Experimental studies of surface roughness shape and spacing effects on heat transfer and skin friction in supersonic and hypersonic flows

Author(s):  
M. HOLDEN
Author(s):  
Stephen T. McClain ◽  
B. Keith Hodge ◽  
Jeffrey P. Bons

The discrete-element method considers the total aerodynamic drag on a rough surface to be the sum of shear drag on the flat part of the surface and the form drag on the individual roughness elements. The total heat transfer from a rough surface is the sum of convection through the fluid on the flat part of the surface and the convection from each of the roughness elements. The discrete-element method has been widely used and validated for predicting heat transfer and skin friction for rough surfaces composed of sparse, ordered, and deterministic elements. Real gas-turbine surface roughness is different from surfaces with sparse, ordered, and deterministic roughness elements. Modifications made to the discrete-element roughness method to extend the validation to real gas-turbine surface roughness are detailed. Two rough surfaces found on high-hour gas-turbine blades were characterized using a Taylor-Hobson Form Talysurf Series 2 profilometer. Two rough surfaces and two elliptical-analog surfaces were generated for wind-tunnel testing using a three-dimensional printer. The printed surfaces were scaled to maintain similar boundary-layer thickness to roughness height ratio in the wind tunnel as found in gas-turbine operation. The results of the wind tunnel skin friction and Stanton number measurements and the discrete-element method predictions for each of the four surfaces are presented and discussed. The discrete-element predictions made considering the gas-turbine roughness modifications are within 7% of the experimentally-measured skin friction coefficients and are within 16% of the experimentally-measured Stanton numbers.


2005 ◽  
Vol 127 (5) ◽  
pp. 472-485 ◽  
Author(s):  
J. Bons

The application of Reynolds analogy 2St/cf≅1 for turbine flows is critically evaluated using experimental data collected in a low-speed wind tunnel. Independent measurements of St and cf over a wide variety of test conditions permit assessments of the variation of the Reynolds analogy factor (i.e., 2St/cf) with Reynolds number, freestream pressure gradient, surface roughness, and freestream turbulence. While the factor is fairly independent of Reynolds number, it increases with positive (adverse) pressure gradient and decreases with negative (favorable) pressure gradient. This variation can be traced directly to the governing equations for momentum and energy which dictate a more direct influence of pressure gradient on wall shear than on energy (heat) transfer. Surface roughness introduces a large pressure drag component to the net skin friction measurement without a corresponding mechanism for a comparable increase in heat transfer. Accordingly, the Reynolds analogy factor decreases dramatically with surface roughness (by as much as 50% as roughness elements become more prominent). Freestream turbulence has the opposite effect of increasing heat transfer more than skin friction, thus the Reynolds analogy factor increases with turbulence level (by up to 35% at a level of 11% freestream turbulence). Physical mechanisms responsible for the observed variations are offered in each case. Finally, synergies resulting from the combinations of pressure gradient and freestream turbulence with surface roughness are evaluated. With this added insight, the Reynolds analogy remains a useful tool for qualitative assessments of complex turbine flows where both heat load management and aerodynamic efficiency are critical design parameters.


2004 ◽  
Vol 126 (2) ◽  
pp. 259-267 ◽  
Author(s):  
Stephen T. McClain ◽  
B. Keith Hodge ◽  
Jeffrey P. Bons

The discrete element method considers the total aerodynamic drag on a rough surface to be the sum of shear drag on the flat part of the surface and the form drag on the individual roughness elements. The total heat transfer from a rough surface is the sum of convection through the fluid on the flat part of the surface and the convection from each of the roughness elements. The discrete element method has been widely used and validated for predicting heat transfer and skin friction for rough surfaces composed of sparse, ordered, and deterministic elements. Real gas turbine surface roughness is different from surfaces with sparse, ordered, and deterministic roughness elements. Modifications made to the discrete element roughness method to extend the validation to real gas turbine surface roughness are detailed. Two rough surfaces found on high-hour gas turbine blades were characterized using a Taylor-Hobson Form Talysurf Series 2 profilometer. Two rough surfaces and two elliptical-analog surfaces were generated for wind tunnel testing using a three-dimensional printer. The printed surfaces were scaled to maintain similar boundary layer thickness to roughness height ratio in the wind tunnel as found in gas turbine operation. The results of the wind tunnel skin friction and Stanton number measurements and the discrete element method predictions for each of the four surfaces are presented and discussed. The discrete element predictions made considering the gas turbine roughness modifications are within 7% of the experimentally measured skin friction coefficients and are within 16% of the experimentally measured Stanton numbers.


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