Tip Leakage Research Articles

The effect of inlet profiles on the repeatability in the single-stage compressor

A novel method has been proposed to design inlet gauzes in single-stage low-speed simulation compressor experiments. The aim is to investigate the method for designing inlet profiles and understand how they affect the repeatability of the compressor. Based on the inlet gauzes, the effect of the inlet profile on the compressor repeatability and its flow mechanisms was investigated by the experiments. The experiment results show that, for the single-stage low-speed compressor, as the inlet flow coefficient decreases, the loss and blockage near the rotor casing caused by the tip leakage flow are enhanced, resulting in an increase in the local absolute velocity and the total pressure. Meanwhile, the radial migration of the secondary cross flow in the stator is enhanced, leading to a thinner boundary layer at the stator outlet near casing region. Consequently, the flow capacity near the casing at the compressor outlet is enhanced with a decrease in the inlet flow coefficient. Given that the flow structure and the local loss of the compressor are not sensitive to the inlet profile at the near-choked condition, employing the inlet profile generated based on the compressor outlet profile at the near-stall condition can simulate the repeating stage environment accurately in the single-stage low-speed compressor experiment.

Numerical investigations on film cooling effectiveness and heat transfer performance of inclined film hole on the turbine blade squealer tip with plasma actuation

The turbine blade tip frequently encounters elevated thermal loads, necessitating effective protection measures. Conventional film cooling techniques, while employed to mitigate erosion, face challenges in achieving optimal performance due to intricate tip leakage flow dynamics. Thus, the development of advanced film cooling methodologies becomes imperative to ensure the optimal operation of blade tips. In this study, a novel film cooling approach is proposed, leveraging a combination of dielectric barrier discharge (DBD) plasma actuators and inclined film holes. This strategy aims to direct cooling jets towards the tip wall surface, enhancing film cooling efficacy on highly-loaded turbine squealer tips. Numerical investigations are conducted to assess film cooling effectiveness, heat transfer coefficients, and coolant jet flow characteristics across varying actuation strengths (0, 0.6, 0.8, and 1.0) by integrating plasma actuation forces into the Reynolds-Averaged Navier-Stokes equations. Additionally, the impact of different blow ratios (0.5, 1.0, and 1.5) on plasma flow control is examined. Results demonstrate that plasma actuation improves film cooling performance and effectively mitigates tip heat transfer, even in the presence of interfering tip leakage flow. Specifically, at an actuation strength of 1.0, the average blade tip film cooling effectiveness increases by 7.1%, accompanied by a 12.3% reduction in average heat transfer coefficient compared to scenarios without plasma actuation. Furthermore, the blow ratio influences plasma actuation performance, with minimal disparity observed between configurations with and without plasma devices under extreme blow ratio conditions.

Blade retrofit design to reduce the noise of an axial flow fan by mitigating the tip leakage vortex

In the context of controlling axial fan aerodynamic noise, one effective approach involves the redesign of the blade. In the present study, a novel blade design was formulated for a specific model of axial flow fan, targeting the mitigation of the tip leakage vortex (TLV) and subsequent reduction of noise levels. The assessed noise-reduction blades have perforations drilled from the leading edge (LE) to the pressure surface (PS) of the blades. By impeding the tip leakage flow (TLF), these perforations effectively weaken the TLV. The three-dimensional non-constant flow field within the channel is computed employing the shear stress transport (SST) turbulence model. The aerodynamic noise prediction, which is based on the Lighthill’s acoustic analogy theory, shows that the designed blades can effectively reduce the aerodynamic noise of the axial fan. Specifically, enhancing the ratio of inlet area to outlet area of the ventilation holes leads to an improved noise reduction effect. Notably, for ratios of 0.44 and 1.06, the designed blades exhibit noise reductions of up to 3.3 dB(A) and 3.9 dB(A), respectively. Meanwhile, the static efficiency of these two fans is reduced by 0.50% and 0.26%, respectively. The study thus provides good theoretical support for the design of axial flow fans in the context of noise reduction.

