Counter Rotating Open Rotor Research Articles

Identification of Turbomachinery Noise Sources via Processing Beamforming Data Using Principal Component Analysis

Complex turbomachinery systems produce a wide range of noise components. The goal is to identify noise source categories, determine their characteristic noise patterns and locations. Researchers can then use this information to quantify the impact of these noise sources, based on which new design guidelines can be proposed. Phased array microphone measurements processed with acoustic beamforming technology provide noise source maps for pre-determined frequency bands (i.e., bins) of the investigated spectrum. However, multiple noise generation mechanisms can be active in any given frequency bin. Therefore, the identification of individual noise sources is difficult and time consuming when using conventional methods, such as manual sorting. This study presents a method for combining beamforming with Principal Component Analysis (PCA) methods in order to identify and separate apart turbomachinery noise sources with strong harmonics. The method is presented through the investigation of Counter-Rotating Open Rotor (CROR) noise sources. It has been found that the proposed semi-automatic method was able to extract even weak noise source patterns that repeat throughout the data set of the beamforming maps. The analysis yields results that are easy to comprehend without special prior knowledge and is an effective tool for identifying and localizing noise sources for the acoustic investigation of various turbomachinery applications.

Effect of a pylon on the broadband noise sources of counter-rotating turbomachinery

Pylons are commonly used for the mounting of engines in the aircraft industry. On the other hand, the installation of a pylon influences the noise generation mechanisms and therefore alters the broadband noise characteristics of a given turbomachinery setup. In this investigation, a counter-rotating open rotor with and without a pylon is investigated in order to determine its effects on broadband noise sources. The various broadband noise sources and their typical frequency ranges have been determined using beamforming maps and spectral analysis. In order to attain a clear impression regarding the broadband noise sources, the Double Filtering beamforming method has been utilized in the investigation. This method removes the tonal components from the recorded signal of a microphone array, resulting in a purely broadband signal. Using beamforming maps, the dominant broadband noise source amplitudes and locations can therefore be investigated in great detail. Compared to other methods, the investigation of measurement data and beamforming maps helps determine the amplitude, the frequency range, and the significance of the various types of broadband noise sources that are truly present in the emitted noise. It has been found for lower frequencies, that the broadband noise sources at the blade root of the aft rotor are dominant, while for higher frequencies, the significant broadband noise sources are localized to the trailing edge region of the forward rotor and the leading edge of the aft rotor. The installation of a pylon has resulted in an additional broadband noise source appearing at the blade tip of the aft rotor.

Noise Source Analysis in Counter-Rotating Open Rotors

Because of their potential to reduce aircraft emissions, counter-rotating open rotors (CRORs) have seen a renewed interest in applications, from civil aviation to urban air mobility. However, there are concerns surrounding their acoustic emissions. In the work presented, the authors investigated the noise sources for a range of CROR configurations for a general aviation class aircraft. Numerical models are used to compute the aerodynamic and aeroacoustic performance of these configurations. Further dissection of the various CROR noise sources is then carried out in order to better understand their contribution to CROR noise, and to direct the design of future low-noise CRORs. Noise reductions were observed when the rotor–rotor spacing was increased. Increased contraction of the wake requires the need for increased clipping to reduce the tip vortex interaction source. Noise reductions were also observed in the case of asynchronous rotational speeds. However, this was accompanied by a reduction in propulsive efficiency. Analysis of the CROR in nonaxial flight demonstrated the need to evaluate noise-reducing strategies at off-design conditions. Although the analysis proved the ability to reduce various CROR noise sources, it highlighted that tradeoffs with aerodynamic performance is necessary.

