Tip Clearance Flows in Turbine Cascades

This article describes the effects of some factors on the tip clearance flow in axial linear turbine cascades. The measurements of the total pressure loss coefficient are made at the cascade outlets by using a five-hole probe at exit Mach numbers of 0.10, 0.14 and 0.19. At each exit Mach number, experiments are performed at the tip clearance heights of 1.0%, 1.5%, 2.0%, 2.5% and 3.0% of the blade height. The effects of the non-uniform tip clearance height of each blade in the pitchwise direction are also studied. The results show that at a given tip clearance height, generally, total pressure loss rises with exit Mach numbers proportionally. At a fixed exit Mach number, the total pressure loss augments nearly proportionally as the tip clearance height increases. The increased tip clearance heights in the tip regions of two adjacent blades are to be blame for the larger clearance loss of the center blade. Compared to the effects of the tip clearance height, the effects of the exit Mach number and the pitchwise variation of the tip clearance height on the cascade total pressure loss are so less significant to be omitted.

Numerical Analysis of Nozzle Clearance's Effect on Turbine Performance

Variable nozzle turbine （VNT） has become a popular variable geometry turbine （VGT） technology for the diesel engine application. Nozzle clearance, which can＇t be avoided on the hub and shroud side of the VNT turbine due to the pivoting stators, can lead to turbine performance deterioration. However, its mechanism is still not clear. In this paper, numerical investigation, which is validated by experiment, is carried out to study the mechanism of the nozzle clearance＇s effect on the turbine performance. Firstly, performance of the mixed flow turbine with fixed nozzle clearances tested on flow bench. Performance of the tested turbine with the same nozzle clearance is numerically simulated. The numerical result agrees well with the test data, which proves correct of the numerical method. Then the turbine performance with different nozzle clearances is numerically analyzed. The research showed that with nozzle clearance, flow loss in the nozzle increases at first and it reaches the maximum value when the clearance ratio is 5%. Flow at the exit of the nozzle becomes less uniform with nozzle clearance. The negative incidence angle of the rotor also increases with nozzle clearance and leads to more incidence angle loss in the rotor. The low energy fluid formed in the nozzle due to the nozzle clearance migrates from hub to shroud side in the rotor, which is another main reason for the rotor＇s performance degradation. The present research exposed the mechanism of the dramatically decrease of the turbine performance with nozzle clearance： （a） The loss associated with the nozzle leakage increases with the nozzle clearance; （b） The flow loss grows up quickly in the rotor due to the incidence angle loss and migration of the low energy fluid from hub to shroud side.

Topology and Vortex Structures of Turbine Cascade with Different Tip Clearances

This paper uses the topology theory to analyze the surface flowspectrums of straight, positively curved and negatively curvedcascades with relative tip clearances of 0.023 and 0.036, findsapparent differences of topology and vortex structures in the bladetip and the suction side wall corner of single type of cascade withthis two clearances, and studies the mechanism of the differenceformation as well as their effects o the energy loss.

TOPOLOGY AND VORTEX STRUCTURES OF A CURVING TURBINE CASCADE WITH TIP CLEARANCE (Ⅰ)- EXPERIMENTAL MODEL AND TOPOLOGICAL FLOW PATTERNS ON BOTH ENDWALLS AND BLADE SURFACES

By means of ink trace visualization of the flows in conventional straight, positively curved and negatively curved cascades with tip clearance, and measurement of the aerodynamic parameters in the transverse section, and by appling topology theory, the structures on both endwalls and blade surfaces were analyzed. Compared with conventional straight cascade, blade positive curving eliminates the separation line of the upper passage vortex and leads the secondary vortex to change from close separation to open separation, while blade negative curving effects merely the positions of singular points and the intensities and scales of vortex.

TOPOLOGY AND VORTEX STRUCTURES OF A CURVING TURBINE CASCADE WITH TIP CLEARANCE (Ⅱ)- TOPOLOGICAL FLOW PATTERN AND VORTEX STRUCTURE IN THE TRANSVERSE SECTION OF A BLADE CASCADE

By means of ink trace visualization of the flows in conventional straight, positively curved and negatively curved cascades with tip clearance, and measurement of the aerodynamic parameters in transverse section, and by appling topology theory, the topological structures and vortex structure in the transverse section of a blade cascade were analyzed. Compared with conventional straight cascade, blade positive curving eliminates the separation line of the upper passage vortex, and leads the secondary vortex to change from close separation to open separation, while blade negative curving effects merely the positions of singular points and the intensities and scales of vortex.

