Wind-tunnel Tests of Two Hamilton Standard Propellers Embodying Clark Y and NACA 16 Series Blade Sections
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AIRFOILS - CLARK Y PROPELLER - CHARATERISTICS↗
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Impact resistant boron/aluminum composites for large fan blades
Blade-like specimens were subjected to static ballistic impact testing to determine their relative FOD impact resistance levels. It was determined that a plus or minus 15 deg layup exhibited good impact resistance. The design of a large solid boron/aluminum fan blade was conducted based on the FOD test results. The CF6 fan blade was used as a baseline for these design studies. The solid boron/aluminum fan blade design was used to fabricate two blades. This effort enabled the assessment of the scale up of existing blade manufacturing details for the fabrication of a large B/Al fan blade. Existing CF6 fan blade tooling was modified for use in fabricating these blades.
Oller, T. L.↗
Reduction of blade-vortex interaction noise using higher harmonic pitch control
An acoustics test using an aeroelastically scaled rotor was conducted to examine the effectiveness of higher harmonic blade pitch control for the reduction of impulsive blade-vortex interaction (BVI) noise. A four-bladed, 110 in. diameter, articulated rotor model was tested in a heavy gas (Freon-12) medium in Langley's Transonic Dynamics Tunnel. Noise and vibration measurements were made for a range of matched flight conditions, where prescribed (open-loop) higher harmonic pitch was superimposed on the normal (baseline) collective and cyclic trim pitch. For the inflow-microphone noise measurements, advantage was taken of the reverberance in the hard walled tunnel by using a sound power determination approach. Initial findings from on-line data processing for three of the test microphones are reported for a 4/rev (4P) collective pitch control for a range of input amplitudes and phases. By comparing these results to corresponding baseline (no control) conditions, significant noise reductions (4 to 5 dB) were found for low-speed descent conditions, where helicopter BVI noise is most intense. For other rotor flight conditions, the overall noise was found to increase. All cases show increased vibration levels.
Brooks, Thomas F.↗
Reduction of blade-vortex interaction noise through higher harmonic pitch control
An acoustics test using an aeroelastically scaled rotor was conducted to examine the effectiveness of higher harmonic blade pitch control for the reduction of impulsive blade-vortex interaction (BVI) noise. A four-bladed, 110 in. diameter, articulated rotor model was tested in a heavy gas (Freon-12) medium in Langley's Transonic Dynamics Tunnel. Noise and vibration measurements were made for a range of matched flight conditions, where prescribed (open-loop) higher harmonic pitch was superimposed on the normal (baseline) collective and cyclic trim pitch. For the inflow-microphone noise measurements, advantage was taken of the reverberance in the hard walled tunnel by using a sound power determination approach. Initial findings from on-line data processing for three of the test microphones are reported for a 4/rev (4P) collective pitch control for a range of input amplitudes and phases. By comparing these results to corresponding baseline (no control) conditions, significant noise reductions (4 to 5 dB) were found for low-speed descent conditions, where helicopter BVI noise is most intense. For other rotor flight conditions, the overall noise was found to increase. All cases show increased vibration levels.
