2007 Vol. 22, No. 5

Display Method:
Investigation of the steam-cooled blade in a steam turbine cascade
Dieter Bohn, Jing Ren, Karsten Kusterer
2007, 22(5): 673-682.
Abstract:
With the increasing demand for electricity,an efficiency improvement and thereby reduced CO2 emissions of the coal-fired plants are expected in order to reach the goals set in the Kyoto protocol.It can be achieved by a rise of the process parameters.Currently,live steam pressures and temperatures up to 300 bars and 923 K are planned as the next step.Closed circuit steam cooling of blades and vanes in modern steam turbines is a promising technology in order to establish elevated live steam temperatures in future steam turbine cycles.In this paper,a steam-cooled test vane in a cascade with external hot steam flow is analyzed numerically with the in-house code CHTflow.A parametric analysis aiming to improve the cooling effectiveness is carried out by varying the cooling mass flow ratio.The results from two investigated cases show that the steam cooling technique has a good application potential in the steam turbine.The internal part of the vane is cooled homogeneously in both cases.With the increased cooling mass flow rate,there is a significant improvement of cooling efficiency at the leading edge.The results show that the increased cooling mass flow ratio can enhance the cooling effectiveness at the leading edge.With respect to trailing edge,there is no observable improvement of cooling effectiveness with the increased cooling mass flow.This implies that due to the limited dimension at the trailing edge,the thermal stress cannot be decreased by increasing the cooling mass flow rate.Therefore,impingement-cooling configuration at the trailing edge might be a solution to overcome the critical thermal stress there.It is also observed that the performance of the cooling effective differs on pressure side and suction side.It implicates that the equilibrium of the cooling effectiveness on two sides are influenced by a coupled relationship between cooling mass flow ratio and hole geometry.In future work,optimizing the hole geometry and cooling steam supply conditions might be the solutions for an equivalent cooling effectiveness along whole profile.
The effect of inlet conditions on the flow and heat transfer in multiple rotating cavity with axial throughflow
Christopher Long, Peter Childs
2007, 22(5): 683-693.
Abstract:
This paper discusses experimental results from two different build configurations of a heated multiple rotating cavity test rig.Measurements of heat transfer from the discs and tangential velocities are presented.The test rig is a 70% full scale version of a high pressure compressor stack of an axial gas turbine engine.Of particular interest are the internal cylindrical cavities formed by adjacent discs and the interaction of these with a central axial throughflow of cooling air.Tests were carried out for a range of non-dimensional parameters representative of high pressure compressor internal air system flows(Re up to 5×106 and Rez up to 2×105).Two different builds have been tested.The most significant difference between these two build configurations is the size of the annular gap between the(non-rotating) drive shaft and the bores of the discs.The heat transfer data were obtained from thermocouple measurements of surface temperature and a conduction solution method.The velocity measurements were made using a two component,LDA system.The heat transfer results from the discs show differences between the two builds.This is attributed to the wider annular gap allowing more of the throughflow to penetrate into the cavity.There are also significant differences between the radial distributions of tangential velocity in the two builds of the test rig.For the narrow annular gap,there is an increase of non-dimensional tangential velocity V/Ωr with radial location to solid body rotation V/Ωr=1.For the wider annular gap,the non-dimensional velocities show a decrease with radial location to solid body rotation.
Combustion modeling in a model combustor
L. Y. Jiang, I. Campbell, K. Su
2007, 22(5): 694-703.
Abstract:
The flow-field of a propane-air diffusion flame combustor with interior and exterior conjugate heat transfers was numerically studied.Results obtained from four combustion models,combined with the re-normalization group(RNG) k-ε turbulence model,discrete ordinates radiation model and enhanced wall treatment are presented and discussed.The results are compared with a comprehensive database obtained from a series of experimental measurements.The flow patterns and the recirculation zone length in the combustion chamber are accurately predicted,and the mean axial velocities are in fairly good agreement with the experimental data,particularly at downstream sections for all four combustion models.The mean temperature profiles are captured fairly well by the eddy dissipation(EDS),probability density function(PDF),and laminar flamelet combustion models.However,the EDS-finite-rate combustion model fails to provide an acceptable temperature field.In general,the flamelet model illustrates little superiority over the PDF model,and to some extent the PDF model shows better performance than the EDS model.