Numerical and experimental investigation of leakage behavior at null position of high-pressure electro-pneumatic servo valve

The high-pressure electro-pneumatic servo valve(HESV)is a core element of the high-pressure pneumatic servo system.The annular clearance and the rounded corner of the spool-sleeve can cause the leakage at null position,thereby affecting high-precision control and stability of the servo system.This paper investigates the effects of the clearance structure on leakage behavior at null position of the HESV.A numerical approach was employed to evaluate the effects,and then a mathematical model was established to obtain the variation law of leakage flow rate at null position.The results indicate that the leakage flow rate at null position varies linearly with supply pressure and rounded corner radius,and is nonlinear as a quadratic concave function with annular clearance.The leakage flow rate of the annular clearance and the rounded corner varies with the valve opening in an invariable−nonlinear−linear trend.A test rig system of leakage behavior at null position of the HESV was built to confirm the validity of the numerical model,which agrees well with the conducted experimental study.

Reliability and sensitivity analyses of HPT blade-tip radial running clearance using multiply response surface model

To reasonably design the blade-tip radial running clearance(BTRRC) of high pressure turbine and improve the performance and reliability of gas turbine, the multi-object multi-discipline reliability sensitivity analysis of BTRRC was accomplished from a probabilistic prospective by considering nonlinear material attributes and dynamic loads. Firstly, multiply response surface model(MRSM) was proposed and the mathematical model of this method was established based on quadratic function. Secondly, the BTRRC was decomposed into three sub-components(turbine disk, blade and casing), and then the single response surface functions(SRSFs) of three structures were built in line with the basic idea of MRSM. Thirdly, the response surface function(MRSM) of BTRRC was reshaped by coordinating SRSFs. From the analysis, it is acquired to probabilistic distribution characteristics of input-output variables, failure probabilities of blade-tip clearance under different static blade-tip clearances δ and major factors impacting BTRRC. Considering the reliability and efficiency of gas turbine, δ=1.87 mm is an optimally acceptable option for rational BTRRC. Through the comparison of three analysis methods(Monte Carlo method, traditional response surface method and MRSM), the results show that MRSM has higher accuracy and higher efficiency in reliability sensitivity analysis of BTRRC. These strengths are likely to become more prominent with the increasing times of simulations. The present study offers an effective and promising approach for reliability sensitivity analysis and optimal design of complex dynamic assembly relationship.

Study on leakage flow characteristics of radial inflow turbines at rotor tip clearance

Tip clearance leakage flow in a radial inflow turbine rotor for microturbines under the stage environment is investigated using a three-dimensional viscous flow simulation. The results indicate that the scraping flow caused by relative motion between casing and rotor tip, and the pressure difference between pressure side and suction side at rotor tip, play important roles in tip clearance leakage flow. The more the rotor tip speed increases and tip clearance height decreases, the more the scraping effect acts. Though the leakage velocity of tip clearance at midsection and exducer regions changes less when the rotor rotational speed is changing, the distance between passage vortex and rotor suction side varies in evidence. Main leakage flow rate of tip clearance takes place at region of exducer tip and some seal configurations will be quite effective for cutting leakage flow if these configurations are arranged over midsection and exducer of the radial inflow rotor.

Active generalized predictive control of turbine tip clearance for aero-engines

Active control of turbine blade tip clearance continues to be a concern in design and control of gas turbines. Ever increasing demands for improved efficiency and higher operating temperatures require more stringent tolerances on turbine tip clearance. In this paper, a turbine tip clearance control apparatus and a model of turbine tip clearance are proposed; an implicit active generalized predictive control （GPC）, with auto-regressive （AR） error modification and fuzzy adjustment on control horizon, is presented, as well as a quantitative analysis method of robust per- turbation radius of the system. The active clearance control （ACC） of aero-engine turbine tip clear- ance is evaluated in a lapse-rate take-off transient, along with the comparative and quantitative analysis of the stability and robustness of the active tip clearance control system. The results show that the resultant active tip clearance control system with the improved GPC has favorable steadystate and dynamic performance and benefits of increased efficiency, reduced specific fuel consump- tion, and additional service life.

