Numerical Analysis of Overall Performance and Flow Phenomena of an Automatically Optimized Three-Dimensional Return Channel System for Multistage Centrifugal Compression Systems

Author(s):  
A. Hildebrandt

For multi-stage compression systems, besides the aerodynamics of the impeller and the diffuser, the U-turn and return channel blades aerodynamics play an important role for the total stage efficiency of the compression system. Due to modern CAD and CAM methodology, three-dimensional blade surfaces of an impeller but also of return channel blades are easily designed and manufactured at a similar price as old-fashioned two-dimensional blade designs. This paper presents the numerical analysis and aerodynamic optimization of a three-dimensional return channel system for multi stage single shaft centrifugal compressor machinery. In a previous paper, a two-dimensional return channel blade system had been optimized by an automatic evolutionary algorithm [1]. This previous study showed further aerodynamic potential by utilizing a three dimensional return channel blade design. The three-dimensional blade comprises of ruling surfaces. In the present paper, for a three-dimensional blade design, both the blade angle and blade thickness distributions are allowed to be varied independently for the hub and the shroud. As a result, the total pressure loss of the three dimensional return channel blade can be relatively reduced by 6% compared with a classical two-dimensional return channel blade. This reduction in total pressure loss is partly caused by the matching of the leading edge angle to the non-uniform flow angle at the U-turn outlet. Furthermore, the different blade angle distribution helps to suppress flow separation at the blade suction side near the shroud and helps to reduce flow friction on the blade surface near the hub.

Author(s):  
Donghyun Kim ◽  
Changmin Son ◽  
Kuisoon Kim

In the present study, a multi-stage transonic compressor has been analyzed to investigate secondary loss structures and flow interactions in the corner region where the hub endwall and blade suction surface meet. The Detached Eddy Simulation (DES) approach is used successfully with the Shear Stress Transport (SST) turbulence model to directly resolve the eddy structure in the separated region. The SST-DES results for a transonic three stage axial compressor are compared with a RANS analysis obtained using ANSYS CFX. The present analysis indicates that the DES is better in simulating secondary losses and vortex structures than the RANS. With the DES, a large three-dimensional separation is predicted in the stator suction surface and hub endwall compared to the RANS prediction. The flow separation affects adversely the loss characteristics such as increases in the entropy and total pressure loss. The DES analysis indicates that the secondary flow phenomenon of the stator rows is apparent in all stages. It is observed to predict two distinct vortices induced by a three dimensional flow separation in the region adjacent to the suction surface and trailing edge of the last stage stator near the hub endwall. For the front two stages, the DES also predicts strong vortices and flow separation in the same corner region while the RANS analysis fails to predict them clearly. The total pressure loss prediction is concerned, the DES analysis predicts significantly larger than the RANS analysis in the region where the hub corner separation occurs. The DES is also found to predict a periodic fluctuations in the entropy, leading to the instantaneous efficiency variations with maximum differences of about 10% compared with the RANS solutions.


Author(s):  
Arindam Bera ◽  
N. K. Singh

Return channel de-swirl vanes form an integral part of a centrifugal compressor stage for multi-stage configuration. In this paper, a few configurations of return channel vanes (RCV) are arrived at by modifying the blade angle and thickness distribution from leading edge to the trailing edge. Influence of these two parameters on the overall performance of return channel in terms of total pressure loss co-efficient and static pressure recovery co-efficient along with stage exit flow angle are evaluated through CFD analysis. CFD results show that, proper thickness distribution after maximum thickness point to the trailing edge improves the stage exit flow angle but not the total pressure loss co-efficient and static pressure recovery co-efficient. Whereas, by suitably modifying the blade angle distribution, all the three performance parameters can be improved considerably.


