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Flow distribution data for solid and honeycomb rotor shrouds to improve stall margin of 0.5 hub tip ratio single stage compressor
Experimental data and performance of honeycomb rotor shroud configuration to improve stall margin of 0.5 hub tip ratio single stage compressor
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An improved rotor assembly shroud includes at least one reinforcing flange on the upper surface of the shroud. The strength provided by the reinforcing flange allows for a smaller shroud thickness resulting in a net reduction of shroud mass. The lower shroud mass reduces the centrifugal stress on the rotor assembly blade during operation. The strength provided by the reinforcing flanges also significantly reduces the centrifugal bending stress on the shroud during operation. The shroud mass may be further reduced by tapering the shroud leading and trailing edges or, for shrouds incorporating a damper, by providing a damper cavity with a lower diameter surface defining an opening therethrough.
The density of Ceramic Matrix Compos-ite(CMC) materials is approximately 1/3 the density of metals currently used for High Pressure Turbine(HPT) blades. A lower density, and consequently lower centrifugal stresses, increases the feasibility of shrouding HPT blades. Shrouding HPT blades improves aerodynamic eciency, especially for low aspect ratio turbine blades. This paper explores aerodynamic and structural issues associated with shrouding HPT rotor blades. Detailed Navier-Stokes analysis of a rotor blade showed that shrouding improved blade row aerodynamic eciency by 1.3%, when the clearance was 2% of the blade span. Recessed casings were used. Without a shroud the depth of the recess equaled the clearance. With a shroud the recess depth increased by the shroud thickness, which included a knife seal. There was good agreement between the predicted stage eciency for the unshrouded blades and the experimentally measured efficiency. Structural analysis showed a strong interaction between stresses in the shroud and peak stresses at the hub of the blade. A thin shroud of uniform thickness only moderately increased maximum blade stress, but there were very high stresses in the shroud itself. Increasing shroud thickness reduced stresses in the shroud, but increased blade stresses near the hub. A single knife seal added to the thin shroud noticeably decreased maximum shroud stress, without increasing maximum blade stress. Maximum stresses due to pressure loads and combined pressure and centrifugal loads were nearly the same as the maximum stresses for individual pressure or cen-trifugal loads. Stresses due to a 100K temperature
A 50.8-cm-tip-diameter turbine equipped with a rotor tip shroud of hexagonal cell (or honeycomb) cross section has been tested in warm air (416 K) for a range of shroud coolant to primary flow rates. Test results were also obtained for the same turbine operated with a solid shroud for comparison. The results showed that the combined effect of the honeycomb shroud and the coolant flow was to cause a reduction of 2.8 points in efficiency at design speed, pressure ratio, and coolant flow rate. With the coolant system inactivated, the honeycomb shroud caused a decrease in efficiency of 2.3 points. These results and those obtained from a small reference turbine indicate that the dominant factor governing honeycomb tip shroud loss is the ratio of honeycomb depth to blade span. The loss results of the two shrouds could be correlated on this basis. The same honeycomb and coolant effects are expected to occur for the hot (2200 K) version of this turbine.
An analytical study was conducted to identify rotorcraft concepts best capable of combining a cruise speed of 350 to 450 knots with helicopter-like low speed attributes, and to define the technology advancements needed to make them viable by the year 2000. A systematic approach was used to compare the relative attributes and mission gross weights for a wide range of concepts, resulting in a downselect to the most promising concept/mission pairs. For transport missions, tilt-wing and variable diameter tilt-rotor (VDTR) concepts were found to be superior. For a military scout/attack role, the VDTR was best, although a shrouded rotor concept could provide a highly agile, low observable alternative if its weight empty fraction could be reduced. A design speed of 375 to 425 knots was found to be the maximum desirable for transport missions, with higher speed producing rapidly diminishing benefits in productivity. The key technologies that require advancement to make the tilt-wing and VDTR concepts viable are in the areas of wing and proprotor aerodynamics, efficient structural design, flight controls, refinement of the geared flap pitch control system, expansion of the speed/descent envelope, and the structural and aerodynamic tradeoffs of wing thickness and forward sweep. For the shrouded rotor, weight reduction is essential, particularly with respect to the mechanism for covering the rotor in cruise.
