Axial Flow Research Articles

Numerical Analysis of a Novel Casing Treatment in an Axial Flow Fan

The present paper reports the use of a slotted casing treatment of trapezoidal shape to enhance the stall margin of an axial flow fan. The Taguchi method was used to optimize the rectangular slotted casing treatment based on that which the trapezoidal slots were designed. The unsteady numerical simulations were carried out using the shear-stress-transport turbulence model. The rotor with trapezoidal slots led to the stall margin improvement of 23.4% and mild pressure rise of 0.54%. Without the casing treatment, the tip leakage trajectory was directed from the suction surface of the blade toward the pressure surface of the adjacent blade. After incorporating the trapezoidal slots, the tip leakage trajectory was significantly shifted toward the suction surface of the same blade. This alteration in flow characteristics near the blade-tip region may be attributed to the exchange of momentum due to the simultaneous suction and blowing through the trapezoidal slots. It was also found that the trapezoidal slots improved the axial flow velocity and reduced the diffusion factor in the blade-tip region as compared to the baseline case.

Advanced diagnostic techniques for turbo compressors: A spectral analysis approach for preventive maintenance

This paper introduces an innovative spectral analysis control approach aimed at monitoring and diagnosing machine malfunctions to prevent potential failures. The research was conducted on a critical machine in a major industrial enterprise. The proposed method involves the use of a new indicator, called Overall Level (OL), that evaluates the machine’s condition before any operation. This study showcases practical methodologies for transitioning from time-based maintenance to predictive strategies, furnishing actionable insights into machine condition. This yields tangible advantages for the industry in terms of optimizing maintenance practices and enhancing asset productivity. Additionally, various methods, including vibration analysis, performance monitoring, and data analysis, are employed to identify the causes of issues and recommend solutions to enhance the reliability of the turbo compressor. The results provide a clear representation of the machine’s vibration state for diagnostic purposes. This noteworthy intervention underscores the potential of incorporating the measured and calculated values of the OL indicator across three specifically chosen frequency bands. To achieve this objective, the average value is employed as an indicator, contributing to the enhancement of reliability and longevity of critical industrial machinery. In this context, the novelty of the findings resides in the advanced diagnostic capabilities of the turbocompressor, thereby augmenting the efficacy of condition-based preventive maintenance for the BP 103 J turbine. The ultimate goal is to extend the equipment’s lifespan, improve the efficiency of the rotating machinery fleet, reduce maintenance costs, and enhance parameters such as availability and reliability through the support of an electronic maintenance system.

Simulation and experiment of the aerodynamic performance of a vane compressor damaged by a bird strike

Based on the purpose of studying the impact of bird strike on compressor aerodynamic performance, this paper takes a single-stage low-speed axial flow compressor as an object to establish a blade model damaged by bird strike, and on this basis, it carries out a three-dimensional full-loop numerical simulation and experiments on the compressor model with damaged blades. Through comparison with the experimental data of undamaged compressors, the results show that after the rotor blades are damaged, the rotor blades are damaged. The aerodynamic performance and stability of the compressor have significantly decreased, which accords with our understanding. The reliability of the numerical simulation method is verified by analyzing the detailed flow field structure of typical working conditions and comparing the experimental data of the compressor, which lays a foundation for the relevant calculation of damaged blades in the future.

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

Controlling Couette flow by alternating axial mass flux

This paper presents numerical simulations of the Taylor vortex flow under the influence of an externally applied alternating axial mass flux (through-flow) in a Taylor–Couette system with axial periodic boundary conditions. Such an axially modulating flow can lead to a significant variation in the onset of primary instabilities. Depending on the system parameters, the effect can be both stabilizing and destabilizing, i.e., shifting the bifurcation threshold to larger or smaller control parameters, respectively. It is found that the system response around the primary instability is sensitive to and critically influenced by an alternating mass flux, particularly the modulation frequency. We show that such an alternating axial flow represents an easily and, more importantly, precisely controllable key parameter to change the nonlinear system response from subcritical to supercritical behavior and vice versa. Furthermore, we observe different parameter regimes with regular and irregular intermittent flow dynamics.

Improving virtual heat transfer description of developed and undeveloped annular gap flows at high Taylor numbers

Increased power densities of electric machines are, amongst other factors, related also to the increase of the rotors’ rotating velocities. These can be combined with axial flow to improve the heat transfer in the annular gap. The resulting high rotating and axial velocities are characterized with high Taylor (Ta) and Reynolds (Re) numbers. Such flow regimes are currently not yet thoroughly described. The reasons are in the complex interactions between the operating conditions, annular gap geometry and the conditions at the gap inlet, which affect the flow development in the gap. Each of these impacts varies between different electric machines, adding to the complexity of description. To address this, a numerical study based on 3D CFD simulations is performed. The study accounts for the impacts of the flow conditioning at the entrance to the annular gap and the possibility that the small scale turbulent structures might not be well resolved at high Ta numbers. Thus, different inflow configurations are applied using both RANS and LES models. The results are compared with available experimental and numerical data and provide a valuable insight into the requirements for reliable heat transfer description in the increasingly interesting flow conditions.

