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All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

Active Control Analysis for Aeroelastic Instabilities in Turbomachines

Turbomachines onboard aircraft operate in a highly complex and harsh environment. The unsteady flowfield inherent to turbomachines leads to several problems associated with safety, stability, performance and noise. In-flight surge or flutter incidents could be catastrophic and impact the safety and reliability of the aircraft. High-Cycle-Fatigue (HCF), on the other hand, can significantly impact safety, readiness and maintenance costs. To avoid or minimize these problems generally a more conservative design method must be initiated which results in thicker blades and a loss of performance. Actively controlled turbomachines have the potential to reduce or even eliminate the instabilities by impacting the unsteady aerodynamic characteristics. By modifying the unsteady aerodynamics, active control may significantly improve the safety and performance especially at off-design conditions, reduce noise, and increase the range of operation of the turbomachine. Active control can also help improve reliability for mission critical applications such as the Mars Flyer. In recent years, HCF has become one of the major issues concerning the cost of operation for current turbomachines. HCF alone accounts for roughly 30% of maintenance cost for the United States Air-Force. Other instabilities (flutter, surge, rotating-stall, etc.) are generally identified during the design and testing phase. Usually a redesign overcomes these problems, often reducing performance and range of operation, and resulting in an increase in the development cost and time. Despite a redesign, the engines do not have the capabilities or means to cope with in-flight unforeseen vibration, stall, flutter or surge related instabilities. This could require the entire fleet worldwide to be stood down for expensive modifications. These problems can be largely overcome by incorporating active control within the turbomachine and its design. Active control can help in maintaining the integrity of the system in unforeseen events and provide for more aggressive designs to reduce the weight and improve efficiency of the turbomachine. Another area where active control can be useful is in controlling and suppressing rotating stall and surge in compressors, thereby increasing its operating range. Although some of these benefits will be offset by the added cost and weight penalty of the control system, the potential benefits in safety, reliability, performance, and noise characteristics are significant enough to warrant research in the area of active control of turbomachines. There is renewed interest within industry to understand unsteady aerodynamic behavior. This improved understanding not only leads to better design of turbomachines, which avoid instabilities but also which helps in understanding the controllability of the instabilities. The proliferation of micro-electro-mechanical-system (MEMS) devices has made available new tools to designers for employing feedback controls at reasonable costs. MEMS have also made the control devices small and unobtrusive enough to be implemented within the turbomachine without significant obstruction to the flow path. This has made active-control very attractive especially for systems requiring extreme confidence.

Keith, Theo G., Jr.↗
NASA NTRS2003

Viscoelastic Vibration Dampers for Turbomachine Blades

Simple viscoelastic dampers have been invented for use on the root attachments of turbomachine blades. These dampers suppress bending- and torsion-mode blade vibrations, which are excited by unsteady aerodynamic forces during operation. In suppressing vibrations, these dampers reduce fatigue (thereby prolonging blade lifetimes) while reducing noise. These dampers can be installed in new turbomachines or in previously constructed turbomachines, without need for structural modifications. Moreover, because these dampers are not exposed to flows, they do not affect the aerodynamic performances of turbomachines. Figure 1 depicts a basic turbomachine rotor, which includes multiple blades affixed to a hub by means of dovetail root attachments. Prior to mounting of the blades, thin layers of a viscoelastic material are applied to selected areas of the blade roots. Once the blades have been installed in the hub and the rotor is set into rotation, centrifugal force compresses these layers between the mating load-bearing surfaces of the hub and the blade root. The layers of viscoelastic material provide load paths through which the vibration energy of the blade can be dissipated. The viscoelasticity of the material converts mechanical vibration energy into shear strain energy and then from shear strain energy to heat. Of the viscoelastic materials that have been considered thus far for this application, the one of choice is a commercial polyurethane that is available in tape form, coated on one side with an adhesive that facilitates bonding to blade roots. The thickness of the tape can be chosen to suit the specific application. The typical thickness of 0.012 in. (.0.3 mm) is small enough that the tape can fit in the clearance between the mating blade-root and hub surfaces in a typical turbomachine. In an experiment, a blade was mounted in a test fixture designed to simulate the blade-end conditions that prevail in a turbocompressor. Vibrations were excited in the blade by use of an impact hammer, and damping of the vibrations was measured by use of a dynamic signal analyzer. Tests were performed without and with viscoelastic dampers installed in the dovetail root attachment. The results of the measurements, some of which are presented in Figure 2, show that the viscoelastic dampers greatly increased the rate of damping of vibrations. Accordingly, dynamic stresses on rotor blades were significantly reduced, as shown in Figure 2.

