Study of nonradial stators for noise reduction
Reducing rotor stator interaction noise by use of nonradial (lean) stator vanes
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Reducing rotor stator interaction noise by use of nonradial (lean) stator vanes
A 0.5 hub/tip radius ratio compressor stage consisting of a 1500 ft/sec tip speed rotor, a variable camber inlet guide vane and a variable stagger stator was designed and tested with undistorted inlet flow, flow with tip radial distortion, and flow with 90 degrees, one-per-rev, circumferential distortion. At the design speed and design IGV and stator setting the design stage pressure ratio was achieved at a weight within 1% of the design flow. Analytical results on rotor tip shock structure, deviation angle and part-span shroud losses at different operating conditions are presented. The variable geometry blading enabled efficient operation with adequate stall margin at the design condition and at 70% speed. Closing the inlet guide vanes to 40 degrees changed the speed-versus-weight flow relationship along the stall line and thus provided the flexibility of operation at off-design conditions. Inlet flow distortion caused considerable losses in peak efficiency, efficiency on a constant throttle line through design pressure ratio at design speed, stall pressure ratio, and stall margin at the 0 degrees IGV setting and high rotative speeds. The use of the 40 degrees inlet guide vane setting enabled partial recovery of the stall margin over the standard constant throttle line.
The results of the high lift blade configuration design study are reported. The three-stage constant-inside-diameter turbine utilizes a ten degree tangentially leaned stator in stage three. All other bladerows use plain blades. Analysis of the leaned stator is discussed, and detailed design data are summarized. Steady-state stresses are discussed, and the results of the mechanical design analysis are presented.
Stage C, comprised of tandem-airfoil rotor C and tandem-airfoil stator B, was designed and tested to establish performance data for comparison with the performance of conventional single-airfoil blading. Velocity diagrams and blade leading and trailing edge metal angles selected for the conventional rotor and stator blading were used in the design of the tandem blading. The rotor had an inlet hub/tip ratio of 0.8 and a design tip velocity of 757 ft/sec. At design equivalent rotor speed, rotor C achieved a maximum adiabatic efficiency of 91.8% at a pressure ratio of 1.31. The stage maximum adiabatic efficiency was 86.5% at a pressure ratio of 1.31.
A theoretical model for the generation of blade-passage noise caused by the interaction of rotor wakes with the downstream stator blades in a fan stage has been compiled. This model has combined a description of the rotor wake based on existing experimental correlations with an existing theory for the response of the stator blades to those wakes. This model of the interaction-caused blade-passage noise has been used to examine some effects of blade geometry and flow conditions on the noise generated. A set of significant parameters has been identified to reduce this interaction-caused blade-passage frequency noise. A redesign of an existing fan with the use of these concepts has produced a theoretical noise reduction of more than 7 decibels.
The flow characteristics of several tandem bladed compressor stators were analytically evaluated over a range of inlet incidence angles. The ratios of rear-segment to front-segment chord and camber were varied. Results were also compared to the analytical performance of a reference solid blade section. All tandem blade sections exhibited lower calculated losses than the solid stator. But no one geometric configuration exhibited clearly superior characteristics. The front segment accepts the major effect of overall incidence angle change. Rear- to front-segment camber ratios of 4 and greater appeared to be limited by boundary-layer separation from the pressure surface of the rear segment.
Stage B, composed of tandem-airfoil rotor B and stator B, was tested with uniform inlet flow and with hub radial, tip radial and 90 degree one-per-revolution circumferential distortion of the inlet flow as part of an overall program to evaluate the effectiveness of tandem airfoils for increasing the design point loading capability and stable operating range of rotor and stator blading. The results of this series of tests provide overall performance and blade element data for evaluating: (1) the potential of tandem blading for extending the loading limit and stable operating range of a stage representative of a middle stage of an advanced high pressure compressor, (2) the effect of loading split between the two airfoils in tandem on the performance of tandem blading, and (3) the effects of inlet flow distortion on the stage performance. The rotor had an inlet hub/tip ratio of 0.8 and a design tip velocity of 757 ft/sec. With uniform inlet flow, rotor B achieved a maximum adiabatic efficiency of 88.4% at design equivalent rotor speed and a pressure ratio of 1.31. The stage maximum adiabatic efficiency at design equivalent rotor speed with uniform inlet flow was 82.5% at a pressure ratio of 1.28. Tip radial and circumferential distortion of the inlet flow caused substantial reductions in surge margin.
A study was made of the effect of increasing the fan rotor-to-stator spacing on the noise level of a full-scale, single-stage, 1.6-pressure-ratio fan. Noise data were obtained with axial spacing of 1.14, 1.65, and 2.27 rotor chord lengths. Over this spacing range, data indicate a reduction of 1.5 PNdb. Apparently, rotor-alone noise at the frequency at which the rotor-stator interaction noise was cut off limited the noise reduction for the QF-5 fan. It seems, however, that the reduction in sound power level with increases in spacing is potentially about 6 db over the range of spacing tested.
Experimentally determined efficiencies of turbine stator blades having trailing-edge coolant ejection are compared with efficiencies predicted from two previously published approximate analytical methods. The experimental results were obtained from two-dimensional data with the temperature of the primary and coolant flows both being nearly ambient. Data from five stator blade configurations having different slotted trailing-edge geometries were included in the comparison. The two analytical methods gave results which agreed reasonably well with experimental results. An average of the absolute values of differences between experimental and predicted efficiencies for all five blade configurations showed that one method gave average efficiency differences which were about 1.3 percent different than experimental efficiencies, while the other method gave average efficiency differences that were about 0.7 percent different than experimental. However, in some instances, maximum differences of as much as 4 percent occurred. A comparison between experimental and analytical results indicated that the ratio of trailing-edge slot width to trailing-edge thickness influences the measured efficiencies to a greater extent than is accounted for by either analytical model.