2016 ◽  
Vol 139 (1) ◽  
Author(s):  
A. Hildebrandt ◽  
F. Schilling

The present paper deals with the numerical and experimental investigation of the effect of return channel (RCH) dimensions of a centrifugal compressor stage on the aerodynamic performance. Three different return channel stages were investigated, two stages comprising three-dimensional (3D) return channel blades and one stage comprising two-dimensional (2D) RCH vanes. The analysis was performed regarding both the investigation of overall performance (stage efficiency, RCH total pressure loss coefficient) and detailed flow-field performance. For detailed experimental flow-field investigation at the stage exit, six circumferentially traversed three-hole probes were positioned downstream the return channel exit in order to get two-dimensional flow-field information. Additionally, static pressure wall measurements were taken at the hub and shroud pressure and suction side (SS) of the 2D and 3D return channel blades. The return channel system overall performance was calculated by measurements of the circumferentially averaged 1D flow field downstream the diffuser exit and downstream the stage exit. Dependent on the type of return channel blade, the numerical and experimental results show a significant effect on the flow field overall and detail performance. In general, satisfactory agreement between computational fluid dynamics (CFD)-prediction and test-rig measurements was achieved regarding overall and flow-field performance. In comparison with the measurements, the CFD-calculated stage performance (efficiency and pressure rise coefficient) of all the 3D-RCH stages was slightly overpredicted. Very good agreement between CFD and measurement results was found for the static pressure distribution on the RCH wall surfaces while small CFD-deviations occur in the measured flow angle at the stage exit, dependent on the turbulence model selected.


Author(s):  
Philipp Amtsfeld ◽  
Michael Lockan ◽  
Dieter Bestle ◽  
Marcus Meyer

State-of-the-art aerodynamic blade design processes mainly consist of two phases: optimal design of 2D blade sections and then stacking them optimally along a three-dimensional stacking line. Such a quasi-3D approach, however, misses the potential of finding optimal blade designs especially in the presence of strong 3D flow effects. Therefore, in this paper a blade optimization process is demonstrated which uses an integral 3D blade model and 3D CFD analysis to account for three-dimensional flow features. Special emphasis is put on shortening design iterations and reducing design costs in order to obtain a rapid automatic optimization process for fully 3D aerodynamic turbine blade design which can be applied in an early design phase already. The three-dimensional parametric blade model is determined by up to 80 design variables. At first, the most important design parameters are chosen based on a non-linear sensitivity analysis. The objective of the subsequent optimization process is to maximize isentropic efficiency while fulfilling a minimal set of constraints. The CFD model contains both important geometric features like tip gaps and fillets, and cooling and leakage flows to sufficiently represent real flow conditions. Two acceleration strategies are used to cut down the turn-around time from weeks to days. Firstly, the aerodynamic multi-stage design evaluation is significantly accelerated with a GPU-based RANS solver running on a multi-GPU workstation. Secondly, a response surface method is used to reduce the number of expensive function evaluations during the optimization process. The feasibility is demonstrated by an application to a blade which is a part of a research rig similar to the high pressure turbine of a small civil jet engine. The proposed approach enables an automatic aerodynamic design of this 3D blade on a single workstation within few days.


1976 ◽  
Vol 98 (4) ◽  
pp. 592-606 ◽  
Author(s):  
David Japikse

Progress achieved in numerical analysis during the past decade now permits the turbo-machinery designer to carry out a wide variety of inviscid, steady flow, two-dimensional calculations for compressible sybsonic and transonic flow fields, including some strongly diffusing flows. Three-dimensional (including viscosity) calculations are under development and should find wide spread use as analysis tools during the next decade. This review offers an introduction to recent advances in numerical turbomachinery design methods guided by the author’s design usage of several of the techniques reported.