Transonic Compressor Darmstadt Open Test Case: Experimental Investigation of Stator Secondary Flows and Hub Leakage

Abstract The future trend of clean sky aviation has led to a smaller core engine, resulting in highly loaded stages with increased relative tip gaps and leakage flows, which causes a reinforced influence of secondary flow phenomena. This article experimentally investigates the secondary flow effects in the 3D-optimized shrouded stator of the TUDa-GLR-OpenStage, representative of a transonic high-pressure compressor front stage, and its susceptibility to typical hub leakage flows. The impact of stator hub leakage on efficiency and total pressure ratio is investigated for several operating speeds, from subsonic to nominal transonic operating conditions. Steady five-hole probe and time-resolved virtual multi-hole probe measurements at different operating conditions at nominal speed are conducted to investigate the underlying loss mechanisms. The leakage mass flow is determined using the measured pressure difference within the fin seal. Steady results show that the optimized 3D stator effectively suppresses the hub corner separation compared to the predecessor 2D stator, but its performance is further limited by a near-tip separation. With the increased stator hub leakage (at a leakage-to-main flow ratio of about 0.4%), the compressor isentropic efficiency generally drops (by about −0.5%) at the full operating range due to an enhanced hub corner separation effect. However, the increased leakage also helps alleviate the tip-corner separation when operating near stall, leading to a smaller efficiency penalty under these conditions. Unsteady results reveal the sensitivity of transient compressor performance to the passing rotor wake, but limited interaction between this phenomenon and the increased leakage is observed. These findings provide insight into the stator hub leakage-related penalties on the compressor aerodynamics efficiency.

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

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

Tip-leakage-flow excited unsteadiness and associated control

Tip leakage flow in turbomachinery inherently generates intense unsteady features, named self-excited unsteadiness, which significantly affects the operating stability, aerodynamic efficiency, and noise but has not been well understood. A zonalized large eddy simulation is employed for a linear cascade, with wall-modeled large eddy simulation active only in the tip region. The simulation is well validated with advantages demonstrated for effectively reducing the computational cost while maintaining an equivalent prediction accuracy in the region of interest. The time-averaged and spatial-spectral characteristics of tip leakage vortex (TLV) structures are systematically discussed. The self-excited unsteady processes of TLV include the tip gap separation, the tip leakage and jet-mainstream interaction, the primary tip leakage vortex (PTLV) wandering motion, and the induced separation near end wall. The Spectral Proper Orthogonal Decomposition (SPOD) is used to examine the dominant frequencies and their coherent structures. It is found that these unsteady features change from a single high frequency to multiple lower frequencies due to the PTLV breakdown. The SPOD and correlation analyses reveal that the self-excited unsteadiness originates initially from unsteady vortex separation in the tip gap and is then fed by the interactions between the tip leakage jet and mainstream. The associated unsteady fluctuations are convected along the tip leakage jet trajectory, causing the wandering motion of PTLV core. Based on the revealed unsteadiness sources, a micro-offset tip design is proposed and shown to be an effective solution to reducing the tip flow unsteadiness. This work improves the understanding of tip-leakage-flow dynamics and informs the control of the associated unsteady fluid oscillation and noise.

Investigation of a rotating stall in a supercritical CO2 centrifugal compressor

Due to the nonlinear behavior of carbon dioxide properties at its critical point and the size effect of the supercritical carbon dioxide (S-CO2) centrifugal compressor, the stall causation mechanism differs between the S-CO2 centrifugal compressor and a conventional air compressor. The comprehension of the induced principle of the S-CO2 compressor rotating stall holds immense significance in enhancing stall margin and efficiency. This paper employs unsteady simulations to investigate the causes of the impeller rotating stall in the S-CO2 centrifugal compressor. The results show that the leading edge breakdown vortex (LEBV) formed by the tip leakage vortex (TLV) breakdown and the reverse flow in the passage are the reasons for blocking the passage and ultimately causing the rotating stall of the impeller. The migration motion of the LEBV not only induces the leading edge spillage phenomenon but also influences the intensity of the tip leakage flow (TLF) in adjacent passages, causing the propagation of the TLV breakdown phenomenon in the opposite direction to that of impeller rotation. The TLV undergoes intermittent breakdown in flow field, which is influenced by variations in TLF intensity. Additionally, there is a preceding process of breakdown-induced vortex formation and disappearance prior to TLV fragmentation.

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.

Numerical study of shock wave boundary layer interaction flows using a novel turbulence model