Broadband noise prediction of a counter rotating open rotor based on LES simulation with phase-lagged assumption (draft)

This paper presents the broadband noise analysis of a Counter Rotating Open Rotor (CROR) configuration. The numerical study is based on a hybrid approach: a Large Eddy Simulation (LES) code solves the near-flow field of the CROR configuration and the near-to-far-field propagation is then predicted by a Ffowcs Williams–Hawkings analogy either based on a solid or porous formulation. The LES solver uses a phase-lagged assumption with a proper orthogonal decomposition for the data storage. The numerical approach is validated against wind tunnel experimental data of a CROR configuration (AI-PX7) at three different operating points focused on the broadband noise. The analysis of the numerical simulations shows the predominant effect of the rear rotor suction side on the radiated broadband noise with an increasing contribution with span location. This source is related to the impingement of front rotor wakes and the development of leading edge vortices that induce large pressure fluctuations close to the leading edge on the suction side.

Loss assessment of a counter rotating open rotor using URANS/LES with phase-lagged assumption (draft)

This paper presents the study of the losses generated in a Counter Rotating Open Rotor (CROR) configuration at three different operating conditions (approach, cutback and sideline). Unsteady Reynolds Averaged Navier-Stokes (URANS) and Large-Eddy Simulation (LES) approaches are used and compared to describe the flow field and the mechanisms of loss. Since no common circumferential periodicity occurs in the two blade rows of the configuration (11 blades for the front rotor and 9 for the rear rotor), a full 360∘ simulation would be required. In order to reduce the related computational cost, a phase-lagged assumption approach is used. This method enables to perform unsteady simulations on multi-stage propulsive configurations including multiple frequency flows with a computational domain reduced to one single blade passage for each row. The phase-lagged approach requires a large data storage reduced in the study by a data compression method. The data compression method is based on a Proper Orthogonal Decomposition (POD) replacing the traditional Fourier Series Decomposition (FSD). The inherent limitation of the phase-shifted periodicity assumption remains with the POD data storage but this compression method alleviates some issues associated with the FSD, especially spectrum content issues. The analysis of the losses generated in the configuration is based on an entropy formulation. In particular, the losses are split between boundary layer contributions and the remaining domain where wakes and secondary flows occur. The study shows the influence of the leading edge vortex on the suction side boundary layer transition of the front and rear rotor blades at high rotational speed (cutback and sideline). The main source of losses is associated with the suction side boundary layer over the front and rear rotor blades with a main peak of loss production at around 75% of the blade chord.

Numerical prediction of vortex trajectories and vortex–blade interaction on the CROR engine

PurposeThe exponential growth in computational capabilities and the increasing reliability of current simulation tools have fostered the use of computational fluid dynamics (CFD) in the design of pioneering aircraft engine architectures, such as the counter rotating open rotor (CROR) engine. Today, this design process is led by tight performance and noise constraints from a very early stage, thus requiring deep investigations of the aerodynamic and acoustic behaviour of the fluid flow. The purpose of this study is to track the trajectory of tip vortices, which is of critical importance to understand and prevent potential vortex–blade interactions with subsequent rows, as this condition strongly influences the aerodynamic and structural performance and acoustic footprints of the engine.Design/methodology/approachIn this paper, a flow feature detection methodology is applied to a particular CROR test case with the goal of visualizing and tracking the development of these coherent structures from the tip of front rotating blades. The suitability and performance of four typical region-based methodologies and one line-based (LB) criteria are firstly evaluated. Then, two novel seeding methodologies are presented as an attempt to improve the performance of the LB algorithm previously investigated.FindingsIt was demonstrated that the new seeding algorithms increase the probability of the selected seeds to grow into a tip vortex line and reduce the user’s dependence upon the selection of candidate seeds, providing faster and more accurate answers during the design-to-noise iterative process.Originality/valueApart from the new vortex detection initialization methodologies, the paper also attempts to assist the user in the endeavour of extracting rotating structures from their own CFD simulations.

