Axial Flow Research Articles

Transient dynamic stress behavior analysis of the axial flow pump as turbine at part loads

To explore the structural dynamic characteristics of the impeller and shaft system of the axial flow pump as turbine, the variation law of impeller transient equivalent stress, deformation, and the impeller and shaft system mode are analyzed by the transient fluid-structure interaction method. Findings indicate that the equivalent stress is centralized at the blade root around the hub and tends to decrease as it moves towards the shroud. The maximum equivalent stress at 1.0Qbep and 1.1Qbep is 1.26 times and 2.0 times higher than that at 0.8Qbep. Blade deformation is significantly influenced by flow rate. The maximum deformation of the blade at 1.0Qbep and 1.1Qbep is 1.6 times and 3.6 times higher than that at 0.8Qbep. The impeller and shaft system with prestress in dry mode has an average natural frequency of the first 10 orders that is 16.7 Hz higher than without prestress. However, with the fluid adding mass and flow damping, the average natural frequency of the first 10 orders of the impeller and shaft system in wet mode is reduced by 278.08 Hz compared with dry mode. In fact, the impeller and shaft system of the axial flow pump as turbine is not prone to vibration.

Research on wake characteristics and HCWF blade number matching of a new coupled propeller

For the purpose of wake energy recovery and hub vortex control in a new Coupled Propeller (CP), three hub cap with fins (HCWF) schemes with different blade numbers are designed for a specific multi-blade CP. A numerical investigation of the CP-HCWF system is conducted using the Large Eddy Simulation (LES) method. Firstly, the analysis focuses on the distribution of axial and tangential flow velocity characteristics of the CP. The wake spectral characterization analysis results reveal that the 10th-order component is equivalent to the 5th-order components within 0.7 R of the HCWF. However, beyond 0.7 R of the HCWF, the 10th-order component becomes more significant. Then, the influence of the HCWF blade number on the CP performance is further analyzed. Hydrodynamic efficiency, post-hub pressure recovery, wake energy recovery, and hub vortex elimination improve with increased HCWF blade numbers. The 10-blade HCWF demonstrates the best performance. Ultimately, the reliability of the numerical findings is verified through the model test. The efficiency variation with the fin number exhibits a consistent trend in the test and calculation results. It is suggested that the HCWF blade number is selected by considering the sum of the CP blades as a reference.

Study and Experiment on Screen Surface Homogenization Technology of Dislodged Material Based on Longitudinal Flow Threshing

Aiming at the problems of uneven distribution of dislodged material on the screen surface of longitudinal axial flow grain combine harvester, a large difference in material clearing time, and large clearing loss, a dislodged material homogenizing device that can realize dislodged material return and homogenization at the rear of longitudinal axial flow was developed. (1) The structure and motion parameters of the reflux plate were determined, and simulation tests were carried out to verify them; (2) A test bench was set up, and the Box-Behnken test method was adopted to determine the influence law of each factor on the operating effect and the optimal parameter combination, and the results showed that the tilt angle of the return plate, motor speed, and amplitude had a significant influence on the distribution uniformity of the material on the screen surface; it was determined that the optimal combination of the angle of the return plate configuration was 28.7°, the speed of the motor was 247 r/min, the amplitude of the return plate was 18.3 mm, and the seed contamination rate was 0.48%. The optimum combination was determined to be 28.7°, 247 r/min, 18.3 mm, and 0.48% impurity rate; (3) under the conditions of the field test validation, the validation error is less than 5%, proving that it can effectively improve the performance of the clearing and reduce the rate of impurity content.

The effects of different impeller combinations in the Sphingan WL gum fermentation process

The fermentation of the high-viscosity polysaccharide WL gum has always been associated with poor mass transfer. Appropriate impeller configurations are key factors in maintaining homogeneity and sufficient mass transfer conditions. Therefore, a flat-folded disc turbine impeller (FFDT) taking into account both the reduced cavitation effect and the increased contact area was designed. Besides, a curved cross impeller (CC) and a fishbone-shaped impeller (FS) generating axial flow were also designed. The energy consumption and efficiency of the designed impellers and eight reported impellers were evaluated through fermentation and principal component analysis (PCA). Compared to the commonly-used six-blade flat-blade disc turbine (FBDT), the ungassed power number of FFDT was reduced by 50 %. Combinations of six-blade Brumajin impeller (BM) + FFDT and CC + FFDT produced high WL gum production and viscosity (34.0 g/L, 35.50 g/L, and 62.64 Pa·s, 61.68 Pa·s, respectively) and were suitable impellers for WL biosynthesis. WL gum from BM + FFDT showed higher viscosity, viscoelasticity, and molecular weight than that from FBDT + FBDT. In addition, fewer amino acids and pyruvic acid intermediates were formed using BM + FFDT, indicating a greater metabolic flux towards WL gum synthesis. This work provided an important reference for the design of impellers in high-viscosity fermentation systems.