Numerical analysis for impacts of nozzle end-clearances on aerodynamic performance and forced response in a VNT turbine

It has been well known that nozzle end-clearances in a Variable Nozzle Turbine（VNT）are unfavorable for aerodynamic performance, especially at small openings, and efforts to further decrease size of the clearances are very hard due to thermal expansion. In this paper, both the different sizes of nozzle end-clearances and the various ratios of their distribution at the hub and shroud sides were modelled and investigated by performing 3D Computational Fluid Dynamics（CFD） and Finite Element Analysis（FEA） simulations with a code of transferring the aerodynamic pressure from the CFD results to the FEA calculations. It was found that increasing the size of the nozzle end-clearances divided equally at the hub and shroud sides deteriorates turbine efficiency and turbine wheel reliability, yet increases turbine flow capacity. And, when the total nozzle endclearances remain the same, varying nozzle end-clearances＇ distribution at the hub and shroud sides not only shifts operation point of a VNT turbine, but also affects the turbine wheel vibration stress.Compared with nozzle hub clearance, the shroud clearance is more sensitive to both aerodynamic performance and reliability of a VNT turbine. Consequently, a possibility is put forward to improve VNT turbine efficiency meanwhile decrease vibration stress by optimizing nozzle end-clearances＇ distribution.

New model-based method for aero-engine turbine blade tip clearance measurement

Active control of aero-engine turbine tip clearance is one of the best chances for engine performance uplift currently.To do that,the first requirement is real-time measurement of tip clearance in aero-engine working environment.However,turbine complexity makes it unlikely for tip clearance sensors to be loaded.In recognition of that,this paper proposed a model-based method for tip clearance measurement.Firstly,by considering previously wrongly neglected factors such as load deformation,a mathematical model to monitor dynamic tip clearance changes is built to improve calculation accuracy.Then,after clarifying the coupling relationship between engine models and tip clearance models,this paper builds a component-level mathematical model integrating dynamic characteristics of turbine tip clearance,which helps realize accurate measurement of tip clearance in working environment.How tip clearance affects turbine efficiency is studied afterwards and reported to aero-engine model,so as to mitigate performance difference between aero-engine model and real engines caused by turbine tip clearance.Lastly,by hardware-in-the-loop simulation,tip clearance model demonstrates 15.9%better accuracy than previously built models in terms of turbine centrifugal deformation calculation.As tip clearance measurement model takes averagely 0.34 ms in calculation,meeting the operation requirement,it proves to be an effective new way.

Experimental Investigations of the Three-DimensionalFlow in a Large Deflection Turbine Cascade with Tip Clearance

Results obtained from an experbontal study of the threedimensional flow survey within and exit of a large defiection linear turbine cascade are presented for a tip clearance levels of 0.08, 1.5, 3.0 percent of chord and compared with the help of boundary layer probes and that within and exit of a blade passage was done with a miniaturised five hole probe. End wall and blade tip surface static pressures were also obtained, in addition to flow visualisation studies. A strong horse-shoe vortex forms in front of the leading edge for zero clearance whereas this vortex does not appear for 3 percent clearance indicating that for large clearance the pressure forces have dominating infiuence than the viscous forces. In addition to normally known clearance vortex, a small tip separation vortex was noticed on the blade tip surface inside the tip gap. Due to the area contraction caused by the tip separation vortex, the fluid movign towards the tip gap from the pressure side is accelerated. Downstream of the vortex, the endwall pressure increases due to flow mixing. Both vortices increase in size and strength along the chord. The miring is incomplete in the aft portion of the blade. The tip gap velocity profiles exhibit wak like characteristics especially at axial positions where the mixing is incomplete. The passage vortex in the present investigations did not diminish with increase in clearance. The discharge coefhcient and the total pressure loss coefficient within the tip gap show similar tendency with lower values near the leading and trailing edge regions.