A radial turbine stage with a variable area nozzle was investigated. A high work capacity turbine design with a known high performance base was modified to accept a fixed vane stagger angle moveable sidewall nozzle. The nozzle area was varied by moving the forward and rearward sidewalls. Diffusing and accelerating rotor inlet ramps were evaluated in combinations with hub and shroud rotor exit rings. Performance of contoured sidewalls and the location of the sidewall split line with respect to the rotor inlet was compared to the baseline. Performance and rotor exit survey data are presented for 31 different geometries. Detail survey data at the nozzle exit are given in contour plot format for five configurations. A data base is provided for a variable geometry concept that is a viable alternative to the more common pivoted vane variable geometry radial turbine.
Researchers are constantly pursuing technologies that will increase the performance of gas turbine engines. The aspirated compressor concept discussed here would allow the compression system to perform its task with about one-half of the compressor blades. To accomplish this, the researchers applied boundary layer control to the blades, casing, and hub. This method of boundary layer control consisted of removing small amounts of air from the main flow path at critical areas of the compressor. This bleed air could be used by other systems such as engine cooling or could be re-injected into lower pressure areas that require air for enhanced performance. This effort was initiated by the Massachusetts Institute of Technology (MIT) in response to a solicitation from the Defense Advanced Research Projects Agency (DARPA) who sought to advance research in flow control technology. The NASA Glenn Research Center partnered with MIT (principal investigator), Honeywell Aircraft Engines (cycle analysis, structural analysis, and mechanical design), and Pratt & Whitney (cycle analysis and aero-analysis) to conceptualize, design, analyze, build, and test the aspirated fan stage. The aero-design and aero-analysis of this fan stage were jointly executed by MIT and Glenn to minimize the amount of bleed flow needed and to maintain the highest efficiency possible (ref. 1). Mechanical design issues were complicated by the need to have a shrouded rotor with hollow blades, with rotor stress levels beyond the capabilities of titanium. The high stress issues were addressed by designing a shroud that was filament wound with a carbon fiber/epoxy matrix, resulting in an assembly that was strong enough to handle the high stresses. Both the rotor (preceding photographs) and stator (following photograph) were fabricated in two halves and then bolted together at the hub and tip, permitting the bleed passages to be machined into each half before assembly.
The limits of the single-stage compression in superchargers at the present state of development are determined by five factors. 1) by the rotor material; 2) by the formation of the flow; 3) by the manufacture of double shrouded rotors; 4) by the bearing problem; 5) by the drive method.
A scaled single-stage, highly-loaded, axial-flow transonic compressor was tested at speeds from 70 to 110% design equivalent speed to evaluate the effects of scaling compromises and the individual and combined effects of rotor tip running clearance and rotor shroud casing treatment on the overall and blade element performance. At design speed and 1% tip clearance the stage demonstrated an efficiency of 83.2% at 96.4% design flow and a pressure ratio of 1.865. Casing treatment increased design speed surge margin 2.0 points to 12.8%. Overall performance was essentially unchanged. An increase in rotor running clearance to 2.2%, with smooth casing, reduced design speed peak efficiency 5.7 points, flow by 7.4%, pressure ratio to 1.740, and surge margin to 5.4%. Reinstalling casing treatment regained 3.5 points in design speed peak efficiency, 4.7% flow, increased pressure ratio to 1.800 and surge margin to 8.7%.
The acoustic tests and data analysis for a 0.508-scale fan vehicle of a 111,300 newton (25,000 pound) thrust, full-size engine, which would have application on an advanced transport aircraft, is described. The single-stage advanced technology fan was designed to a pressure ratio of 1.8 at a tip speed of 503 m/sec (1,650 ft/sec) to achieve the desired pressure ratio in a single-stage fan with low radius ratio (0.38), and to maintain adequate stall margin. The fan has 44 tip-shrouded rotor blades and 90 outlet guide vanes. The two basic approaches taken in the acoustic design were: (1) minimization of noise at the source, and (2) suppression of the generated noise in the inlet and bypass exhaust duct. Suppression of the generated noise was accomplished in the inlet through use of the hybrid concept (wall acoustic treatment plus airflow acceleration suppression) and in the exhaust duct with extensive acoustic treatment including a splitter. The goal of the design was attainment of twenty effective perceived noise decibels (20 EPNdB) below current Federal Air Regulation noise standards for a full-scale fan at the takeoff, cutback, and approach conditions. The suppression goal of FAR 36-20 was not reached, but improvements in the technology of both front and aft fan-noise suppression were realized. The suppressed fan noise was shown to be consistent with the proposed federal regulation on aircraft noise.
