A Systematic Computational Methodology Applied to a Three-Dimensional Film-Cooling Flowfield

1997 ◽  
Vol 119 (4) ◽  
pp. 777-785 ◽  
Author(s):  
D. K. Walters ◽  
J. H. Leylek
Keyword(s):  
Film Cooling ◽  
Gas Turbines ◽  
Turbulence Modeling ◽  
Density Ratio ◽  
Three Dimensional ◽  
Elliptic Solution ◽  
Injection Angle ◽  
Free Stream Turbulence ◽  
Acceleration Techniques ◽  
Computational Methodology

Numerical results are presented for a three-dimensional discrete-jet in crossflow problem typical of a realistic film-cooling application in gas turbines. Key aspects of the study include: (1) application of a systematic computational methodology that stresses accurate computational model of the physical problem, including simultaneous, fully elliptic solution of the crossflow, film-hole, and plenum regions; high-quality three-dimensional unstructured grid generation techniques, which have yet to be documented for this class of problems; the use of a high-order discretization scheme to reduce numerical errors significantly; and effective turbulence modeling; (2) a three-way comparison of results to both code validation quality experimental data and a previously documented structured grid simulation; and (3) identification of sources of discrepancy between predicted and measured results, as well as recommendations to alleviate these discrepancies. Solutions were obtained with a multiblock, unstructured/adaptive grid, fully explicit, time-marching, Reynolds-averaged Navier–Stokes code with multigrid, local time stepping, and residual smoothing type acceleration techniques. The computational methodology was applied to the validation test case of a row of discrete jets on a flat plate with a streamwise injection angle of 35 deg, and two film-hole length-to-diameter ratios of 3.5 and 1.75. The density ratio for all cases was 2.0, blowing ratio was varied from 0.5 to 2.0, and free-stream turbulence intensity was 2 percent. The results demonstrate that the prescribed computational methodology yields consistently more accurate solutions for this class of problems than previous attempts published in the open literature. Sources of disagreement between measured and computed results have been identified, and recommendations made for future prediction of film-cooling problems.

A Systematic Computational Methodology Applied to a Three–Dimensional Film–Cooling Flowfield

1996 ◽  
Author(s):  
Dibbon K. Walters ◽  
James H. Leylek
Keyword(s):  
Film Cooling ◽  
Gas Turbines ◽  
Density Ratio ◽  
Three Dimensional ◽  
Test Case ◽  
Elliptic Solution ◽  
Injection Angle ◽  
Free Stream Turbulence ◽  
Acceleration Techniques ◽  
Computational Methodology

Numerical results are presented for a three–dimensional discrete–jet in crossflow problem typical of a realistic film–cooling application in gas turbines. Key aspects of the study include: (1) Application of a systematic computational methodology that stresses accurate computational model of the physical problem, including simultaneous, fully–elliptic solution of the crossflow, film–hole, and plenum regions; high quality 3–D unstructured grid generation techniques which have yet to be documented for this class of problems; the use of a high order discretization scheme to significantly reduce numerical errors; and effective turbulence modelling; (2) A three–way comparison of results to both code validation quality experimental data and a previously documented structured grid simulation; and (3) Identification of sources of discrepancy between predicted and measured results, as well as recommendations to alleviate these discrepancies. Solutions were obtained with a multi–block, unstructured/adaptive grid, fully explicit, time–marching, Reynolds averaged Navier–Stokes code with multi-grid, local time stepping, and residual smoothing type acceleration techniques. The computational methodology was applied to the validation test case of a row of discrete jets on a flat plate with a streamwise injection angle of 35°, and two film–hole length–to–diameter ratios of 3.5 and 1.75. The density ratio for all cases was 2.0, blowing ratio was varied from 0.5 to 2.0, and free–stream turbulence intensity was 2%. The results demonstrate that the prescribed computational methodology yields consistently more accurate solutions for this class of problems than previous attempts published in the open literature. Sources of disagreement between measured and computed results have been identified, and recommendations made for future prediction of this class of problems.