This study proposes a novel partial average fluctuation velocity (PAFV) turbulence based on the PAFV and the average strain rate tensor, which is used to calculate the shock wave boundary layer interaction flows, including cascade flow and transonic compressor flow. In order to illustrate the adequacy, the calculation results of several other turbulence models were also compared with PAFV, including k-ω, shear stress transport, SA-neg (negative Spalart-Allmaras), and stress-BSL (ω-based Reynolds stress model). The suitability of the PAFV turbulence model was initially tested by calculating the transonic flow in the L030-4 cascade. Subsequently, numerical computations were performed for the 3D (three-dimensional) National Aeronautics and Space Administration Rotor 67 transonic compressor rotor. In the numerical simulation, the flow control equations were transformed in a general curvilinear coordinate system for precision enhancement, and the spatial discretization of control equations was executed using the finite difference method. The convection term was processed using the Steger–Warming flux vector splitting method, the diffusion term was discretized using a second-order central difference scheme, and the time derivative term was discretized using the third-order Runge–Kutta method. A parallel computing strategy with multi-block partitioning was employed to speed up the calculations and facilitate faster convergence alongside a local time step method. All numerical computation procedures were written in Python, revealing the following: (1) The PAFV turbulence model aptly simulates the transonic flow within the cascade channel. The shock wave pattern in the cascade channel aligns well with the experimental schlieren images. (2) During the Rotor 67 transonic compressor rotor calculation, the flow–pressure ratio, flow efficiency, and inlet and outlet total temperatures and pressures align well with the experimental data. Furthermore, the resolution of the flow field structure related to the interaction between the tip leakage vortex and channel shock wave is high. (3) The turbulence model uses PAFV as the turbulence velocity scale, thereby suppressing the fluctuation velocity and turbulence viscosity near shock wave areas, preventing excessive turbulence viscosity. Moreover, PAFV inherently exhibits transport properties and anisotropic characteristics, making it well-suited for handling transonic compressor flows.

The investigation on the flow characteristics during the continuous development of the tip leakage vortex cavitation in an axial pump-jet propulsion

The continuous deterioration and development of tip leakage vortex (TLV) cavitation in the pump-jet propulsion significantly affect propulsion performance and operational stability. Larger eddy simulation and cavitation tunnel experiment are utilized to investigate the temporal and spatial evolution characteristics of TLV cavitation under varying cavitation conditions. The results reveal that the continuous development of TLV cavitation prompts the TLV to gradually move away from the blade suction surface due to increasing pressure difference at the blade tip surface. Furthermore, the development of TLV cavitation amplifies the effect of the radial outward Coriolis force and makes the TLV even more unstable. Under the influence of the tip leakage flow, primary generation of turbulent kinetic energy (TKE) persistently migrates to the TLV core center and subsequently travels downstream. Despite the large magnitude of TKE that occurs at the TLV core center, the TKE generation remains low. With the inception of TLV cavitation, the transport of TKE between the TLV core center and the surrounding flow gradually intensifies, followed by a subsequent weakening of this transport effect. It increases again as the breakdown of TLV becomes more severe.

Flow resistance enhancement for the leakage decrease of labyrinth seals using teeth tip winglets

A novel flow resistance enhancement technology is proposed to decrease the leakage flow for labyrinth seals adopting teeth tip winglets (TTW). The specially designed TTW is utilized to double the throttling effect at each teeth tip. In addition, the annular slots on the TTW can also generate teeth tip vertexes. These vertexes disrupt the direction of teeth tip leakage flow, enhancing the local flow resistance. To validate this concept, a three-dimension computational fluid dynamic model (CFD) is established. The flow field and leakage performance of the seal with TTWs are calculated with compassion to the baseline seal. Results show that the TTW seals increase flow resistance at the teeth tips, resulting in an extra dissipation effect. As a result, the maximum leakage decrease ratio reaches up to 15.1%

Diagnosis of unsteady disturbance characteristics induced by the tip leakage vortex in a compressor based on data-driven modal decomposition methods

The structural information about the tip leakage vortex at the design point remains largely unknown. Here, the dynamic mode decomposition method is utilized to visualize the main coherent structures corresponding to unsteady disturbance frequencies induced by the tip leakage vortex of an isolated rotor at the design point. The results show that the tip clearance size has a significant impact on unsteady disturbance characteristics at the blade tip region. The flow field within the blade tip region can be categorized into four distinct regions: the formation region of the main tip leakage vortex (MTLV), the formation region of the secondary tip leakage vortex (STLV), the merging zone where the MLTV and the STLV interact, and the vortex shedding zone induced by the leakage vortex breakdown. The disturbance peak in the frequency domain decreases from 121.3 RF to 70.96 RF as the tip clearance size increases from 1.5% blade height to 2%, resulting in a reduction of 41.36%. The increase in the tip clearance size amplifies unsteady disturbances caused by the MTLV and STLV. The STLV exhibits more pronounced oscillatory characteristics than the MTLV. The unsteady disturbance induced by the MLTV mainly occurs at around 0.5 blade passing frequency (BPF). In contrast, high-frequency unsteady disturbances (>1 BPF) in the flow field are caused by vortex shedding resulting from the interaction and collision between the STLV and the MTLV. A better understanding of the unsteady disturbance characteristics induced by leakage vortex benefits the study of stall warning technology.

