Corner Flow Control in High Through-Flow Axial Commercial Fan/Booster Using Blade 3-D Optimization

This study is aimed at using blade 3-D optimization to control corner flows in the high through-flow fan/booster of a high bypass ratio commercial turbofan engine. Two kinds of blade 3-D optimization, end-bending and bow, are focused on. On account of the respective operation mode and environment, the approach to 3-D aerodynamic modeling of rotor blades is different from stator vanes. Based on the understanding of the mechanism of the corner flow and the consideration of intensity problem for rotors, this paper uses a variety of blade 3-D optimization approaches, such as loading distribution optimization, perturbation of departure angles and stacking-axis manipulation, which are suitable for rotors and stators respectively. The obtained 3-D blades and vanes can improve the corner flow features by end-bending and bow effects. The results of this study show that flows in corners of the fan/booster, such as the fan hub region, the tip and hub of the vanes of the booster, are very complex and dominated by 3-D effects. The secondary flows there are found to have a strong detrimental effect on the compressor performance. The effects of both end-bending and bow can improve the flow separation in corners, but the specific ways they work and application scope are somewhat different. Redesigning the blades via blade 3-D optimization to control the corner flow has effectively reduced the loss generation and improved the stall margin by a large amount.