Fabian Klausmann

Future aero engine designs must address environmental challenges and meet noise and emissions regulations. To increase efficiency and reduce size, axial compressors require higher pressure ratios and a more compact design, leading to necessary modifications in the variable stator vanes, especially in the stator hub region. This study examines the impact of a variable cantilevered stator on the performance and aerodynamics of a 1.5-stage transonic compressor, representative of a high-pressure compressor front stage. Experimental tests at the transonic compressor test rig at Technical University of Darmstadt involved two variable stators with identical airfoil designs but different hub configurations, using the same inlet guide vane and rotor. Detailed aerodynamic analysis was conducted using steady and unsteady instrumentation. The cantilevered stator achieved a 2% increase in efficiency and a 1% increase in total pressure ratio, due to higher aerodynamic loading and reduced pressure losses. The primary performance gain comes from the reduction of the hub blockage area. The cantilevered stator also performed well at near stall conditions, unlike the shrouded stator. Time-resolved measurements indicated that loss mechanisms are closely linked to the rotor wake phase. Overall, variable cantilevered stators outperformed shrouded stators in this compressor stage.

Reynolds-averaged Navier–Stokes (RANS) simulations currently serve as the prevailing industrial method for simulating axial compressor flows, and this status is expected to persist in the foreseeable future. To evaluate the capabilities of contemporary RANS solvers for compressors, this article presents a statistical analysis of RANS simulation results submitted to the first and the second Global Power and Propulsion Society (GPPS) computational fluid dynamics (CFD) workshops, where blind tests on the TUDa-GLR-OpenStage transonic axial compressor were performed. The workshops were held online in December 2021 and in a hybrid format at Chania, Greece, in September 2022, which are the first primary turbomachinery CFD workshops following the 1994 International Gas Turbine Institute (IGTI) CFD blind test event on NASA Rotor 37. A total of 35 submissions were received from 12 distinct RANS solvers, contributed by 14 participants affiliated with 11 organizations across 5 countries. Participants include academic researchers, engineers from the turbomachinery industry, and developers of commercial CFD solvers. First, the grid convergence behavior exhibited by various solvers employing different turbulence models is examined. Afterward, the prediction accuracy of the ensemble of the simulation results is evaluated, and the representative simulation results are compared and analyzed in detail. The key factors that improve the prediction accuracy are identified. These results foster improved usage and further development of turbomachinery RANS solvers.

The modular compressor at the Transonic Compressor Darmstadt test facility at Technical University of Darmstadt enables investigations of prototype BLISK rotors in single or 1.5-stage setups, operating at high-speed conditions. Within the framework of the European funded research project ARiAS (Advanced Research into Aeromechanical Solutions), forced response blade vibration phenomena and underlying fluid-structure-interaction are investigated. For this, the Darmstadt Open Test Case is enhanced with new rig hardware and equipped with additional steady and unsteady instrumentation to perform extensive aerodynamic and aeromechanical tests. To excite a distinct engine order, a variable wake generator module is applied upstream the rotor BLISK containing 3–16 equally spaced symmetric NACA airfoils. One goal is to experimentally characterize the resulting flow features and determine the impact of wake forcing and rotor tip-clearance on blade vibration and aero-damping by performing a parameter study of various configurations and operating conditions. This paper comprises an overview of the ARiAS compressor stage setup, applied instrumentation and performed measurements. It emphasizes the substantial aerodynamic variations induced by different excitation features, while simultaneously highlighting the inherent independence of the measured system damping from these variations across three fundamental resonance crossings.

An experiment-supported simulation process chain is set up to perform numerical forced response analyses on a transonic high-pressure compressor front stage at varying operating conditions. A wake generator is used upstream of the rotor to excite a specific resonance within the operating range of the compressor. Thereby, extensive aerodynamic and structural dynamic experimental data, obtained from state-of-the-art rig testing at the Transonic Compressor Darmstadt test facility at the Technical University of Darmstadt, are used to validate numerical results and ensure realistic boundary conditions. In the course of this, five-hole-probe measurements at steady operating conditions close to the investigated resonance enable a validation of the steady aerodynamics. Subsequently, numerically obtained aeroelastic quantities, such as resonance frequency, and damping, as well as maximum alternating blade stresses and tip deflections, are compared to experimental blade tip timing data. Experimental trends in damping can be confirmed and better explained by considering numerical results regarding the aerodynamic wall work density and secondary flow phenomena. The influence of varying loading conditions on the resonance frequency is not observed as distinctly in numerical, as in experimental results. Generally, alternating blade stresses and deflections appear to be significantly lower than in the experiments. However, similar to the aerodynamic damping, numerical results contribute to a better understanding of experimental trends. The successive experimental validation shows the capabilities of the numerical forced response analysis setup and enables the highlighting of challenges and identification of potential further adaptations.