Influence of bleeding positions in self-recirculating casing treatments on the stability of a subsonic axial compressor

Influence of bleeding positions in self-recirculating casing treatments on the stability of a subsonic axial compressor

A study of angle parametric optimization of the composite honeycomb on turbine blade tip

To reduce the secondary flow loss of the high-pressure turbine caused by the tip leakage flow, the design of the composite honeycomb tip has been experimentally and numerically examined in this study. The arrangement angle of the composite honeycomb is defined and optimized using the radial basis function and genetic algorithm. The tip flow field of the high-pressure turbine blade with a 2.128 mm clearance is simulated by CFX 18.0, and the arrangement angle of the composite honeycomb is optimized to obtain a lower loss. Moreover, the flat tip, basic honeycomb tip, and optimized honeycomb tip are tested in a low-speed cascade test facility. The results show that the vortices and radial velocity induced by the honeycomb structure cavity increase the kinetic energy loss of the leakage flow and reduce the leakage flow rate. Compared with the basic honeycomb, the optimized honeycomb has a supplemental blocking effect on the tip leakage flow by reducing the crosswise pressure gradient in the blade tip. The optimized honeycomb also changes the outlet angle of the leakage flow in the tip clearance, reduces the leakage vortex, and the total pressure loss is further reduced by 2.5%.

Experimental Investigation of Tip Design Effects on the Unsteady Aerodynamics and Heat Transfer of a High-Speed Turbine

Abstract While modern engine manufacturers devote significant efforts to the development of reliable and efficient machines, the introduction of novel, optimized components in the hot gas path represents a risky opportunity. Accurate experimental and numerical data are critical to assess the impact of new technologies on the harsh engine environment. The present study addresses the impact of a selection of high-performance rotor blade tips on the aerodynamic and heat flux field of a high-pressure turbine (HPT) stage. A combined numerical and experimental approach is employed to characterize the interaction of the tip leakage flow with the rotor secondary flows and the casing heat transfer mechanisms for each individual tip geometry. The turbine stage is tested at engine-scaled conditions in the rotating turbine facility of the von Karman Institute. In the present study, the turbine rotor is operated in rainbow configuration to allow the simultaneous testing of multiple blade tip geometries. Reynolds-averaged Navier–Stokes (RANS) simulations are employed to predict the aerodynamic and thermal fields of the individual profiles using test-calibrated boundary conditions. Isothermal steady computations are performed at different wall temperatures to compute the adiabatic wall temperature and the heat transfer convective coefficient. Low-order models are used to represent the over-tip thermal field and the driving heat transfer mechanisms. The time-resolved outlet flow is characterized using a vortex tracking technique and high-frequency aerodynamic measurements to identify the rotor secondary flow structures.

Enhancing Axial Flow Fan Performance in Air-Cooled Condensers: Tip Vortex Manipulators and Comparative Analysis of Numerical Simulation and Experimental Testing

Abstract Direct dry-cooled power plants typically operate numerous large-diameter axial flow fans in air-cooled condensers (ACCs) to facilitate the condensation of steam in the plant's thermodynamic cycle. Enhanced fan efficiency may, at scale, lead to significant parasitic power reductions and subsequent increases in plant power output. The performance of these fans may be increased by adding blade-tip modifications, which act to control blade-tip leakage flow. Previous studies have shown that manipulating the tip leakage vortex (TLV) increases the blade-to-air momentum transfer and stabilizes the air flow structures as it traverses the fan blade. This paper takes a step toward the development of improved tip vortex manipulators for an ACC fan. Three-dimensional computational fluid dynamics (CFD) simulations, and experimental testing of the modified and unmodified fan within an ISO test facility are performed. The results are then utilized to assess the accuracy of the simulation model, visualize the manipulated flow structures at the blade tip, and ultimately quantify the effect of the endplate designs on fan performance. Excellent correlation between numerical and test results for the unmodified fan is observed, and the benefit of blade-tip modification on fan performance is again confirmed experimentally. The simulation model, however, fails to predict improvements in fan performance under modification, and simulated tip leakage flows are investigated for clarification. It is hypothesized that deflection of tip endplates under operation account for differences between simulation and experiment, and that fluid–structure interaction analyses could potentially resolve discrepancies.