Experimental research on flat surface film cooling by TLC
XU Guo-qing, TIAN Ning, TAO Zhi, DING Shui-ting, LUO Xiang, DENG Hong-wu
2007, 22(5): 704-708.
Abstract:
The performance of flat surface film cooling with 30° film cooling holes along streamwise was experimentally investigated using thermal liquid crystal.The temperature fields of adiabatic wall and conductive wall were measured.The effects of blow ratio and rows on film cooling effectiveness and heat transfer coefficient was studied.The results show that:blow ratio is a main influential factor to the film cooling effectiveness,the film cooling effectiveness decreases with the increasing of blow ratio;the film cooling effectiveness of discrete holes fluctuate dramatically across the transverse section,and dead zone is prone to occur between two discrete holes.TLC technique can be successfully applied to reflect film cooling effectual area and cooling effect.
Influence of central outflow on flow and heat transfer in a pre-swirl rotor-stator system
LUO Xiang, XU Guo-qiang, CAI Yi, TAO Zhi, DING Shui-ting
2007, 22(5): 709-713.
Abstract:
The flow and heat transfer characteristics of a pre-swirl rotor-stator system with three pre-swirl angles(0°,15°and 30°) was analyzed experimentally.The maximum outflow rate from central hole was 10% of total outflow.The experimental results show that,when the central outflow rate is much less than total outflow,it has small effects on average Nu number of rotor surface,without considering the effects of central outflow on heat transfer.An increase of central outflow rate results in quick drop of static pressure near the center of stator.The rotating speed of rotor has different influence on static pressure of stator surface at different pre-swirl nozzles.
Experimental study on initial spray field of EBMC flame holder and the improvement in the numerical simulation of combustion
MA Wen-jie, ZHANG Yu, YANG Yang, FAN Wei-jun, YANG Mao-lin
2007, 22(5): 714-720.
Abstract:
An experimental study on initial spray field of edge blowing mixture curtain(EBMC) flame holder was conducted using a particle dynamics analyzer(PDA).The droplet diameter and velocity of the spray were measured downstream of the flame holder at different locations in static air.The feature of initial spray field was analyzed.The initial spray conditions for the numerical simulation of combustion was given based on the experimental results of initial spray field.The calculated results were compared with the experimental data and the empirical calculated data.The results indicate that the application of initial spray field experimental data to the numerical combustion simulation improves the calculated results of temperature distribution and combustion efficiency,and the improvement in the calculation of combustion efficiency is especially obvious.
Numerical simulation of flow field and heat transfer in two parallel plates with periodic transverse ribs
ZOU Jian-feng, GAO Ye, LIU Cong-lin
2007, 22(5): 721-727.
Abstract:
In order to investigate the flow pattern and heat transfer in two parallel plates with eight periodic transverse ribs,the standard k-ε turbulence model,RNG k-ε turbulence model and Realizable k-ε turbulence model incorporated in computational fluid dynamics software Fluent 6.2 were employed.With the same inflow conditions,the anticlockwise recirculation regions predicated by Realizable k-ε model between adjacent ribs are larger than those obtained from the other two models.It is found that the pressure coefficient and local Nusselt number along the heated surface begin to vary periodically after the second rib.Also,the distributions of local Nusselt number predicated by the three models along the seventh rib surface were compared with experimental data.All the turbulence models can simulate the change of local Nusselt number.Results presented in this paper can be a reference for engineering design and application.
Numerical simulation of airflow field of helicopter inlet cabin
XIE Yong-qi, YU Jian-zu, GAO Hong-xia, WANG Xian-wei
2007, 22(5): 728-732.
Abstract:
Seven improvement packages for inlet cabin were developed to resolve the problem of engine surge in a helicopter under the hovering flight conditions. Airflow field distribution of inlet cabin/intake was numerically studied for setting circular arc baffle in the inlet cabin and moving downward the lower lip of air inlet.And,unstructured grid and grid self-adaptive technology were applied for regional simulation discretion.The results indicate that local flow separation exists in the inlet cabin/intake for each package under the hovering flight conditions,and the airflow quality can be improved by setting baffle inside the cabin and changing the size of the lower lip of air inlet.Flight-test results show that the engine surge under hovering flight conditions can be prevented to ensure engine performance by using the above-specified methods.
