Rotor–Stator Interactions in a 2.5-Stage Axial Compressor—Part II: Impact of Aerodynamic Modeling on Forced Response

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Christoph Sanders ◽  
Marius Terstegen ◽  
Peter Jeschke ◽  
Harald Schoenenborn ◽  
Jan Philipp Heners
Keyword(s):  
Pressure Sensors ◽  
Axial Compressor ◽  
Forced Response ◽  
Correct Prediction ◽  
Nonlinear Frequency ◽  
Blade Vibration ◽  
Acoustic Modes ◽  
Flow Features ◽  
Sst Turbulence Model ◽  
Stress Prediction

Abstract The main objective of this study is the validation of numerical forced response predictions through experimental blade vibration measurements for higher order modes of a blade-integrated disk (blisk). To this end, a linearized and a nonlinear frequency domain CFD methods are used, as well as a tip timing measurement system. The focus is on the blade excitation by downstream vanes, in particular, because this study shows that the correct prediction of acoustic modes is of key importance in this case. The analysis of these modes is presented, both experimentally and numerically, in Part I of this publication. The grid independence study for the aerodynamic work on the blade surface conducted in this part shows a possible prediction uncertainty of more than 100% when a coarse grid is chosen. For the validation of the numerical setup, a study was performed using different turbulence and transition models. The results are compared to the measured performance map, to a 2D field traverse conducted with a pneumatic probe, and to data gained by unsteady pressure sensors mounted in the casing of the compressor. Flow features relevant for the prediction of blade stresses are best represented using the SST turbulence model in combination with the γ–ReΘ transition model. Nonlinear simulations with this setup are able to predict the blade stresses due to downstream excitation with an average difference of 23% compared to tip timing measurements. Single row linearized CFD methods have shown to be incapable of making a correct stress prediction when acoustic modes form a major part of the exciting mechanisms. In summary, this two-part publication proves the importance of acoustic rotor–stator interactions for blade vibrational stresses excited by downstream vanes in a state-of-the-art high-pressure compressor.

scholarly journals Detection of Rotor Forced Response Vibrations Using Stationary Pressure Transducers in a Multistage Axial Compressor

2015 ◽  
Vol 2015 ◽  
pp. 1-10 ◽  
Author(s):  
William L. Murray ◽  
Nicole L. Key
Keyword(s):  
Gas Turbines ◽  
Axial Compressor ◽  
Fast Response ◽  
Forced Response ◽  
Vibration Monitoring ◽  
Blade Vibration ◽  
Response Condition ◽  
Pressure Transducers ◽  
Forcing Function ◽  
Cross Covariance

Blade row interactions in turbomachinery can lead to blade vibrations and even high cycle fatigue. Forced response conditions occur when a forcing function (such as impingement of stator wakes) occurs at a frequency that matches the natural frequency of a blade. The objective of this research is to develop the data processing techniques needed to detect rotor blade vibration in a forced response condition from stationary fast-response pressure transducers to allow for detection of rotor vibration from transient data and lead to techniques for vibration monitoring in gas turbines. This paper marks the first time in the open literature that engine-order resonant response of an embedded bladed disk in a 3-stage intermediate-speed axial compressor was detected using stationary pressure transducers. Experiments were performed in a stage axial research compressor focusing on the embedded rotor of blisk construction. Fourier waterfall graphs from a laser tip timing system were used to detect the vibrations after applying signal processing methods to uncover these pressure waves associated with blade vibration. Individual blade response was investigated using cross covariance to compare blade passage pressure signatures through resonance. Both methods agree with NSMS data that provide a measure of the exact compressor speeds at which individual blades enter resonance.

scholarly journals Reduction of Unsteady Blade Loading by Beneficial Use of Vortical and Potential Disturbances in an Axial Compressor With Rotor Clocking

1998 ◽  
Vol 120 (4) ◽  
pp. 705-713 ◽  
Author(s):  
S. T. Hsu ◽  
A. M. Wo
Keyword(s):  
Large Scale ◽  
Axial Compressor ◽  
Leading Edge ◽  
Forced Response ◽  
Suction Surface ◽  
Blade Loading ◽  
Beneficial Use ◽  
Unsteady Loading ◽  
Vortical Disturbance ◽  
First Time

