed for multi-stage compressors in which stall is initiated by these short wavelength disturbances, also referred to as spikes. The inception process described is fundamentally nonlinear, in contrast to the essentially linear behavior seen in so-called modal stall inception . The model was able to capture the following experimentally observed phenomena: (1) development of rotating stall via short wavelength disturbances, (2) formation and evolution of localized short wavelength stall cells in the first stage of a mismatched compressor, (3) the switch from long to short wavelength stall inception resulting from the re-staggering of the inlet guide vane, (4) the occurrence of rotating stall inception on the negatively sloped portion of the compressor characteristic. Parametric investigations indicated that (1) short wavelength disturbances were supported by the rotor blade row, (2) the disturbance strength was attenuated within the stators, and (3) the reduction of inter-blade row gaps can suppress the growth of short wavelength disturbances. It is argued that each local component group (rotor plus neighboring stators) has its own instability point (i.e. conditions at which disturbances are sustained) for short wavelength disturbances, with the instability point for the compressor set by the most unstable component group.

Suder, Kenneth↗

NASA NTRS2004

Magnetic Circuit Model of PM Motor-Generator to Predict Radial Forces

A magnetic circuit model is developed for a PM motor for flywheel applications. A sample motor is designed and modeled. Motor configuration and selection of materials is discussed, and the choice of winding configuration is described. A magnetic circuit model is described, which includes the stator back iron, rotor yoke, permanent magnets, air gaps and the stator teeth. Iterative solution of this model yields flux linkages, back EMF, torque, power, and radial force at the rotor caused by eccentricity. Calculated radial forces are then used to determine motor negative stiffness.

McLallin, Kerry↗

NASA NTRS2004

Reliable and Affordable Control Systems Active Combustor Pattern Factor Control

Active, closed-loop control of combustor pattern factor is a cooperative effort between Honeywell (formerly AlliedSignal) Engines and Systems and the NASA Glenn Research Center to reduce emissions and turbine-stator vane temperature variations, thereby enhancing engine performance and life, and reducing direct operating costs. Total fuel flow supplied to the engine is established by the speed/power control, but the distribution to individual atomizers will be controlled by the Active Combustor Pattern Factor Control (ACPFC). This system consist of three major components: multiple, thin-film sensors located on the turbine-stator vanes; fuel-flow modulators for individual atomizers; and control logic and algorithms within the electronic control.

McCarty, Bob↗

NASA NTRS2004

Computation of a Single Airfoil Gust Response and Gust-Cascade Interaction Using the CE/SE Method

The problems 1 and 2 in Category 3 are solved using the space-time conservation element and solution element (CE/SE) method. Problem 1 concerns the acoustic field generated by the interaction of a harmonic vertical gust with a single isolated airfoil. Problem 2 models rotor-stator interaction in a 2D cascade. Both problems involve complex geometries and flow physics including vortex shielding and acoustic radiation. An unstructured triangular mesh is used to solve both problems. For problem 2, the Giles approach is incorporated with the CE/SE method to handle non-equal pitches of the rotor and stator. Numerical solution of both near and far fields of problem 1 are presented and compared with a frequency-domain solver GUST3D and a time-domain high-order Discontinuous Spectra Element Method (DSEM) solutions. For problem 2, numerical solutions on the blade surface, inlet and outlet planes are presented.

Wang, Xiao-Yen↗

NASA NTRS1950

Investigation of Performance of Axial-Flow Compressor of XT-46 Turbine-Propeller Engine. II - Performance of Revised Compressor at Design Equivalent Speed: Performance of Revised Compressor at Design Equivalent Speed - II

The compressor from the XT-46 turbine-propeller engine was revised by removing the last two rows of stator blades and by eliminating the interstage leakage paths described in a previous report. With the revised compressor, the flow choking point shifted upstream into the last rotor-blade row but the maximum weight flow was not increased over that of the original compressor. The flow range of the revised compressor was reduced to about two-thirds that obtained with the original compressor. The later stages of the compressor did not produce the design static-pressure increase probably because of excessive boundary-layer build-up in this region. Measurements obtained in the ninth-stage stator showed that the performance up to this station was promising but that the last three stages of the compressor were limiting the useful operating range of the preceding stages. Some modifications in flow-passage geometry and blade settings are believed to be necessary, however, before any major improvements in over-all compressor performance can be obtained.

