Rotor Exit Flow Field Research Articles

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

Considerations for Measuring Compressor Aerodynamic Excitations Including Rotor Wakes and Tip Leakage Flows

The unsteady flow field generated by the rotor provides unsteady aerodynamic excitations to the downstream stator, which can result in vibrations such as forced response. In this paper, measurements of the rotor wake and rotor tip leakage flow from an embedded rotor in a multistage axial compressor are presented. A unique feature of this work is the pitchwise traverse of the flow field used to highlight the changes in the rotor exit flow field with respect to the position of the surrounding vane rows. Results acquired at midspan focus on characterizing an average rotor wake, including the effects on the frequency spectrum, from a forced response perspective. While many analyses use an average rotor wake to characterize the aerodynamic forcing function to the downstream stator, this study explores the factors that influence changes in the rotor wake shape and the resulting impact on the spectrum. Additionally, this paper investigates the flow near the endwall where the tip leakage vortex is an important contributor to the aerodynamic excitations for the downstream vane. For the first time, experimental data are presented at the rotor exit, which show the modulation in size and radial penetration of the tip leakage vortex as the rotor passes through the upstream vane wake. As computational models become more advanced, the ability to incorporate these aerodynamic excitation effects should be considered to provide better predictions for vane vibratory response.

Influence of Upstream and Downstream Compressor Stators on Rotor Exit Flow Field

Measurements acquired at the rotor exit plane illuminate the interaction of the rotor with the upstream vane row and the downstream vane row. The relative phase of the upstream and downstream vane rows is adjusted using vane clocking so that the effect of the upstream propagating potential field from the downstream stator can be distinguished from the effects associated with the wakes shed from the upstream stator. Unsteady absolute flow angle information shows that the downstream potential field causes the absolute flow angle to increase in the vicinity of the downstream stator leading edge. The presence of Stator 1 wake is also detected at this measurement plane using unsteady total pressure data. The rotor wakes are measured at different circumferential locations across the vane passage, and the influence of Stator 1 wake on the suction side of the rotor wake is evident. Also, the influence of the downstream stator is detected on the pressure side of the rotor wake for a particular clocking configuration. Understanding the role of the surrounding vane rows on rotor wake development will lead to improved comparison between experimental data and results from computational models.

Time-Resolved Vane-Rotor Interaction in a High-Pressure Turbine Stage

This paper describes the time-varying aerodynamic interaction mechanisms that have been observed within a transonic high-pressure turbine stage; these are inferred from the time-resolved behavior of the rotor exit flow field. It contains results both from an experimental program in a turbine test facility and from numerical predictions. Experimental data was acquired using a fast-response aerodynamic probe capable of measuring Mach number, whirl angle, pitch angle, total pressure, and static pressure. A 3-D time-unsteady viscous Navier-Stokes solver was used for the numerical predictions. The unsteady rotor exit flowfield is formed from a combination of four flow phenomena: the rotor wake, the rotor trailing edge recompression shock, the tip-leakage flow, and the hub secondary flow. This paper describes the time-resolved behavior of each phenomenon and discusses the interaction mechanisms from which each originates. Two significant vane periodic changes (equivalent to a time-varying flow in the frame of reference of the rotor) in the rotor exit flowfield are identified. The first is a severe vane periodic fluctuation in flow conditions close to the hub wall and the second is a smaller vane periodic fluctuation occurring at equal strength over the entire blade span. These two regions of periodically varying flow are shown to be caused by two groups of interaction mechanisms. The first is thought to be caused by the interaction between the wake and secondary flow of the vane with the downstream rotor; and the second is thought to be caused by a combination of the interaction of the vane trailing edge recompression shock with the rotor, and the interaction between the vane and rotor potential fields.

Unsteady Flow Field Due to Nozzle Wake Interaction With the Rotor in an Axial Flow Turbine: Part II—Rotor Exit Flow Field

The two-dimensional steady and unsteady flow field at midspan in a turbine rotor has been investigated experimentally using an LDV with an emphasis on the interaction of the nozzle wake with the rotor flow field. The velocity measurements are decomposed into a time-averaged velocity, a periodic velocity component, and an unresolved velocity component. The results in the rotor passage were presented in Part I. The flow field downstream of the rotor is presented in this paper. The rotor wake profiles and their decay characteristics were analyzed. Correlations are presented that match the decay of the various wake properties. The rotor wake velocity defect decays rapidly in the trailing edge region, becoming less rapid in the near and far wake regions. The rotor wake semi-wake width increases rapidly in the trailing edge region and then grows more gradually in the near and far wake regions. The decay of the maximum unresolved unsteadiness and maximum unresolved velocity cross correlations is very rapid in the trailing edge region and this trend slows in the far wake region. In the trailing edge region, the maximum periodic velocity correlations are much larger than the maximum unresolved velocity correlations. But the periodic velocity correlations decay much faster than the unresolved velocity correlations. The interactions of the nozzle and rotor wakes are also studied. While the interaction of the nozzle wake with the rotor wake does not influence the decay rate of the various wake properties, it does change the magnitude of the properties. These and other results are presented in this paper.

