Suction Surface Length Research Articles

Flow visualization for investigating stator losses in a multistage axial compressor

The methodology and implementation of a powder-paint-based flow visualization technique along with the illuminated flow physics are presented in detail for application in a three-stage axial compressor. While flow visualization often accompanies detailed studies, the turbomachinery literature lacks a comprehensive study which both utilizes flow visualization to interrupt the flow field and explains the intricacies of execution. Lessons learned for obtaining high-quality images of surface flow patterns are discussed in this study. Fluorescent paint is used to provide clear, high-contrast pictures of the recirculation regions on shrouded vane rows. An edge-finding image processing procedure is implemented to provide a quantitative measure of vane-to-vane variability in flow separation, which is approximately 7 % of the suction surface length for Stator 1. Results include images of vane suction side corner separations from all three stages at three loading conditions. Additionally, streakline patterns obtained experimentally are compared with those calculated from computational models. Flow physics associated with vane clocking and increased rotor tip clearance and their implications to stator loss are also investigated with this flow visualization technique. With increased rotor tip clearance, the vane surface flow patterns show a shift to larger separations and more radial flow at the tip. Finally, the effects of instrumentation on the flow field are highlighted.

Transition Mechanisms in Laminar Separated Flow Under Simulated Low Pressure Turbine Aerofoil Conditions

Based on detailed experimental work conducted at a low speed test facility, this paper describes the transition process in the presence of a separation bubble with low Reynolds number, low free-stream turbulence, and steady main flow conditions. A pressure distribution has been created on a long flat plate by means of a contoured wall opposite of the plate, matching the suction side of a modern low-pressure turbine aerofoil. The main flow conditions for four Reynolds numbers, based on suction surface length and nominal exit velocity, were varied from 80,000 to 300,000, which covers the typical range of flight conditions. Velocity profiles and the overall flow field were acquired in the boundary layer at several streamwise locations using hot-wire anemometry. The data given is in the form of contours for velocity, turbulence intensity, and turbulent intermittency. The results highlight the effects of Reynolds number, the mechanisms of separation, transition, and reattachment, which feature laminar separation-long bubble and laminar separation-short bubble modes. For each Reynolds number, the onset of transition, the transition length, and the general characteristics of separated flow are determined. These findings are compared to the measurement results found in the literature. Furthermore, the experimental data is compared with two categories of correlation functions also given in the literature: (1) correlations predicting the onset of transition and (2) correlations predicting the mode of separated flow transition. Moreover, it is shown that the type of instability involved corresponds to the inviscid Kelvin-Helmholtz instability mode at a dominant frequency that is in agreement with the typical ranges occurring in published studies of separated and free-shear layers.

Low Pressure Turbine Relaminarization Bubble Characterization using Massively-Parallel Large Eddy Simulations

The separation and reattachment of suction surface boundary layer in a low pressure turbine is characterized using large-eddy simulation at Ress = 69000 based on inlet velocity and suction surface length. Favorable comparisons are drawn with experiments using a high pass filtered Smagorinsky model for sub-grid scales. The onset of time mean separation is at s/so = 0.61 and reattachment at s/so = 0.81, extending over 20% of the suction surface. The boundary layer is convectively unstable with a maximum reverse flow velocity of about 13% of freestream. The breakdown to turbulence occurs over a very short distance of suction surface and is followed by reattachment. Turbulence near the bubble is further characterized using anisotropy invariant mapping and time orthogonal decomposition diagnostics. Particularly the vortex shedding and shear layer flapping phenomena are addressed. On the suction side, dominant hairpin structures near the transitional and turbulent flow regime are observed. The hairpin vortices are carried by the freestream even downstream of the trailing edge of the blade with a possibility of reaching the next stage. Longitudinal streaks that evolve from the breakdown of hairpin vortices formed near the leading edge are observed on the pressure surface.