Brooks, Thomas F.↗
Correlation of Full-Scale Isolated Proprotor Performance and Loads
A full-scale isolated proprotor test is currently being conducted in the USAF National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel at NASA Ames. The test article is a 3-bladed research rotor derived from the right-hand rotor of the AW609; this rotor was manufactured by Bell Helicopter under contract to NASA. In this paper, this research rotor is referred to as "699". The test, nearly completed, is an integral part of the initial checkout test of the newly developed Tiltrotor Test Rig (TTR), whose purpose is to test advanced, full-scale proprotors in the NFAC. Figure 1 shows the TTR/699 installed in the 40- by 80-Foot test section. The TTR rotor axis is horizontal and the rig rotates in yaw on the wind tunnel turntable for conversion (transition) and helicopter mode testing. To date, a substantial amount of wind tunnel test data has already been acquired. The completed operational conditions include hover, airplane mode (cruise, wind tunnel airspeed V=61 to 267 knots), and the helicopter and conversion conditions (with a comprehensive sweep of the TTR yaw angle ranging, to date, from 90-deg yaw helicopter mode to 30-deg yaw conversion mode, at varying airspeeds). This 699 proprotor performance and loads correlation study uses these newly acquired wind tunnel test data. This paper represents the third analytical study, coming after two earlier analytical studies on the TTR/699; that is, a 2018 paper on pre-test predictions of 699 performance and loads, Ref. 1, and an upcoming January 2019 paper on aeroelastic stability analysis of the TTR/699 installed in the 40- by 80-Foot Wind Tunnel, Ref. 2. Reference 8 will present an overview of the entire TTR/699 test program. For completeness, Ref. 3 addresses the development and initial testing of the TTR. Background information on the TTR effort at NASA Ames can be found at the Aeromechanics website: https://rotorcraft.arc.nasa.gov/Research/Facilities/ttr.html. To the authors' knowledge, the full-scale results presented in this paper are the first of their kind. A literature survey brought up several existing correlation studies, but these were either based on small-scale test data (for example, the studies performed by the University of Maryland) or full-scale aircraft flight test data (for example, flight tests conducted by Bell Helicopter). Separately, the 2009 NASA study involving the JVX rotor is relevant (see Ref.4). The JVX is closely similar to the 699 in size and aerodynamics, and is accordingly a good reference for performance calculations. In Ref. 1 (as mentioned above), pre-test reality checks of the current analytical model were made by comparing JVX and 699 predictions in hover and forward flight (airplane mode).
Isolated Proprotor Performance↗
Design and Test of Mixed-flow Impellers VI : Performance and Parabolic-bladed Impeller with Shroud Redesigned by Rapid Approximate Method
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Smith, Kenneth J↗
Analysis of 7- X 10-foot high speed wind tunnel shaft loads in support of fan blade failure investigation
This is a report of the investigation of the High-Speed 7- X 10-Foot Wind Tunnel at NASA Langley Research Center, which experienced a catastrophic failure of all 18 Sitka spruce fan blades during operation at 0.8 Mach number on 2 July 1985. The High-Speed Tunnel, a closed-circuit/single-return atmospheric wind tunnel, had been operated since 1945 to support a wide range of subsonic aerodynamic tests and studies. The failed blade set had been in use since 1975. In addition to blade loss, the most significant damage was a bent main drive shaft for a total estimated damage loss of 1.7 million dollars. An analysis of the natural frequency characteristics as well as loads, reactions, stresses, and deflections of the fan drive system resulting from steady-state and dynamic loads due to unbalance was performed. Transient load cases were simulated by step input and ramp input loading functions intended to simulate the loss of one to nine blades (maximum unbalance forces).
Faison, Richard W.↗
Axial-flow fan and compressor blade design data on 52.5 degrees stagger and further verification of cascade data by rotor tests
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AIRFOILS - NACA 65-410↗
Design and Testing of Braided Composite Fan Case Materials and Components
Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.
Roberts, Gary D.↗
Design and Testing of Braided Composite Fan Case Materials and Components
Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.
Roberts, Gary D.↗
A study of casing treatment stall margin improvement phenomena
The results of a program of experimental and analytical research in casing treatments over axial compressor rotor blade tips are presented. Circumferential groove, axial-skewed slot and blade angle slot treatments were tested at low speeds. With the circumferential groove treatment the stalling flow was reduced 5.8% at negligible efficiency sacrifice. The axial-skewed slot treatment improved the stalling flow by 15.3%; 1.8 points in peak efficiency were sacrificed. The blade angle slot treatment improved the stalling flow by 15.0%; 1.4 points in peak efficiency were sacrificed. The favorable stalling flow situations correlated well with observations of higher-than-normal surface pressures on the rotor blade pressure surfaces in the tip region, and with increased maximum diffusions on the suction surfaces. Annulus wall pressure gradients, especially in the 50 to 75% chord region, are also increased and blade surface pressure loadings are shifted toward the trailing edge for treated configurations.