The performance of the first stage of a transonic, multistage compressor was mapped over a range of inlet-guide-vane and stator-blade settings. Both stall-free and deep-stall performance data were obtained. For the settings tested, as stall was encountered and flow was further reduced, a relatively sharp drop in pressure ratio occurred and was followed by a continuing but more gradual reduction in pressure ratio with reduced flow. The position of the stall line on the map of pressure ratio against equivalent weight flow was essentially unaffected over the range of inlet-guide-vane and stator-blade settings.
Four monolithic stator vane rings from reaction-bonded silicon nitride were produced. This paper describes the various steps involved: wax injection of stator vane patterns, precise fixturing of patterns, mold fabrication, slip preparation, casting, prenitriding, nitriding, and ceramic machining. Each process step is discussed and illustrated, and tables of property measurements are included.
An experimental evaluation of the aerodynamic performance of the axial flow, variable area stator power turbine stage for the Department of Energy upgraded automotive gas turbine engine was conducted in cold air. The interstage transition duct, the variable area stator, the rotor, and the exit diffuser were included in the evaluation of the turbine stage. The measured total blading efficiency was 0.096 less than the design value of 0.85. Large radial gradients in flow conditions were found at the exit of the interstage duct that adversely affected power turbine performance. Although power turbine efficiency was less than design, the turbine operating line corresponding to the steady state road load power curve was within 0.02 of the maximum available stage efficiency at any given speed.
A program was conducted to design and develop an advanced-concept motor specifically created for propulsion of electric vehicles with increased range, reduced energy consumption, and reduced life-cycle costs in comparison with conventional systems. The motor developed is a brushless, dc, rare-earth cobalt, permanent magnet, axial air gap inductor machine that uses an ironless stator. Air cooling is inherent provided by the centrifugal-fan action of the rotor poles. An extensive design phase was conducted, which included analysis of the system performance versus the SAE J227a(D) driving cycle. A proof-of-principle model was developed and tested, and a functional model was developed and tested. Full generator-level testing was conducted on the functional model, recording electromagnetic, thermal, aerodynamic, and acoustic noise data. The machine demonstrated 20.3 kW output at 1466 rad/s and 160 dc. The novel ironless stator demonstated the capability to continuously operate at peak current. The projected system performance based on the use of a transistor inverter is 23.6 kW output power at 1466 rad/s and 83.3 percent efficiency. Design areas of concern regarding electric vehicle applications include the inherently high windage loss and rotor inertia.
A model of the spanwise variation of deviation for stator blades is presented. Deviation is defined as the difference between the passage mean flow angle and the metal angle at the outlet of a blade element of an axial compressor stage. The variation of deviation is taken as the difference above or below that predicted by blade element, (i.e., two-dimensional) theory at any spanwise location. The variation of deviation is dependent upon the blade camber, solidity and inlet boundary layer thickness at the hub or tip end-wall, and the blade channel aspect ratio. If these parameters are known or can be calculated, the model provides a reasonable approximation of the spanwise variation of deviation for most compressor middle stage stators operating at subsonic inlet Mach numbers.
An accurate numerical analysis of the flows associated with rotor-stator configurations in turbomachinery can be very helpful in optimizing the performance of turbomachinery. In this study the unsteady, thin-layer, Navier-Stokes equations are solved using a system of patched and overlaid grids for a rotor-stator configuration of an axial turbine. The equations necessary for an accurate transfer of information between the several grids are briefly described within the framework of an iterative, implicit algorithm. Results in the form of Mach number contours, time-averaged pressures, unsteady pressures, amplitudes, and phase are presented. The numerical results are also compared with experimental data and the agreement is found to be good.
An experimental test facility is used to measure the rotordynamic coefficients of teeth-on-rotor and teeth-on-stator labyrinth gas seals. Direct damping coefficients are presented for these seals for the first time. The results are presented for the two seal configurations at identical operating conditions, and show that, in a rotordynamic sense, the teeth-on-stator seal is more stable than the teeth-on-rotor seal, for inlet tangential velocity in the direction of rotation.
An experimental test facility is used to measure the rotordynamic coefficients of teeth-on-rotor and teeth-on-stator labyrinth gas seals. Direct damping coefficients are presented for these seals for the first time. The results are presented for the two seal configurations at identical operating conditions, and show that, in a rotordynamic sense, the teeth-on-stator seal is more stable than the teeth-on-rotor seal, for inlet tangential velocity in the direction of rotation.
Fluid flows within turbomachinery tend to be extremely complex in nature. Understanding such flows is crucial to improving current designs of turbomachinery. The computational approach can be used to great advantage in understanding flows in turbomachinery. A finite difference, unsteady, thin layer, Navier-Stokes approach to calculating the flow within an axial turbine stage is presented. The relative motion between the stator and rotor airfoils is made possible with the use of patched grids that move relative to each other. The calculation includes endwall and tip leakage effects. An introduction to the rotor-stator problem and sample results in the form of time averaged surface pressures are presented. The numerical data are compared with experimental data and the agreement between the two is found to be good.