Separation control on high lift low-pressure turbine airfoils using pulsed vortex generator jets

Boundary layer separation control has been studied using vortex generator jets (VGJs) on a very high lift, low-pressure turbine airfoil. Experiments were done under low (0.6%) freestream turbulence conditions on a linear cascade in a low speed wind tunnel. Pressure surveys on the airfoil surface and downstream total pressure loss surveys were documented. Instantaneous velocity profile measurements were acquired in the suction surface boundary layer. Cases were considered at Reynolds numbers (based on the suction surface length and the nominal exit velocity from the cascade) of 25000 and 50000. Jet pulsing frequency and duty cycle were varied. In cases without flow control, the boundary layer separated and did not reattach. With the VGJs, separation control was achieved. At sufficiently high pulsing frequencies, separation control was possible with low jet velocities and 10% duty cycle. At lower frequencies, a 50% duty cycle helped by separating the disturbances associated with the jets turning on and turning off, thereby doubling the frequency of separation control events above the pulsing frequency. Phase averaged velocity profiles and wavelet spectra of the velocity show the VGJ disturbance causes the boundary layer to reattach, but that it can re-separate between disturbances. When the disturbances occur at high enough frequency, the time available for separation is reduced, and the separation bubble remains closed at all times.

Effect of Unsteady Wakes on Boundary Layer Separation on a Very High Lift Low Pressure Turbine Airfoil

Boundary layer separation has been studied on a very high lift, low pressure turbine airfoil in the presence of unsteady wakes. Experiments were done under low (0.6%) and high (4%) freestream turbulence conditions on a linear cascade in a low speed wind tunnel. Wakes were produced from moving rods upstream of the cascade. Flow coefficients were varied from 0.35 to 1.4 and wake spacing was varied from one to two blade spacings, resulting in dimensionless wake passing frequencies F=fLj-te/Uave (f is the frequency, Lj-te is the length of the adverse pressure gradient region on the suction surface of the airfoils, and Uave is the average freestream velocity) ranging from 0.14 to 0.56. Pressure surveys on the airfoil surface and downstream total pressure loss surveys were documented. Instantaneous velocity profile measurements were acquired in the suction surface boundary layer and downstream of the cascade. Cases were considered at Reynolds numbers (based on the suction surface length and the nominal exit velocity from the cascade) of 25,000 and 50,000. In cases without wakes, the boundary layer separated and did not reattach. With wakes, separation was largely suppressed, particularly if the wake passing frequency was sufficiently high. At lower frequencies the boundary layer separated between wakes. Background freestream turbulence had some effect on separation, but its role was secondary to the wake effect.

Separation Control on a Very High Lift Low Pressure Turbine Airfoil Using Pulsed Vortex Generator Jets

Boundary layer separation control has been studied using vortex generator jets (VGJs) on a very high lift, low-pressure turbine airfoil. Experiments were done under high (4%) freestream turbulence conditions on a linear cascade in a low speed wind tunnel. Pressure surveys on the airfoil surface and downstream total pressure loss surveys were documented. Instantaneous velocity profile measurements were acquired in the suction surface boundary layer. Cases were considered at Reynolds numbers (based on the suction surface length and the nominal exit velocity from the cascade) of 25,000 and 50,000. Jet pulsing frequency, duty cycle, and blowing ratio were all varied. Computational results from a large eddy simulation of one case showed reattachment in agreement with the experiment. In cases without flow control, the boundary layer separated and did not reattach. With the VGJs, separation control was possible even at the lowest Reynolds number. Pulsed VGJs were more effective than steady jets. At sufficiently high pulsing frequencies, separation control was possible even with low jet velocities and low duty cycles. At lower frequencies, higher jet velocity was required, particularly at low Reynolds numbers. Effective separation control resulted in an increase in lift and a reduction in total pressure losses. Phase averaged velocity profiles and wavelet spectra of the velocity show the VGJ disturbance causes the boundary layer to reattach, but that it can reseparate between disturbances. When the disturbances occur at high enough frequency, the time available for separation is reduced, and the separation bubble remains closed at all times.