Acoustic Analysis of Counter-Rotating Open Rotors with a Locked Blade Row

Counter-rotating open rotors (CRORs) have the potential to reduce environmental emissions thanks to their high propulsive efficiency. However, there are a number of concerns surrounding their acoustic emissions. This contribution presents a novel multiconfiguration CROR that offers considerable noise reductions. In particular, locking either the fore or aft rotor during takeoff is considered, with the running rotor providing the required thrust. During cruise, both rotors are operated to retain the high efficiency of the CROR. A coupled computational fluid dynamics/computational aeroacoustics analysis has shown the potential of this multiconfiguration concept to offer substantial noise reductions when compared to a baseline CROR. During a simulated constant-altitude flyover at takeoff conditions, reductions of 3.5 and 7.9 dBA have been demonstrated when either the fore or aft row is locked, respectively. Using the effective perceived noise level metric, this result corresponded to 7 and 12 Effective Perceived Noise Level (in Decibels), respectively, for the same flyover.

Beamforming Method for Extracting the Broadband Noise Sources of Counter-Rotating Open Rotors

Counter-rotating open rotors (CRORs) are known to have advantageous propulsive efficiency properties but, at the same time, many noise emission issues related to this technology still need to be investigated. The noise they generate consists of tonal and broadband components, of which the tonal components often appear in narrow frequency bands with large amplitudes. During beamforming investigations, this often makes sorting them out from among other noise sources in the same frequency bin rather straightforward. On the other hand, the broadband noise sources can be characterized as having small amplitudes: in general, they are not the dominant noise sources in many frequency bins; but, overall, a significant noise component that needs to be investigated. The literature has provided a single microphone signal preprocessing method for removing the tonal components, hence isolating the broadband noise of a CROR: the signal of which has been shown to be appropriate for the investigation of broadband spectra. In this paper, this preprocessing method is further developed into a beamforming method that can be used in order to localize the broadband noise sources of CRORs. The resulting beamforming maps have been compared to the results of earlier broadband noise CROR studies, showing the validity of the new method and the advantages of using it as compared to methods used in other investigations.

3D Generalized Inverse Beamforming in wind tunnel aeroacoustic testing: application to a Counter Rotating Open Rotor aircraft model

Inverse methods are gaining relevance in the aeroacoustic community for their capability to accurately localize and quantify noise sources. Indeed, since modern aircraft are more targeted to the reduction of fuel consumption, and very often some design choices, like Open Rotor (OR) propulsion systems, cause excessive acoustic emissions, accurate knowledge of noise source locations is of fundamental importance. This paper describes the use of an inverse method, namely Generalized Inverse Beamforming (GIBF), to characterize a Counter Rotating Open Rotor (CROR) installed on a 1/7th scale aircraft model. The model was tested in a large Low-Speed Wind Tunnel (WT) at The Pininfarina Aerodynamic and Aeroacoustic Research Center in Turin, Italy, within the framework of the FP7 EU Clean-Sky WENEMOR (Wind tunnel tests for the Evaluation of the installation effects of Noise EMissions of an Open Rotor advanced regional aircraft) project. With respect to previous works already published, the pros and cons of 3D GIBF formulation will be discussed on data collected from an industrial test case. A comparison of L2 and L1 norm formulations, as well as multiplicative approach and single array processing in 3D GIBF, will be performed, discussing their differences in terms of source localization accuracy. Since a quantitative analysis on real data cannot be provided because of confidentiality issues, the capability of the present approach to correctly quantify the source strength will be evaluated by considering a synthetic monopole source emitting white noise at different signal-to-noise-ratios (SNRs). Finally, it will be shown that 3D GIBF can provide engineers with more reliable data regarding the acoustic behavior of CROR-based aircrafts, this proving the advantages in exploiting this inverse method in WT aeroacoustic applications.