Effect of Tip Gap Size on the Tip Flow Structure and Turbulence Generation in a Low Reynolds Number Compressor Cascade

Abstract Efficient and compact axial compressors are currently undergoing rapid development for use in microcooling systems and small-scale vehicles. Limited experimental work concentrates on the inner flow field of the compressors working at such low Reynolds numbers (Re∼104). This study examines the vortical structures and the resulting turbulence production in the transitional flow over a C4 compressor blade at a Reynolds number Re of 24,000, with a specific focus on the impact of tip clearance. The particle image velocimetry measurements reveal the tip flow structures in detail, including the tip leakage vortex (TLV) and its induced complex vortical structures. The tip secondary flow at the low Reynolds number can be divided as the tip leakage flow (TLF)/vortex and transitional boundary layer both at the end walls and the blade surfaces. The TLV propagates at the highest spanwise positions and farthest pitchwise positions at the middle tip gap size (τ/C = 3%) for the three tip gap sizes investigated. The tip flow fluctuations decrease from τ/C = 5% to τ/C = 3% and then increase from τ/C = 3% to τ/C = 1%. The spatial distribution, streamwise evolution, and individual Reynolds normal stress components contributing to the turbulent kinetic energy (TKE) are discussed. The primary contributors to the turbulence generation are examined to elucidate the flow mechanism leading to the distinct anisotropic turbulence structure in the tip region with various tip gap sizes.

Aerodynamic Optimization of a Single-Stage Transonic Axial Compressor with a Circumferential Feedback Channel

Aerodynamic Optimization of a Single-Stage Transonic Axial Compressor with a Circumferential Feedback Channel

Enhancement of Convection and Molecular Transport into Film Stacked Structures by Introduction of Notch Shape for Micro-Immunoassay

A 3D-stack microfluidic device that can be used in combination with 96-well plates for micro-immunoassay was developed by the authors. ELISA for detecting IgA by the 3D-stack can be performed in one-ninth of the time of the conventional method by using only 96-well plates. In this study, a notched-shape film was designed and utilized for the 3D-stack to promote circulation by enhancing and utilizing the axial flow and circumferential flow in order to further reduce the reaction time. A finite element analysis was performed to evaluate the axial flow and circumferential flow while using the 3D-stack in a well and design the optimal shape. The 3D-stack with the notched-shape film was fabricated and utilized for the binding rate test of the antibody and antigen and ELISA. As a result, by promoting circulation using 3D-stack with notched-shape film, the reaction time for each process of ELISA was reduced to 1 min, which is 1/60 for 96 wells at low concentrations.

CFD Analysis and Validation of Axial Compressor Rotor Blade

This research paper employs computational simulations to investigate the consequences of inlet flow distortion, focusing specifically on inlet swirl and total pressure distortion, on the operational characteristics and robustness of an axial transonic compressor. Various permutations of inlet swirl and total pressure distortion are examined, uncovering diverse impacts on the compressor's operational robustness and efficiency. The analysis demonstrates that while co-swirl configurations marginally enhance the operational robustness of the compressor, counter-swirl configurations tend to diminish it. The combination of the effects of individual distortion patterns can provide insights into certain aspects of how a composite pattern of distortion would affect the compressor's efficiency, yet this approach falls short in accurately evaluating the compressor's operational robustness when subjected to a composite distortion pattern.

A New Axial Compressor Test Facility for the Investigation of Aerodynamic Damping Featuring an Electromagnetic Excitation System