Experimental research on a centimeter-scale micro combustor with vaporizing tube
XIONG Qing-rong, LEI Yu-bing, HUANG Guo-ping, LIANG De-wang
2007, 22(5): 733-738.
Abstract:
A micro combustor experimental and testing system was designed to learn the performance of centimeter-scale micro combustor with vaporizing tube,and also provide some technical data for subsequent design.Under room temperature and pressure,the performance of micro combustion combustor was tested,during which some data were made available,such as:resistance characteristic,weak extinction characteristic,combustion efficiency,specific volume calorific intensity and exit temperature distribution.
Potentials of manufacture and repair of nickel base turbine components used in aero engines and power plants by laser metal deposition and laser drilling
I. Kelbassa, K. Walther, L. Trippe, W. Meiners, C. Over
2007, 22(5): 739-748.
Abstract:
High pressure turbine(HPT) parts like blades and vanes with integrated cooling channels are challenging concerning overhaul and repair.So far damaged parts have to be replaced by the operator.The aim is to design and implement a refurbishment process chain to avoid scrapping of used parts.This process chain implies three different laser applications 1.Direct Laser Forming(DLF),2.Laser Metal Deposition(LMD) and 3.Laser Drilling(LD).The laser processing was extended in the last years towards application near materials like Nickel and Titanium base alloys.Concerning LMD and DLF the achieved results are investigated regarding macro and micro structure,hardness,defects(e.g.cracks,bonding defects,porosity) and contamination with atmospheric elements(e.g.O, N,C and H) are presented for Titanium alloys like Ti-6Al-4V,Ti-6246 and Ti-17 as well as for Nickel base alloys like Inconel 718 and Rene 80.Suitable process parameters are presented with the achieved static(tensile) and dynamic mechanical properties(HCF) and compared to those of heat treated raw materials.One innovative solution(manufacturing case) is to fabricate the small and complex shaped geometrical elements by LMD and/or DLF.By LMD these elements are built-up directly.With DLF the elements are manufactured separately in the DLF machine and connected by a subsequent joining technique with the large parts.With DLF small complex shaped parts like combustor swirlers,HPT blades and vanes with internal cooling channels are manufactured completely.LMD and DLF can be used in combination with subsequent LD.Depending on the application two different drilling techniques by dominant melt ejection-percussion drilling and trepanning-are classified and characterised.The drilling techniques are exemplarily presented for stainless steel and nickel base alloys(diameter 0.2~0.6 mm,aspect ratio<30,inclination up to 60°) using pulsed laser radiation(Nd:YAG,1064 nm,0.5~1 ms).The experimental results of coaxial process control,metallography and optical microscopy regarding hole depth and hole diameter as well as the thickness of recast are presented.
Research on impact damage of T300/BMP-316 composite laminates
WEN Wei-dong, CUI Hai-po, XU Ying
2007, 22(5): 749-754.
Abstract:
The experimental research of low speed impact damage has been carried out on composite laminates with different geometries and layer direction angle,and the impact process was simulated by the progressive damage method.The geometries of composite laminates have much effect on the impact damage projected area.The layer direction angle of composite laminates has little effect on the impact damage projected area,but it has influence on the impact damage figure.
A multi-stage hardening constitutive model considering mean stress relaxation
SHI Duo-qi, YANG Xiao-guang, WANG Yan-rong
2007, 22(5): 755-760.
Abstract:
In the framework of visco-plastic constitutive theory without yield condition,some assumptions dealing with internal variables,internal stress and different potential hardening of material were used to develop new evolutionary equation of internal variables.Based on the Bodner-Partom model,a two-stage hardening (TSH) model and a multi-stage hardening(MSH) model were established to improve the accuracy of modeling strain rate-dependent tension and cyclic visco-plasticity,especially for ratcheting.The TSH model improves the precision of modeling monotonic tension and cyclic hardening,while the MSH model has more capability of modeling cyclic mean stress relaxation and ratcheting under asymmetric loading condition.
