Blade Tip Research Articles

Numerical investigation on boiling crisis characteristic of a 7-rod HCF assembly in hexagonal lattice

Helical cruciform fuel (HCF) has the advantages of larger heat transfer area, enhanced coolant mixing and self-supporting, which contribute to increasing power density and safety margins. Compared with the square lattice configuration, the hexagonal arrangement of HCF assembly is more compact, which can help achieve a higher power density. In this paper, the flow characteristics and heat transfer behaviors of HCF in hexagonal lattice were predicted at high and low vapor quality during boiling crisis based on Eulerian two-fluid model. The influence of twist pitches and cross-sections of the fuel rod on heat transfer efficiency and fuel temperature was also studied. The cross-flow intensity changed periodically with a 30° cycle at low vapor quality, and did not fluctuate periodically at high vapor quality, which decreased with the increase of flow resistance. The highest heat flux of HCF rod was the at the blade root and the lowest was at the blade tip, and the maximum to average heat flux ratio was about 1.8. The peak vapor fraction and temperature occurred at leeside side of the fuel rods. The increase of the twist pitch reduced the critical heat flux (CHF), and the increase of blade length enhanced the non-uniformity of heat flux distribution. During boiling crisis, the maximum temperature of the fuel was lower than the phase transition temperature of U-50 wt%Zr alloy, which means the cladding meltdown caused by boiling crisis will occur before phase transition of the fuel.

On the evolution of the shock waves systems created by the fan blades

Fan is one of the noise sources in a modern engine. The fan noise is especially noticeable during takeoff at high angular rotation speeds. In such operating modes, supersonic flow around the tips of the fan blades is realized, which leads to the formation of shock waves that propagate upstream until they exit of the engine channel. As a result, a specific noise is emitted into the front hemisphere, consisting of harmonics that are multiples of the fan rotation frequency. The paper analyzes the described effect based on a simple model of the propagation of a shock waves system. By using energy analysis, it is shown that the system of shock waves with equal amplitude decays faster than a system of shock waves with a spread in amplitude.

Study of unsteady shear flow near stall in a shrouded supercritical carbon dioxide centrifugal compressor

This study investigates the unsteady shear flow patterns and their relation with the aerodynamic instability of a shrouded supercritical carbon dioxide (SCO2) centrifugal compressor impeller using the dynamic mode decomposition method combined with detached eddy simulation. The results demonstrate that discrete shedding vortex array in the blade tip region is the dominant mode of the SCO2 shrouded centrifugal compressor impeller, with a frequency of 0.5 times the blade passing frequency. In contrast, the main flow structures in the identical impeller using ideal air consist of small-scale shedding vortices near the suction surface and the separated secondary flow. Further analysis of flow field details indicates that the shedding vortex structure inside the shrouded centrifugal impeller originates from the Kelvin–Helmholtz instability generated on the shear interface between the mainstream and the recirculation flow. The greater shear intensity within the SCO2 centrifugal impeller is the reason for the evident occurrence of vortex shedding phenomena in its flow field. Additionally, during the transition from near-stall to stall, vortex pairing phenomena happens at the throat of the centrifugal impeller due to evolutional behaviors of the vortexes. The occurrence of vortex pairing leads to faster blockage of the blade tip region and then the secondary flow spillage over to adjacent passage, ultimately resulting in reverse flow in the blade tip region and extensive blockage at the impeller inlet. The unsteady shear flow evolution clearly demonstrates the processes of stall in SCO2 shrouded impellers.

Implementation of cooling slots at the pressure side rims of squealer tips

The blade tip is a particularly critical component of the high pressure turbine due to the hot overtip leakage gas being responsible for efficiency losses and thermal degradation, often limiting engine life. Squealer tip designs reduce the over-tip leakage mass flow, increasing efficiency, but the thin pressure side rims can be vulnerable to damage because of their large surface area and the difficulties of shielding them from hot overtip leakage flow. This paper considers a new approach to cooling these pressure side rims, by employing an inclined slot inside a recessed step. Compared to conventional cooling strategies, in which coolant is provided by multiple cylindrical holes, the slot feature improves cooling effectiveness by more than 50% in key regions of the pressure side rim, whilst also allowing for a substantial reduction in coolant mass flow. The concept design is developed and explored using Computational Fluid Dynamics (CFD) calculations, and the performance is validated experimentally in a linear cascade with representative Mach and Reynolds numbers.