Nguyen, Nhan↗
NASA NTRS1979

A calculation procedure for viscous flow in turbomachines, volume 1

A method for analyzing the nonadiabatic viscous flow through turbomachine rotors is presented. The field analysis is based upon the numerical integration of the full incompressible stream function vorticity form of the Navier-Stokes equations, together with the energy equation, over the rotor blade-to-blade stream channels. The numerical code used to solve the governing equations employs a nonorthogonal boundary fitted coordinate system that suits the most complicated blade geometries. A numerical scheme is used to carry out the necessary integration of the elliptic governing equations. The flow characteristics within the rotor of a radial inflow turbine are investigated over a wide range of operating conditions. The calculated results are compared to existing experimental data. The flow in a radial compressor is analyzed in order to study the behavior of viscous flow in diffusing cascades. The results are compared qualitatively to known experimental trends. The solution obtained provides insight into the flow phenomena in this type of turbomachine. It is concluded that the method of analysis is quite general and gives a good representation of the actual flow behavior within turbomachine passages.

Khalil, I.↗
NASA NTRS1974

Prediction of turbulent shear layers in turbomachines

The characteristics of turbulent shear layers in turbomachines are compared with the turbulent boundary layers on airfoils. Seven different aspects are examined. The limits of boundary layer theory are investigated. Boundary layer prediction methods are applied to analysis of the flow in turbomachines.

Bradshaw, P.↗
NASA NTRS1977

FORTRAN program for calculating leading and trailing-edge geometry of turbomachine blades

A FORTRAN IV program which calculates leading- and trailing-edge circle radii, tangency angles on the leading- and trailing-edge circles, and stagger angles of turbomachinery blade sections using only spline points defining the blade surfaces is described. The program shifts the origin of the blade coordinates to the leading edge of the blade. Required input includes (m, theta) coordinates of a sufficient number of spline points to adequately define the two surfaces of the blade. Other required input are the radii from the axis of rotation of the leading- and trailing-edges. The output from this program is used directly as the geometrical input for a NASA developed program for calculating transonic velocities on a blade-to-blade stream surface of a turbomachine. The program is used for axial, radial, and mixed flow turbomachine blades.

Schumann, L. F.↗
NASA NTRS1980

A calculation procedure for viscous flow in turbomachines, volume 2

Turbulent flow within turbomachines having arbitrary blade geometries is examined. Effects of turbulence are modeled using two equations, one expressing the development of the turbulence kinetic energy and the other its dissipation rate. To account for complicated blade geometries, the flow equations are formulated in terms of a nonorthogonal boundary fitted coordinate system. The analysis is applied to a radial inflow turbine. The solution obtained indicates the severity of the complex interaction mechanism that occurs between the different flow regimes (i.e., boundary layers, recirculating eddies, separation zones, etc.). Comparison with nonviscous flow solutions tend to justify strongly the inadequacy of using the latter with standard boundary layer techniques to obtain viscous flow details within turbomachine rotors. Capabilities and limitations of the present method of analysis are discussed.

Khalil, J.↗
NASA NTRS1991

Research on inverse, hybrid and optimization problems in engineering sciences with emphasis on turbomachine aerodynamics: Review of Chinese advances

Advances in inverse design and optimization theory in engineering fields in China are presented. Two original approaches, the image-space approach and the variational approach, are discussed in terms of turbomachine aerodynamic inverse design. Other areas of research in turbomachine aerodynamic inverse design include the improved mean-streamline (stream surface) method and optimization theory based on optimal control. Among the additional engineering fields discussed are the following: the inverse problem of heat conduction, free-surface flow, variational cogeneration of optimal grid and flow field, and optimal meshing theory of gears.

Liu, Gao-Lian↗
NASA NTRS1998

Minnowbrook II 1997 Workshop on Boundary Layer Transition in Turbomachines

The volume contains materials presented at the Minnowbrook II - 1997 Workshop on Boundary Layer Transition in Turbomachines, held at Syracuse University Minnowbrook Conference Center, New York, on September 7-10, 1997. The workshop followed the informal format at the 1993 Minnowbrook I workshop, focusing on improving the understanding of late stage (final breakdown) boundary layer transition, with the engineering application of improving design codes for turbomachinery in mind. Among the physical mechanisms discussed were hydrodynamic instabilities, laminar to turbulent transition, bypass transition, turbulent spots, wake interaction with boundary layers, calmed regions, and separation, all in the context of flow in turbomachinery, particularly in compressors and high and low pressure turbines. Results from experiments, DNS, computation, modeling and theoretical analysis were presented. Abstracts and copies of viewgraphs, a specifically commissioned summation paper prepared after the workshop, and a transcript of the extensive working group reports and discussions are included in this volume. They provide recommendations for future research and clearly highlight the need for continued vigorous research in the technologically important area of transition in turbomachines.