Abstract Aerodynamic damping simulations involving detailed computational fluid dynamics (CFD) models are nowadays an integral part of turbomachinery design processes, thanks to advancements made in simulation tools and in computer hardware over the last decades. However, the test cases available in the open literature suitable for the validation and continued development of simulation tools is rather limited. On this background, a new test facility is introduced that allows acquiring relevant and high-quality aerodynamic damping test data on axial compressor rotor test objects in a controlled manner. The test facility is built as a closed loop and thus enables operation at variable pressure levels ranging from near-vacuum to overpressure and with different operating media. Overall damping test data are acquired at controlled synchronous and nonsynchronous vibration conditions. While vibrations of the blades at controlled nonsynchronous vibration conditions can be introduced in the test facility by means of a proprietary electromagnetic excitation system that is acting below the hub line, vibrations at controlled synchronous conditions can be introduced from a set of magnets integrated into the casing. Great care has been spent to create a clean test case without any intruding parts or openings in the test section. In addition, an axial compressor blisk is presented, which acts as test object to show the capabilities of the test facility as well as to allow for detailed investigations of aerodynamic damping. While the first part of the article discusses the setup and the instrumentation of the test facility to excite and measure blade vibration in a nonintrusive way, flow-field measurements and the validation accompanying steady-state Reynolds-averaged Navier-Stokes (RANS) simulations are shown in the second part. The third part of the article focuses on aerodynamic damping measurements for seven different modes at three different pressure levels in total. It can be shown that aerodynamic damping is by far the largest contributor to the overall damping.

On the Origin of “Rotating Instabilities”—Stability and Frequency Studies of Channel Flows

Abstract A group of unsteady flow phenomena in turbomachinery is often referred to as “rotating instabilities.” They occur at flow conditions with very asymmetric velocity profiles, as found downstream of blade rows in axial compressors with large rotor tip clearance in stable operating points close to compressor stall or off-design operating points in steam turbines. In the present work, it is shown that such instabilities do not depend on the blading but also occur in blading-free flow channels. The theoretical proof is carried out with the tools and computational programs of spatial stability theory and Reynolds number dependent jumps in the transverse wavelengths at characteristic perturbation frequencies of the present asymmetric turbulent channel flow are discovered. Experimental investigations in a straight flow channel confirm the calculated frequency field and other characteristics of the perturbations. In agreement to theoretical results, a very asymmetric velocity profile across the channel height was found to trigger disturbances within a limited range of frequencies and not bound to the existence of blading. The notion of rotating instability is misleading in the characterization of this disturbance.

A tensor basis neural network-based turbulence model for transonic axial compressor flows

Traditional turbulence models encounter limitations when simulating intricate flows within transonic axial compressors. In contrast, recent advancements in machine learning turbulence models have demonstrated enhanced potential in refining the precision of turbulence modeling. Notably, the tensor basis neural network (TBNN) methodology has successfully developed non-linear eddy viscosity turbulence models. These models possess the capability to capture the anisotropic characteristic of Reynolds stress. However, applying machine learning non-linear eddy viscosity models to aircraft turbomachinery remains relatively infrequent. Current research mainly focuses on linear eddy viscosity turbulence models based on the Boussinesq hypothesis that presupposes isotropy in Reynolds stress. In this work, we introduce a non-linear eddy viscosity turbulence model, denoted as the k-ω-SST-TBNN model based on the TBNN framework. This model has been employed to simulate the transonic axial compressor NASA Rotor 37. The TBNN is trained using large eddy simulation (LES) results datasets. The importance of input scalar features is analyzed using the random forest method, from which significant and low-degree variables are selected as inputs for the TBNN. Furthermore, this study proposes including the turbulent Mach number as one of the extra features, representing fluid compressibility, thereby extending the computational mass flow rate range of compressor. Additionally, this paper proposes a method involving the weighted average of Reynolds stress, combining the high-precision but less robust TBNN predictions with results based on the Boussinesq assumption to enhance the turbulence model's robustness. The trained k-ω-SST-TBNN model undergoes validation on Rotor 37, where it exhibits a marked improvement in the prediction of overall performance, tip-gap vortex, and radial distribution of flow parameters. The model also displays a commendable capacity for generalization.

An Improved Body Force Model to Simulate Blade Loading Variation Under Various Operating Conditions in Transonic Axial Flow Compressor

Abstract In order to analyze the unsteady aerodynamic response of compressors with limited computational resources, the development of the body force (BF) model has been pursued for decades. This model can simulate the effects of the compressor blade on the flow by applying a three-dimensional (3D) force field. Indeed, the accuracy of the BF model simulation highly depends on the construction strategy of BF field. However, for a transonic compressor, the influence of shock waves on the spatial distribution of blade loading is significant, which makes the construction of an appropriate BF field challenging. To solve this issue, an accurate BF model is proposed to describe the effects of the blade on the flow with high spatial fidelity in transonic compressors. For verification, a typical transonic fan rotor, NASA-Rotor 67, is selected. The numerical results calculated by the new BF model are compared with those obtained by the Reynolds-averaged Navier–Stokes (RANS) solver. According to the results, the new model can accurately capture the distribution of blade loading in the transonic blade channel at various operating conditions, eventually leading to a good prediction of compressor performance and the radial distribution of flow parameters downstream of the rotor. Moreover, this study discusses the causes of modeling errors and presents the application of the model in inlet distortion simulation at the end.

