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Tests were conducted on a high-tip-speed low-loading transonic fan stage to determine the performance and inlet flow distortion tolerance of the design. Test data were recorded for overall and blade element performance with both uniform and distorted inlet flows. A tabular summary of the data and a representative selection of the computer data reduction sheets are presented.
The results of impact tests on large, fiber composite fan blades for aircraft turbofan engine applications are discussed. Solid composite blades of two different sizes and designs were tested. Both graphite/epoxy and boron/epoxy were evaluated. In addition, a spar-shell blade design was tested that had a boron/epoxy shell bonded to a titanium spar. All blades were tested one at a time in a rotating arm rig to simulate engine operating conditions. Impacting media included small gravel, two inch diameter ice balls, gelatin and RTV foam-simulated birds, as well as starlings and pigeons. The results showed little difference in performance between the graphite and boron/epoxy blades. The results also indicate that composite blades may be able to tolerate ice ball and small bird impacts but need improvement to tolerate birds in the small duck and larger category.
Radially extending rotor blades are disposed on a hub to form a supersonic propulsion fan for a turbofan engine. The peripheral spacing of the blades is such as to avoid forming a channel or passageway between adjacent blades. Each has a flat trailing surface extending from the leading edge at least as far to the rear as to cause any pressure waves which might originate on the blade surface to strike the leading surface of the following blade rather than propagate upstream of the blade row. The flat trailing surface of each blade makes an angle with the axis of rotation such that the blade is parallel to a gas inflow into the blades.
The overall and blade-element performance of a low-solidity, low-pressure-ratio, low-tip-speed fan stage is presented over the stable operating range at rotative speeds from 90 to 120 percent of design speed. At design speed a stage peak efficiency of 0.836 was obtained at a weight flow of 30.27 kilograms per second and a pressure ratio of 1.111. The pressure ratio was less than design pressure ratio, and the design energy input into the rotor was not achieved. A mismatch of the rotor and stator blade elements resulted due to the lower than design pressure ratio of the rotor.
A two-stage axial-flow fan with a tip speed of 1450 ft/sec (442 m/sec) and an overall pressure ratio of 2.8 was designed, built, and tested. At design speed and pressure ratio, the measured flow matched the design value of 184.2 lbm/sec (83.55kg/sec). The adiabatic efficiency at the design operating point was 85.7 percent. The stall margin at design speed was 10 percent. A first-bending-mode flutter of the second-stage rotor blades was encountered near stall at speeds between 77 and 93 percent of design, and also at high pressure ratios at speeds above 105 percent of design. A 5 deg closed reset of the first-stage stator eliminated second-stage flutter for all but a narrow speed range near 90 percent of design.
A 51-cm-diam. model of a short-haul fan stage was tested. Surveys of the air flow conditions ahead of the rotor, between the rotor and stator, and behind the stator were made over the stable operating range of the stage. At the design speed of 213.3 m/sec and weight flow of 26.7 kg/sec, the stage pressure ratio and efficiency are 1.18 and 0.87, respectively. The rotor peak efficiency of 0.92 occurred at flow rate of 30.5 kg/sec. Peak stage efficiency of 0.09 was obtained at 110 percent speed at a pressure ratio of 1.218 and a weight flow of 30.2 kg/sec. Maximum stage pressure ratio is 1.269 at 120 percent speed.
Aerodynamic design parameters and overall and blade-element performances of a 1.25-pressure-ratio fan stage are reported. Detailed radial surveys were made over the stable operating flow range at rotative speeds from 70 to 120 percent of design speed. At design speed, the measured stage peak efficiency of 0.872 occurred at a weight flow of 34.92 kilograms per second and a pressure ratio of 1.242. Stage stall margin is about 20 percent based on the peak efficiency and stall conditions. The overall peak efficiency for the rotor was 0.911. The overall stage performance showed no significant change when the stators were positioned at 1, 2, or 4 chords downstream of the rotor.
The results of impact tests on large, fiber composite fan blades for aircraft turbofan engine applications are discussed. Solid composite blades of two different sizes and designs were tested. Both graphite/epoxy and boron/epoxy were evaluated. In addition, a spar-shell blade design was tested that had a boron/epoxy shell bonded to a titanium spar. All blades were tested one at a time in a rotating arm rig to simulate engine operating conditions. Impacting media included small gravel, two inch diameter ice balls, gelatin, and RTV foam-simulated birds, as well as starlings and pigeons. The results showed little difference in performance between the graphite and boron/epoxy blades. The results also indicate that composite blades may be able to tolerate ice ball and small bird impacts but need improvement to tolerate birds in the small duck and larger category.
The results of impact tests on large, fiber composite fan blades for aircraft turbofan engine applications are discussed. Solid composite blades of two different sizes and designs were tested. Both graphite/epoxy and boron/epoxy were evaluated. In addition, a spar-shell blade design was tested that had a boron/epoxy shell bonded to a titanium spar. All blades were tested one at a time in a rotating arm rig to simulate engine operating conditions. Impacting media included small gravel, two inch diameter ice balls, gelatin and RTV foam-simulated birds, as well as starlings and pigeons. The results showed little difference in performance between the graphite and boron/epoxy blades. The results also indicate that composite blades may be able to tolerate ice ball and small bird impacts but need improvement to tolerate birds in the small duck and larger category.