Prince, D. C., Jr.↗
Maximum Mean Lift Coefficient Characteristics at Low Tip Mach Numbers of a Hovering Helicopter Rotor Having an NACA 64(1)A012 Airfoil Section
An investigation has been conducted on the Langley helicopter test tower to determine experimentally the maximum mean lift-coefficient characteristics at low tip Mach number and a limited amount of drag- divergence data at high tip Mach number of a helicopter rotor having an NACA 64(1)AO12 airfoil section and 8 deg of linear washout. Data are presented for blade tip Mach numbers M(t) of 0.29 to 0.74 with corresponding values 6 6 of tip Reynolds number of 2.59 x 10(exp 6) and 6.58 x 10(exp 6). Comparisons are made between the data from the present rotor with results previously obtained from two other rotors: one having NACA 0012 airfoil sections and the other having an NACA 0009 airfoil tip section. At low tip Mach numbers, the maximum mean lift coefficient for the blade having the NACA 64(1)AO12 section was about 0.08 less than that obtained with the blade having the NACA 0009 tip section and 0.21 less than the value obtained with the blade having the NACA 0012 tip section. Blade maximum mean lift coefficient values were not obtained for Mach number values greater than 0.47 because of a blade failure encountered during the tests. The effective mean lift-curve slope required for predicting rotor thrust varied from 5.8 for the tip Mach nuniber range of 0.29 to 0.55 to a value of 6.65 for a tip Mach number of 0.71. The blade pitching-moment coefficients were small and relatively unaffected by changes in thrust coefficient and Mach number. In the instances in which stall was reached, the break in the blade pitching-moment curve was in a stable direction. The efficiency of the rotor decreased with an increase in tip speed. Expressed as figure of merit, at a tip Mach number of 0.29 the maximum value was about 0.74. Similar measurements made on another rotor having an NACA 0012 airfoil and with a rotor having an NACA 0009 tip section, showed a value of 0.75. Synthesized section lift and profile-drag characteristics for the rotor-blade airfoil section are presented as an aid in predicting the high-tip-speed performance of rotors having similar airfoils.
Powell, Robert D., Jr.↗
Inducer Hydrodynamic Forces in a Cavitating Environment
Marshall Space Flight Center has developed and demonstrated a measurement device for sensing and resolving the hydrodynamic loads on fluid machinery. The device - a derivative of the six-component wind tunnel balance - senses the forces and moments on the rotating device through a weakened shaft section instrumented with a series of strain gauges. This rotating balance was designed to directly measure the steady and unsteady hydrodynamic loads on an inducer, thereby defining the amplitude and frequency content associated with operating in various cavitation modes. The rotating balance was calibrated statically using a dead-weight load system in order to generate the 6 x 12 calibration matrix later used to convert measured voltages to engineering units. Structural modeling suggested that the rotating assembly first bending mode would be significantly reduced with the balance s inclusion. This reduction in structural stiffness was later confirmed experimentally with a hammer-impact test. This effect, coupled with the relatively large damping associated with the rotating balance waterproofing material, limited the device s bandwidth to approximately 50 Hertz Other pre-test validations included sensing the test article rotating assembly built-in imbalance for two configurations and directly measuring the assembly mass and buoyancy while submerged under water. Both tests matched predictions and confirmed the device s sensitivity while stationary and rotating. The rotating balance was then demonstrated in a water test of a full-scale Space Shuttle Main Engine high-pressure liquid oxygen pump inducer. Experimental data was collected a scaled operating conditions at three flow coefficients across a range of cavitation numbers for the single inducer geometry and radial clearance. Two distinct cavitation modes were observed symmetric tip vortex cavitation and alternate-blade cavitation. Although previous experimental tests on the same inducer demonstrated two additional cavitation modes at lower inlet pressures, these conditions proved unreachable with the rotating balance installed due to the intense dynamic environment. The sensed radial load was less influenced by flow coefficient than by cavitation number or cavitation mode although the flow coefficient range was relatively narrow. Transition from symmetric tip vortex to alternate-blade cavitation corresponded to changes in both radial load magnitude and radial load orientation relative to the inducer. Sensed moments indicated that the effective load center moved downstream during this change in cavitation mode. An occurrence of "higher+rdex cavitation" was also detected in both the stationary pressures and the rotating balance data although the frequency of the phenomena was well above the reliable bandwidth of the rotating balance. In summary the experimental tests proved both the concept and device s capability despite the limitations and confirmed that hydrodynamically-induced forces and moments develop in response to the unbalanced pressure field, which is, in turn, a product of the cavitation environment.