Nonlinear panel flutter computation with subcycling and predict-correct scheme
LIU Zhan-sheng, ZHANG Yun-feng
2007, 22(5): 761-767.
Abstract:
Weak coupling scheme in fluid-structure interaction introduces lag error which results in divergence of computation.To eliminate the error and enhance computing efficiency,subcycling and predict-correct scheme were combined and applied to the supersonic nonlinear panel flutter problem.Dynamic response of the panel was simulated with finite element method,while the geometric nonlinear effect caused by large deflection of the panel was considered.The fluid flow disturbed by panel vibration was computed with Fluent,which has the ability to calculate the governing equations with geometry conservation law.It is demonstrated that the subcycling predict-correct scheme is able to eliminate the lag error of weak coupling and keep the long running time of computation stable.
Scan mode and its reconstruction algorithm for improving spatial resolution of 3D-ICT
WEI Dong-bo, FU Jian, LI Bin, ZHANG Lei
2007, 22(5): 768-772.
Abstract:
Spatial resolution improvement techniques for three dimensional industrial computed tomography(3D-ICT) have been researched in this paper.A cone-beam 3D-ICT scan mode was proposed to improve the spatial resolution by the quarter-detector offset.Its filter back-projection reconstruction algorithm based on the parallel beam rebin principle was deduced.Firstly this method acquires the two dimensional projection sequence by offsetting the detector center a quarter of the detector channel width with respect to the iso-center.Secondly it rebins these projects into parallel data.Finally it doubles the sampling frequency of parallel data with the symmetry between two projection view angles with an angle interval 180°.Computer simulation results prove the correction and the validity of this algorithm.Using this algorithm,the spatial resolution can be improved approximate 100% along the horizontal reconstruction direction.
Study on the creep behavior of model specimens of nickel-based single crystal air-cooled blades
QING Hua, JIANG He-fu, WEN Wei-dong, WU Chang-bo, SUN Jing-guo
2007, 22(5): 773-778.
Abstract:
Plate specimens were used to model turbine blades with cooling holes.Experimental and numerical study on the creep behavior of a second generation nickel-based single crystal alloy has been performed with these model specimens.The results of creep test at high temperature show that crystallographic orientations and cooling holes have noticeable influence on the creep life.Compared with that of the specimen without cooling holes,the creep life of specimen with cooling holes is lower for both and orientations.The cooling holes have larger influence on the creep life of orientation than that of orientation.The creep behavior under high temperature and low stress conditions of orientation is better than that of orientation.The finite element analysis(FEA) results reveal that the cooling holes change the stress distribution in the specimen and cause stress concentration near the holes,which results in the decrease of creep life.As the creep life obtained from FEA is accordant to the experimental result,it is reasonable to calculate the creep life using the simulation model based on the resolved slip stress.
Study on the stability and bifurcation of nonlinear rotor-seal system
YE Jian-huai, LIU Zhan-sheng
2007, 22(5): 779-784.
Abstract:
The bifurcations of a rigid rotor-seal system were studied in a relatively wide parameter range.The transition boundaries of the system were obtained and the effect of the degree of rotor imbalance,clearance of the seal and the pressure drop of the flow in the seal on the bifurcations characteristics of the system was analyzed with fast Galerkin method in combination with Floquet theory.The result shows that the rotor system may undergo period doubling or Hopf bifurcations caused by the fluid-induced vibration.In some typical parameter ranges,the bifurcation diagrams of the rotor-seal system are acquired with numerical integral method.The simulation result verifies the correctness of the transition boundaries.The result provides the theoretical base for qualitatively controlling the stable operating state of rotors.
Overall design study of micro-turbofan engine using single blisk of fan and compressor rotor
SHAN Peng, LAN Ke
2007, 22(5): 785-791.
Abstract:
The presented overall aero-thermodynamic cycle analysis and engine flight altitude-velocity performance simulation revealed that with a group of well compromised parameters,the micro-turbofan engines with today commonly used low pressure ratio is still efficient for a lower specific fuel consumption(SFC) than that of turbojet.Furthermore,to resolve the difficulties of complex structure in micro-turbofan engines,a newly conceived integral fan-compressor component with both high-low blades and splitter blades is claimed.The features of the aerodynamic design and structural design of the new type fan-compressor component are introduced briefly.Finally one of the principia overall structure design of this kind of turbofan engine was worked out.