Discrete-Jet Film Cooling: A Comparison of Computational Results With Experiments

1993 ◽  
Author(s):  
J. H. Leylek ◽  
R. D. Zerkle
Keyword(s):  
Film Cooling ◽  
Large Scale ◽  
Turbulence Modeling ◽  
Density Ratio ◽  
Three Dimensional ◽  
Diameter Ratio ◽  
Navier Stokes ◽  
Complex Flow ◽  
Coupled Flow ◽  
Injection Angle

Large scale computational analyses have been conducted and results compared with experiments to understand coolant jet and crossflow interaction in discrete–jet film cooling. Detailed three–dimensional elliptic Navier–Stokes solutions, with high order turbulence modeling, are presented for film cooling using a new model enabling simultaneous solution of fully coupled flow in plenum, film–hole, and cross–stream regions. Computations are carried out for the following range of film cooling parameters typically found in gas turbine airfoil applications: single row of jets with a film–hole length–to–diameter ratio of 1.75 and 3.5; blowing ratio from 0.5 up to 2; coolant–to–crossflow density ratio of 2; streamwise injection angle of 35 degrees; and pitch–to–diameter ratio of 3. Comparison of computational solutions with experimental data are in good agreement Moreover, the current results complement experiments and support previous interpretations of measured data and flow visualization. The results also explain important aspects of film cooling, such as the development of complex flow within the film–hole in addition to the well known counterrotating vortex structure in the cross–stream.

Discrete-Jet Film Cooling: A Comparison of Computational Results With Experiments

1994 ◽  
Vol 116 (3) ◽  
pp. 358-368 ◽  
Author(s):  
J. H. Leylek ◽  
R. D. Zerkle
Keyword(s):  
Film Cooling ◽  
Large Scale ◽  
Density Ratio ◽  
Three Dimensional ◽  
Diameter Ratio ◽  
Navier Stokes ◽  
Complex Flow ◽  
Coupled Flow ◽  
Injection Angle ◽  
Computational Analyses

Large-scale computational analyses have been conducted and results compared with experiments to understand coolant jet and crossflow interaction in discrete-jet film cooling. Detailed three-dimensional elliptic Navier–Stokes solutions, with high-order turbuence modeling, are presented for film cooling using a new model enabling simultaneous solution of fully coupled flow in plenum, film-hole, and cross-stream regions. Computations are carried out for the following range of film cooling parameters typically found in gas turbine airfoil applications: single row of jets with a film-hole length-to-diameter ratio of 1.75 and 3.5; blowing ratio from 0.5 up to 2; coolant-to-crossflow density ratio of 2; streamwise injection angle of 35 deg; and pitch-to-diameter ratio of 3. Comparison of computational solutions with experimental data give good agreement. Moreover, the current results complement experiments and support previous interpretations of measured data and flow visualization. The results also explain important aspects of film cooling, such as the development of complex flow within the film-hole in addition to the well-known counterrotating vortex structure in the cross-stream.

Leading-Edge Film-Cooling Physics: Part I — Adiabatic Effectiveness

2002 ◽  
Author(s):  
William D. York ◽  
James H. Leylek
Keyword(s):  
Film Cooling ◽  
Gas Turbines ◽  
Density Ratio ◽  
Leading Edge ◽  
Navier Stokes ◽  
Stagnation Region ◽  
Stagnation Line ◽  
Injection Angle ◽  
Fully Implicit ◽  
Numerical Predictions

