Removal of Secondary-flow Accumulations in a Two-dimensional Turbine Nozzle Passage by Boundary-layer Bleed
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The complexity and variety of turbomachinery flow circuits created a need for a general fluid system simulation program for test data anomaly resolution as well as design review. The objective of the paper is to present a computer program that has been developed to support Marshall Space Flight Center's turbomachinery internal flow analysis efforts. The computer program solves for the mass. energy and species conservation equation at each node and flow rate equation at each branch of the network by a novel numerical procedure which is a combination of both Newton-Ralphson and successive substitution method and uses a thermodynamic property program for computing real gas properties. A generalized, robust, modular, and 'user-friendly' computer program has been developed to model internal flow rates, pressures, temperatures, concentrations of gas mixtures and axial thrusts. The program can be used for any network for compressible and incompressible flows, choked flow, change of phase and gaseous mixturecs. The code has been validated by comparing the predictions with Space Shuttle Main Engine test data.
This paper highlights bulk flow and CFD-based models prepared to calculate force and leakage properties for seals and shrouded impeller leakage paths. The bulk flow approach uses a Hir's based friction model and the CFD approach solves the Navier Stoke's (NS) equation with a finite whirl orbit or via analytical perturbation. The results show good agreement in most instances with available benchmarks.
Today's computational methods enable the determination of forces in complex systems, but without field validation data, or feedback, there is a high risk of failure when the design envelope is challenged. The data of Childs and Bently and field data reported in NASA Conference Proceedings serve as sources of design information for the development of these computational codes. Over time all turbomachines degrade and instabilities often develop, requiring responsible, accurate, turbomachine diagnostics with proper decisions to prevent failures. Tam et al. (numerical) and Bently and Muszynska (analytical) models corroborate and implicate that destabilizing factors are related through increases in the fluid-force average circumferential velocity. The stability threshold can be controlled by external swirl and swirl brakes and increases in radial fluid film stiffness (e.g., hydrostatic and ambient pressures) to enhance rotor stability. Also cited are drum rotor self-excited oscillations, where the classic fix is to add a split or severed damper ring or cylindrical damper drum, and the Benkert-Wachter work that engendered swirl brake concepts. For a smooth-operating, reliable, long-lived machine, designers must pay very close attention to sealing dynamics and diagnostic methods. Correcting the seals enabled the space shuttle main engine high-pressure fuel turbopump (SSME HPFTP) to operate successfully.
The issues and components supporting the engine power stream are reviewed. It is essential that companies pay close attention to engine sealing issues, particularly on the high-pressure spool or high-pressure pumps. Small changes in these systems are reflected throughout the entire engine. Although cavity, platform, and tip sealing are complex and have a significant effect on component and engine performance, computational tools (e.g., NASA-developed INDSEAL, SCISEAL, and ADPAC) are available to help guide the designer and the experimenter. Gas turbine engine and rocket engine externals must all function efficiently with a high degree of reliability in order for the engine to run but often receive little attention until they malfunction. Within the open literature statistically significant data for critical engine components are virtually nonexistent; the classic approach is deterministic. Studies show that variations with loading can have a significant effect on component performance and life. Without validation data they are just studies. These variations and deficits in statistical databases require immediate attention.
Each single reusable Space Launch Initiative (SLI) booster rocket is an engine operating at a record vacuum thrust level of over 730,000 Ibf using LOX and LH2. This thrust is more than 10% greater than that of the Delta IV rocket, resulting in relatively large LOX and LH2 turbopumps. Since the SLI rocket employs a staged combustion cycle the level of pressure is very high (thousands of psia). This high pressure creates many engineering challenges, including the balancing of axial-forces on the turbopumps. One of the main parameters in the calculation of the axial force is the cavity pressure upstream of the turbine disk. The flow in this cavity is very complex. The lack of understanding of this flow environment hinders the accurate prediction of axial thrust. In order to narrow down the uncertainty band around the actual turbine axial force, a coupled, unsteady computational methodology has been developed to simulate the interaction between the turbine main flow path and the cavity flow. The CORSAIR solver, an unsteady three- dimensional Navier-Stokes code for turbomachinery applications, was used to solve for both the main and the secondary flow fields. Turbine axial thrust values are presented in conjunction with the CFD simulation, together with several considerations regarding the turbine instrumentation for axial thrust estimations during test.
Two numerical approaches are used to model the interaction between the turbine main gas flow and the wheelspace cavity seal flow. The 3-D, unsteady Reynolds-averaged Navier-Stokes equations are solved with a CFD code based on a structured grid to study the interaction between the turbine main gas flow and the wheelspace cavity seal flow. A CFD code based on an unstructured grid is used to solve detailed flow feature in the cavity seal which has a complex geometry. The numerical results confirm various observations from earlier experimental studies under similar flow conditions. When the flow rate through the rim cavity seal is increased, the ingestion of the main turbine flow into the rim seal area decreases drastically. However, a small amount of main gas flow is ingested to the rim seal area even with very high level of seal flow rate. This is due to the complex nature of 3-D, unsteady flow interaction near the hub of the turbine stage.