Skelley, Stephen E.↗
Experimental investigation of model variable-geometry and ogee tip rotors
An experimental investigation was conducted to systematically explore the effects of inter-blade spatial relationships and pitch variations on rotor performance and wake geometry. Variable-geometry rotors consisting of various combinations of blade length, axial spacing, azimuth spacing, and collective pitch were tested at model scale in hover and forward flight. In addition, a hover test of a model rotor with an ogee blade tip design was conducted to determine its performance and wake characteristics. The results of this investigation indicate that properly selected variable geometry rotor configurations can offer substantial improvements in hover performance without adversely affecting forward flight performance. Axial spacing of alternate blades was found to provide the greatest performance benefit, and further improvements were achieved by combining azimuth spacing with axial spacing. The performance benefit appears to be related to the relief of local adverse aerodynamic phenomena produced by vortex interference. The ogee tip design was found to substantially reduce the concentrated core intensity of the tip vortex, and could thus prove beneficial for the relief of blade-vortex interaction problems. However, the ogee tip was found to reduce hover performance at model scale.
Landgrebe, A. J.↗
Fabrication of low-cost Mod-OA wood composite wind turbine blades
The wood composite blades were fabricated by using epoxy resin-bonded laminates of Douglas fir veneers for the leading edge spar sections and honeycomb-cored birch plywood panels for the blade trailing edge or afterbody sections. The blade was joined to the wind turbine hub assembly by epoxy resin-bonded steel load take-off studs. The wood composite blades were installed in the Mod-OA wind turbine test facility at Kahuku, Hawaii. The wood composite blades have successfully completed high power (average of 150 kW) operations for an eighteen month period (nearly 8,000 hr) before replacement with another set of wood composite blades. The original set of blades was taken out of service because of the failure of the shank on one stud. An inspection of the blades at NASA-Lewis showed that the shank failure was caused by a high stress concentration at a corrosion pit on the shank fillet radius which resulted in fatigue stresses in excess of the endurance limit.
Lark, R. F.↗
Effect of Favorable Pressure Gradients on Turbine Blade Pressure Surface Heat Transfer
Recent measurements on a turbine rotor showed significant relaminarization effects. These effects were evident on the pressure surface heat transfer measurements. The character of the heat transfer varied with Reynolds number. Data were obtained for exit Reynolds numbers between 500,000 and 880,000. Tests were done with a high level of inlet turbulence, 7.5%. At lower Reynolds numbers the heat transfer was similar to that for laminar flow, but at a level higher than for laminar flow. At higher Reynolds numbers the heat transfer was similar to turbulent flow, when the acceleration parameter, K, was sufficiently small. The proposed paper discusses the experimental results, and also discusses approaches to calculating the surface heat transfer for the blade surface. Calculations were done using a three-dimensional Navier-Stokes CFD analysis. The results of these tests, when compared with previous blade tests in the same facility, illustrate modeling difficulties that were encountered in CFD predictions. The two blades were in many ways similar. However, the degree of agreement between the same analysis and the experimental data was significantly different. These differences are highlighted to illustrate where improvements in modeling approaches are needed for transitional flows.
Boyle, Robert J.↗
Measurement of Rotorcraft Blade Deformation using Projection Moire Interferometry
Projection Moire Interferometry (PMI) has been used to obtain near instantaneous, quantitative blade deformation measurements of a generic rotorcraft model at several test conditions. These laser-based measurements provide quantitative, whole field, dynamic blade deformation profiles conditionally sampled as a function of rotor azimuth. The instantaneous nature of the measurements permits computation of the mean and unsteady blade deformation, blade bending, and twist. The PMI method is presented, and the image processing steps required to obtain quantitative deformation profiles from PMI interferograms are described. Experimental results are provided which show blade bending, twist, and unsteady motion. This initial proof-of-concept test has demonstrated the capability of PMI to acquire accurate, full field rotorcraft blade deformation data.
Fleming, Gary A.↗
Model tests on unsteady rotor wake effects.
A qualitative model of unsteady asymmetric wake effects is considered, taking into account a progressing blade flapping mode in which each blade flaps in a rotating frame of reference. The rotor model used for the tests is two bladed. The experimental data are compared with an analytical flapping response. It is found that the steady wake effects are largest at zero advance ratio and low collective pitch. The effects remain significant at higher advance ratios and collective pitch settings.
Hohenemser, K. H.↗