Two versions of a three dimensional multistage Navier-Stokes code were used to optimize the design of an eleven stage high pressure compressor. The first version of the code utilized a “mixing plane” approach to compute the flow through multistage machines. The effects due to tip clearances and flowpath cavities were not modeled. This code was used to minimize the regions of separation on airfoil and endwall surfaces for the compressor. The resulting compressor contained bowed stators and rotor airfoils with contoured endwalls. Experimental data acquired for the HPC showed that it achieved 2% higher efficiency than a baseline machine, but it had 14% lower stall margin. Increased stall margin of the HPC was achieved by modifying the stator airfoils without compromising the gain in efficiency as demonstrated in subsequent rig and engine tests. The modifications to the stators were defined by using the second version of the multistage Navier-Stokes code, which models the effects of tip clearance and endwall flowpath cavities, as well as the effects of adjacent airfoil rows through the use of “bodyforces” and “deterministic stresses”. The application of the Navier-Stokes code was assessed to yield up to 50% reduction in the compressor development time and cost.
A fan performance analysis method based upon three-dimensional steady Navier–Stokes equations is presented in this paper. Its accuracy is established through extensive code validation effort. Validation data comparisons ranging from a two-dimensional compressor cascade to three-dimensional fans are shown in this paper to highlight the accuracy and reliability of the code. The overall fan design procedure using this code is then presented. Typical results of this design process are shown for a current engine fan design. This new design method introduces a major improvement over the conventional design methods based on inviscid flow and boundary layer concepts. Using the Navier–Stokes design method, fan designers can confidently refine their designs prior to rig testing. This results in reduced rig testing and cost savings as the bulk of the iteration between design and experimental verification is transferred to an iteration between design and computational verification.
A Low Pressure Compressor (LPC) is unique in its requirements for wide operating range during a flight mission. As a result, the aerodynamic design involves a trade-off between performance and stall margin. The requirement to reduce engine development cost and schedule has resulted in developing LPCs during the engine validation program. With engine validation and certification schedules being compressed continuously, getting the initial design right has become critical. Multistage CFD analysis is used in the current design process to optimize the airfoils and stage matching. Three-dimensional airfoil features, such as bow, that improve secondary flow features and can be optimized using CFD. The PW6000 LPC engine test data has validated the analytical results and demonstrated surge margin and efficiency levels above the requirements. The LPC also achieved all other design objectives in its first build, representing a significant cost saving for a new centerline engine development program.
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