PMR polyimides are safe, easy to handle, can be processed with relatively wide process controls, and offer excellent mechanical properties, with thermo-oxidative stability. Procedures, staging and cure schedules fully dense, crackfree, dimensionally controlled, complex structure: high tip speed fan blades 1.27 cm (0.5 in) thick.
Results for a three-stage highly loaded fan drive turbine follow-on test program are presented. The effects of combinations of tandem and leaned bladerows on three-stage turbine performance were tested. The three-stage turbine with a tandem stator in stage two exhibited a total-to-total efficiency of approximately 0.887 as compared to 0.886 for the plain blade turbine base case.
The existence of clusters of pure tones at integral multiples of shaft speed has been noted for supersonic-tip-speed operation of fans and compressors. A continuing program to explore this phenomenon, often called combination-tone noise, has been in effect for several years. This paper reviews the research program, which involves a wide range of engines, compressor rigs, and special apparatus. Elements of the aerodynamics of the blade-associated shock waves are outlined and causes of blade-to-blade shock inequalities, responsible for the multiple tones, are described.
The effect of length of acoustic treatment was studied on a full scale fan using two different inlets. Analysis of the data revealed that measured suppression varied linearly with the length of the ringed liner segments as anticipated. Further analysis indicated that the wall only portion of the treatment was substantially more effective than anticipated, suggesting that, if only moderate suppression is needed, wall only treatment may suffice. The two inlets behaved similarly. Introduction of a hard exhaust splitter into the configuration resulted in a noise increase at certain frequencies.
The method of computing radiated noise from a ducted rotor due to inflow distortion and turbulence are examined. Analytical investigations include an appropriate description of sources, the cut-off conditions imposed on the modal propagation of the pressure waves in the annular duct, and reflections at the upstream end of the duct. Far field sound pressure levels at blade passing frequency due to acoustic radiation from a small scale low speed fan are computed. Theoretical predictions are in reasonable agreement with experimental measurements.
A 1.2-pressure-ratio, 1.83-meter-(6-ft-) diameter experimental fan stage with characteristics suitable for use in STOL aircraft engines was tested for acoustic and aerodynamic performance. The design incorporated features for low noise, including absence of inlet guide vanes, low rotor-blade-tip speed, low aerodynamic blade loading, and long axial spacing between the rotor and stator rows. The stage was run with four nozzles of different area. The perceived noise along a 152.4 meter (500-ft) sideline was rear-quadrant dominated with a maximum design-point level of 103.9 PNdb. The acoustic 1/3-octave results were analytically separated into broadband and pure-tone components. It was found that the stage noise levels generally increase with a decrease in nozzle area, with this increase observed primarily in the broadband noise component. A stall condition was documented acoustically with a 90-percent-of-design-area nozzle.
Overall and blade-element aerodynamic performance of a 0.271-scale model of QF-1 are presented, examined, and then compared and evaluated with that from similar low noise fan stage designs. The tests cover a wide range of speeds and weight flows along with variations in stator setting angle and stator axial spacing from the rotor. At design speed with stator at design setting angle and a fixed distance between stage measuring stations, there were no significant effects of increasing the axial spacing between rotor stator from 1.0 to 3.5 rotor chords on stage overall pressure ratio, efficiency or stall margin.
A theoretical investigation was performed to determine the structural response of a fiber composite airfoil typical of those encountered in high-tip speed compressor fan blades when subjected to load conditions anticipated in such applications. The analysis method consisted of composite mechanics embedded in pre- and post-processors coupled with NASTRAN. The load conditions examined include thermal due to aerodynamic heating, pressure due to aerodynamic forces, and centrifugal. Root reactions due to various load conditions, average composite and ply stresses, ply delaminations, and the fundamental modes and the corresponding reactions were investigated. The results show that the thermal and pressure stresses are negligible compared to those caused by the centrifugal forces. The core-shell concept for composite blades is an inefficient design and is sensitive to interply delaminations. The results are presented in graphical and tabular forms to illustrate the types and amount of data required for the analysis, and to provide quantitative data associated with the various responses which can be helpful in designing composite blades.
A two stage fan with a 1st-stage rotor design tip speed of 1450 ft/sec, a design pressure ratio of 2.8, and corrected flow of 184.2 lbm/sec was tested with axial skewed slots in the casings over the tips of both rotors. The variable stagger stators were set in the nominal positions. Casing treatment improved stall margin by nine percentage points at 70 percent speed but decreased stall margin, efficiency, and flow by small amounts at design speed. Treatment improved first stage performance at low speed only and decreased second stage performance at all operating conditions. Casing treatment did not affect the stall line with tip radially distorted flow but improved stall margin with circumferentially distorted flow. Casing treatment increased the attenuation for both types of inlet flow distortion.