A systematic, computational methodology was employed to study film cooling on a turbine airfoil leading edge. In this paper, numerical predictions are compared with surface effectiveness measurements from a code-validation quality experiment in the open literature, and a detailed discussion of the physical mechanisms involved in leading edge film cooling is presented. The leading edge model was elliptic in shape to accurately simulate a rotor airfoil, and other geometric parameters were in the range of current design practice for aviation gas turbines. Three laterally-staggered rows of cylindrical film-cooling holes were investigated. One row of holes was centered on the stagnation line, and the other rows were located 3.5 hole-diameters downstream, mirrored about the stagnation line. All holes had an injection angle of 20° with the surface, and a 90° compound angle (radial injection). The average blowing ratio was varied from 1.0 to 2.5, and the coolant-to-mainstream density ratio was 1.8 in all simulations. Converged and grid independent solutions were obtained using a high-quality, multi-topology grid with 3.6 million cells and a fully-implicit, pressure correction-based Navier-Stokes solver. Turbulence closure was obtained with a realizable k-ε model, which has been demonstrated to be especially effective in controlling spurious production of turbulent kinetic energy in regions of rapid, irrotational strain. The predictions of laterally averaged effectiveness agreed well with the experimental data, especially at low-range blowing ratios. Highly nonuniform coolant coverage was seen to exist downstream of the second row of holes, caused mainly by interaction between the two rows of jets and by a strong vortex that reduced the spread of coolant from the downstream row. The results of the present study demonstrate that computational methods can accurately model the highly-complex film-cooling flowfield in the stagnation region.

Measurement of Eddy Diffusivity of Momentum in Film Cooling Flows With Streamwise Injection

1999 ◽  
Vol 122 (1) ◽  
pp. 178-183 ◽  
Author(s):  
R. W. Kaszeta ◽  
T. W. Simon
Keyword(s):  
Film Cooling ◽  
Density Ratio ◽  
Flux Ratio ◽  
Eddy Diffusivity ◽  
Turbulent Shear ◽  
Spanwise Direction ◽  
Intensity Level ◽  
Mean Velocity ◽  
Injection Angle ◽  
Free Stream Turbulence

Measurement of mean velocity and turbulent shear stress are presented for the mixing region of a film cooling situation in which the coolant is streamwise injected with an injection angle of 35 deg. Measurements are performed using triple-sensor anemometry so that all three instantaneous velocity components are documented. The free-stream turbulence intensity level is 12 percent, the ratio of the integral length scale to injection hole diameter is 4.0, the coolant-to-mainstream momentum flux ratio is 1.0, and the density ratio is unity. From these measurements, values for the eddy diffusivities of momentum in the lateral and wall-normal directions are calculated. Additionally, calculated values of the ratio of eddy diffusivity in the spanwise direction to eddy diffusivity in the wall-normal direction are presented, which provide documentation of the anisotropy of turbulent transport in this film cooling flow. [S0889-504X(00)02001-8]

scholarly journals A Film-Cooling CFD Bibliography: 1971–1996

1998 ◽  
Vol 4 (1) ◽  
pp. 61-72 ◽  
Author(s):  
D. M. Kercher
Keyword(s):  
High Temperature ◽  
Film Cooling ◽  
Gas Turbines ◽  
Turbulence Modeling ◽  
Three Dimensional ◽  
Design Tool ◽  
Navier Stokes ◽  
Experimental Investigations ◽  
Rocket Engines ◽  
Development Environment

After more than 25 years of three-dimensional film cooling experimental investigations, analytical correlations and modeling, film cooling utilizing computational fluid dynamics has emerged from a similar development-applications growth process into a near-attainable heat transfer engineering tool. Analytical applications include high temperature subsonic to hypersonic flow with complex wall-geometry coolant injection film performance analysis techniques spanning usage from gas turbines to rocket engines to scramjets. In recent years there has been significant development in increased computer power and modeling capacity, increasingly more complex and successful Navier-Stokes turbulence modeling techniques, innovative labor-saving meshing techniques, and more successful validation of experimental results. These combined innovations have continued to transition computational film cooling technology from the academic, government and commercial research and development environment to the industrial design-analysis environment. This bibliography is an openliterature reference resource whose papers collectively describe the continual emerging of numerical film cooling as a viable design tool for high temperature components.

scholarly journals Numerical Prediction of Mainstream Pressure Gradient Effects in Film Cooling

1999 ◽  
Author(s):  
William D. York ◽  
James H. Leylek
Keyword(s):  
Pressure Gradient ◽  
Gas Turbine ◽  
Film Cooling ◽  
Applied Pressure ◽  
Density Ratio ◽  
Pressure Gradients ◽  
Suction Surface ◽  
Reference Case ◽  
Injection Angle ◽  
Computational Methodology