Separated Flow Measurements on a Highly Loaded Low-Pressure Turbine Airfoil

Boundary layer separation, transition, and reattachment have been studied on a new, very high lift, low-pressure turbine airfoil. Experiments were done under low freestream turbulence conditions on a linear cascade in a low speed wind tunnel. Pressure surveys on the airfoil surface and downstream total pressure loss surveys were documented. Velocity profiles were acquired in the suction side boundary layer at several streamwise locations using hot-wire anemometry. Cases were considered at Reynolds numbers (based on the suction surface length and the nominal exit velocity from the cascade) ranging from 25,000 to 330,000. In all cases, the boundary layer separated, but at high Reynolds number the separation bubble remained very thin and quickly reattached after transition to turbulence. In the low Reynolds number cases, the boundary layer separated and did not reattach, even when transition occurred. This behavior contrasts with previous research on other airfoils, in which transition, if it occurred, always induced reattachment, regardless of Reynolds number.

On the Physics of Heat Transfer and Aerodynamic Behavior of Separated Flow Along a Highly Loaded Low Pressure Turbine Blade Under Periodic Unsteady Wake Flow and Varying of Turbulence Intensity

AbstractThis paper attempts to provide a detailed insight into the heat transfer and aerodynamic behavior of a separation zone that is generated as a result of boundary layer development along the suction surface of a highly loaded low pressure turbine blade. This paper experimentally investigates the individual and combined effects of periodic unsteady wake flows and freestream turbulence intensity (Tu) on heat transfer and aerodynamic behavior of the separation zone. Heat transfer experiments were carried out at Reynolds numbers of 110,000, 150,000, and 250,000 based on the suction surface length and the cascade exit velocity. Aerodynamic experiments were performed at Re=110,000. For the above Re numbers, the experimental matrix includes Tu’s of 1.9%, 3.0%, 8.0%, and 13.0% and three different unsteady wake frequencies with the steady inlet flow as the reference configuration. Detailed heat transfer and boundary layer measurements are performed with particular attention paid to the heat transfer and aerodynamic behavior of the separation zone at different Tu’s at steady and periodic unsteady flow conditions. The objectives of the research are (a) to quantify the effect of Tu on the aerothermal behavior of the separation bubble at steady inlet flow conditions, (b) to investigate the combined effects of Tu and the unsteady wake flow on the aerothermal behavior of the separation bubble, and (c) to provide a complete set of heat transfer and aerodynamic data for numerical simulation that incorporates Navier–Stokes and energy equations. The experimental investigations were performed in a large-scale, subsonic, unsteady turbine cascade research facility at the Turbomachinery Performance and Flow Research Laboratory of Texas A&M University.

Large-Eddy Simulation of wake convection and unsteady flow in an LP turbine blade passage

The Large-Eddy Simulations (LES) of unsteady flows within the passage of a highly cambered Low-Pressure (LP) turbine blade (T106 profile) interacted by impinging wakes are performed for a Reynolds number of 1.6 ? 105 (based on the chord and exit velocity). The wake-data generated from a precursor LES are interpolated at the inlet plane of the cascade replacing a moving bar wake-generator in front of it. The three-dimensional, time-dependent, incompressible Navier-Stokes equations in fully covariant form are solved using a symmetry-preserving finite difference scheme of second-order spatial and temporal accuracy. An attempt is made to describe the effects of wake kinematics and wake turbulence on the development of unsteady boundary layer on the suction surface of the LP turbine blade. When compared with experiments, the present LES qualitatively resolves high production of Turbulent Kinetic Energy (TKE) due to distortion of migrating wakes within the blade passage. Interactions of this turbulent wake with the inflexional boundary layer on the rear half of the suction surface trigger rollup of shear layer via Kelvin-Helmholtz (K?H) instabilities leading to transition. This results in increased level of turbulence along the last 20% of the suction surface length.

Effect of Turbulence Intensity and Periodic Unsteady Wake Flow Condition on Boundary Layer Development, Separation, and Reattachment Along the Suction Surface of a Low-Pressure Turbine Blade

This paper experimentally investigates the individual and combined effects of periodic unsteady wake flows and freestream turbulence intensity (FSTI) on flow separation along the suction surface of a low-pressure turbine blade. The experiments were carried out at a Reynolds number of 110,000 based on the suction surface length and the cascade exit velocity. The experimental matrix includes freestream turbulence intensities of 1.9%, 3.0%, 8.0%, and 13.0%, and three different unsteady wake frequencies with the steady inlet flow as the reference configuration. Detailed boundary layer measurements are performed along the suction surface of a highly loaded turbine blade with a separation zone. Particular attention is paid to the aerodynamic behavior of the separation zone at different FSTIs at steady and periodic unsteady flow conditions. The objective of the research is (i) to quantify the effect of FSTIs on the dynamics of the separation bubble at steady inlet flow conditions and (ii) to investigate the combined effects of Tuin and the unsteady wake flow on the behavior of the separation bubble.

