Scale-Resolving Simulations of a Fundamental Trailing-Edge Cooling Slot Using a Discontinuous-Galerkin Spectral-Element Method

The accurate prediction of turbulent mixing in high-pressure turbines that incorporate various airfoil surface-cooling strategies is becoming increasing critical to the design of modern gas turbine engines where the quest for improved efficiency is driving compressor overall pressure ratios and turbine inlet temperatures to much higher levels than ever before. In the present paper, a recently developed computational capability for accurate and efficient scale–resolving simulations of turbomachinery is extended to study the turbulent mixing mechanism of a simplified abstraction of an airfoil trailing-edge cooling slot — a plane wall jet with finite lip thickness discharging into an ambient flow. The computational capability is based on an entropy–stable, discontinuous–Galerkin approach that extends to arbitrarily high orders of spatial and temporal accuracy. The numerical results show that the present simulations capture the trends observed in the experiments. Discrepancies between the simulations and experiments are believed to be due to differences in the inflow profiles and tunnel side–wall effects. The thick lip configuration leads to a thicker wake and higher unsteadiness in the wall jet compared to the thin lip. A detailed comparison of the turbulent flowfields is presented to highlight differences arising due to lip thickness variations.

Assessment of an Enhanced Thin Film Model to Capture Wetting and Drying Behavior in an Aero-Engine Bearing Chamber

In the present work, a wetting and drying model is coupled with Eulerian Thin-Film model (ETFM) to analyze the wetting and drying behavior inside the bearing chamber. In the enhanced model, an additional source term is included to account for the contact angle effect. These models were coupled with volume-of-fluid (VOF) such that the core region is resolved by VOF and region close to the chamber walls, where a thin film is expected is resolved by either ETFM or enhanced ETFM model. Numerical studies are conducted for a shaft speed of 5,000 rpm, lubricant and air flow rates of 100 1/hr and 10 g/s respectively, at a scavenging ratio of 4. In the case of enhanced ETFM model lubricant to surface contact angle was varied from 10° to 45°. The performance of enhanced ETFM model is evaluated to capture drying and wetting behavior on a flat plate and found to be satisfactory. Film thickness prediction of enhanced ETFM model is found to be comparable with the VOF predictions reported in the literature. The effect of contact angle on the spreading of oil and film thickness is found to be small for the investigated conditions on an aero-engine bearing chamber.

Modelling the Unsteady Dynamics of a Turbine Research Facility

The accuracy with which experimental investigations of turbine performance need to be undertaken require either a semi- or fully-automated control of the operating point as any variation can compromise the reliability of the measurements. Fundamentally, both the mass flow rate through the turbine and the applied brake torque need to be adjusted in real-time so that the required operating point is maintained. This paper describes the development of a time accurate computational simulation of the unsteady dynamics of a large-scale, low-speed turbine facility when its operating point is determined by a full-authority control system. The motivation for the development of the computational simulation was to be able to safely undertake parametric studies to refine the control system and to investigate the cause of monotonic excursions of the operating point which were observed after a major rebuild. The monotonic excursions of the turbine operating point could only be reproduced by the computational simulation after an unsteady aerodynamic coupling between the turbine exit flow and the downstream centrifugal fan had been incorporated. Based on this observation a honeycomb was installed upstream of the fan in the turbine facility. This eliminated the monotonic excursions and the fractional noise of the operating point was reduced by 37%. When combined with an earlier refinement of the control system the factional noise was reduced by a factor of three. This enables the number of repeated measurements to be reduced by nine and still obtain the same quality of data.

Modeling of Combustor and Turbine Vane Interaction

Modern aero-engines are characterized by compact components (fan, compressor, combustor, and turbine). Such proximity creates a complex interaction between the components and poses a modeling challenge due to the difficulties in identifying a clear interface between components since they are usually modeled separately. From a numerical point of view, the simulation of a complex compact aero-engine system requires interaction between these individual components, especially the combustor-turbine interaction. The combustor is characterized by a subsonic chemically reacting and swirling flow while the high-pressure turbine (HPT) stage has flow which is transonic. Furthermore, the simulation of combustor-turbine interactions is more challenging due to aggressive flow conditions such as non-uniform temperature, non-uniform total-pressure, strong swirl, and high turbulence intensity. The simulation of aero-engines, where combustor-turbine interactions are important, requires a methodology that can be used in a real engine framework while ensuring numerical requirements of accuracy and stability. Conventionally, such a simulation is carried out using one of the two approaches: a combined simulation (or joint-simulation) of the combustor and the HPT geometries, or a co-simulation between the combustor and the turbine with the exchange of boundary conditions between these two separate domains. The primary objective of this paper is to assess the effectiveness of the joint simulation versus the co-simulation and propose a more practical approach for modeling combustor and turbine interactions. First, a detailed grid independence study with hexahedral and polyhedral meshes is performed to select the required polyhedral mesh. Then, an optimal location of the interface between the combustor and the nozzle guide vane (NGV) is identified. Co-simulations are then performed by exchanging information between the combustor and the NGV at the interface, wherein the combustor is solved using LES while the NGV is solved using RANS. The joint combustor-NGV simulations are solved using LES. The effect of the combustor-NGV interaction on the flow field and hot streak migration is analyzed. The results suggest that the joint simulation is computationally efficient and more accurate since both components are modelled together.

Reduced-Order Model of Unsteady Flows in a Turbomachinery Fan Modeled Using a Novel Proper Orthogonal Decomposition

This paper presents a novel, more efficient reduced-order model based on the proper orthogonal decomposition (POD) for the prediction of flows in turbomachinery. To further reduce the computational time, the governing equations were written as a function of specific volume instead of density. This allowed for the pre-computation of the coefficients of the system of ordinary differential equations that describe the reduced-order model. A penalty method was developed to implement time-dependent boundary conditions and achieve a stable solution for the reduced-order model. Rotor 67 was used as a validation case for the reduced-order model, which was tested for both on- and off-reference conditions. This reduced-order model was shown to be more than 10,000 times faster than the full-order model.