This paper demonstrates reduction of stator unsteady loading due to forced response in a large-scale, low-speed, rotor/stator/rotor axial compressor rig by clocking the downstream rotor. Data from the rotor/stator configuration showed that the stator response due to the upstream vortical disturbance reaches a maximum when the wake impinges against the suction surface immediately downstream of the leading edge. Results from the stator/rotor configuration revealed that the stator response due to the downstream potential disturbance reaches a minimum with a slight time delay after the rotor sweeps pass the stator trailing edge. For the rotor/stator/rotor configuration, with Gap1 = 10 percent chord and Gap2 = 30 percent chord, results showed a 60 percent reduction in the stator force amplitude by clocking the downstream rotor so that the time occurrence of the maximum force due to the upstream vortical disturbance coincides with that of the minimum force due to the downstream potential disturbance. This is the first time, the authors believe, that beneficial use of flow unsteadiness is definitively demonstrated to reduce the blade unsteady loading.

Characteristics of Stable Rotating Stall Cells in an Axial Compressor

2017 ◽  
Author(s):  
Adam R. Hickman ◽  
Scott C. Morris
Keyword(s):  
Flow Field ◽  
High Speed ◽  
Pressure Ratio ◽  
Pressure Sensors ◽  
Axial Compressor ◽  
Field Measurements ◽  
Rotating Stall ◽  
Flow Coefficient ◽  
Stable Operation ◽  
Double Phase

Flow field measurements of a high-speed axial compressor are presented during pre-stall and post-stall conditions. The paper provides an analysis of measurements from a circumferential array of unsteady shroud static pressure sensors during stall cell development. At low-speed, the stall cell approached a stable size in approximately two rotor revolutions. At higher speeds, the stall cell developed within a short amount of time after stall inception, but then fluctuated in circumferential extent as the compressor transiently approached a stable post-stall operating point. The size of the stall cell was found to be related to the annulus average flow coefficient. A discussion of Phase-Locked Average (PLA) statistics on flow field measurements during stable operation is also included. In conditions where rotating stall is present, flow field measurements can be Double Phase-Locked Averaged (DPLA) using a once-per-revolution (1/Rev) pulse and the period of the stall cell. The DPLA method provides greater detail and understanding into the structure of the stall cell. DPLA data indicated that a stalled compressor annulus can be considered to contained three main regions: over-pressurized passages, stalled passages, and recovering passages. Within the over-pressured region, rotor passages exhibited increased blade loading and pressure ratio compared to pre-stall values.

Blade Forcing Function and Aerodynamic Work Measurements in a High Speed Centrifugal Compressor With Inlet Distortion

2009 ◽  
Author(s):  
Albert Kammerer ◽  
Reza S. Abhari
Keyword(s):  
Failure Modes ◽  
Pressure Sensors ◽  
Forced Response ◽  
Blade Surface ◽  
Centrifugal Compressors ◽  
Flow Distortion ◽  
Unsteady Pressure ◽  
Inlet Distortion ◽  
Forcing Function ◽  
Work Distribution

Centrifugal compressors operating at varying rotational speeds, such as in helicopters or turbochargers, can experience forced response failure modes. The response of the compressors can be triggered by aerodynamic flow non-uniformities, such as with diffuser-impeller interaction or with inlet distortions. The work presented here addresses experimental investigations of forced response in centrifugal compressors with inlet distortions. This research is part of an ongoing effort to develop related experimental techniques and to provide data for validation of computational tools. In this work measurements of blade surface pressure and aerodynamic work distribution were addressed. A series of pressure sensors were designed and installed on rotating impeller blades and simultaneous measurements with blade-mounted strain gauges were performed under engine representative conditions. To the best knowledge of the authors, this is the first publication which presents comprehensive experimental unsteady pressure measurements during forced response for highspeed radial compressors. Experimental data were obtained for both resonance and off-resonance conditions with uniquely tailored inlet distortion. This paper covers aspects relating to the design of fast response pressure sensors and their installation on thin impeller blades. Additionally, sensor properties are outlined with a focus on calibration and measurement uncertainty estimations. The second part of this paper presents unsteady pressure results taken for a number of inlet distortion cases. It will be shown that the intended excitation order due to inlet flow distortion is of comparable magnitude to the second and third harmonics which are consistently observed in all measurements. Finally, an experimental method will be outlined that enables the measurement aerodynamic work on the blade surface during resonant crossing. This approach quantifies the energy exchange between the blade and the flow in terms of cyclic work along the blade surface. The phase angle between the unsteady pressure and the blade movement will be shown to determine the direction of energy transfer between the blade and the fluid.