Influence of Wake Passing Frequency and Elevated Turbulence Intensity on Transition.

Experimental results from a study of the effects of passing wakes upon laminar-to-turbulent transition in a low-pressure turbine passage are presented. The test section simulates the effects of unsteady wakes resulting from rotor-stator interaction In turbine blade boundary layers and separated flow regions over suction surfaces. Single-wire thermal anemometry techniques are used to measure time-resolved and phase-averaged wall-normal profiles of streamwise velocity, turbulence intensity, and intermittency at multiple streamwise locations over the turbine airfoil suction surface. The Reynolds number based on suction surface length and stage exit velocity is 5 X 10 4 . This low Reynolds number would apply to small engines flying at high altitude

On the Physics of Flow Separation Along a Low Pressure Turbine Blade Under Unsteady Flow Conditions

The present study, which is the first of a series of investigations dealing with specific issues of low pressure turbine (LPT) boundary layer aerodynamics, is aimed at providing detailed unsteady boundary flow information to understand the underlying physics of the inception, onset, and extent of the separation zone. A detailed experimental study on the behavior of the separation zone on the suction surface of a highly loaded LPT-blade under periodic unsteady wake flow is presented. Experimental investigations were performed at Texas A&M Turbomachinery Performance and Flow Research Laboratory using a large-scale unsteady turbine cascade research facility with an integrated wake generator and test section unit. To account for a high flow deflection of LPT-cascades at design and off-design operating points, the entire wake generator and test section unit including the traversing system is designed to allow a precise angle adjustment of the cascade relative to the incoming flow. This is done by a hydraulic platform, which simultaneously lifts and rotates the wake generator and test section unit. The unit is then attached to the tunnel exit nozzle with an angular accuracy of better than 0.05°, which is measured electronically. Utilizing a Reynolds number of 110,000 based on the blade suction surface length and the exit velocity, one steady and two different unsteady inlet flow conditions with the corresponding passing frequencies, wake velocities and turbulence intensities are investigated using hot-wire anemometry. In addition to the unsteady boundary layer measurements, blade surface pressure measurements were performed at Re=50,000, 75,000, 100,000, and 125,000 at one steady and two periodic unsteady inlet flow conditions. Detailed unsteady boundary layer measurement identifies the onset and extent of the separation zone as well as its behavior under unsteady wake flow. The results presented in ensemble-averaged and contour plot forms contribute to understanding the physics of the separation phenomenon under periodic unsteady wake flow. Several physical mechanisms are discussed.

Effect of Reynolds Number and Periodic Unsteady Wake Flow Condition on Boundary Layer Development, Separation, and Intermittency Behavior Along the Suction Surface of a Low Pressure Turbine Blade

The paper experimentally studies the effects of periodic unsteady wake flow and Reynolds number on boundary layer development, separation, reattachment, and the intermittency behavior along the suction surface of a low pressure turbine blade. Extensive unsteady boundary layer experiments were carried out at Reynolds numbers of 110,000 and 150,000 based on suction surface length and exit velocity. One steady and two different unsteady inlet flow conditions with the corresponding passing frequencies, wake velocities, and turbulence intensities were investigated. The analysis of the experimental data reveals details of boundary layer separation dynamics which is essential for understanding the physics of the separation phenomenon under periodic unsteady wake flow and different Reynolds numbers. To provide a complete picture of the transition process and separation dynamics, extensive intermittency analysis was conducted. Ensemble-averaged maximum and minimum intermittency functions were determined, leading to the relative intermittency function. In addition, the detailed intermittency analysis was aimed at answering the question as to whether the relative intermittency of a separated flow fulfills the universality criterion.