Design and Numeric Simulation of a Thermoacoustic Bi-Directional Turbine Test Rig

As a new type of acoustic-electric conversion method, bi-directional impulse turbine provides great potential for developing large scale and economic thermoacoustic power generators. A test rig for turbine tests in acoustic fields, which are provided through two reciprocating pistons, has been introduced. A three-dimensional numerical model has been used to simulate the whole system. The fundamental characteristics of the turbine in oscillating flow are analyzed. Impact of acoustic field features on the turbine performance has been studied. The results show that the performance is sensitive to the acoustic field. For the test rig, a typical result is that with a shaft power of 187 W, the turbine can reach an efficiency around 32%.

Improving Steady CFD to Capture the Effects of Radial Mixing in Axial Compressors

The axial compressors of power-generation gas turbines have a high stage count, blades with low aspect ratios and relatively large clearances in the rear section. These features promote the development of strong secondary flows. An important outcome deriving from the convection of intense secondary flows is the enhanced span-wise transport of fluid properties mainly involving the rear stages, generally referred to as “radial mixing”. An incorrect prediction of this key phenomenon may result in inaccurate performance evaluation and could mislead the designers during the compressor design phase. As shown in a previous work, in the rear stages of an axial compressor the stream-wise vorticity associated with tip clearance flows is one of the main drivers of the overall span-wise transport phenomenon. Limiting it by circumferentially averaging the flow at row interfaces is the reason why a steady-state analysis strongly under-predicts radial mixing. To properly forecast the span-wise transport within the flow-path, an unsteady analysis should be adopted. However, due to the high blade count, this approach has a computational cost not yet suitable for industrial purposes. Currently, only the steady-state full-compressor simulation can fit in a lean industrial design chain and any model upgrade improving its radial mixing prediction would be highly beneficial for the daily design practice. To attain some progresses in RANS model, its inherent lack of convection of stream-wise vorticity must be addressed. This can be done by acting on another mixing driver, able to provide the same outcome, that is turbulent diffusion. In particular, by enhancing turbulent viscosity one can promote span-wise diffusion, thus improving the radial mixing prediction of the steady approach. In this paper, this strategy to update the RANS model and its application in simulations on a compressor of the Ansaldo Energia fleet is presented, together with the model tuning that has been performed using the results of unsteady simulations as the target.

Numerical Investigations on the Power Generation of Turbo-Expander During the Propane De-Hydrogenation Process

A turboexpander for the propane de-hydrogenation process with blade and splitter has been numerically investigated. Since the turboexpander expands fluid from higher inlet pressure to lower discharge pressure, the kinetic energy of fluid is converted into useful mechanical energy. The efficiency and power generation with the designed turboexpander have been simulated with different operating conditions. The pressure ratio between inlet and outlet and rotational speed are varied to characterize the performance of the turboexpander as an electrical power generator. The numerical simulations have shown the vortex at the trailing edges of blade and splitter which decreases the efficiency. The rotational speed and the pressure ratio are parameterized to obtain operation conditions which achieve high power generation and efficiency. Consequently, the generated power from 614.12 kW to 693.45kW is obtained at the normal rotational speed and the pressure ratio between 1.75 to 2.22.

Adjoint Based Aerodynamic Optimization of a Multi-Splitter Turbine Vane Frame

This work presents a 2D optimization of a multi-body turbine vane frame (TVF), a particular configuration that can lead to considerable shortening of the aero-engine shaft as well as weight reduction. Traditionally, the turbine vane frame is used to guide the flow from the high pressure (HP) turbine to the low pressure (LP) turbine. Current designs have a mid turbine frame equipped with non lifting bodies that have structural and servicing functions, while multi-body configurations are characterized by the fact that, in order to shorten the duct length, the mid turbine struts are merged with the LP stator vanes, traditionally located downstream. This design architecture consists therefore of a multi-body vane row, where lifting long-chord struts replace some of the low pressure vane airfoils. However, the bulky struts cause significant aerodynamics losses and penalize the aerodynamics of the small vanes. The objective of the present work is to numerically optimize a TVF geometry with multi-body architecture using a gradient based algorithm coupled with the adjoint approach, enabling the use of a rich design space. Steady-state CFD simulations have been used to this end. The aim of this study is to reduce the total pressure losses of the TVF, while imposing several aerodynamic and structural constraints. The parametrization of the TVF geometry represents the airfoil shapes and their relative pitch-wise positions. The outcome of the optimization is to evaluate the potential improvements introduced by the optimized TVF geometry and to quantify the influence of the different design parameters on the total pressure losses.

Prediction of Film Thickness of an Aero-Engine Bearing Chamber Using Coupled VOF and Thin Film Model

In the present work, a coupled volume-of-fluid (VOF) model with Eulerian thin-film model (ETFM) approach is used to predict the film thickness in an aero-engine bearing chamber. Numerical studies are conducted for a wide range of shaft speeds with lubricant and air flow rates of 100 1/hr and 10 g/s respectively, at a scavenge ratio of 4 on a simplified bearing chamber test rig. Air-flow analysis inside the bearing chamber is also assessed. Primary and secondary airflow predictions are found to be in good agreement with the experimental results. The coupled ETFM+VOF approach is found to be sensitive enough to capture the qualitative trend of oil film formation and distribution over the chamber wall. Oil collection near the sump at a low shaft speed and a rotating oil film at a higher shaft speed are well captured.