Effect of component deterioration on turbofan engine performance
WANG Zhan-xue, LIU Zeng-wen, YE Xin-nong
2007, 22(5): 792-796.
Abstract:
The effect of component deterioration on engine performance is considerable.This influence can not be easily computed with normal engine steady performance computer program.A new mathematical method and computer program were developed to accurately compute the effect of component deterioration on engine performance.First,the mechanisms of the effect of component deterioration on engine performance were analyzed;then,statistical method was used to calculate this influence.Taking a turbofan engine as an example,the effect of component deterioration on engine performance,such as specific fuel consumption and temperature at turbine inlet was computed with this method,and compared with experimental data.The results indicate that the mathematical model in this paper can be used to compute the effect of component deterioration on engine performance.
Study and numerical calculation on the new design method for supersonic mixer of sloped lobed shape
HAN Dong, LI Yu-quan
2007, 22(5): 797-802.
Abstract:
According to the mixing feature of two supersonic flow streams,a new design method of supersonic mixer of sloped lobed shape was presented based on the concept of lobed nozzle.The principle of design is to achieve high efficient mixing at low flow loss.A finite volume method was used to solve the three dimensional compressible viscous Navier-Stokes equations,and the turbulence model was k-ε model.The numerical simulation for under-expansion,optimum-expansion and over-expansion situation has been completed.The calculated results show that the vortex and saddle-shape shock wave caused by the jet can improve the mixing efficiency at a special angle between the top of the inside passage and outside passage.The flow condition of the two supersonic flow streams in the mixer meets the design requirements.The result of under-expansion,optimum-expansion is satisfactory,but the result of over-expansion is not good enough.
Experimental investigation of the correlation between the inlet distortion and the rotating stall
ZHANG Jing-Xuan, TONG Zhi-Ting, NIE Chao-Qun
2007, 22(5): 803-807.
Abstract:
The effects of different circumferential total pressure distortion in inlet on the rotating stall of a three-stage low-speed axial flow compressor were investigated.Inlet total pressure distortion was created by the gauze mounted upstream of the rotor.Hot wires and high-frequency response transducers were used to capture the dynamic signals of unsteady flow.The experimental results show that the stall point will change not only with the number of the gauze but also with the position of the gauze.We also find that although the asymmetric flows caused by the inlet distortion initiate large-scale disturbance before the onset of rotating stall,the frequency of rotating stall is not altered.
Loss models and loss analysis of variable geometry radial inflow turbine
LIU Xiao-lan, GU Chuan-gang, Yang Bo, Wang Tong, XING Wei-dong, ZHANG Ji-zhong
2007, 22(5): 808-813.
Abstract:
Based on the experimental data of a 99 mm rotor,various losses and loss models of the stator of variable geometry radial inflow turbine(VGT) was analyzed.Also,a quantitative analysis was performed for the incidence loss in VGT's stator.When calculating the blade passage loss,Glassman loss model was proved to match the test results by calculating comparatively the boundary layer friction loss in blade row with different stator throat widths.The trailing-edge loss of radial inflow turbine stator was discussed based on the loss models of NASA,showing that the loss increases linearly with the trailing edge thickness.Thus,an efficient method of reducing trailing-edge loss is to cut down the trailing edge thickness.
Numerical simulation on cascade characteristics with slot from pressure surface to suction surface
CAO Chao-hui, WANG Ru-gen, ZHOU Min, WANG Qing-wei
2007, 22(5): 814-817.
Abstract:
The CFD method was used for the analysis of the cascade characteristics with and without slots.The computed results indicate that the cascade with slot can control and delay the separation of the boundary layer on the suction surface.This can facilitate the gas to turn greater angle,and decrease the total pressure loss together with the enlargement of the stable operating range.Compared with the cascade without slot,the surface load of cascade with slot increases near the leading edge and trailing edge and decreases at the slot inlet.
Tests on GH2/GO2 engine of 3-cell aerospike nozzle
WANG Chang-hui, LIU Yu, LIAO Yun-fei
2007, 22(5): 818-822.