Noise reduction of a Counter Rotating Open Rotor through a locked blade row

Counter Rotating Open Rotors (CROR) have the potential to significantly reduce aircraft emissions. However, there are a number of concerns surrounding their noise levels. In this contribution, we propose a number of novel configurations to reduce the noise of CROR for general aviation aircraft. In particular, we lock either fore or aft blade row on departure and approach, and keep the CROR trimmed at the same thrust as in design configuration (both rotors running). The CROR is switched back to design configuration at cruise to regain the high propulsive efficiency. To further reduce noise, two additional cases are investigated: 1) folded aft rotor; 2) increased diameter fore rotor (with locked-aft blade row). A low-order CROR trim code that has been developed to compute the aerodynamic and aeroacoustic performance of new design configurations is used in the numerical analysis. The results demonstrate significant noise gains for a number of blade count combinations during a constant altitude flyover. The analysis found that using a locked-fore and locked-aft configuration resulted in a maximum noise reduction of around 3 dB(A) (or 3 dB (EPNL)) and 3 dB(A) (or 6 dB (EPNL)) respectively. Folding the aft rotor backward could result in a maximum noise gain of around 12 dB(A). Increasing the fore rotor diameter by 30% was shown to reduce noise by a maximum of 8 dB(A) against an operative CROR of the same tip extension.

Full-scale experiments on the reduction of propeller-induced aircraft interior noise with active trim panels

Results are presented of full-scale experiments on the active reduction of rotor-induced passenger cabin noise in a Dornier Do728 aircraft. Two active sidewall panels (smart linings) are used to reduce the sound pressure in a control region in front of the linings. The fuselage pressure distribution associated with the first five harmonics of a generic counter-rotating open rotor (CROR) engine is emulated with a loudspeaker array. Each smart lining is equipped with two inertial force actuators. It uses up to eight error microphones and implements an adaptive feedforward controller. The two smart linings are driven in parallel. A maximum SPL reduction of 11.3 dB is achieved in the controlled area. The mean SPL reduction over 18 microphones is 6.8 dB. At the most critical second frequency, a mean SPL reduction of 9.3 dB is achieved by the two smart linings working in parallel. It is observed that the SPLs near the lining (at the window seat positions) are significantly higher than the SPLs near the aisle. This leads to the conclusion that the major part of the sound energy is transmitted through the linings, which is seen as an argument for the suitability of the smart lining concept.

MUSIC-haic: 3D Multidisciplinary Tools for the Simulation of In-Flight Icing due to High Altitude Ice Crystals

<div class="section abstract"><div class="htmlview paragraph">Icing is a major hazard for aviation safety. Over the last decades an additional risk has been identified when flying in clouds with high concentrations of ice-crystals where ice accretion may occur on warm parts of the engine core, resulting in engine incidents such as loss of engine thrust, strong vibrations, blade damage, or even the inability to restart engines. Performing physical engine tests in icing wind tunnels is extremely challenging, therefore, the need for numerical simulation tools able to accurately predict ICI (Ice Crystal Icing) is urgent and paramount for the aeronautics industry, especially regarding the development of new generation engines (UHBR = Ultra High Bypass Ratio, CROR = Counter rotating Open Rotor, ATP = Advanced Turboprop) for which analysis methods largely based on previous engines experience may be less and less applicable. The European research project MUSIC-haic has been conceived to fill this gap and has started in September 2018. MUSIC-haic brings together the main European research institutions working on icing modelling as well as engine manufacturers and aircraft manufacturers. The project will develop advanced ice crystal icing models, implement them in existing industrial 3D multi-disciplinary tools, and finally perform extensive validation of the new ICI numerical capability through comparison of numerical results with both academic and industrial experimental data. The aim of the present paper is to provide an overview of the project technical objectives, scientific ambition and methodology, and work breakdown structure.</div></div>

Investigation of a Pylons Effect on the Character of Counter-Rotating Open Rotor Noise Using Beamforming Technology

Investigation of a Pylons Effect on the Character of Counter-Rotating Open Rotor Noise Using Beamforming Technology

Design and Application of a Multidisciplinary Predesign Process for Novel Engine Concepts