The future trend of clean sky aviation has led to a smaller core engine, resulting in highly loaded stages with increased relative tip gaps and leakage flows, which causes a reinforced influence of secondary flow phenomena. This article experimentally investigates the secondary flow effects in the 3D-optimized shrouded stator of the TUDa-GLR-OpenStage, representative of a transonic high-pressure compressor front stage, and its susceptibility to typical hub leakage flows. The impact of stator hub leakage on efficiency and total pressure ratio is investigated for several operating speeds, from subsonic to nominal transonic operating conditions. Steady five-hole probe and time-resolved virtual multi-hole probe measurements at different operating conditions at nominal speed are conducted to investigate the underlying loss mechanisms. The leakage mass flow is determined using the measured pressure difference within the fin seal. Steady results show that the optimized 3D stator effectively suppresses the hub corner separation compared to the predecessor 2D stator, but its performance is further limited by a near-tip separation. With the increased stator hub leakage (at a leakage-to-main flow ratio of about 0.4%), the compressor isentropic efficiency generally drops (by about −0.5%) at the full operating range due to an enhanced hub corner separation effect. However, the increased leakage also helps alleviate the tip-corner separation when operating near stall, leading to a smaller efficiency penalty under these conditions. Unsteady results reveal the sensitivity of transient compressor performance to the passing rotor wake, but limited interaction between this phenomenon and the increased leakage is observed. These findings provide insight into the stator hub leakage-related penalties on the compressor aerodynamics efficiency.

Predicting unsteady aerodynamics and related phenomena in the vicinity of the stability limit of transonic compressors has been a challenging topic within the turbomachinery community since decades. To improve numerical tools and prediction capabilities the Transonic Compressor Darmstadt Open...

Shrouded stator cavity flow increases the stator total pressure loss, reduces the compressor isentropic efficiency, and thus limits the compressor pressure rise capability. This paper proposes a simplified cavity flow model that consists of flow injection at the stator inlet and flow suction at the stator outlet. Based on this model, a full-factorial parametric study on the leakage flow ratio and the leakage swirl angle is performed at different rotational speeds and incidences. In the first place, the effectiveness of the numerical method is validated against the experimental data based on the full-scale cavity geometry; then, the numerical simulations on the simplified cavity geometry are validated against that of the full-scale one. Results show that the leakage flow ratio plays a dominant role in determining the compressor performance penalty. The isentropic efficiency drops almost linearly with the leakage flow ratio due to deteriorated near-hub separations, and the slope becomes steeper at higher operating speeds and incidences. The leakage swirl angle only has a pronounced effect under a high leakage flow ratio. The efficiency penalty reduces with increasing swirl angle due to an alleviated tangential flow mixing and suppressed near-hub separations. The swirl angle effect is more pronounced at lower incidence conditions. These findings advance the fundamental understanding of shrouded stator cavity flow effects and provide useful guidance for cavity seal designs.

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...

This paper presents a comprehensive validation and verification study of turbomachinery Reynolds-averaged Navier-Stokes flow solvers on the transonic axial compressor TUDa-GLR-OpenStage. Two commercial solvers namely Ansys CFX and Numeca FineTurbo are adopted to provide the benchmark solutions, which can be used for verification of other RANS solvers in the future. Based on these solvers, five sets of grids, two advection schemes (i.e., central difference and second-order upwind), four turbulence models (i.e., SA, SA-RC, SST and EARSM) and two rotor-stator interface models (i.e., mixing plane and sliding plane) are investigated to quantify their effects on predicting the performance and the flow field of the compressor stage. Results show that the choices of grid density and turbulence model are most sensitive to the prediction, leading to 5% and 7% variation in compressor performance characteristics, respectively. Regarding the choice of grid density, a method to estimate the grid discretization error is demonstrated, which is transferrable to other cases. Regarding the choice of turbulence model, the EARSM model is found overall most accurate among the investigated models, and the limitations and deficiencies of the rest models are discussed in detail based on the analysis of the mean flow fields and the eddy viscosity fields. The grids and the major CFD results presented in this work are open-accessed to the community for further research. The results and discussions presented in this paper provide a useful reference for future practices of RANS simulations for compressors.

Designs for future aero engines aim for increased efficiency with reduced exhaust gas and noise emissions. To achieve these goals, comprehensive physical understanding and highly innovative solutions are necessary. Even though computational capabilities are rising, the required confidence level is restrained. To understand and validate theoretical and numerical models, extensive experiments at realistic operating conditions are crucial. The modular compressor at the Transonic Compressor Darmstadt test facility at Technical University of Darmstadt enables investigations of prototype BLISK rotors in single or 1.5-stage setups, operating at high-speed conditions. Extensive steady and time-resolving instrumentation is used to determine the compressor aerodynamics and performance as well as aeroelastics. To foster improvements in numerical modelling and predictability based on high quality experimental data, the TUDa-GLR-OpenStage test case is introduced. It comprises a single stage setup, including the BLISK rotor, a 3D-optimized stator as well as the annulus contour. The data set is supplemented with comprehensive measurement data at stage inlet and outlet as well as running tip clearances. This paper describes the open test case, related geometries, measurement procedures and corresponding experimental results, including steady state performance and unsteady aerodynamics. Ultimately, it is aiming to provide a standard case for future development of numerical models and comparable validation.