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 novel self-supervised representation learning framework based on time-frequency alignment and interaction for mechanical fault diagnosis

Recently, supervised learning methods for intelligent mechanical fault diagnosis have achieved considerable advancements, while they heavily rely on labeled information and neglect massive unlabeled signals. Consequently, some self-supervised research has emerged and employs contrastive learning to mine general knowledge from unlabeled samples. However, these methods emphasize independent feature extraction and lack deep feature interaction, which limits better representation learning. Furthermore, it also restricts the performance improvement of fault diagnosis. To fill this gap, a novel self-supervised representation learning framework based on time-frequency alignment and interaction (TFAI) is proposed to improve the diagnosis reliability under limited labeled data. Comprising a dual encoder and a cross-modal encoder based on Transformers, the proposed TFAI model takes paired time-frequency data as input for self-supervised pretraining. Two self-supervised learning strategies, namely time-frequency alignment and time-frequency interaction, are proposed to enable the model to gain valuable knowledge from unlabeled data. The former leverages a time-frequency contrastive loss to drive the dual encoder to extract profound features from unlabeled data. The latter involves utilizing a time-frequency matching loss to guide the cross-modal encoder to perform deep feature fusion in an unsupervised manner. The well pretrained TFAI model can learn informative representations and can be fine-tuned for specific downstream fault diagnosis tasks to improve the diagnosis accuracy. By conducting three experimental cases on an axial flow pump system and a public gearbox platform system, the effectiveness, generalizability, and domain adaptability of the proposed method are validated.

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.

Flow-induced vibrations of dual-cylinders in axial flow via LES simulations

The axial-flow-induced vibration of fuel rods in the nuclear power plant is closely related to nuclear safety. In this article, a numerical study is performed on vibration of two elastic cylinders arranged side-by-side in axial flow. Large eddy simulation is employed to predict the turbulent flow. The numerical method has been verified using the experimental root-mean-square vibration amplitude of a single cylinder. A wide range of inflow velocities u∗, incident turbulence intensity Tu and space ratio P/D have been examined, where D and P are the diameter and centre-to-centre distance of the cylinders, respectively. The results show that the vibration amplitudes increase with an increasing u∗, comparable to the case of a single cylinder in axial flow. However, the two cylinders could bend outwards during a relatively high u∗ and low Tu. Although Tu significantly affects the amplitudes of the cylinders, it does not change the vibration frequency and the critical velocity at which buckling instability occurs. As the gap between the two cylinders is sufficiently small, the vibration amplitude enhances significantly due to the pronounced hydrodynamic interaction between the two elastic cylinders and surrounding fluid. The direction of buckling is no longer random but fixed.

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.

Multiscale effects of radial mixing on mixotrophic microalgal growth and macromolecular synthesis in tubular bubble-column photobioreactors

Extremophillic microalga Chlorella sorokiniana is grown mixotrophically in a 5 L externally-illuminated tubular bubble-column photobioreactor with an external light intensity of 10,500 lx (≈195 μmol-photons.m−2.s−1) at atmospheric (0.04 %), 1 %, 2 %, 3 %, 4 %, and 5 % CO2 concentrations, with acetic acid and urea as the organic carbon and nitrogen sources, respectively, for 6–8 days. Two different setups are employed: one permits axial air flow, and another promotes radial mixing of algal particles, dissolved CO2 and nutrients along with axial sparging. We show that radial mixing increases biomass yields by reducing both photo-limitation and photo-inhibition up to CO2 concentrations <3 %, above which substrate (CO2) inhibition necessitates lower reactor mixing. Radial mixing increases the lipid yield from 1.06 and 1.61 g/L to 1.27 and 1.78 g/L at 2 % and 3 % CO2, respectively, in nitrogen-limited cases, resulting in a 10–20 % increase. We show that complete reactor mixing, facilitated by the dual effects of branched (radial) and axial sparger, is preferred only in the absence of substrate (CO2) inhibition. Subsequently, we stratify the tubular photobioreactor design strategy into two regimes based on CO2 inlet concentrations. In one regime (for inlet CO2 < 3 %), we recommend the deployment of branched sparger to facilitate both radial and axial mixing simultaneously, thereby creating a well-mixed reactor at lower CO2 concentrations. In the other regime (for inlet CO2 > 3 %), axial sparging alone is recommended since complete mixing of CO2 increases substrate inhibition by reducing the reactor pH below 7.5.

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.