Studying and analysis of deformation and stresses in horizontal-axis wind turbine using fluid-structure interaction method

Fluid-structure interaction (FSI) studies have become an important tool in the development of wind turbine blades as well as for analyzing and optimizing Horizontal Axis Wind Turbine (HAWT). The most essential elements for estimating the turbine blade strength to withstand extreme wind loads and aerodynamic performance are the blade deformation and the associated stresses. This study aims to compare the strength and analyze the deformation behavior of two models of HAWT blades. A three-dimensional model was created and loaded into a Finite Element (FE) model for analysis. The Computational Fluid Dynamics (CFD) investigation was coupled with the structural model using one-way FSI. In this article, the effect of the aerodynamics on the blade surface of a small HAWT has been studied numerically and experimentally. The airfoil used for the blade profile is S826 airfoil. To provide an appropriate displacement for static measurements, the blade in the experimental investigation is made of thermoplastic polyurethane material (TPU). It is noted that the current experimental findings verify the simulation results, and a comparison between the simulations and the experimental findings reveals a reasonable agreement. The numerical simulations are also implemented on a HAWT epoxy E-glass unidirectional (EEGUD) material. It can be concluded from this study that the blade deformation and stress on the blades are related to the wind speed. The deformation along the span length exhibits nonlinear variation that gradually increases from the blade root and reaches its maximum at the blade tip position. The tip deflection and equivalent stress were found to increase with an increase in wind speed. The dynamic analysis at different tip speed ratios shows the highest deformation at λ = 4, for wind speed of 20 m/s.

Comprehensive Experimental Assessment Of Unsteady Pressure And Heat Flux In A Small-Core Turbine Over-Tip Shroud

Abstract For novel high-speed small core turbines, with tip clearance below 0.5mm, even small blade-to-blade tip clearance variation is significant. The assessment of these complex flows is pertinent to the design of the next generation of small-core turbines. This manuscript provides a thorough experimental analysis of the shroud?s unsteady heat flux and static pressure in a small-core squealer-tip blade turbine. Atomic Layer Thermopile sensors and fast response pressure transducers were used to perform high-frequency acquisition at 2MHz around the 51% axial blade chord on the shroud. Measurements were taken at engine-representative conditions at several operational conditions and tip clearances. The signals were phase-locked averaged over the revolution period and synchronized to identify individual blade and row signatures. The linear relationship between the rotational tip Reynolds and the static pressure ratio across the blade tip reveals the transition point to reverse over-tip flows. Total heat flux is decomposed into different steady and unsteady heat flux contributions. It is demonstrated that the adiabatic wall temperature governs the unsteady heat flux and contributes to one third of the total surface heat flux. A linear trend was observed between the unsteady heat flux and the tip clearance measured at the pressure and suction side rims. Similar trends were observed between the local heat flux and the pressure ratio across the tip. A comparison with CFD predictions highlights some limitations on resolving the detached and secondary flows, evidencing the necessity of complementary experimental data.

Optimization of Tip Seal Grooves for Aerodynamic and Durability Improvements of Small-Core Turbines

Abstract While the gap between the turbine rotor tip and the outer case in a gas turbine engine is necessary for engine function, the gap is kept as small as possible due to the detrimental effect of the flow over the turbine tip. With the increased investments in ultra-high bypass turbofans, blade tip clearances are increasing in relative size to the turbine rotor, as engines move towards smaller cores. In this work, an optimization of a rotor tip seal with discrete axisymmetric grooves was explored computationally using RANS simulations. The optimization was applied at two tip clearances representing a nominal and small-core-scaled geometry, and with both flat- and squealer-tipped blades. The multi-objective optimization was designed to maximize rotor efficiency and minimize tip heat load. Several casing designs were identified for each tip configuration that both increased efficiency and reduced the heat load into the rotor tip. However, some optimal tip seal designs were composed of grooves that were demonstrated to be detrimental in prior work. Furthermore, grooves were more effective at increasing efficiency when applied to flat tipped geometries – increasing efficiency by 0.9 points over the ungrooved baseline with flat tipped blades, as opposed to 0.25 points over the ungrooved case with squealer tipped blades. Finally, optimal seal geometries that were obtained from the small-core scaled clearance gap optimizations maintained near optimal performance when evaluated at the design tip clearance, while those geometries developed at the design clearance experienced greater tip gap sensitivity.

