Stator–rotor interaction in the tip leakage flow of an inlet vaned low-speed axial fan

Abstract

Purpose The purpose of the paper is to quantify the impact of the non-uniform flow generated by the upstream stator on the generation and convection of the tip leakage flow (TLF) structures in the passages of the rotor blades in a low-speed axial fan. Design/methodology/approach A full three dimensional (3D)-viscous unsteady Reynolds-averaged Navier-stokes (RANS) (URANS) simulation of the flow within a periodic domain of the axial stage has been performed at three different flow rate coefficients (φ = 0.38, 0.32, 0.27) using ReNormalization Group k-ε turbulence modelling. A typical tip clearance of 2.3 per cent of the blade span has been modelled on a reduced domain comprising a three-vaned stator and a two-bladed rotor with circumferential periodicity. A non-conformal grid with hybrid meshing, locally refined O-meshes on both blades and vanes walls with (100 × 25 × 80) elements, a 15-node meshed tip gap and circumferential interfaces for sliding mesh computations were also implemented. The unsteady motion of the rotor has been covered with 60 time steps per blade event. The simulations were validated with experimental measurements of the static pressure in the shroud of the blade tip region. Findings It has been observed that both TLF and intensities of the tip leakage vortex (TLV) are significantly influenced by upstream stator wakes, especially at nominal and partial load conditions. In particular, the leakage flow, which represents 12.4 per cent and 11.3 per cent of the working flow rate, respectively, has shown a clear periodic fluctuation clocked with the vane passing period in the relative domain. The periodic fluctuation of the TLF is in the range of 2.8-3.4 per cent of the mean value. In addition, the trajectory of the tip vortex is also notably perturbed, with root-mean squared fluctuations reaching up to 18 per cent and 6 per cent in the regions of maximum interaction at 50 per cent and 25 per cent of the blade chord for nominal and partial load conditions, respectively. On the contrary, the massive flow separation observed in the tip region of the blades for near-stall conditions prevents the formation of TLV structures and neglects any further interaction with the upstream vanes. Research limitations/implications Despite the increasing use of large eddy simulation modelling in turbomachinery environments, which requires extremely high computational costs, URANS modelling is still revealed as a useful technique to describe highly complex viscous mechanisms in 3D swirl flows, such as unsteady tip flow structures, with reasonable accuracy. Originality/value The paper presents a validated numerical model that simulates the unsteady response of the TLF to upstream perturbations in an axial fan stage. It also provides levels of instabilities in the TLV derived from the deterministic non-uniformities associated to the vane wakes.