Double Scroll Turbine for Automotive Applications: Engine Operating Point Versus Dynamic Blade Stress From Forced Response Vibration

2018 ◽  
Author(s):  
David Hemberger ◽  
Roberto De Santis ◽  
Dietmar Filsinger
Keyword(s):  
Pulse Energy ◽  
Internal Combustion Engines ◽  
Forced Response ◽  
Operating Conditions ◽  
Blade Vibration ◽  
Structural Dynamic ◽  
Vibration Excitation ◽  
Engine Combustion ◽  
Operating Points ◽  
Combustion Cycle

As a means of meeting ever increasing emissions and fuel economy demands car manufacturers are using aggressive engine downsizing. To maintain the power output of the engine turbocharging is typically used. Compared to Mono scroll turbines, with a multi-entry system the individual volute sizing can be better matched to the single mass flow pulse from the engine cylinders. The exhaust pulse energy can be better utilised by the turbocharger turbine improving turbocharger response. Additionally the interaction of the engine exhaust pulses can be better avoided, improving the scavenging of the engine. Besides the thermodynamic advantages, the multi-entry turbine represents a challenge to the structural dynamic design of the turbine. A higher number of turbine wheel resonance points can be expected during operation. In addition, the increased use of exhaust pulse energy leads to a distinct accentuation of the blade vibration excitation. Using validated engine models, the interaction of the multi-entry turbine with the engine has been analyzed and various operating points, which may be critical for the blade vibration excitation, have been classified. These operating points deliver the input variables for unsteady computational flow dynamics (CFD) analyses. From these calculations unsteady blade forces were derived providing the necessary boundary conditions for the structural dynamic analyses by spatially and temporally high-resolved absolute pressures on the turbine surface. Goal of the investigation is to identify critical operating conditions. Important is also to investigate the effect of a scroll connection valve on blade excitation. The investigations utilize validated tools that were introduced and successfully applied to several turbine types in a series of publications over recent years. It can be stated that the engine operating condition and the admission type significantly influence the forced response reaction of the blade to the different excitation orders (EO). In case of equal admission even (or multiples of two) EOs generate the largest dynamic blade stress as can be expected due to the two turbine inlet segments. This reaction also increases with the engine speed. In the case of unequal admission, the odd EOs produce the largest forced response reaction. The maximum dynamic blade stress occurs in the region where the scroll connection is just closed. Above all, the scroll connection valve influences the Beta value and thus the basic behavior — unequal or equal admission. It has been possible to reconstruct the forced response behavior of the turbine blade within an engine combustion cycle. For the first time it could be shown for a double scroll application that there is a significant dynamic blade stress change dependent on the engine crankshaft angle. Certainly, due to the inertia of the mass and damping (mass, structure, flow), the blade will not exactly follow the predicted course. However, it is clear that the transient processes within an engine combustion cycle will affect the dynamic blade stress. This applies to the turbine wheels investigated in the work at hand with low damping, high eigenfrequencies and the considered internal combustion engines — as they are typically used in the passenger car sector.

scholarly journals Determination of Aerodynamic Damping at High Reduced Frequencies

2018 ◽  
Author(s):  
Minghao Pan ◽  
Paul Petrie-Repar ◽  
Hans Mårtensson ◽  
Tianrui Sun ◽  
Tobias Gezork
Keyword(s):  
Acoustic Resonance ◽  
Forced Response ◽  
Economic Consequences ◽  
Navier Stokes ◽  
Flow Solver ◽  
Aerodynamic Damping ◽  
Acoustic Modes ◽  
Reduced Frequency ◽  
Standard Configuration