Author(s):  
Ping-Ping Chen ◽  
Wei-Yang Qiao ◽  
Karsten Liesner ◽  
Robert Meyer

The large secondary flow area in the compressor hub-corner region usually leads to three-dimensional separation in the passage with large amounts of total pressure loss. In this paper numerical simulations of a linear high-speed compressor cascade, consisting of five NACA 65-K48 stator profiles, were performed to analyze the flow mechanism of hub-corner separation for the base flow. Experimental validation is used to verify the numerical results. Active control of the hub-corner separation was investigated by using boundary layer suction. The influence of the selected locations of the endwall suction slot was investigated in an effort to quantify the gains of the compressor cascade performance. The results show that the optimal chordwise location should contain the development section of the three-dimensional corner separation downstream of the 3D corner separation onset. The best pitchwise location should be close enough to the vanes’ suction surface. Therefore the optimal endwall suction location is the MTE slot, the one from 50% to 75% chord at the hub, close to the blade suction surface. By use of the MTE slot with 1% suction flow ratio, the total-pressure loss is substantially decreased by about 15.2% in the CFD calculations and 9.7% in the measurement at the design operating condition.


Author(s):  
L. J. Lenke ◽  
H. Simon

The numerical simulation of the flow within a return channel is reported in this paper. The investigated return channel is typically to join the exit from one stage of a centrifugal machine to the inlet of the next stage. These channel covers the range of extremely low flow coefficients. Different 3-D calculations with two different turbulence models (low-Reynolds-number k-ϵ and explicit algebraic Reynolds stress model) at the design point and part load range show the strongly three-dimensional flow structure with secondary flows on hub and shroud of the deswirl vanes. There are also significant separations downstream of the 180°-bend at suction and pressure side of the vanes. The presented numerical results are compared with experimental data in different planes and at the vane contour. The results indicate small differences between the turbulence models in the prediction of losses, flow angles and separation behavior at design point. At off-design conditions the turbulence models begin to deviate notably in their prediction of separation.


Author(s):  
Y.-H. Ho ◽  
B. Lakshminarayana

A steady, three-dimensional Navier-Stokes solver which utilizes a pressure-based technique for incompressible flows is used to simulate the three-dimensional flow field in a turbine cascade. A new feature of the numerical scheme is the implementation of a second-order plus fourth-order artificial dissipation formulation, which provides a precise control of the numerical dissipation. A low-Reynolds-number form of a two-equation turbulence model is used to account for the turbulence effects. Comparison between the numerical predictions and the experimental data indicates that the numerical model is able to capture most of the complex flow phenomena in the endwall region of a turbine cascade, except the high gradient region in the secondary vortex core. The effects of inlet turbulence intensity and turbulence length scale on secondary vortices, total pressure loss, and turbulence kinetic energy inside the passage are presented and interpreted. It is found that higher turbulence intensity energizes the vortical motions and tends to move the passage vortex away from the endwall. With a larger turbulence length scale the secondary flow inside the passage is reduced. However, the total pressure loss increases due to higher turbulence kinetic energy production.


Author(s):  
Qingzong Xu ◽  
Pei Wang ◽  
Qiang Du ◽  
Jun Liu ◽  
Guang Liu

With the increasing demand of high bypass ratio and thrust-to-weight ratio in civil aero-engine, the intermediate turbine duct between the high pressure and low pressure turbines of a modern gas turbine tends to shorter axial length, larger outlet-to-inlet area ratio and high pressure-to-low pressure radial offset. This paper experimentally and numerically investigated the three-dimensional flow characteristics of traditional (ITD1) and aggressive intermediate turbine duct (ITD2) at low Reynolds number. The baseline case of ITD1 is representative of a traditional intermediate turbine duct of aero-engine design with non-dimensional length of L/dR = 2.79 and middle angle of 20.12°. The detailed flow fields inside ITD1 and flow visualization were measured. Results showed the migration of boundary layer and a pair of counter-rotating vortexes were formed due to the radial migration of low momentum fluid. With the decreasing axial length of intermediate turbine duct, the radial and streamwise reverse pressure gradient in aggressive intermediate turbine duct (ITD2) were increased resulting in severe three-dimensional separation of boundary layer near casing surface and higher total pressure loss. The secondary flow and separation of boundary layer near the endwall were deeply analyzed to figure out the main source of high total pressure loss in the aggressive intermediate turbine duct (ITD2). Based on that, employing wide-chord guide vane to substitute “strut + guide vane”, this paper designed the super-aggressive intermediate turbine duct and realized the suppression of the three-dimensional separation and secondary flow.


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