A quantitative, flow visualization study was made of a partially elliptic cross section, inward curving duct (scroll duct), with an axial outflow through a vaneless annular cutlet. The working fluid was water, with a Re(d) of 40,000 at the inlet to the scroll duct, this Reynolds number being representative of the conditions in an actual gas turbine scroll. Both still and high speed moving pictures of fluorescein dye injected into the flow and illuminated by an argon ion laser were used to document the flow. Strong secondary flow, similar to the secondary flow in a pipe bend, was found in the bottom half of the scroll within the first 180 degs of turning. The pressure field set up by the turning duct was strong enough to affect the inlet flow condition. At 90 degs downstream, the large scale secondary flow was found to be oscillatory in nature. The exit flow was nonuniform in the annular exit. By 270 degs downstream, the flow appeared unorganized with no distinctive secondary flow pattern. Large scale structures from the upstream core region appeared by 90 degs and continued through the duct to reenter at the inlet section.
The Western Desert of Egypt is one of the most arid regions on earth and is probably the closest terrestrial analog to the surface of Mars. An expedition to the area in 1978 revealed an abundance of quartzite and basalt rocks that have been pitted and fluted by wind erosion and deflation of the desert surface. These pitted rocks are internally homogeneous, show no internal holes or vesicles, and are considered an important but neglected type of ventifact. They bear a striking resemblance to the pitted and fluted rocks seen by the Viking Landers, rocks that have generally been interpreted as vesicular basalts only slightly modified by wind erosion. Wind tunnel studies of the air flow over and around nonstreamlined hand specimens from the Western Desert show that windward abrasion coupled with negative flow, secondary flow, and vorticity in a unidirectional wind can explain the complex arrays of pits and flutes. These field and laboratory observations suggest that the pitted rocks at the Viking Lander sites are also ventifacts, and thus the Martian surface may be far more wind eroded than previously thought.
Viscous flow calculations are important for the determination of separated flows, recirculating flows, secondary flows and so on. This paper presents a penalty function approach for the finite element analysis of steady incompressible viscous flow. A simplex element is used with linear velocity and constant pressure in contrast to other works which usually employ higher order elements. Simplex elements yield analytical expressions for the element matrices which in turn lead to efficient solutions. Earlier works have partially indicated how constraint and lock-up problems might be avoided for simplex elements. This paper extends the earlier works by indicating the approach in detail and verifying that it is successful for several applications not discussed in the literature so far. Solution times and accuracy considerations are discussed for Couette flow, plane Poiseuille flow, a driven cavity problem, and laminar and turbulent flow over a step.
Secondary injection of gases into supersonic flow
Developing flows in two out-of-plane double S-bend configurations have been measured by laser-Doppler anemometry. The first duct had a rectangular cross-section 40mmx40mm at the inlet and consisted of a uniform area 22.5 deg. - 22.5 deg. S-duct upstream with a 22.5 deg.- 22.5 deg. S- diffuser downstream. The second duct had a circular cross-section and consisted of a 45 deg. - 45 deg. uniform area S-duct upstream with a 22.5 deg. -22.5 deg. S-diffuser downstream. In both configurations the ratio of the mean radius of curvature to the inlet hydraulic diameter was 7.0, the exit-to-inlet area ratio of the diffusers was 1.5 and the ducts were connected so that the centerline of the S-duct lay in a plane normal to that of the S-diffuser. Streamwise and cross-stream velocity components were measured in laminar flow for the rectangular duct and in turbulent flow for both configurations; measurements of the turbulence levels, cross-correlations and wall static pressures were also made in the turbulent flow cases. Secondary flows of the first kind are present in the first S-duct and they are complemented or counteracted by the secondary flows generated by the area expansion and by the curvature of the S-diffusers downstream. Cross-stream velocities with magnitudes up to 0.19 and 0.11 of the bulk velocity were measured in the laminar and turbulent flows respectively in the rectangular duct and six cross-flow vortices were evident at the exit of the duct in both flow cases. The turbulent flow in the circular duct was qualitatively similar to that in the rectangular configuration, but the cross-stream velocities measured at the exit plane were smaller in the circular geometry. The results are presented in sufficient detail and accuracy for the assessment of numerical calculation methods and are listed in tabular form for this purpose.
Independent evidence suggests that both sulfur and silicate materials exist on the surface of Io. Spectral data indicate the presence of sulfur compounds, some of which are suggested to be of fumarolic origin. Morphological evidence and inferences of the physical properties of some land-forms suggest that silicate volcanism has occurred, which would involve temperatures 650 C or greater. Because the liquidus of sulfur is only about 115 C, it is likely that sulfur in close proximity to 'hot spots' or to active silicate volcanic areas on Io would be melted and mobilized as flows. The Mauna Loa sulfur flow may serve as an analog for such flows, as it consists of fumarolic sulfur that was melted as a consequence of a basaltic eruption and produced a small flow superimposed on silicate lavas.
Steady, developing, adiabatic supersonic flow in a square duct is investigated for an inlet Mach number of 3.91 and a unit Reynolds number of 1.8 x 10 to the 6th/m. The numerical results for laminar flow show that two secondary flow cells develop in the near vicinity of the corner which are centered about the corner bisector and distort the primary flow in this region. For turbulent flow, the experimental results indicate that two secondary flow cells also develop about the corner bisector, but are directed in an opposite sense to that observed for the laminar case. Numerical results based on the Baldwin-Lomax model show that this model is incapable of predicting turbulence-generated secondary flow cells. For a suitable choice of constants, the Gessner-Emery model is able to predict the strength of these cells, but is deficient with respect to predicting their positions in the flow and their distorting influence on the primary flow. These observations are based on comparisons made in this paper between predicted and measured total pressure contours, cross flow velocity profiles, and local wall shear stress distributions.
Flow measurements of secondary motions in axial flow impellers