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Axial flow compressor design computer programs incorporating radial distribution of total pressure and flow path or axial velocity ratio
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The cyclic, high-temperature deformation behavior of a wrought cobalt-base super-alloy, Haynes 188, is investigated under combined axial and torsional loads. This is accomplished through the examination of hysteresis loops generated from a biaxial fatigue test program. A high-temperature axial, torsional, and combined axial-torsional fatigue database has been generated on Haynes 188 at 760 C. Cyclic loading tests have been conducted on uniform gage section tubular specimens in a servohydraulic axial-torsional test rig. Test control and data acquisition were accomplished with a minicomputer. The fatigue behavior of Haynes 188 at 760 C under axial, torsional, and combined axial-torsional loads and the monotonic and cyclic deformation behaviors under axial and torsional loads have been previously reported. In this paper, the cyclic hardening characteristics and typical hysteresis loops in the axial stress versus axial strain, shear stress ,versus engineering shear strain, axial strain versus engineering shear strain. and axial stress versus shear stress spaces are presented for cyclic in-phase and out-of-phase axial-torsional tests. For in-phase tests, three different values of the proportionality constant lambda (the ratio of engineering shear strain amplitude to axial strain amplitude, are examined, viz. 0.86, 1.73, and 3.46. In the out-of-phase tests, three different values of the phase angle, phi (between the axial and engineering shear strain waveforms), are studied, viz., 30, 60, and 90 degrees with lambda equals 1.73. The cyclic hardening behaviors of all the tests conducted on Haynes 188 at 760 C are evaluated using the von Mises equivalent stress-strain and the maximum shear stress-maximum engineering shear strain (Tresca) curves. Comparisons are also made between the hardening behaviors of cyclic axial, torsional, and combined in-phase (lambda = 1.73 and phi = 0) and out-of-phase (lambda = 1.73 and phi = 90') axial-torsional fatigue tests. These comparisons are accomplished through simple Ramberg-Osgood type stress-strain functions for cyclic, axial stress-strain and shear stress-engineering shear strain curves.
Multiaxial loading, especially at elevated temperature, can cause the inelastic response of a material to differ significantly from that predicted by simple flow rules, i.e., von Mises or Tresca. To quantify some of these differences, the cyclic high-temperature, deformation behavior of a wrought cobalt-based superalloy, Haynes 188, is investigated under combined axial and torsional loads. Haynes 188 is currently used in many aerospace gas turbine and rocket engine applications, e.g., the combustor liner for the T800 turboshaft engine for the RAH-66 Comanche helicopter and the liquid oxygen posts in the main injector of the space shuttle main engine. The deformation behavior of this material is assessed through the examination of hysteresis loops generated from a biaxial fatigue test program. A high-temperature axial, torsional, and combined axial-torsional fatigue data base has been generated on Haynes 188 at 760 C. Cyclic loading tests have been conducted on uniform gauge section tubular specimens in a servohydraulic axial-torsional test rig. Test control and data acquisition were accomplished with a minicomputer. In this paper, the cyclic hardening characteristics and typical hysteresis loops in the axial stress versus axial strain, shear stress versus engineering shear strain, axial strain versus engineering shear strain, and axial stress versus shear stress spaces are presented for cyclic, in-phase and out-of-phase, axial torsional tests. For in-phase tests three different values of the proportionality constant, lambda (ratio of engineering shear strain amplitude to axial strain amplitude), are examined, viz., 0.86, 1.73, and 3.46. In the out-of-phase tests, three different values of the phase angle, phi (between the axial and engineering shear strain waveforms), are studied, viz., 30, 60, and 90 deg with lambda = 1.73. The cyclic hardening behaviors of all the tests conducted on Haynes 188 at 760 C are evaluated using the von Mises equivalent stress-strain and the maximum shear stress-maximum engineering shear strain (Tresca) curves. Comparisons are also made between the hardening behaviors of cyclic axial, torsional, and combined in-phase and out-of-phase axial-torsional fatigue tests. These comparisons are accomplished through simple Ramberg-Osgood type stress-strain functions for cyclic, axial stress-strain and shear stress-engineering shear strain curves.
