An investigation of rotor tip leakage flows in the rear-block of a multistage compressor

John Richard Brossman, Purdue University

Abstract

An effective method to improve gas turbine propulsive efficiency is to increase the bypass ratio. With fan diameter reaching a practical limit, increases in bypass ratio can be obtained from reduced core engine size. Decreasing the engine core, results in small, high pressure compressor blading, and large relative tip clearances. At general rule of 1% reduction in compressor efficiency with a 1% increase in tip clearance, a 0.66% change in SFC indicates the entire engine is sensitive to high pressure compressor tip leakage flows. Therefore, further investigations and understanding of the rotor tip leakage flows can help to improve gas turbine engine efficiency. The objectives of this research were to investigate tip leakage flows through computational modeling, examine the baseline experimental steady-stage performance, and acquire unsteady static pressure, over-the rotor to observe the tip leakage flow structure. While tip leakage flows have been investigated in the past, there have been no facilities capable of matching engine representative Reynolds number and Mach number while maintaining blade row interactions, presenting a unique and original flow field to investigate at the Purdue 3-stage axial compressor facility. To aid the design of experimental hardware and determine the influence of clearance geometry on compressor performance, a computational model of the Purdue 3-stage compressor was investigated using a steady RANS CFD analysis. A cropped rotor and casing recess design was investigated to increase the rotor tip clearance. While there were small performance differences between the geometries, the tip leakage flow field was found independent of the design therefore designing future experimental hardware around a casing recess is valid. The largest clearance with flow margin past the design point was 4% tip clearance based on the computational model. The Purdue 3-stage axial compressor facility was rebuilt and setup for high quality, detailed flow measurements during this investigation. A detailed investigation and sensitivity analysis of the inlet flow field found the influence by the inlet total temperature profile was important to performance calculations. This finding was significant and original as previous investigations have been conducted on low-speed machines where there is minimal temperature rise. The steady state performance of the baseline 1.5% tip clearance case was outlined at design speed and three off-design speeds. The leakage flow from the rear seal, the inlet flow field and a thermal boundary condition over the casing was recorded at each operating point. Stage 1 was found to be the limiting stage independent of speed. Few datasets exist on multistage compressor performance with full boundary condition definitions, especially with off-design operating points presenting this as a unique dataset for CFD comparison. The detailed unsteady pressure measurements were conducted over Rotor 1 at design and a near-stall operating condition to characterize the leakage trajectory and position. The leakage flow initial point closer to the leading edge and trajectory angle increased at the higher loading condition. The over-the-rotor static pressure field on Rotor 1 indicated similar trends between the computational model and the leakage trajectory.

Degree

Ph.D.

Advisors

Key, Purdue University.

Subject Area

Aerospace engineering|Mechanical engineering

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