LaGraff John E.↗
NASA NTRS2004

Turbomachine Sealing and Secondary Flows: Review of Sealing Performance, Customer, Engine Designer, and Research Issues - Part 1

Although forces outside our control shape our industry, turbomachine sealing research, design, and customer agendas established in 1978 by Ludwig, Campbell, and Smith in terms of specific fuel consumption and performance remain as objectives today. Advances have been made because failures of the space shuttle main engine turbomachinery ushered in a new understanding of sealing in high-power-density systems. Further, it has been shown that changes in sealing, especially for high-pressure rotors, dramatically change the performance of the entire engine or turbomachine. Maintaining seal leakages and secondary flows within engine design specifications remains the most efficient and cost effective way to enhance performance and minimize maintenance costs. This three-part review summarizes experiences, ideas, successes, and failures by NASA and the U.S. aerospace industry in secondary flow management in advanced turbomachinery. Part 1 presents system sealing, part 2 system rotordynamics, and part 3 modeling, with some overlap of each part.

Hendricks, R. C.↗
NASA NTRS2004

Turbomachine Sealing and Secondary Flows: Review of Rotordynamics Issues in Inherently Unsteady Flow Systems With Small Clearances - Part 2

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.

Hendricks, R. C.↗
NASA NTRS2005

Turbomachine Interface Sealing

Sealing interfaces and coatings, like lubricants, are sacrificial, giving up their integrity for the benefit of the component. Clearance control is a major issue in power systems turbomachine design and operational life. Sealing becomes the most cost-effective way to enhance system performance. Coatings, films, and combined use of both metals and ceramics play a major role in maintaining interface clearances in turbomachine sealing and component life. This paper focuses on conventional and innovative materials and design practices for sealing interfaces.

Hendricks, Robert C.↗
NASA NTRS2007

Aspects of Transition in Turbomachines

This talk provides a description of several types of transition encountered in turbomachines. It is based largely on personal experience of the detection of transition in turbomachines. Examples are taken from axial compressors, axial turbines and radial turbines. The illustrations are concerned with transition in steady and unsteady boundary layers that develop under the influence of two-dimensional and three-dimensional flow fields.

Hodson, H. P.↗
NASA NTRS2010

Investigating Dynamics of Eccentricity in Turbomachines

A methodology (and hardware and software to implement the methodology) has been developed as a means of investigating coupling between certain rotordynamic and hydrodynamic phenomena in turbomachines. Originally, the methodology was intended for application in an investigation of coupled rotordynamic and hydrodynamic effects postulated to have caused high synchronous vibration in the space shuttle s high-pressure oxygen turbopump (HPOTP). The methodology can also be applied in investigating (for the purpose of developing means of suppressing) undesired hydrodynamic rotor/stator interactions in turbomachines in general. The methodology and the types of phenomena that can be investigated by use of the methodology are best summarized by citing the original application as an example. In that application, in consideration of the high synchronous vibration in the space-shuttle main engine (SSME) HPOTP, it was determined to be necessary to perform tests to investigate the influence of inducer eccentricity and/or synchronous whirl motion on inducer hydrodynamic forces under prescribed flow and cavitation conditions. It was believed that manufacturing tolerances of the turbopump resulted in some induced runout of the pump rotor. Such runout, if oriented with an inducer blade, would cause that blade to run with tip clearance smaller than the tip clearances of the other inducer blades. It was hypothesized that the resulting hydraulic asymmetry, coupled with alternating blade cavitation, could give rise to the observed high synchronous vibration. In tests performed to investigate this hypothesis, prescribed rotor whirl motions have been imposed on a 1/3-scale water-rig version of the SSME LPOTP inducer (which is also a 4-biased inducer having similar cavitation dynamics as the HPOTP) in a magnetic-bearing test facility. The particular magnetic-bearing test facility, through active vibration control, affords a capability to impose, on the rotor, whirl orbits having shapes and whirl rates prescribed by the user, and to simultaneously measure the resulting hydrodynamic forces generated by the impeller. Active control also made it possible to modulate the inducer-blade running tip clearance and consequently effect alternating blade cavitation. The measured hydraulic forces have been compared and correlated with shroud dynamic-pressure measurements.

Baun, Daniel↗