Optimization of Sweep and Blade Lean for Diffuser to Suppress Hub Corner Vortex in Multistage Pump

The bowl diffuser is the main flow component in multistage submersible pumps; however, secondary flow fields can easily induce a separation vortex in the hub corner region of the bowl diffuser during normal operation. To explore the flow mechanism of the hub corner separation vortex and develop a method for suppressing hub corner separation vortices, the lean and sweep of the diffuser blade were optimized using computational fluid dynamics (CFD) simulations and central composite design. Diffuser efficiency, static pressure recovery coefficient, and non-uniformity were selected as the optimization objectives. Details of the internal flow were revealed and the collaborative response relationships between blade lean/sweep parameter equations and optimization objectives were established. The optimization results show that a greater pressure difference between the pressure surface and suction surface (PS–SS) at the inlet can offset transverse secondary flow, whereas a lower PS–SS pressure difference will cause a drop in low-energy fluid in the diffuser mid-section. The blade’s lean scheme suppresses the hub corner separation vortex, leading to an increase in pressure recovery and diffuser efficiency. Moreover, optimizing the sweep scheme can reduce the shroud–hub pressure difference at the inlet to offset spanwise secondary flow and enhance the hub–shroud pressure difference at the outlet, thus driving low-energy fluid further downstream. The sweep scheme suppresses the hub corner vortex, with a resulting drop in non-uniformity of 13.1%. Therefore, optimization of the diffuser blade’s lean and sweep can result in less low-energy fluid or drive it further away from hub, thereby suppressing the hub corner vortex and improving hydraulic performance. The outcomes of this work are relevant to the advanced design of bowl diffusers for multistage submersible pumps.

On the Interactions of a Rotor Blade Tip Flow With Axial Casing Grooves in an Axial Compressor Near the Best Efficiency Point

Previous studies have shown that axial casing grooves (ACGs) are effective in delaying the onset of stall, but degrade the performance of axial turbomachines around the best efficiency point (BEP). Our recent experimental study [1] in the JHU refractive index-matched liquid facility have examined the effects of ACGs on delaying stall of a one and half stage compressor. The semicircular ACGs based on Müller et al. [2] reduce the stall flow rate by 40% with a slight decrease in pressure rise at higher flow rates. Stereo-PIV (SPIV) measurements at a flow rate corresponding to the pre-stall condition of the untreated machine have identified three flow features that contribute to the delay in stall. Efficiency measurements conducted as part of the present study show that the ACGs cause a 2.4% peak efficiency loss. They are followed by detailed characterizations of the impact of the ACGs on the flow structure and turbulence in the tip region at high flow rates away from stall. Comparisons with the flow structure without casing grooves and at low flow rate are aimed at exploring relevant flow features that might be associated with the reduced efficiency. The SPIV measurements in several meridional and radial planes show that the periodic inflow into the groove peaks when the rotor blade pressure side (PS) overlaps with the downstream end of the groove, but diminishes when this end faces the blade suction side (SS). The inflow velocity magnitude is substantially lower than that occurring at a flow rate corresponding to the pre-stall conditions of the untreated machine. Yet, entrainment of the PS boundary layer and its vorticity during the inflow phase generates counter-rotating radial vortices at the entrance to the groove, and a “discontinuity” in the appearance of the tip leakage vortex (TLV). While being exposed to the blade SS, the backward tip leakage flow causes flow separation and formation of a counter-rotating vortex at the downstream corner of the groove, which migrates towards the passage with increasing flow rate. Interactions of this corner vortex with the TLV cause fragmentation of the latter, creating a broad area with secondary flows and elevated turbulence level. Consequently, the vorticity shed from the blade tip remains scattered from the groove corner to the blade tip long after the blade clears this groove. The turbulence peaks around the corner vortex, the TLV, and the shear layer connecting it to the SS corner. During periods of inflow, there is a weak outflow from the upstream end of the groove. At other phases, most of the high secondary flows are confined to the downstream corner, leaving only weak internal circulation in the rest of the groove, but with a growing shear layer with elevated (but weak) turbulence originating from the upstream corner. Compared to a smooth endwall, the groove also increases the flow angle near the blade tip leading edge (LE) and varies it periodically. Accordingly, the magnitude of circulation shed from the blade tip and leakage flow increase near the leading edge. The insight from these observations might guide the development of ACGs that take advantage of the effective stall suppression by the ACGs but alleviate the adverse effects at high flowrates.

Reducing Nacelle Pressure Drag

Decreasing drag on aircraft components was beneficial towards improving fuel economy and operational range. A generic axisymmetric nacelle-strut configuration typical of those housing fuselage-mounted engines was evaluated at a Reynolds number of 6 × 105 based on the nacelle maximum diameter d = 26.5 cm and an angle of attack of 20 deg. It was estimated that drag could be reduced by 20%. Three case studies were evaluated that added a fillet to the nacelle-strut corner, vortex generating triangular tabs, and flow-path obstructing vanes to improve flow control by reducing suction-side separation. Experimental results showed that a 0.11 d radius of curvature fillet reduced drag by 8% with respect to the baseline case. Numerical results employing the realizable k-ε turbulence model with wall functions predicted no improvements with the tabs and an 8% reduction with the vanes.

Turbulent Flows Over a Backward Facing Step Simulated Using a Modified Partially Averaged Navier–Stokes Model

A modified partially averaged Navier–Stokes model (MPANS) is proposed by treating the standard k–ε model as the parent model and formulating the unresolved-to-total kinetic energy ratio fk as a function of the local grid size and turbulence length scale. Flows over a backward facing step are used to evaluate the performance of MPANS mode. Computations of the standard k–ε model, the constant fk partially averaged Navier–Stokes (PANS) models (fk = 0.6, 0.7), and the two-stage PANS model are carried out for comparisons. Based on the detailed analyses of calculated results and experimental data, the MPANS model performs better to predict the reattachment length together with the corner vortex and provides overall improved statistics of skin frictions, pressures, velocity profiles, and Reynolds stresses, demonstrating its promising applications in industrial turbomachines that often encounter with flow separations.