A documented, systematic, computational methodology is applied to singularly investigate the effects of mainstream pressure gradients on film cooling over a flat surface for realistic gas turbine parameters. Key aspects of the study include: (1) validation of the ability of computational fluid dynamics to simulate film cooling in regions of mainstream pressure gradients, accomplished through the isolation of this parameter and the careful modeling of a published experimental study; (2) documentation of the effects of the applied pressure gradient on film cooling adiabatic effectiveness, as compared to the zero-pressure gradient case; and (3) detailed discussion of the pertinent physical mechanisms involved, with appropriate flowfield results. The imposed pressure gradient is typical of the suction surface of a gas turbine airfoil, with a strong favorable pressure gradient (the acceleration parameter was K = 1.5×10−6 at injection) transitioning to a mild adverse pressure gradient region beyond 30 diameters downstream. A single row of cylindrical film-cooling holes had an injection angle of 35°, with hole length-to-diameter ratio of 4.0 and a lateral spacing of 3.0 diameters. The simulated mass flux ratios were M = 0.6, 1.0, and 1.5, and the density ratio was held constant at 1.6. Solutions were obtained using a multi-block, multi-topology grid and a pressure-correction based, fully-implicit Navier-Stokes solver. A “realizeable” k-ε turbulence model, which eliminates the documented unrealistic turbulence production of the standard k-ε model in regions of large flow strain, was employed to obtain practical results economically. The applied pressure gradient resulted in a small advantage in center-line effectiveness, while laterally averaged effectiveness was slightly lower as compared to the zero-pressure gradient reference case. The results of this study demonstrate the ability of the applied computational methodology to accurately model film cooling in the presence of mainstream pressure gradients and resolve one of the key fundamental issues in turbine airfoil film cooling.

Conjugate Heat Transfer and Film Cooling of a Multi-Stage Cooling Scheme

2008 ◽  
Author(s):  
M. Ghorab ◽  
S. I. Kim ◽  
I. Hassan
Keyword(s):  
Heat Transfer ◽  
Film Cooling ◽  
Gas Turbines ◽  
Conjugate Heat Transfer ◽  
Density Ratio ◽  
Design Parameters ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Multi Stage ◽  
Internal Gap

Cooling techniques play a key role in improving efficiency and power output of modern gas turbines. The conjugate technique of film and impingement cooling schemes is considered in this study. The Multi-Stage Cooling Scheme (MSCS) involves coolant passing from inside to outside turbine blade through two stages. The first stage; the coolant passes through first hole to internal gap where the impinging jet cools the external layer of the blade. Finally, the coolant passes through the internal gap to the second hole which has specific designed geometry for external film cooling. The effect of design parameters, such as, offset distance between two-stage holes, gap height, and inclination angle of the first hole, on upstream conjugate heat transfer rate and downstream film cooling effectiveness performance are investigated computationally. An Inconel 617 alloy with variable properties is selected for the solid material. The conjugate heat transfer and film cooling characteristics of MSCS are analyzed across blowing ratios of Br = 1 and 2 for density ratio, 2. This study presents upstream wall temperature distributions due to conjugate heat transfer for different gap design parameters. The maximum film cooling effectiveness with upstream conjugate heat transfer is less than adiabatic film cooling effectiveness by 24–34%. However, the full coverage of cooling effectiveness in spanwise direction can be obtained using internal cooling with conjugate heat transfer, whereas adiabatic film cooling effectiveness has narrow distribution.