The Influence of Bleed Position on the Stability Expansion Effect of Self-Circulating Casing Treatment

The self-circulating casing treatment can effectively expand the stable working range of the compressor, with little impact on its efficiency. With a single-stage transonic axial flow compressor NASA (National Aeronautics and Space Administration) Stage 35 as the research object, a multi-channel unsteady numerical calculation method was used here to design three types of self-circulating casing treatment structures: 20% Ca (axial chord length of the rotor blade tip), 60% Ca, and 178% Ca (at this time, the bleed position is at the stator channel casing) from the leading edge of the blade tip. The effects of these three bleed positions on the self-circulating stability expansion effect and compressor performance were studied separately. The calculation results indicate that the further the bleed position is from the leading edge of the blade tip, the weaker the expansion ability of the self-circulating casing treatment, and the greater the negative impact on the peak efficiency and design point efficiency of the compressor. This is because the air inlet of the self-circulating casing with an air intake position of 20% Ca is located directly above the core area of the rotor blade top blockage, which can more effectively extract low-energy fluid from the blockage area. Compared to the other two bleed positions, it has the greatest inhibitory effect on the leakage vortex in the rotor blade tip gap and has the strongest ability to improve the blockage at the rotor blade tip. Therefore, 20% Ca from the leading edge of the blade tip has the strongest stability expansion ability, achieving a stall margin improvement of 11.28%.

Aerodynamic Feasibility Investigation of the Novel Experimental Rig on Turbine Blade Tip With High Relative Motion

Abstract The relative casing motion can significantly alter the over-tip-leakage (OTL) flow aerodynamic performances. Traditional tip experimental facilities for relative motion researches, including stationary linear cascade with low-speed moving belt, annular cascade with rotating outer wall, and full-scale experimental rig with rotating blade, were either extremely costly or not capable to reproduce engine-representative casing Mach number. Very recently, a novel design concept for high-speed disk rotor rig has been proposed for tip research. Subsequent to this research, the present study evaluates the aerodynamic performances and the periodicity of the disk rotor rig design using Reynolds-averaged Navier–Stokes computational fluid dynamics simulation. Furthermore, first-of-its-kind experimental results of total pressure loss distributions measured by five-hole probe under high relative casing Mach number are reported. The results demonstrate the applicability of the disk rotor experimental rig for tip aerodynamic investigations.

Influence of manufacturing errors on the aerodynamic working stability of axial flow compressors

In turbomachinery, manufacturing errors in blades have been found to impact aerodynamic performance. This paper aims to investigate the effect of manufacturing errors on the stability of compressor operation. To this end, a geometric uncertainty reduced-order model is developed to generate the normal profile error of rotor blades based on specific tolerances, considering the simultaneous variation of blade parameters during manufacturing. The stability margin improvement of the compressor is then calculated using computational fluid dynamics (CFD), and a neural network is employed to predict the relationship between the uncertainty input variables and the stability margin improvement. Finally, a large number of samples are generated using the Quasi-Monte Carlo method, and Sobol sensitivity analysis is performed. According to the results, manufacturing errors can reduce the stability margin by an average of 0.9% and up to 3% in the limiting case. The parameters that have the greatest impact on the stability of the compressor are the blade chord length of the hub section and the maximum thickness of the tip section. These two parameters affect blade tip blockage by influencing spanwise secondary flow on the suction surface. Additionally, the decrease in maximum thickness at the tip section affects the separation of the boundary layers on the suction surface, resulting in additional effects.

Computational Exploration of Variable-Pitch Fans as Thrust Reversers and Their Influence on Noise Abatement in Turbofan Propulsion Systems

Variable pitch propellers, once confined to turboprop engines, are now revolutionizing turbofan applications. Recent breakthroughs in materials and technology, exemplified by Pratt & Whitney’s geared turbofan engine, underscore the practicality of variable pitch systems. Ongoing research promises to extend their adoption across diverse engine types, significantly enhancing safety and performance. This study investigates a novel approach to enhance reverse thrust using dual-row radial fans with adjustable pitch angles. These fan blades exhibit geometry variations, combining features from both turbofan motor fan blades and turbo- propeller motor blades. The results are promising: this configuration nearly triples the thrust force, producing approximately 292.917 kilo-newtons. Moreover, it enables the generation of reverse thrust equivalent to 25.077 kilo- newtons. These enhancements are achieved while reducing blade rotational speed from 5200 revolutions per minute to 3200 revolutions per minute and inlet airspeed from 660 km/h (at maximum power) to 220 km/h. Additionally, a notable 11% reduction in noise level at the blade tips has been observed. This research sheds light on the potential of innovative fan blade designs to revolutionize reverse thrust capabilities in turbofan engines, contributing to safer and more efficient aircraft landings.

