Mehdi Vahdati

In this paper, a new aeroelastic phenomena for fans, referred to as non-synchronous forced vibration (NSFV), is presented. This type of aeroelastic instability can occur at high crosswind conditions when the flow at the intake lip separates and the disturbances caused by flow separation become unsteady. The results show that in the presence of unsteady separation in the intake, the fan can experience non-synchronous frequency excitations, which can result in resonant response in modes that are not identified by the Campbell diagram. The findings are corroborated by aeroacoustic theories. To the best of authors knowledge, this is the first time that fan forced response due to unsteady distortion is studied and the findings can unlock some of unexplained and unexpected vibrations experienced by engines.

This work investigates the impact of acoustically treated intakes on fan flutter. The propagation of the fan acoustic perturbations is studied using a simplified model, where the frequency of the waves in the intake is the natural frequency of the fan blade in the stationary frame of reference. The model consists of a constant cross-sectional annular duct, where the acoustic modes are computed for hard wall and lined wall regions, assuming a uniform axial flow. The interfaces between the lined and hard wall sections are solved by doing mode matching. The acoustic reflections in the zero-thickness intake are computed using the Wiener–Hopf technique following Rienstra’s model. Analytical results show that the waves propagating from the fan are reflected and scattered radially at the interfaces between the hard wall and the liner. Furthermore, the liner damps and changes the phase velocity of acoustic modes. Due to the low frequency of the flutter waves, the radial scattering can activate different cut-off modes, which need to be retained in order to make accurate predictions. The likelihood of fan flutter is estimated using the phase of the reflected cut-on waves reaching the fan. This strategy is used to assess the impact of the acoustic liners on the stability of a realistic fan. It is concluded that the impact of the phasing and reflections induced by the acoustic liners is comparable to that of the intake and can alter the flutter characteristics of the fan significantly.

Modern aircraft engines need to meet ever more stringent requirements that greatly increase the complexity of design, which strives for enhanced performance, reduced operating costs, emissions and noise simultaneously. The drive for performance leads to the development of thin, lightweight, highly loaded fan and compressor blades which are increasingly more prone to incur high, sustained vibratory stresses and aeroelastic problems such as flutter. The current practice employs preliminary design tools for flutter that are often based on empiricism or simplified analytical models, requiring extensive use of computational fluid dynamics to verify aeroelastic stability. As the industry moves to new designs, fast and accurate prediction tools are needed. In this work, data-driven techniques are employed to model the aeroelastic response of compressor blades. Machine learning has been applied to a plethora of engineering problems, with particular success in the field of turbulence modelling. However, conventional, black-box data-driven methods based on simple input parameters require large databases and are unable to generalise. In this work a combination of machine learning techniques and reduced order models is proposed to address both limitations at the same time. Previous knowledge of flutter is introduced in the physics guided framework by formulating relevant, steady state input features, and by injecting results from low-fidelity analytical models. The models are tested on several unseen cascades and it is found that training on even a single geometry yields accurate results. The models developed here allow flutter prediction of fan and compressor flutter stability based on the steady state flow only without a need for any CPU intensive unsteady simulations. Hence, one can predict flutter stability of a given blade for different mechanical properties (mode shape, frequency) at near zero additional cost once the mean flow is known.

Computational Fluid Dynamic (CFD) tools have revolutionized the way to design engineering systems, but most established codes are proprietary and closed-source, making it difficult, if not impossible, to modify, debug, or add new features to the code. To provide a freely available open-source CFD code for turbomachinery aerodynamics and aeroelasticity, this paper enhances the turbomachinery capabilities of the open-source SU2 code and demonstrates its capabilities of single-passage steady simulation, full-annulus unsteady simulation, and aeroelasticity analysis in two high-speed compressors, namely NASA Stage 35 and TUDa-GLR-OpenStage, and a linear cascade SC1. For the single-passage steady simulation of NASA Stage 35, the SU2 results are validated against the measured data and verified against the commercial solver ansys cfx, and the performance characteristics results are in reasonably good agreement with each other. For the single-passage steady simulation of TUDa-GLR-OpenStage, grid and turbulence model sensitivity studies are performed and results are validated against the measured data, and SU2 can predict both the performance characteristics and the radial profiles with sufficient accuracy. For the full-annulus unsteady simulation of NASA Stage 35, it is demonstrated that SU2 can predict the propagation of inlet distortion equally well as ansys cfx. For the linear cascade, SU2 can predict the unsteady pressure and aerodynamic damping coefficient accurately. The presented results demonstrate the turbomachinery aerodynamics and aeroelasticity capabilities of SU2. The major modifications of SU2 made in this work will be shared with the code maintainer and the community in the future.

In this paper an efficient numerical strategy for computational fluid dynamics (CFD) simulation of surge events in a three-shaft engine compression system is presented. Numerical results are compared against measured data and the sources of discrepancies and uncertainties are addressed. It is discovered that the engine bleed system has a major impact in reducing the aerodynamic loading during surge in the core system. To the best knowledge of the authors, this is the first time that such a complex CFD computation is attempted and compared against real engine measured data and will provide valuable information to other CFD users as well as gas turbine manufacturers.