Creagh, John W. R.↗

NASA NTRS2005

Flow Measurements and Multiple Pure Tone Noise From a Forward Swept Fan

A forward-swept fan, designated the Quiet High Speed Fan (QHSF), was tested in the NASA Glenn 9- by 15-foot Low Speed Wind Tunnel to investigate its noise reduction relative to a baseline fan of the same aerodynamic performance. The objective of the Quiet High Speed Fan was a 6-dB reduction in the Effective Perceived Noise Level relative to the baseline fan at the takeoff condition. The intent of the Quiet High Speed Fan design was to provide both a multiple pure tone noise reduction from the forward sweep of the fan rotor and a rotor-stator interaction blade passing tone noise reduction from a leaned stator. The tunnel noise data indicted that the Quiet High Speed Fan was quieter than the baseline fan for a significant portion of the operating line and was 6 dB quieter near the takeoff condition. Although reductions in the multiple pure tones were observed, the vast majority of the EPNdB reduction was a result of the reduction in the blade passing tone and its harmonics. Laser Doppler Velocimetry (LDV) and shroud unsteady pressure measurement data were obtained upstream of the QHSF and baseline rotors to improve the understanding of the shocks which propagate upstream of the two fans when they are operated at high speeds. The flow phenomena that produce multiple pure tone noise is discussed and compared to measurements of the fan acoustic inlet modes and the far field noise signature of the fan.

Weir, Donald S.↗

NASA NTRS1996

High-Temperature Magnetic Bearings for Gas Turbine Engines

Magnetic bearings are the subject of a new NASA Lewis Research Center and U.S. Army thrust with significant industry participation, and coordination with other Government agencies. The NASA/Army emphasis is on high-temperature applications for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of these engines by eliminating the lubrication system. They could also increase the DN (diameter of the bearing times rpm) limit on engine speed and allow active vibration cancellation systems to be used--resulting in a more efficient, "more electric" engine. Finally, the Integrated High-Performance Turbine Engine Technology (IHPTET) Program, a joint Department of Defense/industry program, identified a need for a hightemperature (as high as 1200 F) magnetic bearing that could be demonstrated in a phase III engine. This magnetic bearing is similar to an electric motor. It has a laminated rotor and stator made of cobalt steel. Wound around the stator are a series of electrical wire coils that form a series of electric magnets around the circumference. The magnets exert a force on the rotor. A probe senses the position of the rotor, and a feedback controller keeps it in the center of the cavity. The engine rotor, bearings, and case form a flexible structure that contains a large number of modes. The bearing feedback controller, which could cause some of these modes to become unstable, could be adapted to varying flight conditions to minimize seal clearances and monitor the health of the system. Cobalt steel has a curie point greater than 1700 F, and copper wire has a melting point beyond that. Therefore, practical limitations associated with the maximum magnetic field strength in the cobalt steel and the stress in the rotating components limit the temperature to about 1200 F. The objective of this effort is to determine the limits in temperature and speed of a magnetic bearing operating in an engine. Our approach is to use our in-house experience in magnets, mechanical components, high-temperature materials, and surface lubrication to build and test a magnetic bearing in both a rig and an engine. Testing will be done at Lewis or through cooperative programs in industrial facilities.

Source record↗

NASA NTRS1998

High-Temperature Magnetic Bearings Being Developed for Gas Turbine Engines

Magnetic bearings are the subject of a new NASA Lewis Research Center and U.S. Army thrust with significant industry participation, and cooperation with other Government agencies. The NASA/Army emphasis is on high-temperature applications for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of these engines by eliminating the lubrication system. They could also increase the DN (diameter of bearing times the rpm) limit on engine speed and allow active vibration cancellation systems to be used, resulting in a more efficient, "more electric" engine. Finally, the Integrated High Performance Turbine Engine Technology (IHPTET) program, a joint Department of Defense/industry program, identified a need for a high-temperature (1200 F) magnetic bearing that could be demonstrated in their Phase III engine. This magnetic bearing is similar to an electric motor. It has a laminated rotor and stator made of cobalt steel. Wound around the stator's circumference are a series of electrical wire coils which form a series of electric magnets that exert a force on the rotor. A probe senses the position of the rotor, and a feedback controller keeps it centered in the cavity. The engine rotor, bearings, and casing form a flexible structure with many modes. The bearing feedback controller, which could cause some of these modes to become unstable, could be adapted to varying flight conditions to minimize seal clearances and monitor the health of the system.