CFD investigation of flow hydrodynamics and optimization in an industrial‐scale annular lance with swirl flow

AbstractSwirling flow has been applied in various fields due to its ability to enhance mass, heat, and momentum transfer performance. However, the generation of swirling flow occurs at the price of augmenting the pressure drop, and enhancing the friction and shear intensity of the jet with respect to the reactor wall. In the present work, the impact of geometrical configurations of the swirler on the hydrodynamics of the fluid in an industrial‐scale annular lance is investigated via the computational fluid dynamics method, with the discussion of the friction coefficient of the lance walls. It shows that the axial flow injected from the central lance is transformed into a weak swirl flow upon the introduction of swirl flow generated in the casing pipe. Within the mixing region, the interaction between axial and swirl flows results in elevated turbulent kinetic energy. Notably, under varying geometrical configuration conditions, the pressure drop between the inlet of the central pipe and the outlet is maximized. Additionally, the highest friction factor appears at a height of 1.35 m along the middle shell, with a value of 96.67.

Aerodynamics of a Tandem-Bladed Axial Compressor Rotor under Circumferential Distortion at Different Rotational Speeds

Aerodynamics of a Tandem-Bladed Axial Compressor Rotor under Circumferential Distortion at Different Rotational Speeds

Effect of asymmetric leading edge on transition of suction side

Abstract Asymmetric leading edge offers several advantages over conventional leading edge. However, there are few related published research on compressor blades. This study proposes a blade parameterization method that superimposing the thickness distribution on the camber line at the middle and curve fitting at the leading and trailing edges. This parameterization method is applied to a stator in the final stage of an axial compressor, and numerical simulation is used to calculate the aerodynamic performance at various attack angles under the designed inlet Mach number. There is an optimal deflection angle regardless of which side of the leading edge deflects, and deflection toward the pressure side is conducive to the suppression of separation bubble near the leading edge at positive attack angle. When the maximum curvature of the pressure side is decreased, the operating range changed slightly, but the positive attack angle range grew from 5.166° to 5.466°.

Immediate inflammatory response to mechanical circulatory support in a porcine model of severe cardiogenic shock

BackgroundIn selected cases of cardiogenic shock, veno-arterial extracorporeal membrane oxygenation (V-A ECMO) is combined with trans valvular micro axial flow pumps (ECMELLA). Observational studies indicate that ECMELLA may reduce mortality but exposing the patient to two advanced mechanical support devices may affect the early inflammatory response. We aimed to explore inflammatory biomarkers in a porcine cardiogenic shock model managed with V-A ECMO or ECMELLA.MethodsFourteen landrace pigs had acute myocardial infarction-induced cardiogenic shock with minimal arterial pulsatility by microsphere embolization and were afterwards managed 1:1 with either V-A ECMO or ECMELLA for 4 h. Serial blood samples were drawn hourly and analyzed for serum concentrations of interleukin 6 (IL-6), IL-8, tumor necrosis factor alpha, and serum amyloid A (SAA).ResultsAn increase in IL-6, IL-8, and SAA levels was observed during the experiment for both groups. At 2–4 h of support, IL-6 levels were higher in ECMELLA compared to V-A ECMO animals (difference: 1416 pg/ml, 1278 pg/ml, and 1030 pg/ml). SAA levels were higher in ECMELLA animals after 3 and 4 h of support (difference: 401 ng/ml and 524 ng/ml) and a significant treatment-by-time effect of ECMELLA on SAA was identified (p = 0.04). No statistical significant between-group differences were observed in carotid artery blood flow, urine output, and lactate levels.ConclusionsLeft ventricular unloading with Impella during V-A ECMO resulted in a more extensive inflammatory reaction despite similar end-organ perfusion.

Axial Compressor Transonic Rotor Shock Interaction With Upstream Stator Row

Abstract Modern multistage axial compressors are designed for high aerodynamic loading and wide range with front stages rotor inlet relative Mach number above one over a large portion of span. Rotor shock waves propagate and reflect in the upstream stator where they provoke extra aerodynamic losses and aeromechanic risks. This paper discusses stator–rotor shock interactions using both steady and unsteady numerical simulations. The computations focus on three different stage designs with the same capacity and total pressure ratio, but different axial gaps and load distribution in stator and rotor. Speedlines from steady and unsteady computations compare the designs, and the detailed flow fields are analyzed at design and close to stall conditions. The steady and unsteady calculations predict similar stage performance, but different stator–rotor loss split. The analyses reveal how the rotor shocks orientation with respect to the upstream stator camber line controls the intensity of shocks interaction with the stator row and its propagation upstream. Finally, the paper indicates the ways to reduce the shock-driven rotor–stator interaction and suggests simple criteria to determine when to switch from steady to unsteady calculations for a reliable transonic stage performance prediction.