Experiments With Three-Dimensional Passive Flow Control Devices on Low-Pressure Turbine Airfoils

The effectiveness of three-dimensional passive devices for flow control on low pressure turbine airfoils was investigated experimentally. A row of small cylinders was placed at the pressure minimum on the suction side of a typical airfoil. Cases with Reynolds numbers ranging from 25,000 to 300,000 (based on suction surface length and exit velocity) were considered under low freestream turbulence conditions. Streamwise pressure profiles and velocity profiles near the trailing edge were documented. Without flow control a separation bubble was present, and at the lower Reynolds numbers the bubble did not close. Cylinders with two different heights and a wide range of spanwise spacings were considered. Reattachment moved upstream as the cylinder height was increased or the spacing was decreased. If the spanwise spacing was sufficiently small, the flow at the trailing edge was essentially uniform across the span. The cylinder size and spacing could be optimized to minimize losses at a given Reynolds number, but cylinders optimized for low Reynolds number conditions caused increased losses at high Reynolds numbers. The effectiveness of two-dimensional bars had been studied previously under the same flow conditions. The cylinders were not as effective for maintaining low losses over a range of Reynolds numbers as the bars.

Experimental Study of the Effect of Periodic Unsteady Wake Flow on Boundary Layer Development, Separation, and Reattachment Along the Surface of a Low Pressure Turbine Blade

The paper experimentally studies the effects of periodic unsteady wake flow on boundary layer development, separation and reattachment along the suction surface of a low pressure turbine blade. The experimental investigations were performed on a large scale, subsonic unsteady turbine cascade research facility at the Turbomachinery Performance and Flow Research Laboratory (TPFL), Texas A&M University. The experiments were carried out at a Reynolds number of 110,000 (based on suction surface length and exit velocity) with a free-stream turbulence intensity of 1.9%. One steady and two different unsteady inlet flow conditions with the corresponding passing frequencies, wake velocities, and turbulence intensities were investigated. The reduced frequencies cover the entire operating range of LP turbines. In addition to the unsteady boundary layer measurements, blade surface measurements were performed at the same Reynolds number. The surface pressure measurements were also carried out at one steady and two periodic unsteady inlet flow conditions. The results presented in ensemble-averaged, and the contour plot forms help to understand the physics of the separation phenomenon under periodic unsteady wake flow. It was found that the suction surface displayed a strong separation bubble for these three different reduced frequencies. For each condition, the locations and the heights defining the separation bubble were determined by carefully analyzing and examining the pressure and the mean velocity profile data. The location of boundary layer separation was independent of the reduced frequency level. However, the extent of the separation was strongly dependent on the reduced frequency level. Once the unsteady wake started to penetrate into the separation bubble, the turbulent spot produced in the wake paths caused a reduction of the separation bubble height.

Aerodynamic Entropy Generation Rate in a Boundary Layer With High Free Stream Turbulence

Aerodynamic Entropy Generation Rate in a Boundary Layer With High Free Stream Turbulence

Passive Flow Control on Low-Pressure Turbine Airfoils

Two-dimensional rectangular bars have been used in an experimental study to control boundary layer transition and reattachment under low-pressure turbine conditions. Cases with Reynolds numbers (Re) ranging from 25,000 to 300,000 (based on suction surface length and exit velocity) have been considered at low (0.5%) and high (8.5% inlet) free-stream turbulence levels. Three different bars were considered, with heights ranging from 0.2% to 0.7% of suction surface length. Mean and fluctuating velocity and intermittency profiles are presented and compared to results of baseline cases from a previous study. Bar performance depends on the bar height and the location of the bar trailing edge. Bars located near the suction surface velocity maximum are most effective. Large bars trip the boundary layer to turbulent and prevent separation, but create unnecessarily high losses. Somewhat smaller bars had no immediate detectable effect on the boundary layer, but introduced small disturbances that caused transition and reattachment to move upstream from their locations in the corresponding baseline case. The smaller bars were effective under both high and low free-stream turbulence conditions, indicating that the high free-stream turbulence transition is not simply a bypass transition induced by the free stream. Losses appear to be minimized when a small separation bubble is present, so long as reattachment begins far enough upstream for the boundary layer to recover from the separation. Correlations for determining optimal bar height are presented. The bars appear to provide a simple and effective means of passive flow control. Bars that are large enough to induce reattachment at low Re, however, cause higher losses at the highest Re. Some compromise would, therefore, be needed when choosing a bar height for best overall performance.