Reynolds-averaged Navier–Stokes (RANS) simulation is a routinely used tool for turbomachinery research and development, but it often over-predicts the pressure ratio of centrifugal compressors especially in the high impeller tip Mach number regime. In this work, the effects of a series of geometrical and numerical uncertainties and errors on the aerodynamic performance of a centrifugal compressor are investigated systematically. The investigated compressor is the NASA CC3 centrifugal compressor under different impeller tip Mach number conditions. The investigated geometrical/numerical factors include the impeller blade fillet, the impeller hub cavity, the impeller running tip clearance, the averaging method in the post-process, the turbulence model, the inlet duct hub rotation, and the inlet turbulence boundary condition. Results show that the uncertainty of the predicted total pressure ratio generally increases with the impeller tip Mach number. Among the investigated factors, the averaging method, the impeller blade fillet, the turbulence model, and the impeller hub cavity have the most pronounced effects in determining the compressor total pressure ratio. By adopting realistic geometric features, advanced turbulence modeling treatments, and the same averaging method as the experiment, the over-prediction in the total pressure ratio can be alleviated. Detailed flow mechanism analysis with respect to the impeller hub cavity and the turbulence model has been performed. These findings provide valuable guidance for future RANS simulations of centrifugal compressors.

The hub and casing walls of axial compressors are often modeled as smooth continuous surfaces in CFD simulations, but in real geometries, non-smooth pinches, steps and leakage cavities may exist. In the GPPS first Turbomachinery CFD Workshop, a comprehensive validation and verification campaign...

The Spalart–Allmaras (SA) turbulence model is one of the most popular models applied to compressors, but it often over-predicts blockage size and hence under-predicts the stall margin. In this paper, a novel modification to the SA model is proposed to improve the prediction of compressor near-stall flows. The modification is based on the dimensionless vortical pressure gradient, which identifies blockage cells featured by 3D swirling, adverse pressure gradient, and low-momentum flows. It unblocks the compressor passage by enhancing the eddy viscosity in the identified blockage cells; whereas in canonical 2D flows the modification is automatically switched off. The model coefficients are calibrated via Bayesian inference, which considers the uncertainties involved in experiments and computational fluid dynamics (CFD) simulations of turbomachinery. The rotor exit radial profile data of NASA Rotor 67 at peak-efficiency and near-stall points are used for calibration. The calibrated model is tested extensively in four compressors covering both tip blockage and corner separation as well as both industrial and laboratory Reynolds number and Mach number. For the NASA Rotor 67 and the TUDa-GLR-OpenStage, the proposed model predicts more accurate stall margins at all operating speeds due to the tip unblocking effect. For the BUAA Stage B rotor, the proposed model predicts the tip blockage size and thus the stall margin more accurately. For the LMFA NACA65 cascade, the proposed model with the quadratic constitutive relation (QCR) achieves significant improvement in predicting the exit profiles due to the unblocking effect on the corner separation. The proposed model, termed as SA-PGω in this work, is a promising engineering tool for future Reynolds-averaged Navier–Stokes (RANS) simulations of compressor near-stall flows.

The occurrence of stall and surge in axial compressors has a great impact on the performance and reliability of aero-engines. Accurate and efficient prediction of the key features during these events has long been the focus of engine design processes. In this paper, a new body-force model that can capture the three-dimensional and unsteady features of stall and surge in compressors at a fraction of time required for URANS computations is proposed. To predict the rotating stall characteristics, the deviation of local airflow angle from the blade surface is calculated locally during the simulation. According to this local deviation, the computational domain is divided into stalled and forward flow regions, and the body-force field is updated accordingly; to predict the surge characteristics, the local airflow direction is used to divide the computational domain into reverse flow regions and forward flow regions. A single-stage axial compressor and a three-stage axial compressor are used to verify the proposed model. The results show that the method is capable of capturing stall and surge characteristics correctly. Compared to the traditional fully three-dimensional URANS method (fRANS), the simulation time for multistage axial compressors is reduced by 1–2 orders of magnitude.

This paper presents the effect of manufacturing tolerance on performance and stability boundaries of a transonic fan using a Reynolds-averaged Navier–Stokes simulation. The effects of tip gap and stagger angle variations were analyzed through a series of single passage and double passage simulation; based on which an optimal arrangement was proposed for random tip gap and random stagger angle variation for a whole annulus rotor. All simulations were carried out using NASA rotor 67 as a test case and AU3D as an in-house computational fluid dynamics solver. Results illustrate that the stagger angle variation mainly affects efficiency and its circumferential variation must be as smooth as possible. Furthermore, the tip gap variation affects the stability boundary as well as performance and its optimal configuration mandates a zigzag arrangement of blades around the annulus, i.e., larger tip gap between two smaller ones.