Insight into blade tip vibration and deformation characteristics of boiler circulation pumps induced by tip leakage vortex under different tip clearances

For circulating pumps in large power plant boilers, tip leakage flow is the main cause of blade fatigue. To investigate the correlation between tip leakage vortex and blade fatigue, in this paper, the bidirectional fluid structure coupling method is used to simulate the full flow field of the boiler circulating pump under different tip clearance sizes. The accuracy of the delayed detached vortex simulation method is verified by combining the external characteristics and vibration characteristics of the pump. It is obtained that tip leakage vortex is the main cause of blade tip vibration and deformation. Under deep stall conditions, the increase in tip clearance size suppresses the vibration displacement of the blade leading edge, while the opposite is true under optimal conditions. After decomposing tip leakage vortex, it is found that the compression–expansion term played a major role in the deformation of the blade tip, while the viscous dissipation term and the stretching term mainly affected the vibration frequency. At optimal working conditions, the main frequency of blade vibration is basically consistent with the main frequency of vortex generation. In deep stall condition, as the tip clearance size increases, the amplitude of the vibration main frequency decreases and the number of harmonic frequencies decreases, while the optimal condition is the opposite.

Complicated flow in tip flow field of a compressor tandem cascade using delayed detached eddy simulation

The complex flow characteristics in the tip region of a tandem cascade with tip clearance have been calculated and analyzed using Delayed Detached Eddy Simulation (DDES). The coherent mechanism of the vortex structures near the blade tip was discussed, and the unsteady behaviors and features in the tip flow field were analyzed. Additionally, the interaction between the tip leakage flow and the gap jet was revealed. The results show that, compared to the datum cascade, the blade tip load of the rear blade increases while that of the front blade decreases. Unsteady fluctuations of the tandem cascade are mainly caused by the interaction between the tip leakage flow and gap jet, and by the mixing of the vortex structures, but there is no essential change in the spectrum feature of the tip leakage flow. Finally, a detailed analysis of the development of vortices in the tip region is conducted by the topological structures of the flow field. Combined with the three-dimensional vortex structures, the schematic diagram of the vortex system of the datum single-row cascade and tandem cascade is summarized.

Experimental and numerical investigations on non-synchronous vibration and frequency lock-in of transonic compressor rotor blades

Non-synchronous vibration (NSV) problems in axial compressors are challenging and frequently result in high vibration stress or structural failure within the frequency lock-in region. A deeper understanding of the lock-in phenomenon in NSV is necessary to improve blade reliability and safety. In this study, an experiment was conducted on a multistage transonic axial compressor to obtain frequency lock-in characteristics. The enforced motion of the flexible blade simulation method was used to study the frequency lock-in mechanism between blade vibration and tip unstable flow. The results showed that the aerodynamic frequency characteristic changed from a broadband spectrum to a distinct frequency peak as the NSV onset. The nonlinear vibration pattern could maintain the limited cycle oscillation for 26 s. The vibration stress of the frequency locked-in case was approximately 19 times that of the frequency unlocked one. The pressure fluctuations generated by the large-scale radial separation vortex structures were stronger than those of the tip leakage flow, and the third-order harmonic frequency of the circumferential instability flow was close to the first-order bending model natural frequency. The periodic shedding and reattachment process of flow separation provided the initial non-synchronous aerodynamic excitation source. The frequency lock-in phenomenon occurred at a maximum vibration amplitude of 2 % and 3 % tip chord length. The tip unstable flow characteristics were consistent and entirely dominated by blade vibration.

Study on the Tip Leakage Loss Mechanism of a Compressor Cascade Using the Enhanced Delay Detached Eddy Simulation Method.

The leakage flow has a significant impact on the aerodynamic losses and efficiency of the compressor. This paper investigates the loss mechanism in the tip region based on a high-load cantilevered stator cascade. Firstly, a high-fidelity flow field structure was obtained based on the Enhanced Delay Detached Eddy Simulation (EDDES) method. Subsequently, the Liutex method was employed to study the vortex structures in the tip region. The results indicate the presence of a tip leakage vortex (TLV), passage vortex (PV), and induced vortex (IV) in the tip region. At i=4°,8°, the induced vortex interacts with the PV and low-energy fluid, forming a "three-shape" mixed vortex. Finally, a qualitative and quantitative analysis of the loss sources in the tip flow field was conducted based on the entropy generation rate, and the impact of the incidence on the losses was explored. The loss sources in the tip flow field included endwall loss, blade profile loss, wake loss, and secondary flow loss. At i=0°, the loss primarily originated from the endwall and blade profile, accounting for 40% and 39%, respectively. As the incidence increased, the absolute value of losses increased, and the proportion of loss caused by secondary flow significantly increased. At i=8°, the proportion of secondary flow loss reached 47%, indicating the most significant impact.