Separated Flow Transition Under Simulated Low-Pressure Turbine Airfoil Conditions—Part 1: Mean Flow and Turbulence Statistics

Boundary layer separation, transition and reattachment have been studied experimentally under low-pressure turbine airfoil conditions. Cases with Reynolds numbers (Re) ranging from 25,000 to 300,000 (based on suction surface length and exit velocity) have been considered at low (0.5%) and high (9% inlet) free-stream turbulence levels. Mean and fluctuating velocity and intermittency profiles are presented for streamwise locations all along the airfoil, and turbulent shear stress profiles are provided for the downstream region where separation and transition occur. Higher Re or free-stream turbulence level moves transition upstream. Transition is initiated in the shear layer over the separation bubble and leads to rapid boundary layer reattachment. At the lowest Re, transition did not occur before the trailing edge, and the boundary layer did not reattach. Turbulent shear stress levels can remain low in spite of high free-stream turbulence and high fluctuating streamwise velocity in the shear layer. The beginning of a significant rise in the turbulent shear stress signals the beginning of transition. A slight rise in the turbulent shear stress near the trailing edge was noted even in those cases which did not undergo transition or reattachment. The present results provide detailed documentation of the boundary layer and extend the existing database to lower Re. The present results also serve as a baseline for an investigation of turbulence spectra in Part 2 of the present paper, and for ongoing work involving transition and separation control.

Separated Flow Transition Under Simulated Low-Pressure Turbine Airfoil Conditions—Part 2: Turbulence Spectra

Spectral analysis was used to investigate boundary layer separation, transition and reattachment under low-pressure turbine airfoil conditions. Cases with Reynolds numbers ranging from 25,000 to 300,000 (based on suction surface length and exit velocity) have been considered at low (0.5%) and high (9% inlet) free-stream turbulence levels. Spectra of the fluctuating streamwise velocity and the turbulent shear stress are presented. The spectra for the low free-stream turbulence cases are characterized by sharp peaks. The high free-stream turbulence case spectra exhibit more broadband peaks, but these peaks are centered at the same frequencies observed in the corresponding low turbulence cases. The frequencies of the peaks suggest that a Tollmien-Schlichting instability mechanism drives transition, even in the high turbulence cases. The turbulent shear stress spectra proved particularly valuable for detection of the early growth of the instability. The predictable nature of the instability may prove useful for future flow control work.

Measurements in a Turbine Cascade Flow Under Ultra Low Reynolds Number Conditions

With the new generation of gas turbine engines, low Reynolds number flows have become increasingly important. Designers must properly account for transition from laminar to turbulent flow and separation of the flow from the suction surface, which is strongly dependent upon transition. Of interest to industry are Reynolds numbers based upon suction surface length and flow exit velocity below 150,000 and as low as 25,000. In this paper, the extreme low end of this Reynolds number range is documented by way of pressure distributions, loss coefficients, and identification of separation zones. Reynolds numbers of 25,000 and 50,000 and with 1 percent and 8-9 percent turbulence intensity of the approach flow (free-stream turbulence intensity, FSTI) were investigated. At 25,000 Reynolds number and low FSTI, the suction surface displayed a strong and steady separation region. Raising the turbulence intensity resulted in a very unsteady separation region of nearly the same size on the suction surface. Vortex generators were added to the suction surface, but they appeared to do very little at this Reynolds number. At the higher Reynolds number of 50,000, the low-FSTI case was strongly separated on the downstream portion of the suction surface. The separation zone was eliminated when the turbulence level was increased to 8-9 percent. Vortex generators were added to the suction surface of the low-FSTI case. In this instance, the vortices were able to provide the mixing needed to re-establish flow attachment. This paper shows that massive separation at very low Reynolds numbers (25,000) is persistent, in spite of elevated FSTI and added vortices. However, at a higher Reynolds number, there is opportunity for flow reattachment either with elevated free-stream turbulence or with added vortices. This may be the first documentation of flow behavior at such low Reynolds numbers. Although it is undesirable to operate under these conditions, it is important to know what to expect and how performance may be improved if such conditions are unavoidable.