The purpose of this paper is to present a multidisciplinary predesign process and its application to three aero-engine models. First, a twin spool mixed flow turbofan engine model is created for validation purposes. The second and third engine models investigated comprise future engine concepts: a counter rotating open rotor (CROR) and an ultrahigh bypass turbofan. The turbofan used for validation is based on publicly available reference data from manufacturing and emission certification. At first, the identified interfaces and constraints of the entire predesign process are presented. An important factor of complexity in this highly iterative procedure is the intricate data flow, as well as the extensive amount of data transferred between all involved disciplines and among different fidelity levels applied within the design phases. To cope with the inherent complexity, data modeling techniques have been applied to explicitly determine required data structures of those complex systems. The resulting data model characterizing the components of a gas turbine and their relationships in the design process is presented in detail. Based on the data model, the entire engine predesign process is presented. Starting with the definition of a flight mission scenario and resulting top level engine requirements, thermodynamic engine performance models are developed. By means of these thermodynamic models, a detailed engine component predesign is conducted. The aerodynamic and structural design of the engine components are executed using a stepwise increase in level of detail and are continuously evaluated in context of the overall engine system.

Influence of Variable Geometry Compressor on Transient Performance of Counter-Rotating Open Rotor Engines

This work describes a methodology used for counter-rotating (CR) propellers performance estimation. The method is implemented in an in-house program for gas turbine performance prediction, making possible the simulation of the counter-rotating open rotor (CROR) architecture. The methodology is used together with a variable geometry compressor control strategy to avoid surge conditions. Two cases are simulated under transient operation for both fixed and variable geometry compressor. The influence of the variable geometry control on the transient performance of CROR engines is evaluated and a comprehensive understanding on the transient behavior of this type of engine could be obtained. It is shown that the use of the variable geometry compressor control does not significantly affect the overall engine performance, while avoiding the surge conditions, thus ensuring the engine operation safety.

A Propeller Model for Steady-State and Transient Performance Prediction of Turboprop and Counter-Rotating Open Rotor Engines

This paper describes a methodology used for propeller performance estimation, which was implemented in an in-house modular program for gas turbine performance prediction. A model based on subsonic generic propeller maps and corrected for compressibility effects, under high subsonic speeds, was proposed and implemented. Considering this methodology, it is possible to simulate conventional turboprop architectures and counter-rotating open rotor (CROR) engines in both steady-state and transient operating conditions. Two simulation scenarios are available: variable pitch angle propeller with constant speed; or variable speed propeller with constant pitch angle. The simulations results were compared with test bench data and two gas turbine performance commercial software packages were used to fulfill the model validation for conventional turboprop configurations. Furthermore, a direct drive CROR engine was simulated using a variable inlet guide vanes (VIGV) control strategy during transient operation. The model has shown to be able to provide several information about propeller-based engine performance using few input data, and a comprehensive understanding on steady-state and transient performance behavior was achieved in the obtained results.

A 3D analytical model for orthogonal blade-vortex interaction noise

A 3D analytical model of an Orthogonal Blade-Vortex Interaction (OBVI) for Counter-Rotating Open Rotor (CROR) tonal noise is investigated. The specific influence of two parameters taking into account the three-dimensionality of both the vortex velocity and the convection velocity within the rotor-rotor volume is addressed. The first step is to extract the vortex parameters from a recent unsteady Reynolds-Averaged Navier-Stokes computation and validate different vortex models. Lamb-Oseen and Scully vortices reproduce the behavior of the tip-vortex tangential velocity fairly well. Regarding the vortex axial velocity modeling, a Gaussian profile fits well with numerical results. On the one hand, the impact of the stream-tube contraction unbalances the lobes of the unsteady pressure with opposite phases produced by the OBVI event. This effect is larger than that of an equivalent blade sweep. On the other hand, adding the axial velocity deficit to the tangential one also unbalances the pressure lobes. Finally, from an acoustic point of view using Curle's acoustic analogy, both the stream-tube contraction and the axial velocity deficit have the same effect: they turn an acoustically-low efficient quadrupole into a strong dipole making these parameters fundamental for future CROR OBVI investigations.