Effect of Different Outlet Structure of Axial Flow Cyclone Separator in Drying Tower

The axial flow cyclone separator used in drying tower is characterized by the diameter of the dust outlet at the tail is larger than that of the cylinder, and the dust removal efficiency is increased by a series dust outlet. The numerical analysis of its separation characteristics is carried out by using the RSM model of CFD. The results show that the separation efficiency can be increased by appropriately increasing the diameter of the dust outlet, and the separation efficiency will not change when the diameter of the dust outlet increases to a certain value. When the insertion depth of the air outlet is reduced from 150mm to 100mm, the average separation efficiency of particles with a diameter of 15-30um is reduced by 4.5%. When the insertion depth of the air outlet is greater than the width of the dust outlet, the insertion depth has no effect on the dust removal efficiency. The tandem dust outlet and parallel dust outlet have the same separation effect on small particles, and the gas flow rate is equivalent to twice the gas flow rate of a single dust outlet. The average particle separation efficiency of 1 - 30um is increased by 16.5% compared with that of a single dust outlet. The flow velocity of the tandem dust outlet is higher than that of the parallel dust outlet.

Fluid–structure–surface interaction of a flexibly mounted pitching and plunging flat plate in proximity to the free surface

This experimental study investigates the fluid–structure–surface interactions of a flexibly mounted rigid plate in axial flow, focusing on flow-induced vibration (FIV) response and vortex dynamics of the system within a reduced velocity range of $U^*=0.29\unicode{x2013}8.73$ , corresponding to a Reynolds number range of $Re=518\unicode{x2013}15\,331$ . The plate, with one and two degrees of freedom (DoFs) for pitching and plunging oscillations, is examined at various submerged heights near the free surface. Results show that the plate exhibits divergence instability at low reduced velocities in both 1DoF and 2DoF systems. As the flow velocity surpasses a critical reduced velocity, periodic limit-cycle oscillations (LCOs) occur, increasing in amplitude until a second critical reduced velocity is reached. Beyond this point, LCOs are suppressed, and the plate experiences an increased static divergence angle with further flow velocity increase. The proximity to the free surface significantly influences the FIV response, with decreasing submerged heights leading to reduced LCO amplitudes and a shift of instabilities to higher reduced velocities. Vortex dynamics are analysed using time-resolved volumetric particle tracking velocimetry and hydrogen bubble flow visualisation. The analysis reveals disruptions in the symmetric flow field near the free surface, causing elongation and fragmentation of vortices in the wake of the plate, as well as vortex coupling. Proper orthogonal decomposition (POD) identifies dominant coherent structures, including leading-edge and trailing-edge vortices, captured in the first and second paired modes. On the other hand, higher POD modes capture the interaction of vortices in the wake and near the free surface.

Internal Flow Characteristics of Centrifugal Pumps under Different Startup Combination Schemes

Pump station engineering is a water conservancy project used for long-distance water transfer, irrigation and drainage, and urban living and industrial water supply. Centrifugal pumps are one of the main pump types commonly used in pumping stations, and their operation is of considerable importance for the safety, stability, and efficient operation of pumping stations. This paper takes a large pumping station with seven centrifugal pump units as the research object and combines experimental research and numerical simulation. The axial flow velocity uniformity, average cross-sectional deviation angle, and hydraulic loss of the pump inlet section are evaluated, and the internal flow characteristics of the pump under different startup combination conditions are analyzed based on entropy generation and vorticity. This study also explores the operational performance of the pump station under different startup combination conditions, revealing the mutual influence mechanism between different startup combinations of pump stations and the internal and external characteristics of centrifugal pumps and introducing the optimal startup combination scheme for the pump station system. Research results indicate that the difference in energy loss of centrifugal pumps under different startup combinations is mainly manifested in the impeller and guide vane flow channels. For the two existing inlet flow channel structures in the pump station, the unit effectively operates when the inlet flow channel is tilted to the left. The optimal startup combination method of the pump station under different startup combinations is determined.