A systematic procedure for reducing losses in axial-flow compressors is presented. In this procedure, a large, low-speed, aerodynamic model of a high-speed core compressor is designed and fabricated based on aerodynamic similarity principles. This model is then tested at low speed where high-loss regions associated with three-dimensional endwall boundary layers, flow separation, leakage, and secondary flows can be located, detailed measurements made, and loss mechanisms determined with much greater accuracy and much lower cost and risk than is possible in small, high-speed compressors. Design modifications are made by using custom-tailored airfoils and vector diagrams, airfoil endbends, and modified wall geometries in the high-loss regions. The design improvements resulting in reduced loss or increased stall margin are then scaled to high speed. This paper describes the procedure and presents experimental results to show that in some cases endwall loss has been reduced by as much as 10 percent, flow separation has been reduced or eliminated, and stall margin has been substantially improved by using these techniques.
The results of a program of experimental and analytical research in casing treatments over axial compressor rotor blade tips are presented. Circumferential groove, axial-skewed slot, and blade angle slot treatments were tested at low speeds. With the circumferential groove treatment the stalling flow was reduced 5.8 percent at negligible efficiency sacrifice. The axial-skewed slot treatment improved the stalling flow by 15.3 percent; 1.8 points in peak efficiency were sacrificed. The blade angle slot treatment improved the stalling flow by 15.0 percent; 1.4 points in peak efficiency were sacrificed. These values are consistent with previous experience at transonic speeds. The favorable stalling flow situations correlated well with observations of higher-than-normal surface pressures on the rotor blade pressure surfaces in the tip region, and with increased maximum diffusions on the suction surfaces. Annulus wall pressure gradients, especially in the 50 to 75 percent chord region, are also increased and blade surface pressure loadings are shifted toward the trailing edge for treated configurations. Rotor blade wakes may be somewhat thinner in the presence of good treatments, particularly under operating conditions close to the baseline stall. Annulus wall boundary layer profiles are only slightly influenced by casing treatment.
This is Part Two of a four-part paper. It begins with Section 6.0 and continues to describe the comprehensive experiments and computational analyses that have led to a detailed picture of boundary layer development on airfoil surfaces in multistage turbomachinery. In this part, we present the experimental evidence used to construct the composite picture for compressors given in the discussion in Section 5.0 of Part 1. We show the data from the surface hot-film gages and the boundary layer surveys, give a thorough interpretation for the baseline operating condition, and then show how this picture changes with variations in Reynolds number, airfoil loading, frequency of occurrence of wakes and wake turbulence intensity. Detailed flow features are described using raw time traces. The use of rods to simulate airfoil wakes is also evaluated.
Comprehensive experiments and computational analyses were conducted to understand boundary layer development on airfoil surfaces in multistage, axial-flow compressors and LP turbines. The tests were run over a broad range of Reynolds numbers and loading levels in large, low-speed research facilities which simulate the relevant aerodynamic features of modern engine components. Measurements of boundary layer characteristics were obtained by using arrays of densely packed, hot-film gauges mounted on airfoil surfaces and by making boundary layer surveys with hot wire probes. Computational predictions were made using both steady flow codes and an unsteady flow code. This is the first time that time-resolved boundary layer measurements and detailed comparisons of measured data with predictions of boundary layer codes have been reported for multistage compressor and turbine blading. Part 1 of this paper summarizes all of our experimental findings by using sketches to show how boundary layers develop on compressor and turbine blading. Parts 2 and 3 present the detailed experimental results for the compressor and turbine, respectively. Part 4 presents computational analyses and discusses comparisons with experimental data. Readers not interested in experimental detail can go directly from Part 1 to Part 4. For both compressor and turbine blading, the experimental results show large extents of laminar and transitional flow on the suction surface of embedded stages, with the boundary layer generally developing along two distinct but coupled paths. One path lies approximately under the wake trajectory while the other lies between wakes. Along both paths the boundary layer clearly goes from laminar to transitional to turbulent. The wake path and the non-wake path are coupled by a calmed region, which, being generated by turbulent spots produced in the wake path, is effective in suppressing flow separation and delaying transition in the non-wake path. The location and strength of the various regions within the paths, such as wake-induced transitional and turbulent strips, vary with Reynolds number, loading level, and turbulence intensity. On the pressure surface, transition takes place near the leading edge for the blading tested. For both surfaces, bypass transition and separated-flow transition were observed. Classical Tollmien–Schlichting transition did not play a significant role. Comparisons of embedded and first-stage results were also made to assess the relevance of applying single-stage and cascade studies to the multistage environment. Although doing well under certain conditions, the codes in general could not adequately predict the onset and extent of transition in regions affected by calming. However, assessments are made to guide designers in using current predictive schemes to compute boundary layer features and obtain reasonable loss predictions.
The relative importance of convection by secondary flows and diffusion by turbulence as mechanisms responsible for mixing in multistage, axial-flow compressors has been investigated by using the ethylene tracer-gas technique and hot-wire anemometry. The tests were conducted at two loading levels in a large, low-speed, four-stage compressor. The experimental results show that considerable cross-passage and spanwise fluid motion can occur and that both secondary flow and turbulent diffusion can play important roles in the mixing process, depending upon location in the compressor and loading level. In the so-called freestream region, turbulent diffusion appeared to be the dominant mixing mechanism. However, near the endwalls and along airfoil surfaces at both loading levels, the convective effects from secondary flow were of the same order of magnitude as, and in some cases greater than, the diffusive effects from turbulence. Calculations of the secondary flowfield and mixing coefficients support the experimental findings.
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