In turbomachines, forced response of blades is blade vibrations due to external aerodynamic excitations and it can lead to blade failures which can have fatal or severe economic consequences. The estimation of the level of vibration due to forced response is dependent on the determination of aerodynamic damping. The most critical cases for forced response occur at high reduced frequencies. This paper investigates the determination of aerodynamic damping at high reduced frequencies. The aerodynamic damping was calculated by a linearized Navier-Stokes flow solver with exact 3D non-reflecting boundary conditions. The method was validated using Standard Configuration 8, a two-dimensional flat plate. Good agreement with the reference data at reduced frequency 2.0 was achieved and grid converged solutions with reduced frequency up to 16.0 were obtained. It was concluded that at least 20 cells per wavelength is required. A 3D profile was also investigated: an aeroelastic turbine rig (AETR) which is a subsonic turbine case. In the AETR case, the first bending mode with reduced frequency 2.0 was studied. The 3D acoustic modes were calculated at the far-fields and the propagating amplitude was plotted as a function of circumferential mode index and radial order. This plot identified six acoustic resonance points which included two points corresponding to the first radial modes. The aerodynamic damping as a function of nodal diameter was also calculated and plotted. There were six distinct peaks which occurred in the damping curve and these peaks correspond to the six resonance points. This demonstrates for the first time that acoustic resonances due to higher order radial acoustic modes can affect the aerodynamic damping at high reduced frequencies.

scholarly journals Aeromechanical Analysis of a Complete Wind Turbine Using Nonlinear Frequency Domain Solution Method

2020 ◽  
Author(s):  
Shine Win Naung ◽  
Mohammad Rahmati ◽  
Hamed Farokhi
Keyword(s):  
Wind Turbine ◽  
Frequency Domain ◽  
Solution Method ◽  
Computational Cost ◽  
Turbine Rotor ◽  
Forced Response ◽  
High Fidelity ◽  
Nonlinear Frequency ◽  
Cfd Method ◽  
Turbine Model

Abstract The high-fidelity computational fluid dynamics (CFD) simulations of a complete wind turbine model usually require significant computational resources. It will require much more resources if the fluid-structure interactions between the blade and the flow are considered, and it has been the major challenge in the industry. The aeromechanical analysis of a complete wind turbine model using a high-fidelity CFD method is discussed in this paper. The distinctiveness of this paper is the application of the nonlinear frequency domain solution method to analyse the forced response and flutter instability of the blade as well as to investigate the unsteady flow field across the wind turbine rotor and the tower. This method also enables the aeromechanical simulations of wind turbines for various inter blade phase angles in a combination with a phase shift solution method. Extensive validations of the nonlinear frequency domain solution method against the conventional time domain solution method reveal that the proposed frequency domain solution method can reduce the computational cost by one to two orders of magnitude.

On the Application of Frequency-Domain Methods to Multistage Turbomachinery

2015 ◽  
Author(s):  
Laura Junge ◽  
Graham Ashcroft ◽  
Peter Jeschke ◽  
Christian Frey
Keyword(s):  
Frequency Domain ◽  
Time Domain ◽  
Harmonic Balance ◽  
Axial Compressor ◽  
Harmonic Balance Method ◽  
Nonlinear Frequency ◽  
Solution Quality ◽  
Multi Stage ◽  
Frequency Domain Methods ◽  
Blade Row

Due to the relative motion between adjacent blade rows the aerodynamic flow fields within turbomachinery are normally dominated by deterministic, periodic phenomena. In the numerical simulation of such unsteady flows (nonlinear) frequency-domain methods are therefore attractive as they are capable of fully exploiting the given spatial and temporal periodicity, as well as capturing or modelling flow nonlinearity. Central to the efficiency and accuracy of such frequency-domain methods is the selection of the frequencies and the circumferential modes to be resolved in simulations. Whilst trivial in the context of the simulation of a single compressor- or turbine-stage, the choice of solution modes becomes substantially more involved in multi-stage configurations. In this work the importance of mode scattering, in the context of the unsteady aerodynamic field, is investigated and quantified. It is shown that scattered modes can substantially impact the unsteady flow field and are essential for the accurate modelling of wake propagation within multistage configurations. Furthermore, an iterative approach is outlined, based on the spectral analysis of the circumferential modes at the interfaces between blade rows, to identify the dominant solution modes that should be resolved in the adjacent blade row. To demonstrate the importance of mode scattering and validate the approach for their identification the unsteady blade row interaction within a 4.5 stage axial compressor is computed using both the harmonic balance method and, based on a full annulus midspan simulation, a time-domain method. Through the inclusion of scattered modes it is shown that the solution quality of the harmonic balance results is comparable to that of the nonlinear time-domain simulation.