The aerodynamic design and test results of the fan and quarter-stage component for the GE/NASA Energy Efficient Engine (EEE) are presented. The fan is a high bypass ratio, single-stage design having 32 part-span shrouded rotor blades, coupled with a unique quarter-stage arrangement that provides additional core-stream pressure ratio and particle separation. The fan produces a bypass pressure ratio of 1.65 at the exit of the low aspect ratio vane/frame and a core-stream pressure ratio of 1.67 at the entrance to the core frame struts. The full-scale fan vehicle was instrumented, assembled and tested as a component in November 1981. Performance mapping was conducted over a range of speeds and bypass ratios using individually-controlled bypass and core-stream discharge valves. The fan bypass and core-stream test data showed excellent results, with the fan exceeding all performance goals at the important engine operating conditions.
An investigation of the mode localization phenomenon associated with mistuning is presented for shrouded blade assemblies. The calculations are based on a generic finite element model, which permits modeling of arbitrary mistuning and both slipping and nonslipping shroud interfaces. The results presented indicate that interactions occur between mistuning and slip effects, with maximum mode localization occurring when the shrouds slip freely. Certain modes are found to be very sensitive to shroud slip, and in some cases completely change character when slip occurs. Mode localization is most pronounced in the predominantly bending modes, and varies considerably from mode to mode. As the ratio of interblade coupling strength to mistuning strength is increased, the effect of mistuning is observed to decrease significantly. This result has important implications for the flutter problem, since it suggests that the stabilization effect available from mistuning is significantly less for a shrouded rotor as compared to an unshrouded rotor.
Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.
Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.
The shrouded-impeller leakage path forces calculated by Childs have been analyzed to answer two questions. First, because of certain characteristics or the results of Childs, the forces could not be modeled with traditional approaches. Therefore, an approach has been devised to include the forces in conventional rotordynamic analyses. The forces were found to be well-modeled with this approach. Finally, the effect these forces had on a simple rotor-bearing system was analyzed, and, therefore, they, in addition to seal forces, were applied to a Jeffcott rotor. The traditional methods of dynamic system analysis were modified to incorporate the impeller forces and yielded results for the eigenproblem, frequency response, critical speed, transient response, and an iterative technique for finding the frequency of free vibration as well as system stability. All results lead to the conclusion that the forces have little influence on natural frequency but can have appreciable effects on system stability. Specifically, at higher values of fluid swirl at the leakage path entrance, relative stability is reduced. The only unexpected response characteristics that occurred are attributed to the nonlinearity of the model.
The shrouded-impeller leakage path forces calculated by Childs (1987) have been analyzed to answer two questions. First, because of certain characteristics of the results of Childs, the forces could not be modeled with traditional approaches. Therefore, an approach has been devised to include the forces in conventional rotordynamic analyses. The forces were approximated by traditional stiffness, damping and inertia coefficients with the addition of whirl-frequency-dependent direct and cross-coupled stiffness terms. The forces were found to be well-modeled with this approach. Finally, the effect these forces had on a simple rotor-bearing system was analyzed, and, therefore, they, in addition to seal forces, were applied to a Jeffcott rotor. The traditional methods of dynamic system analysis were modified to incorporate the impeller forces and yielded results for the eigenproblem, frequency response, critical speed, transient response and an iterative technique for finding the frequency of free vibration as well as system stability. All results lead to the conclusion that the forces have little influence on natural frequency but can have appreciable effects on system stability. Specifically, at higher values of fluid swirl at the leakage path entrance, relative stability is reduced. The only unexpected response characteristics that occurred are attributed to the nonlinearity of the model.