Typically, fully active magnetically suspended systems require one axial and two radial magnetic bearings. Combining radial and axial functions into a single device allows for more compact and elegant packaging. Furthermore, in the case of high-speed devices such as energy storage flywheels, it is beneficial to minimize shaft length to keep rotor mode frequencies as high as possible. Attempts have been made to combine radial and axial functionality, but with certain drawbacks. One approach requires magnetic control flux to flow through a bias magnet reducing control effectiveness, thus resulting in increased resistive losses. This approach also requires axial force producing magnetic flux to flow in a direction into the rotor laminate that is undesirable for minimizing eddy-current losses resulting in rotational losses. Another approach applies a conical rotor shape to what otherwise would be a radial heteropolar magnetic bearing configuration. However, positional non-linear effects are introduced with this scheme and the same windings are used for bias, radial, and axial control adding complexity to the controller and electronics. For this approach, the amount of axial capability must be limited. It would be desirable for an integrated radial and axial magnetic bearing to have the following characteristics, separate inputs for radial and axial control for electronics and control simplicity, all magnetic control fluxes should only flow through their respective air gaps and should not flow through any bias magnets for minimal resistive losses, be of a homopolar design to minimize rotational losses, position related non-linear effects should be minimized, and dependent upon the design parameters, be able to achieve any radial/axial force or power ratio as desired. The integrated radial and axial magnetic bearing described in this paper exhibits all these characteristics. Magnetic circuit design, design equations, and analysis results will be presented.
Typically, fully active magnetically suspended systems require one axial and two radial magnetic bearings. Combining radial and axial functions into a single device allows for more compact and elegant packaging. Furthermore, in the case of high-speed devices such as energy storage flywheels, it is beneficial to minimize shaft length to keep rotor mode frequencies as high as possible. Attempts have been made to combine radial and axial functionality, but with certain drawbacks. One approach requires magnetic control flux to flow through a bias magnet reducing control effectiveness, thus resulting in increased resistive losses. This approach also requires axial force producing magnetic flux to flow in a direction into the rotor laminate that is undesirable for minimizing eddy-current losses resulting in rotational losses. Another approach applies a conical rotor shape to what otherwise would be a radial heteropolar magnetic bearing configuration. However, positional non-linear effects are introduced with this scheme and the same windings are used for bias, radial, and axial control adding complexity to the controller and electronics. For this approach, the amount of axial capability must be limited. It would be desirable for an integrated radial and axial magnetic bearing to have the following characteristics; separate inputs for radial and axial control for electronics and control simplicity, all magnetic control fluxes should only flow through their respective air gaps and should not flow through any bias magnets for minimal resistive losses, be of a homopolar design to minimize rotational losses, position related non-linear effects should be minimized, and dependent upon the design parameters, be able to achieve any radial/axial force or power ratio as desired. The integrated radial and axial magnetic bearing described in this paper exhibits all these characteristics. Magnetic circuit design, design equations, and magnetic field modeling results will be presented.
The analysis and design of co-axial winding transformers is presented. The design equations are derived and the different design approaches are discussed. One of the most important features of co-axial winding transformers is the fact that the leakage inductance is well controlled and can be made low. This is not the case in conventional winding transformers. In addition, the power density of co-axial winding transformers is higher than conventional ones. Hence, using co-axial winding transformers in a certain converter topology improves the power density of the converter. The design methodology used in meeting the proposed specifications of the co-axial winding transformer specifications are presented and discussed. The final transformer design was constructed in the lab. Co-axial winding transformers proved to be a good choice for high power density and high frequency applications. They have a more predictable performance compared with conventional transformers. In addition, the leakage inductance of the transformer can be controlled easily to suit a specific application. For space applications, one major concern is the extraction of heat from power apparatus to prevent excessive heating and hence damaging of these units. Because of the vacuum environment, the only way to extract heat is by using a cold plate. One advantage of co-axial winding transformers is that the surface area available to extract heat from is very large compared to conventional transformers. This stems from the unique structure of the co-axial transformer where the whole core surface area is exposed and can be utilized for cooling effectively. This is a crucial issue here since most of the losses are core losses.