Prediction of Aerodynamically Induced Blade Vibrations in a Radial Turbine Rotor Using the Nonlinear Harmonic Approach

2018 ◽  
Author(s):  
Nikola Kovachev ◽  
Christian U. Waldherr ◽  
Jürgen F. Mayer ◽  
Damian M. Vogt
Keyword(s):  
Structural Model ◽  
Measurement Data ◽  
Turbine Rotor ◽  
Forced Response ◽  
Response Analysis ◽  
Blade Vibration ◽  
Computational Costs ◽  
Alternative Approach ◽  
Turbomachinery Blades ◽  
Predicted Values

Resonant response of turbomachinery blades can lead to high cycle fatigue (HCF) if the vibration amplitudes are excessive. Accurate and reliable simulations of the forced response phenomenon require detailed CFD and FE models that may consume immense computational costs. In the present study, an alternative approach is applied, which incorporates nonlinear harmonic (NLH) CFD simulations in a one-way fluid-structure interaction (FSI) workflow for the prediction of the forced response phenomenon at reduced computational costs. Five resonance crossings excited by the stator in a radial inflow turbocharger turbine are investigated and the aerodynamic excitation and damping are predicted using this approach. Blade vibration amplitudes are obtained from a subsequent forced response analysis combining the aerodynamic excitation with aerodynamic damping and a detailed structural model of the investigated turbine rotor. A comparison with tip timing measurement data shows that all predicted values lay within the range of the mistuned blade response underlining the high quality of the utilized workflow.

Acoustic Resonance in an Axial Multistage Compressor Leading to Non-Synchronous Blade Vibration

2020 ◽  
Author(s):  
Anne-Lise Fiquet ◽  
Agathe Vercoutter ◽  
Nicolas Buffaz ◽  
Stéphane Aubert ◽  
Christoph Brandstetter
Keyword(s):  
Acoustic Waves ◽  
High Speed ◽  
Numerical Study ◽  
Acoustic Resonance ◽  
Structural Vibration ◽  
Wave Number ◽  
Blade Vibration ◽  
Acoustic Modes ◽  
Blade Vibrations ◽  
Circumferential Wave

Abstract Significant non-synchronous blade vibrations (NSV) have been observed in an experimental three-stage high-speed compressor at part-speed conditions. High amplitude acoustic modes, propagating around the circumference and originating in the highly loaded Stage-3 have been observed in coherence with the structural vibration mode. In order to understand the occurring phenomena, a detailed numerical study has been carried out to reproduce the mechanism. Unsteady full annulus RANS simulations of the whole setup have been performed using the solver elsA. The results revealed the development of propagating acoustic modes which are partially trapped in the annulus and are in resonance with an aerodynamic disturbance in Rotor-3. The aerodynamic disturbance is identified as an unsteady separation of the blade boundary layer in Rotor-3. The results indicate that the frequency and phase of the separation adapt to match those of the acoustic wave, and are therefore governed by acoustic propagation conditions. Furthermore, the simulations clearly show the modulation of the propagating wave with the rotor blades, leading to a change of circumferential wave numbers while passing the blade row. To analyze if the effect is self-induced by the blade vibration, a noncoherent structural mode has been imposed in the simulations. Even at high vibration amplitude the formerly observed acoustic mode did not change its circumferential wave number. This phenomenon is highly relevant to modern compressor designs, since the appearance of the axially propagating acoustic waves can excite blade vibrations if they coincide with a structural eigenmode, as observed in the presented experiments.

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