Unsteady Flow Structure of Rotating Instability in a 1.5-Stage Axial Compressor

Abstract Unsteady flow structure of the rotating instability (RI) in a 1.5-stage axial compressor is investigated through experimental and numerical analyses. In the tested compressor, the total pressure rise of the rotor stagnates at a certain flow coefficient before it increases again towards lower flow rate in a case involving a wide tip clearance. The RI appears beyond this stagnant point as the compressor is throttled. The RI indicates a gentle hump in the frequency spectra of wall pressure or the flow velocity near the tip in a range approximately 20 to 40% of the blade-passing frequency. As the flow rate decreases, the mode order of the RI increases, in contrast to more commonly reported tendency, while the propagation velocity remains constant. These features are well captured by DES of the half-annulus model. At its onset, RI is formed by the collision of the tip leakage vortex onto the pressure surface of the adjacent blade and subsequent vortex segmentation. This vortex structure spans two blade passages and propagates in the direction opposite to the rotor rotation. As the compressor is throttled, RI becomes more dominated by the circumferential propagation of vortex breakdown of tip leakage vortices, which occur simultaneously among neighboring passages with slight phase differences. The mechanism is discussed in relation to the temporal change in the blade tip loading. The frequency of vortex shedding increases with the reduction in flow rate and thus the increase in the number of RI disturbances.

COOLING INJECTION EFFECT ON THE SUCTION SIDE NEAR-TIP REGION OF TURBINE BLADE WITH HIGH-SPEED RELATIVE CASING MOTION

Abstract The high-speed relative casing motion between the casing and the turbine blade tip introduces significant complexities to the flow field near the tip, resulting in alterations to the heat transfer distribution on the suction surface of the blade near the tip, and further influence the arrangement of film cooling arrangements. However, due to the challenges associated with measuring heat transfer, the influence of cooling injection on the near-tip region of the suction side under high-speed relative casing motion still remains uncertain. This study aims to address this knowledge gap by conducting experiments on a high-speed disk rotor experimental rig. The heat transfer coefficient and cooling effectiveness are investigated for different cooling hole arrangements. Additionally, based on Computational Fluid Dynamic (CFD) method, the interaction mechanism of cooling injections under high-speed relative casing movement is comprehensively discussed. It is observed that the cooling effect, which would be effective under stationary conditions, is greatly diminished or even rendered ineffective when subjected to high-speed relative casing conditions. Furthermore, arranging the cooling holes at the location where the interaction between the Over-Tip-Leakage flow and the passage flow occurs would be an effective approach to enhance the cooling performance on blade near-tip suction side. The effect of different relative casing speed on suction side near-tip region cooling injection performances are also numerically investigated. These findings contribute to a better understanding of the considerations involved in the film cooling design of turbine blades.

Research on the Influence of Particles and Blade Tip Clearance on the Wear Characteristics of a Submersible Sewage Pump

A submersible sewage pump is designed for conveying solid–liquid two-phase media containing sewage, waste, and fiber components, through its small and compact design and its excellent anti-winding and anti-clogging capabilities. In this paper, the computational fluid dynamics–discrete element method (CFD-DEM) coupling model is used to study the influence of different conveying conditions and particle parameters on the wear of the flow components in a submersible sewage pump. At the same time, the energy balance equation is used to explore the influence mechanism of different tip clearance sizes on the internal flow pattern, wear, and energy conversion mechanism of the pump. This study demonstrates that increasing the particle volume fraction decreases the inlet particle velocity and intensifies wear in critical areas. When enlarging the tip clearance thickness from 0.4 mm to 1.0 mm, the leakage vortex formation at the inlet is enhanced, leading to increased wear rates in terms of the blade and volute. Consequently, the total energy loss and turbulent kinetic energy generation increased by 3.57% and 2.25%, respectively, while the local loss coefficient in regard to the impeller channel cross-section increased significantly. The findings in this study offer essential knowledge for enhancing the performance and ensuring the stable operation of pumps under solid–liquid two-phase flow conditions.

Introduction of oblique plane waves through a forcing source term in Euler equations

The propagation of shock waves generated by a transonic flow at the tip of a propeller blade is numerically calculated in order to determine the pressure footprint on an aircraft fuselage. An academic case is first proposed to validate the methodology. An incoming signal is built up as oblique harmonic plane waves. The signal is introduced in the computational domain using a Gaussian volume forcing term in the conservation of mass and energy equations. The Euler equations are solved in two dimensions using finite-difference schemes with low dispersion and dissipation. Selective filtering has also been integrated in the algorithm to remove grid-to-grid oscillations. The numerical solution is compared to an analytical solution based on the tailored Green function. An illustration for a realistic open rotor is then considered. The pressure signal near the blade tip, determined from a preliminary RANS simulation, is introduced using a volume source in a solver of the Euler equations.