Kascak, Albert F.↗

NASA NTRS2005

Closed Loop Active Flow Separation Detection and Control in a Multistage Compressor

Active closed loop flow control was successfully demonstrated on a full annulus of stator vanes in a low speed axial compressor. Two independent methods of detecting separated flow conditions on the vane suction surface were developed. The first technique detects changes in static pressure along the vane suction surface, while the second method monitors variation in the potential field of the downstream rotor. Both methods may feasibly be used in future engines employing embedded flow control technology. In response to the detection of separated conditions, injection along the suction surface of each vane was used. Injected mass flow on the suction surface of stator vanes is known to reduce separation and the resulting limitation on static pressure rise due to lowered diffusion in the vane passage. A control algorithm was developed which provided a proportional response of the injected mass flow to the degree of separation, thereby minimizing the performance penalty on the compressor system.

Bright, Michelle M.↗

NASA NTRS2004

Fan Noise Prediction

Aircraft noise emission level restrictions in and around airports continue to grow more stringent every few years. Thus, it is important to predict noise emissions from aircraft accurately. Predicting noise from the engine(s) is an integral part of the efforts to characterize the noise signature of an aircraft. An important source of engine noise is the rotor-stator interaction noise produced as a result of impingement of fan rotor wakes on the fan exit guide vanes. Interaction noise propagates through the inlet and exhaust ducts of the engine and radiates to the far field. noise levels for a range of model fans stages that represent current aircraft engine designs. Eversman's radiation codes calculate both the inlet and exhaust noise radiation by propagating the internally measured rotor-stator interaction noise to the far field. Predicted far field sound pressure levels are then compared to the measured levels from wind tunnel tests. This effort's objective is to prove that the predicted levels actually describe the measured levels.

France, Joshua I.↗

NASA NTRS2002

Life-Extending Control for Aircraft Engines Studied

Current aircraft engine controllers are designed and operated to provide both performance and stability margins. However, the standard method of operation results in significant wear and tear on the engine and negatively affects the on-wing life--the time between cycles when the engine must be physically removed from the aircraft for maintenance. The NASA Glenn Research Center and its industrial and academic partners have been working together toward a new control concept that will include engine life usage as part of the control function. The resulting controller will be able to significantly extend the engine's on-wing life with little or no impact on engine performance and operability. The new controller design will utilize damage models to estimate and mitigate the rate and overall accumulation of damage to critical engine parts. The control methods will also provide a means to assess tradeoffs between performance and structural durability on the basis of mission requirements and remaining engine life. Two life-extending control methodologies were studied to reduce the overall life-cycle cost of aircraft engines. The first methodology is to modify the baseline control logic to reduce the thermomechanical fatigue (TMF) damage of cooled stators during acceleration. To accomplish this, an innovative algorithm limits the low-speed rotor acceleration command when the engine has reached a threshold close to the requested thrust. This algorithm allows a significant reduction in TMF damage with only a very small increase in the rise time to reach the commanded rotor speed. The second methodology is to reduce stress rupture/creep damage to turbine blades and uncooled stators by incorporating an engine damage model into the flight mission. Overall operation cost is reduced by an optimization among the flight time, fuel consumption, and component damages. Recent efforts have focused on applying life-extending control technology to an existing commercial turbine engine, and doing so without modifying the hardware or adding sensors. This approach makes it possible to retrofit existing engines with life-extending control technology by changing only the control software in the full-authority digital engine controller (FADEC). The significant results include demonstrating a 20- to 30-percent reduction in TMF damage to the hot section by developing and implementing smart acceleration logic during takeoff. The tradeoff is an increase, from 5.0 to 5.2 sec, in the time required to reach maximum power from ground idle. On a typical flight profile of a cruise at Mach 0.8 at an altitude of 41,000 ft, and cruise time of 104 min, the optimized system showed that a reduction in cruise speed from Mach 0.8 to 0.79 can achieve an estimated 25-to 35-percent creep/rupture damage reduction in the engine's hot section and a fuel savings of 2.1 percent. The tradeoff is an increase in flight time of 1.3 percent (1.4 min).

