The paper examines in detail the structure of the tip leakage flow and its effect on the blade loading in a large-scale planar cascade of turbine blades. The tip clearance was varied from 0.0 to 2.86 percent of the blade chord. One of the blades is instrumented with 14 rows of 73 static taps which allowed a very detailed picture of the loading near the tip to be obtained. In addition to the measurements, extensive flow visualization was conducted using both smoke and surface oil flow. A new feature found in the present experiment was the formation of multiple, discrete tip-leakage vortices as the clearance was increased. Their presence is clearly evident from the surface oil flow and they account for the multiple suction peaks found in the blade pressure distributions. Integration of the pressure distributions showed that for larger values of the clearance the blade loading increases as the tip is approached and only begins to decline very near the tip. The increase was found to occur primarily in the axial component of the force.
Here we report on the application of non-axisymmetric endwall contouring to mitigate the endwall losses of one conventional- and two high-lift low-pressure turbine airfoil designs. The design methodology presented combines a gradient-based optimization algorithm with a three-dimensional CFD flow solver to systematically vary a free-form parameterization of the endwall. The ability of the CFD solver employed in this work to predict endwall loss modifications resulting from non-axisymmetric contouring is demonstrated with previously published data. Based on the validated trend accuracy of the solver for predicting the effects of endwall contouring, the magnitude of predicted viscous losses forms the objective function for the endwall design methodology. This system has subsequently been employed to optimize contours for the conventional-lift Pack B and high-lift Pack D-F and Pack D-A low-pressure turbine airfoil designs. Comparisons between the predicted and measured loss benefits associated with the contouring for Pack D-F design are shown to be in reasonable agreement. Additionally, the predictions and data demonstrate that the Pack D-F endwall contour is effective at reducing losses primarily associated with the passage vortex. However, some deficiencies in predictive capabilities demonstrate here highlight the need for a better understanding of the physics of endwall loss-generation and improved predictive capabilities. More detailed analysis of the contouring results for the Pack B design is presented in a companion paper (Knesevici et al. [1]).
Existing methods for predicting the tip-leakage losses in turbomachinery are based on a variety of assumptions, many of which have not been fully verified experimentally. Recently, several detailed experimental studies in turbine cascades have helped to clarify the physics of the flow and provide data on the evolution of the losses. The paper examines the assumptions underlying the prediction methods in the light of these data. An improved model for the losses is developed, using one of the existing models as the starting point.
The paper presents further results from a continuing study on tip leakage in axial turbines. Rotation has been simulated in a linear cascade test section by using a moving-belt tip wall. Measurements were made inside the tip gap with a three-hole pressure probe for a clearance size of 3.8 percent of the blade chord. Two wall speeds are considered and the results are compared with the case of no rotation. As in other experiments, significant reduction in the gap mass flow rate is observed due to the relative motion. The detailed nature of the measurements allows the dominant physical mechanism by which wall motion affects the tip gap flow to be identified. Based on the experimental observations, an earlier model for predicting the tip gap flow field is extended to the case of relative wall motion. Part II of the paper examines the effect of the relative motion on the downstream flow field and the blade loading.
SummaryEvidence is presented to show that the universal law of the wall has a wider range of validity than the assumptionl= ky, with k a universal constant. If an effective value of k is defined for the wall region its value is shown to vary between wide limits, and keffcan be correlated with other parameters describing the flow in the wall region.
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