A technique for conducting strain-controlled, thermomechanical, axial-torsional fatigue tests on thin-walled tubular specimens was developed. Three waveforms of loading, namely, the axial strain waveform, the engineering shear strain waveform, and the temperature waveform were required in these tests. The phasing relationships between the mechanical strain waveforms and the temperature and axial strain waveforms were used to define a set of four axial-torsional, thermomechanical fatigue (AT-TMF) tests. Real-time test control (3 channels) and data acquisition (a minimum of 7 channels) were performed with a software program written in C language and executed on a personal computer. The AT-TMF testing technique was used to investigate the axial-torsional thermomechanical fatigue behavior of a cobalt-base superalloy, Haynes 188. The maximum and minimum temperatures selected for the AT-TMF tests were 760 and 316 C, respectively. Details of the testing system, calibration of the dynamic temperature profile of the thin-walled tubular specimen, thermal strain compensation technique, and test control and data acquisition schemes, are reported. The isothermal, axial, torsional, and in- and out-of-phase axial-torsional fatigue behaviors of Haynes 188 at 316 and 760 C were characterized in previous investigations. The cyclic deformation and fatigue behaviors of Haynes 188 in AT-TMF tests are compared to the previously reported isothermal axial-torsional behavior of this superalloy at the maximum and minimum temperatures.
A computational study is carried out to understand the physical mechanism responsible for the improvement in stall margin of an axial flow rotor due to the circumferential casing grooves. It is shown that the computational tool used predicts an increase in operating range of the rotor when casing grooves are present. A budget of the axial momentum equation is carried out at the rotor casing in the tip gap in order to uncover the physical process behind this stall margin improvement. It is shown that for the smooth casing the net axial pressure force . However in the presence of casing grooves the net axial shear stress force acting at the casing is augmented by the axial force due to the radial transport of axial momentum, which occurs across the grooves and power stream interface. This additional force adds to the net axial viscous sheer force and thus leads to an increase in the stall margin of the rotor.
Cumulative fatigue under axial and torsional loading conditions can include both load-order (higMow and low/high) as well as load-type sequence (axial/torsional and torsional/axial) effects. Previously reported experimental studies on a cobalt-base superalloy, Haynes 188 at 538 C, addressed these effects. These studies characterized the cumulative axial and torsional fatigue behavior under high amplitude followed by low amplitude (Kalluri, S. and Bonacuse, P. J., "Cumulative Axial and Torsional Fatigue: An Investigation of Load-Type Sequance Effects," in Multiaxial Fatigue and Deformation: Testing and Prediction, ASTM STP 1387, S. Kalluri, and P. J. Bonacuse, Eds., American Society for Testing and Materials, West Conshohocken, PA, 2000, pp. 281-301) and low amplitude followed by high amplitude (Bonacuse, P. and Kalluri, S. "Sequenced Axial and Torsional Cumulative Fatigue: Low Amplitude Followed by High Amplitude Loading," Biaxial/Multiaxial Fatigue and Fracture, ESIS Publication 31, A. Carpinteri, M. De Freitas, and A. Spagnoli, Eds., Elsevier, New York, 2003, pp. 165-182) conditions. In both studies, experiments with the following four load-type sequences were performed: (a) axial/axial, (b) torsional/torsional, (c) axial/torsional, and (d) torsional/axial. In this paper, the cumulative axial and torsional fatigue data generated in the two previous studies are combined to generate a comprehensive cumulative fatigue database on both the load-order and load-type sequence effects. This comprehensive database is used to examine applicability of the Palmgren-langer-Miner linear damage rule and a nonlinear damage curve approach for Haynes 188 subjected to the load-order and load-type sequencing described above. Summations of life fractions from the experiments are compared to the predictions from both the linear and nonlinear cumulative fatigue damage approaches. The significance of load-order versus load-type sequence effects for axial and torsional loading conditions is discussed. Possible reasons for the observed differences between the computed and observed summations of cycle fractions are rationalized in terms of the observed ever lutions of cyclic axial and shear stress ranges in the cumulative fatigue tests.
A flow conditioning device for incrementally stepping down pressure within a piping system is presented. The invention includes an outer annular housing, a center element, and at least one intermediate annular element. The outer annular housing includes an inlet end attachable to an inlet pipe and an outlet end attachable to an outlet pipe. The outer annular housing and the intermediate annular element(s) are concentrically disposed about the center element. The intermediate annular element(s) separates an axial flow within the outer annular housing into at least two axial flow paths. Each axial flow path includes at least two annular extensions that alternately and locally direct the axial flow radially outward and inward or radially inward and outward thereby inducing a pressure loss or a pressure gradient within the axial flow. The pressure within the axial flow paths is lower than the pressure at the inlet end and greater than the vapor pressure for the axial flow. The invention minimizes fluidic instabilities, pressure pulses, vortex formation and shedding, and/or cavitation during pressure step down to yield a stabilized flow within a piping system.
