The purpose of this paper is to present a multidisciplinary predesign process and its application to three aero-engine models. First, a twin spool mixed flow turbofan engine model is created for validation purposes. The second and third engine models investigated comprise future engine concepts: a counter rotating open rotor (CROR) and an ultrahigh bypass turbofan. The turbofan used for validation is based on publicly available reference data from manufacturing and emission certification. At first, the identified interfaces and constraints of the entire predesign process are presented. An important factor of complexity in this highly iterative procedure is the intricate data flow, as well as the extensive amount of data transferred between all involved disciplines and among different fidelity levels applied within the design phases. To cope with the inherent complexity, data modeling techniques have been applied to explicitly determine required data structures of those complex systems. The resulting data model characterizing the components of a gas turbine and their relationships in the design process is presented in detail. Based on the data model, the entire engine predesign process is presented. Starting with the definition of a flight mission scenario and resulting top level engine requirements, thermodynamic engine performance models are developed. By means of these thermodynamic models, a detailed engine component predesign is conducted. The aerodynamic and structural design of the engine components are executed using a stepwise increase in level of detail and are continuously evaluated in context of the overall engine system.
Reliable predictions for wind turbines become more and more difficult with the increase in overall size and weight. On the one hand external factors such as the influence of wind shear become more important for bigger turbines, internal factors such as structural layout and challenges in the manufacturing process need to be addressed on the other hand. Accurate aerodynamic simulations are an essential requirement for further analyses of aeroelastic stability and aeroacoustic footprint. While the calculations in all of these individual disciplines are challenging the combined simulation of all these disciplines, namely the multidisciplinary simulation is a tough but gainful undertaking. This task is being addressed in the DLR project MERWind which will be presented here. The focus of the paper lays on the aerodynamic and aeroelastic simulation of the NREL 5MW wind turbine using high-fidelity methods.
Reducing the uncertainties in the prediction of turbine inlet conditions is a crucial aspect to improve aero engine designs and further increase engine efficiencies. To meet constantly stricter emission regulations, lean burn combustion could play a key role for future engine designs. However, these combustion systems are characterized by significant swirl for flame stabilization and reduced cooling air mass flows. As a result, substantial spatial and transient variations of the turbine inlet conditions are encountered. To investigate the effect of the combustor on the high pressure turbine, a rotating cooled transonic high-pressure configuration has been designed and investigated experimentally at the DLR turbine test facility ‘NG-Turb’ in Göttingen, Germany. It is a rotating full annular 1.5 stage turbine configuration which is coupled to a combustor simulator. The combustor simulator is designed to create turbine inlet conditions which are hydrodynamically representative for a lean-burn aero engine. A detailed description of the test rig and its instrumentation as well as a discussion of the measurement results is presented in part I of this paper. Part II focuses on numerical modeling of the test rig to further extend the understanding of the measurement results. Integrated simulations of the configuration including combustor simulator and nozzle guide vanes are performed for leading edge and passage clocking position and the effect on the hot streak migration is discussed. The simulation and experimental results at the combustor-turbine interface are compared showing a good overall agreement. The relevant flow features are correctly predicted in the simulations, proving the suitability of the numerical model for application to integrated combustor-turbine interaction analysis.
Within the scope of European Commission FP7 project FACTOR, dedicated to combustor-turbine-interaction research, a clean-sheet design of a rotating turbine test rig featuring a non-reacting combustor simulator was created and built among the partners. German Aerospace Center DLR provided the operational facility NG-Turb to which the rig was adapted and was responsible for global rig integration and operation, also including aerodynamic probe measurements of the flow field. The rig and experimental set-up is described and post-processed results from probe traverses in several measurement planes are presented and discussed. Special attention is paid to the comparison and influence of two combustor-NGV clocking positions on the periodic turbine flow field, made possible by rig adaptation during the campaign. The strongly distorted and nonuniform turbine inlet flow created by the combustor simulator proved challenging for the probe measurements, but at the same time set a realistic boundary condition enabling the analysis of ‘CTI’ by flow structures migrating through the blade rows.
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