Effects of swirl and hot streak on thermal performances of a high-pressure turbine

Advanced civil aero-engines tend to adopt lean burn combustors to meet emission requirements.The exit of a lean burn combustor experiences highly non-uniformities in both temperature(Hot Streak,HS)and flow(swirl).This paper presents a numerical investigation on the behaviors of a High-Pressure(HP)turbine under a combined effect of swirl and hot streak.The investigation was conducted on a GE-E3 HP turbine with unsteady numerical simulations,which considered the realistic clocking position of the HP Nozzle Guide Vane(NGV)relative to the combustor.The influences of swirl orientations on the HS migration and thermal performances on the blade surface were examined.Results indicate that,inside the NGV passage,the swirl’s induced incidence angle effect dominates the HS radial migration.The transversal movement of HS follows the cross flow and thus makes itself approach the Suction Side(SS)and keep away from the Pressure Side(PS)as passing through the NGV,so that HS near the SS is more influenced by the incidence angle effect than that near the PS.As for the heat transfer,swirl affects the Heat Transfer Coefficient(HTC)on the NGV’s PS and SS mainly through the incidence angle effect.Different from the NGV,the inlet swirl and HS have limited effect on the HTC on the rotor blade’s PS,while on the rotor blade’s SS,the original vortex system dominates;therefore,the inlet non-uniformities merely enhance the HTC on the SS rather than alter its distribution characteristics.

Experimental Investigation of Aerodynamic Performance due to Blade Tip Clearance in a Gas Turbine Rotor Cascade

This study examines how the complex flow structure within a gas turbine rotor affects aerodynamic loss. An unshrouded linear turbine cascade was built, and velocity and pressure fields were measured using a 5-hole probe. In order to elucidate the effect of tip clearance, the overall aerodynamic loss was evaluated by varying the tip clearance and examining the total pressure field for each case. The tip clearance was varied from 0% to 4.2% of blade span and the chord length based Reynolds number was fixed at 2×10^(5). For the case without tip clearance, a wake downstream of the blade trailing edge is observed, along with hub and tip passage vortices. These flow structures result in profile loss at the center of the blade span, and passage vortex related losses towards the hub and tip. As the tip clearance increases, a tip leakage vortex is formed, and it becomes stronger and eventually alters the tip passage vortex. Because of the interference of the secondary tip leakage flow with the main flow, the streamwise velocity decreases while the total pressure loss increases significantly by tenfold in the last 30% blade span region towards the tip for the 4.2% tip clearance case. It was additionally observed that the overall aerodynamic loss increases linearly with tip clearance.

Flow Visualization and Topological Analysis of a Turbine Rotor Cascade with Tip Clearance

By means of ink trace visualization and topological allalysis, this paper investigates the topological structure of the flow pattern surrounding both endwalls and blade surfaces for a low aspect ratio linear rotor cascade with tip cIearance. The structure of the flow pattern shows that most of the singular points and separation lines are located in the upper half span region of the tested cascade where the aerodynamic behaviors are deteriorated.

3D modeling of transformation of gaseous pollutants in the high-pressure turbine of an aircraft engine

Aircraft emissions contribute to global climate change and regional air pollution near airports.Understanding the formation and the transformation of emissions in the aircraft engine is essential to properly quantify the environmental impact and air pollution.However,precise investigation of chemical process in the turbine is challenging because of the complexity of the transformation process in the complex flow relating to the moving blade at high temperature and high pressure.We present here,the first published model study of 3D chemical formations inside a high-pressure turbine and first time to compare three numerical solutions(1D,2D and 3D calculations)of transformation of trace species inside an aircraft engine.The model has simulated the evolution of principal precursor pollutant gases(NOx and SOx)and other species(hydrogen,oxygen species and carbon oxides).Our results also indicated strong dissimilarities in chemical transformations of 3D calculations.In comparing the three solutions,the results obtained showed that the difference of mole fractions of species can be under predicted by 75%between 1D and 2D calculations and in the comparison of 2D and 3D calculation,the under predicted difference may be 90%.