This review indicates the possible future directions for research on endwall flows in axial flow compressors. Theoretical investigations on the rotor blade endwall flows in axial flow compressors reported here include the secondary flow calculation and the development of the momentum integral equations for the prediction of the annulus wall boundary layer. The equations for secondary vorticity at the rotor exit are solved analytically. The solution includes the effects of rotation and the viscosity. The momentum integral equations derived include the effect of the blade boundary layers. The axial flow compressor facility of the Department of Aerospace Engineering at The Pennsylvania State University, which is used for the experimental investigations of the endwall flows, is described in some detail. The overall performance and other preliminary experimental results are presented. Extensive radial flow surveys are carried out at the design and various off design conditions. These are presented and interpreted in this report. The following experimental investigations of the blade endwall flows are carried out. (1) Rotor blade endwall flows: The following measurements are carried out at four flow coefficients. (a) The rotor blade static pressures at various axial and radial stations (with special emphasis near the blade tips). (b) The hub wall static pressures inside the rotor blade passage at various axial and tangential stations. (2) IGV endwall flows: The following measurements are carried out at the design flow coefficient. (a) The boundary layer profiles at various axial and tangential stations inside the blade passage and at the blade exit. (b) Casing static pressures and limiting streamline angles inside the blade passage.
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.
Embodiments of a launch lock assembly are provided, as are embodiments of a spacecraft isolation system including one or more launch lock assemblies. In one embodiment, the launch lock assembly includes first and second mount pieces, a releasable clamp device, and an axial gap amplification device. The releasable clamp device normally maintains the first and second mount pieces in clamped engagement; and, when actuated, releases the first and second mount pieces from clamped engagement to allow relative axial motion there between. The axial gap amplification device normally residing in a blocking position wherein the gap amplification device obstructs relative axial motion between the first and second mount pieces. The axial gap amplification device moves into a non-blocking position when the first and second mount pieces are released from clamped engagement to increase the range of axial motion between the first and second mount pieces.
The mainshaft support bearings of long life turbopumps for use on the space shuttle were evaluated to determine possible causes of failure. Specific aspects examined include the sensitivity of 15 degree versus 25 degree contact angle bearings with regard to heat damage and thermal runaway, the L/D aspects of the turbine end bearing pair with regard to hang-up due to cocking, the hang-up required to support a 44.5 KN axial load without cartridge slipping, the outer race growth as a result of a 44.5 KN axial load, and bearing torque as a function of axial load. Results indicate that hang-up of the cartridge due to bearing heating is a serious problem especially if poor lubrication of the bearing occurs and that race growth due to axial load can contribute to cartridge lock-up. The experimental evaluation of bearing performance under axial loads indicates that the bearing torque is a strong function of surface lubrication.
This report characterizes the sets of small disturbances possible in cylindrical and annular ducts with mean flow whose axial and tangential components vary arbitrarily with radius. The linearized equations of motion are presented and discussed, and then exponential forms for the axial, circumferential, and time dependencies of any unsteady disturbances are assumed. The resultant equations form a generalized eigenvalue problem, the solution of which yields the axial wavenumbers and radial mode shapes of the unsteady disturbances. Two numerical discretizations are applied to the system of equations: (1) a spectral collocation technique based on Chebyshev polynomial expansions on the Gauss-Lobatto points, and (2) second and fourth order finite differences on uniform grids. The discretized equations are solved using a standard eigensystem package employing the QR algorithm. The eigenvalues fall into two primary categories: a discrete set (analogous to the acoustic modes found in uniform mean flows) and a continuous band (analogous to convected disturbances in uniform mean flows) where the phase velocities of the disturbances correspond to the local mean flow velocities. Sample mode shapes and eigensystem distributions are presented for both sheared axial and swirling flows. The physics of swirling flows is examined with reference to hydrodynamic stability and completeness of the eigensystem expansions. The effect of assuming exponential dependence in the axial direction is discussed.