The effect of fan-type inducer blade tip geometry on cavitation behavior and noise in an industrial centrifugal pump

Cavitation is one of the biggest problems in industrial centrifugal pumps because it causes serious vibration and noise. Therefore, there is a demand for pump manufacturers to prevent problems due to the cavitation before delivering products to the site. Noise is considered to increase due to the development of cavitation at the tip of the inducer blades. In this study, the location of cavitation development was controlled by changing the inducer blade tip geometry to reduce noise. A centrifugal pump with a fan-type inducer was operated to measure noise at various cavitation numbers and flow rates with a microphone set up on the outer wall near the inducer. A visualization experiment using an acrylic casing around the inducer, a high-speed camera, and strobe light was also conducted to observe the behavior of cavitation development. The relationship between cavitation form and noise was investigated in detail.

Protective coatings for aeroengine blade tips: a review

Protective coatings for aeroengine blade tips: a review

Techno‐Economic Analysis of Additively‐Manufactured Wind Turbine Blade Tips That Enable Technology Integration

ABSTRACTThe Additively‐Manufactured, System‐Integrated Tip (AMSIT) project is leveraging the flexibility of 3D printing to integrate several technologies in a wind turbine blade tip, while reducing the levelized cost of electricity (LCOE) produced. The design integration is demonstrated for a 200‐kW–scale turbine with 13‐m blades, with the outer 15% of the blade replaced with a 3D‐printed design. Aerodynamic performance is enhanced without increasing swept area through inclusion of a winglet and surface texturing, both challenging for traditional manufacturing. Longevity and durability are improved through integrated lightning and leading edge erosion protection. Increased power, reduced repair frequency, and ease of repair through blade modularity all contribute to reduced LCOE. The analysis is also extended to modern MW‐scale designs to estimate the impact of the technology at scale, demonstrating the potential to reduce LCOE significantly for modern onshore turbines, with even higher potential savings offshore.

Three-dimensional configuration tip rotor dynamics analysis

Abstract In order to analyze and study the dynamic characteristics of the 3D blade tip rotor, an aeroelastic dynamic model for a complex 3D blade tip rotor is established based on mechanics principles. The theory of medium deformation beam or large deformation beam is adopted as the blade structural dynamic model, and the quasi-steady and unsteady aerodynamic models (ONERA model) are adopted as the aerodynamic model. The rotor dynamics, aeroelastic stability and rotor loads of three-dimensional blade tip and rectangular blade tip are compared by examples. The analysis shows that both the forward and backward sweep angles have a certain effect on the rotor blade frequency, but the downward dihedral angle has little effect. The 3D tip configuration has the greatest influence on torsion mode frequency, followed by lagging mode frequency, which has little impact on flapping frequency. Reasonable design of forward and backward sweep angles and downward dihedral angles of 3D tip configuration can effectively reduce rotor loads, increase damping margin for aeroelastic stability, and improve stability.

Measurement of unsteady force on rotor blade surfaces in axial flow compressor

To assess the aerodynamic performance and vibration characteristics of rotor blades during rotation, a study of unsteady blade surface forces is conducted in a low-speed axial flow compressor under a rotating coordinate system. The capture, modulation, and acquisition of unsteady blade surface forces are achieved by using pressure sensors and strain gauges attached to the rotor blades, in conjunction with a wireless telemetry system. Based on the measurement reliability verification, this approach allows for the determination of the static pressure distribution on rotor blade surfaces, enabling the quantitative description of loadability at different spanwise positions along the blade chord. Effects caused by the factors such as Tip Leakage Flow (TLF) and flow separation can be perceived and reflected in the trends of static pressure on the blade surfaces. Simultaneously, the dynamic characteristics of unsteady pressure and stress on the blade surfaces are analyzed. The results indicate that only the pressure signals measured at the mid-chord of the blade tip can distinctly detect the unsteady frequency of TLF due to the oscillation of the low-pressure spot on the pressure surface. Subsequently, with the help of one-dimensional continuous wavelet analysis method, it can be inferred that as the compressor enters stall, the sensors are capable of capturing stall cell frequency under a rotating coordinate system. Furthermore, the stress at the blade root is higher than that at the blade tip, and the frequency band of the vibration can also be measured by the pressure sensors fixed on the casing wall in a stationary frame. While the compressor stalls, the stress at the blade root can be higher, which can provide valuable guidance for monitoring the lifecycle of compressor blades.