Fast computation of time-dependent acoustic fields.

A method for the fast evaluation of time-dependent acoustic fields from complex sources is presented. The technique is based on a fast integration method for the boundary integral arising in a Kirchhoff formulation and requires a small, and roughly constant, computation time to compute a transient signal, at the expense of a pre-processing stage. In the calculations in this paper, based on test cases for a single rotor, a counter-rotating open rotor, and a broadband volume source, it is found that transient field calculations require an order of magnitude less computational time for the field from an array of 16 384 sources, a computational advantage that increases with source number.

Active control of counter-rotating open rotor interior noise in a Dornier 728 experimental aircraft

The fuel consumption of future civil aircraft needs to be reduced because of the CO2 restrictions declared by the European Union. A consequent lightweight design and a new engine concept called counter-rotating open rotor are seen as key technologies in the attempt to reach this ambitious goals. Bearing in mind that counter-rotating open rotor engines emit very high sound pressures at low frequencies and that lightweight structures have a poor transmission loss in the lower frequency range, these key technologies raise new questions in regard to acoustic passenger comfort. One of the promising solutions for the reduction of sound pressure levels inside the aircraft cabin are active sound and vibration systems. So far, active concepts have rarely been investigated for a counter-rotating open rotor pressure excitation on complex airframe structures.Hence, the state of the art is augmented by the preliminary study presented in this paper. The study shows how an active vibration control system can influence the sound transmission of counter-rotating open rotor noise through a complex airframe structure into the cabin. Furthermore, open questions on the way towards the realisation of an active control system are addressed. In this phase, an active feedforward control system is investigated in a fully equipped Dornier 728 experimental prototype aircraft. In particular, the sound transmission through the airframe, the coupling of classical actuators (inertial and piezoelectric patch actuators) into the structure and the performance of the active vibration control system with different error sensors are investigated. It can be shown that the active control system achieves a reduction up to 5dB at several counter-rotating open rotor frequencies but also that a better performance could be achieved through further optimisations.

Active Control of Counter-Rotating Open Rotor Interior Noise in a Dornier 728 Experimental Aircraft: Optimised Sensor Placement

For the next generation of aircraft, new engine and fuselage concepts are investigated because of the increasing demand for fuel efficiency and the CO2/NOx restrictions declared by the European Union. A lightweight design of civil aircraft combined with efficient engines like the counter-rotating open rotor (CROR) is a key technology to reach these ambitious goals. Especially in the lower frequency range, where the CROR blade-passing frequencies (BPF’s) are dominating the acoustic response, the transmission loss of lightweight structures is typically poor. Active control techniques was tested on plates and beams to increase the system performance in terms of global vibration or sound power reduction. Yet to the authors’ best knowledge, only very little work has been conducted to establish sensor or actuator position optimisation on a complex aircraft structure. The presented paper investigates the potential of a sensor position optimisation on a Dornier 728 experimental aircraft of the German Aerospace center (DLR). This experimental aircraft provides a real fuselage structure and the multi-sinusoidal CROR excitation is induced by a 112-channel loud speaker array. The system model of a fuselage segment is experimentally identified, a sensor optimisation is established and compared to empirically placed sensor configurations. The sensor optimisation includes the simulation of an multiple-input multipleoutput (MIMO) active feedforward vibration controller and the resulting sound radiating vibration patterns. It is shown in the experiments that the feedforward controller using optimised sensor locations reduces the radiated sound power by 7 dB, whereas the empirically placed sensors achieve only 4.5 dB. Furthermore, the potential of the proposed optimisation method regarding sound power reduction performance and the number of required sensors is shown for a real aircraft structure and a complex acoustic excitation.