Abstract:
Hot-firing tests were carried out on a 3-cell GH2/GO2 linear aerospike nozzle engine with round-to-rectangle primary nozzles.The primary nozzles and inner layer of the combustion chambers were made of ablation-resistant W-Cu alloy and the aerospike ramp was made of steel.Data measured in the tests and data analyses were presented.The aerospike nozzle performance and pressure at five locations along aerospike ramp were obtained under two NPR(nozzle pressure ratio),which is the ratio of combustion chamber pressure to ambient pressure.It is shown that test aerospike nozzle has good altitude compensability of thrust.High nozzle thrust efficiencies were yielded in the tests.Near NPR value of 50,nozzle efficiency was 92% to 93.5% and nozzle efficiency is 95% to 96% near NPR value of 350.Numerically predicted results are in good agreements with test data.
2D thermal environment numerical simulation of scramjets
ZHENG Li-ming, SUN Bing
2007, 22(5): 823-828.
Abstract:
The scramjet thermal environment was studied in this paper.The computational model for the scramjet thermal environment was established based on the two-dimensional N-S equation and one-dimensional Raleigh heating law.The simulation program was developed using MacCormark forecast-calibration scheme.Thermal environment of the scramjet with Mach 6 and Mach 8 was computed,the scramjet internal flow field temperature and wall heat flux distribution were gained.The analysis of the results shows that the combination of 2D no reaction flow field calculation and 1D heating law of the thermal environment research of scramjets are feasible and effective.
Investigation of state feedback control based on internal model principle for an turbo-shaft Engine
LI Sheng-quan, YANG Zheng-shan, SUN Jian-guo
2007, 22(5): 829-832.
Abstract:
A turbo-shaft engine FADEC system is subjected to the state feedback control mode.Based on the internal principle,a servo-compensator was introduced such that the control system could present strong robustness,and also eliminate steady state errors when tracking with commands.According to performance index,a states feedback controller was also designed to improve the performance of the control system.As compared with PID control method,the test results show an outstanding performance of the control system.
Study on fuzzy fault diagnosis of aero-engines
CAI Kai-long, XIE Shou-sheng, WU Yong
2007, 22(5): 833-837.
Abstract:
An algorithm of fault diagnosis based on T-S fuzzy model was proposed.In the algorithm,fuzzy rules were obtained from sample book data.The structure of fuzzy system is adaptively optimized when the parameters of fuzzy system are optimized.A method to determine fault diagnosis threshold was introduced.According to the airborne recorded aeroengine steady state data obtained during fixed time check,the algorithm was used to diagnose the turbofan engine fault.The results show that the algorithm can exactly diagnose some turbofan engine fault.This shows the feasibility of applying this algorithm to aeroengine fault diagnosis.
Traction calculation of a new aviation lubricating oil
DENG Si-er, TENG Hong-fei, WANG Yan-shuang, YANG Bo-yuan, MA Fu-jian
2007, 22(5): 838-842.
Abstract:
The traction of a new aviation lubricating oil was measured on a self-made test rig.The calculating formulae of the rheological parameters of the oil such as Erying characteristic stress,shear stress limit,and shear elastic modulus were given under the condition of the high shear rate in elasto-hydrodynamic lubrication.Then the constitutive equation of this oil was determined,and the calculating formulae of the oil traction was given and verified by test.The experimental results show that the behavior of new aviation lubricating oil behaves as the visco-elastic fluid,the calculated traction coefficients agree fairly well with the measured data.The method of the traction force calculation can be used to guide the lubrication analysis in engineering computation.
Analysis of tooth root bending stress for spiral bevel gears
LI Sheng-peng, FANG Zong-de, ZHANG Jin-liang, GUO Hui
2007, 22(5): 843-848.
Abstract:
Spiral bevel gear is an important transmission part in aero-engine,and the tooth root bending stress has direct effect on its natural life and safety.By using the analytical system of spiral bevel gear developed by the authors,the mesh grid models of spiral bevel gear were obtained.We use certain contact arithmetic of ANSYS to perform contact analysis of spiral bevel gear,and obtain the distributions and trend of variation of the tooth root bending stress.