Multidisciplinary Design Optimization of a Low-Noise and Efficient Next-Generation Aero-Engine Fan

Abstract

Abstract Due to the increasing bypass ratios of modern engines, the fan stage is increasingly becoming the dominant source of engine noise. Accordingly, it is becoming more and more important to develop not only efficient but also quiet fan stages. In this paper the noise emission of a fan for an aero-engine with a bypass ratio of 19 is reduced within a multidisciplinary design optimization (MDO) by means of an hybrid noise prediction method while at the same time optimizing the aerodynamic efficiency. The aerodynamic performance of each configuration in the optimization is evaluated by stationary Reynolds-Averaged Navier-Stokes (RANS) simulations. These stationary flow simulations are also used to extract the aerodynamic excitation sources for the analytical fan noise prediction. The resulting large database of the optimization provides new insights into which extent an MDO can contribute to the design of both quiet and efficient fan stages. In addition to that the hybrid approach of numerical flow solutions and analytical description of the noise sources enables to understand the noise reduction mechanisms. In particular, the influence of rotor blade loading on the aerodynamic efficiency and the noise sources as well as the potential of configurations with a comparatively low number of outlet guide vanes (OGV) is explored. The acoustic results of selected configurations are confirmed by unsteady RANS simulations.