Guo, Te-Huei↗

NASA NTRS2004

Computation of Gust-Cascade Interaction Using the CE/SE Method

The problem 2 in Category 3 of the 4th Computational Aeroacoustic(CAA) Workshop is solved using the space-time conservation element and solution element (CE/SE) method. This problem models rotor-stator interaction in a 2D cascade. It involves complex geometries and flow physics including vortex shedding and acoustic radiation. The parallel version of the 2D nonlinear Euler solver is used with an unstructured triangular mesh to solve this problem. The Giles approach is incorporated with the CE/SE method to handle non-equal pitches of the rotor and stator. Validation on the Giles approach is performed using Problem 3.1 in the 2nd CAA Workshop. The space-time CE/SE method is a finite volume method with second-order accuracy in both space and time. The flux conservation is enforced in both space and time instead of space only. It has low numerical dissipation and dispersion errors. It uses simple non-reflecting boundary conditions and is compatible with unstructured meshes. It is simple, flexible, and generate reasonably accurate solutions. The CE/SE method has been successfully applied to solve numerous practical problems, especially aeroacoustic problems. Some preliminary numerical results of the benchmark problem 3.2 of the 4th CAA Workshop are shown. The steady-state pressure contour is plotted. The mean pressure distribution on the blade surface is compared with Turbo solution showing a good agreement. The sound pressure level versus the rotor harmonic n at the six designated positions on the blade surface, three locations at inlet plane, and three locations at the outlet plane are plotted. It can be seen that the acoustic response exists only at the excitation frequencies (n = 1,2,3). On the blade surface, the acoustic wave at n = 1 is dominant, while at the inlet and outlet planes, the sound pressure level at n = 2 becomes the largest, which is similar to the results presented. The distribution of sound pressure level at different spatial modes along the z- direction is plotted for n = 1,2,3, respectively. It shows that the spatial modes m = -32 and 22 at n = 1 exponentially decay, and the spatial modes m = 10 at n = 2, m = -42 and 12 at n = 3 propagate both upstream and downstream, which agrees with the prediction based on the linearized theory. Some oscillations are observed, which needs to be investigated further. In the final paper, the numerical results will be compared with a frequency-domain solver LINFLUX solution if it is available.

Wang, X.-Y.↗

NASA NTRS2003

Ultra-High-Power-Density Motor Being Developed for Future Aircraft

To support the Revolutionary Aeropropulsion Concept Program, NASA Glenn Research Center' s Structural Mechanics and Dynamics Branch is developing a compact, nonpolluting, bearingless electric machine with electric power supplied by fuel cells for future more-electric aircraft. The use of such electric drives for propulsive fans or propellers depends on the successful development of ultra-high-power-density machines that can generate power densities of 50 hp/lb or more, whereas conventional electric machines generate usually 0.2 hp/lb. One possible candidate for such ultra-high-power-density machines, a round-rotor synchronous machine with an engineering current density as high as 20 000 A/cm2 was selected to investigate how much torque and power can be produced. A simple synchronous machine model that consists of rotor and stator windings and back-irons was considered first. The model had a sinusoidally distributed winding that produces a sinusoidal distribution of flux P poles. Excitation of the rotor winding produced P poles of rotor flux, which interacted with the P stator poles to produce torque.

Choi, Benjamin B.↗

NASA NTRS2004

Flutter Stability of the Efficient Low Noise Fan Calculated

The TURBO-AE aeroelastic code has been used to verify the flutter stability of the Efficient Low Noise Fan (ELNF), which is also referred to as the trailing-edge blowing fan. The ELNF is a unique technology demonstrator being designed and fabricated at the NASA Glenn Research Center for testing in Glenn's 9-by-15-Foot Low-Speed Wind Tunnel. In the ELNF, air can be blown out of slots near the trailing edges of the fan blades to fill in the wakes downstream of the rotating blades. This filling of the wakes leads to a reduction of the rotor-stator interaction (tone) noise that results from the interaction of wakes with the downstream stators. The ELNF will demonstrate a 1.6-EPNdB1 reduction in tone noise through wake filling, without increasing the broadband noise. Furthermore, the reduced blade row interaction will decrease the possibility of forced response and enable closer spacing of blade rows, thus reducing engine length and weight. During the design of the ELNF, the rotor blades were checked for flutter stability using the detailed aeroelastic analysis capability of the three-dimensional Navier-Stokes TURBOAE code. The aeroelastic calculations were preceded by steady calculations in which the blades were not allowed to vibrate. For each rotational speed, as the back-pressure was increased, the mass flow rate decreased, and the operating point moved along the constant speed characteristic (speed-line) from choke to stall as shown on the fan map. The TURBO-AE aeroelastic analyses were performed separately for the first two vibration modes (bending and torsion) and covered the complete range of interblade phase angles or nodal diameters at which flutter can occur. The results indicated that the ELNF blades would not encounter flutter at takeoff conditions. The calculations were then repeated for a part-speed condition (70-percent rotational speed), and the results again showed no flutter in the operating region. On the fan map (shown), the predicted flutter point at part speed condition was located beyond the stall line, which means that the ELNF will not encounter flutter since it will never operate beyond the stall line. All the calculations done so far have been for the nonblowing case, and selected calculations will be repeated with air blowing from the trailing edge of the fan.

Bakhle, Milind A.↗