流线隧道式涡轮增压器转子动力学特性分析

为研究流线隧道式涡轮对涡轮增压器转子动力学特性的影响,将某型号车用涡轮增压器叶片式涡轮替换为流线隧道式涡轮,建立了密封流体激振、叶尖间隙激振和隧道涡轮轮缘间隙激振耦合条件下的转子系统模型,计算分析了涡轮材料和轮缘间隙对转子临界转速、稳态响应以及瞬态响应的影响。结果表明,K418高温合金隧道涡轮转子一阶临界转速大幅降低,稳态响应稳定性较好,但瞬态响应振动剧烈、失稳,表明隧道涡轮采用K418高温合金需要调整结构设计;SiC陶瓷隧道涡轮转子一阶临界转速下降、稳态响应振幅增加,但对转子稳定性影响不大,二阶临界转速有微小增加,稳态响应振幅下降,瞬态响应稳定性较佳。

凹槽叶顶的气膜冷却特性

涡轮工作时,叶顶间隙内高速高温的间隙泄露流会直接冲刷动叶顶部,产生局部高温区域,因此控制间隙泄露流至关重要。基于压敏漆涂料(PSP)实验,研究了密度比、吹风比和间隙高度对凹槽叶顶气膜冷却特性的影响。研究结果表明:密度比增大,凹槽叶顶气膜冷却效果逐渐提高,尤其是大间隙下冷效提高较为明显,叶顶面平均冷效增加了35%;间隙高度和吹风比对叶顶表面冷效的作用不是单一的,小间隙条件下,叶顶表面气膜冷效随着吹风比增大而增大,大间隙条件下,吹风比的增加使得叶顶表面气膜冷效先减小后增加,同时小吹风比时,间隙高度增加提高了叶顶尾缘区域和孔周围的气膜冷效,叶顶面平均冷效提高了6.85%。

涡轮导叶端壁安装间隙泄漏流气动特征数值模拟研究

为研究导叶端壁安装间隙泄漏流的影响,本文围绕某双级涡轮开展了数值研究,分析了导叶端壁有无间隙、间隙大小等因素对涡轮流场和性能的影响。结果表明,端壁安装间隙的泄漏流仅在后半段形成,前半段受通道内较大压力的影响形成主流入侵现象,主流入侵范围占间隙出口面积的44%以上;随间隙宽度的增大,主流入侵现象呈增强趋势,这必然使得端壁侧面面临极大的热负荷;泄漏流流出后卷起泄漏涡,并引起端区气流欠转,导致下游动叶负荷降低,且影响了动叶通道端区旋涡演化,其带来的涡轮级效率差异为0.41%~1.12%,总功率差异为0.38%~0.82%。

涡轮叶片裂纹方位角的三维叶尖间隙动态响应特性研究

针对叶尖定时故障诊断方法在检测叶片裂纹时仅关注一维信息、提取故障特征有限的不足,利用叶尖间隙具有三维特征的特点,提出了航空发动机涡轮叶-盘-轴耦合系统的三维叶尖间隙(3D-BTC)有限元模型。以该模型为基础,分析了航空发动机涡轮叶片裂纹方位角对三维叶尖间隙的影响规律。首先,建立了航空发动机涡轮叶-盘-轴耦合系统有限元模型;其次,在叶片尾缘处引入贯穿裂纹,通过瞬态动力学分析计算了在不同横滚角、俯仰角裂纹作用下叶片的变形;最后,采用三维叶尖间隙计算方法获取了叶片三维叶尖间隙时域波形及频谱,研究了航空发动机涡轮叶片裂纹方位角的三维叶尖间隙动态响应特性。计算结果表明:裂纹的出现会降低叶片刚度,从而影响叶片的三维叶尖间隙;叶片三维叶尖间隙随裂纹横滚角的增大而减小,随裂纹俯仰角的增大先减小后增大;随着裂纹两类方位角变化,不同测点位置的叶尖径向间隙基本谐波分量峰值变化率的差值最大为6.1%,周向滑移角和轴向偏转角基本谐波分量峰值变化率的差值小于0.12%,可见综合三维叶尖间隙能够更准确地反映裂纹信息。