Endwall and Unsteady Flow Phenomena in an Axial Turbine Stage

Detailed experimental and numerical studies have been performed in a subsonic, axial-flow turbine stage to investigate the secondary flow field, the aerodynamic loss generation, and the spanwise mixing under a stage environment. The experimental study includes measurements of the static pressure distribution on the rotor blade surface and the rotor exit flow field using three-dimensional hot-wire and pneumatic probes. The rotor exit flow field was measured with an unsteady hot-wire probe, which has high temporal and spatial resolution. Both steady and unsteady numerical analyses were performed with a three-dimensional Navier–Stokes code for the multiple blade rows. Special attention was focused on how well the steady multiple-blade-row calculation predicts the rotor exit flow field and how much the blade interaction affects the radial distribution of flow properties at the stage exit. Detailed comparisons between the measurement and the steady calculation indicate that the steady multiple-blade-row calculation predicts the overall time-averaged flow field very well. However, the steady calculation does not predict the secondary flow at the stage exit accurately. The current study indicates that the passage vortex near the hub of the rotor is transported toward the midspan due to the blade interaction effects. Also, the structure of the secondary flow field at the exit of the rotor is significantly modified by the unsteady effects. The time-averaged secondary flow field and the radial distribution of the flow properties, which are used for the design of the following stage, can be predicted more accurately with the unsteady flow calculation.

Unsteady Three-Dimensional Flow in a Single-Stage Transonic Fan: Part I—Unsteady Rotor Exit Flow Field

Detailed unsteady aerodynamic measurements have been taken in a single-stage transonic fan with a very high stator-hub loading. Two-dimensional dynamic yawmeter probes, capable of measuring mean and fluctuating levels of stagnation pressure, static pressure, and yaw angle have been traversed at rotor exit, and downstream of the stator along with several types of pneumatic three-dimensional probe. Part I of this paper describes the dynamic yawmeters and their performance, and presents ensemble-averaged stagnation pressure and random stagnation pressure unsteadiness measurements taken at rotor exit. These are used to illustrate the salient features of the rotor flow field, and the effects of compressor aerodynamic loading. Part II presents measurements taken at stator exit.

Effects of Stator Wakes and Spanwise Nonuniform Inlet Conditions on the Rotor Flow of an Axial Turbine Stage

Detailed measurements have been performed in a subsonic, axial-flow turbine stage to investigate the structure of the secondary flow field and the loss generation. The data include the static pressure distribution on the rotor blade passage surfaces and radial-circumferential measurements of the rotor exit flow field using three-dimensional hot-wire and pneumatic probes. The flow field at the rotor outlet is derived from unsteady hot-wire measurements with high temporal and spatial resolution. The paper presents the formation of the tip clearance vortex and the passage vortices, which are strongly influenced by the spanwise nonuniform stator outlet flow. Taking the experimental values for the unsteady flow velocities and turbulence properties, the effect of the periodic stator wakes on the rotor flow is discussed.

Application of an inverse cascade design method to an axial fan.

In order to demonstrate the applicability of an inverse cascade design method for blade design for an axial turbomachine, rotor and stator blades of a single stage axial fan are designed and tested. This design concept, proposed in the previous reports, is based on an inverse boundary layer method and an inverse cascade method. Overall performance and the rotor exit flow field are measured and are compared with a conventional fan designed using NACA 65 series cascade. The inversely designed fan obtains higher efficiency and a wider operating range compared with the conventional one. The midspan wake of the rotor blade in the trailing edge region reveals an extremely low velocity defect, a low wake shape factor, and low momentum thickness. boundary layer separation on the rotor blade suction surface seems to be avoided and the losses are low. The experimental results show the validity of the practical aplication of the inverse design concept, especially for rotating blades.

Through-Flow Modeling of Axial Turbomachinery

Through-flow analysis, which is at the heart of the aerodynamic design of turbomachinery, requires as aerodynamic input a row-by-row description of the airfoil loss, deviation, and blockage. Loss and deviation have been investigated extensively in both cascades and rotating rigs as well as in numerous two- and three-dimensional analytical studies. Blockage, however, has received far less attention. As defined herein, blockage is a measure of the departure of the flow field from the condition of axisymmetry which is assumed in the through-flow analysis. The full-span blockage distributions calculated from measured single-stage rotor wake data were used to provide the input to the through-flow analysis, along with the measured full-span distributions of loss and deviation. Measured and computed results are compared for the single-stage rotor operating with both thick and thin inlet hub and tip boundary layers. It is demonstrated that both the level and the spanwise and streamwise distributions of blockage have a strong impact on the computed rotor exit flow field.

A Fundamental Criterion for the Application of Rotor Casing Treatment

An experimental investigation has been carried out on the influence of grooved casing treatment on the stall margin of a compressor rotor. Tests were conducted with two rotor builds having different solidities (but all other parameters identical) so that one of the rotors exhibited a wall, or casing, type of stall, while the other showed a blade stall. It was found that the casing treatment, when compared to the solid casing, was very effective in increasing the stall margin of the wall stall configuration, whereas there was little or no change in the stall point of the blade stall configuration. Detailed relative frame measurements of the rotor exit flow field were also taken as part of the program. These showed that in a wall stall situation, the use of casing treatment produced a substantial decrease in the relative total pressure defect, compared with the solid casing, while this was not true for the blade stall type of blading. The results of the experiments, both in overall measurements and in the detailed relative frame traverses, support the hypothesis that casing treatment is effective only in a situation in which a wall stall exists.