Assessment of a Double Hole Film Cooling Geometry Using S-PIV and PSP

2013 ◽  
Author(s):  
Lesley M. Wright ◽  
Stephen T. McClain ◽  
Charles P. Brown ◽  
Weston V. Harmon
Keyword(s):  
Film Cooling ◽  
Density Ratio ◽  
Three Dimensional ◽  
Field Measurements ◽  
Secondary Flows ◽  
Cylindrical Hole ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Hole Geometry ◽  
Compound Angle

A novel, double hole film cooling configuration is investigated as an alternative to traditional cylindrical and fanshaped, laidback holes. This experimental investigation utilizes a Stereo-Particle Image Velocimetry (S-PIV) to quantitatively assess the ability of the proposed, double hole geometry to weaken or mitigate the counter-rotating vortices formed within the jet structure. The three-dimensional flow field measurements are combined with surface film cooling effectiveness measurements obtained using Pressure Sensitive Paint (PSP). The double hole geometry consists of two compound angle holes. The inclination of each hole is θ = 35°, and the compound angle of the holes is β = ± 45° (with the holes angled toward one another). The simple angle cylindrical and shaped holes both have an inclination angle of θ = 35°. The blowing ratio is varied from M = 0.5 to 1.5 for all three film cooling geometries while the density ratio is maintained at DR = 1.0. Time averaged velocity distributions are obtained for both the mainstream and coolant flows at five streamwise planes across the fluid domain (x/d = −4, 0, 1, 5, and 10). These transverse velocity distributions are combined with the detailed film cooling effectiveness distributions on the surface to evaluate the proposed double hole configuration (compared to the traditional hole designs). The fanshaped, laidback geometry effectively reduces the strength of the kidney-shaped vortices within the structure of the jet (over the entire range of blowing ratios considered). The three-dimensional velocity field measurements indicate the secondary flows formed from the double hole geometry strengthen in the plane perpendicular to the mainstream flow. At the exit of the double hole geometry, the streamwise momentum of the jets is reduced (compared to the single, cylindrical hole), and the geometry offers improved film cooling coverage. However, moving downstream in the steamwise direction, the two jets form a single jet, and the counter-rotating vortices are comparable to those formed within the jet from a single, cylindrical hole. These strong secondary flows lift the coolant off the surface, and the film cooling coverage offered by the double hole geometry is reduced.

Numerical Investigation of Effects of Blockage, Inclination Angle, and Hole-Size on Film Cooling Effectiveness at Concave Surface

2021 ◽  
Vol 143 (2) ◽  
Author(s):  
Fu-qiang Wang ◽  
Jian Pu ◽  
Jian-hua Wang ◽  
Wei-dong Xia
Keyword(s):  
Film Cooling ◽  
Pressure Loss ◽  
Numerical Study ◽  
Density Ratio ◽  
Concave Surface ◽  
Blockage Ratio ◽  
Coverage Area ◽  
Cooling Effectiveness ◽  
Film Cooling Effectiveness ◽  
Injection Angle

Abstract Film-hole can be often blocked by thermal-barrier coatings (TBCs) spraying, resulting in the variations of aerodynamic and thermal performances of film cooling. In this study, a numerical study of the blockage effect on the film cooling effectiveness of inclined cylindrical-holes was carried out on a concave surface to simulate the airfoil pressure side. Three typical blowing ratios (BRs) of 0.5, 1.0, and 1.5 were chosen at an engine-similar density ratio (DR) of 2.0. Two common inclination angles of 30 deg and 45 deg were designed. The blockage ratios were adjusted from 0 to 20%. The results indicated the blockage could enhance the penetration of film cooling flow to the mainstream. Thus, the averaged effectiveness and coolant coverage area were reduced. Moreover, the pressure loss inside of the hole was increased. With the increase of BR, the decrement of film cooling effectiveness caused by blockage rapidly increased. At BR = 1.5, the decrement could be acquired up to 70% for a blockage ratio of 20%. The decrement of film cooling effectiveness caused by blockage was nearly nonsensitive to the injection angle; however, the larger angle could generate the higher increment of pressure loss caused by blockage. A new design method for the couple scheme of film cooling and TBC was proposed, i.e., increasing the inlet diameter according to the blockage ratio before TBC spraying. In comparison with the original unblocked-hole, the enlarged blocked-hole not only kept the nearly same area-averaged effectiveness but also reduced slightly the pressure loss inside of the hole. Unfortunately, application of enlarged blocked-hole at large BR could lead to a more obvious reduction of effectiveness near hole-exit, in comparison with the original common-hole.

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