Wind-Tunnel Results of Advanced High-Speed Propellers at Takeoff, Climb, and Landing Mach Numbers

Low-speed wind-tunnel performance tests of two advanced propellers have been completed at the NASA Lewis Research Center as part of the NASA Advanced Turboprop Program. The 62.2 cm (24.5 in.) diameter adjustable-pitch models were tested at Mach numbers typical of takeoff, initial climbout, and landing speeds (i.e., from Mach 0.10 to 0.34) at zero angle of attack in the NASA Lewis 10 by 10 Foot Supersonic Wind Tunnel. Both models had eight blades and a cruise-design-point operating condition of Mach 0.80, and 10.668 km (35,000 ft) I.S.A. altitude, a 243.8 m/s (800 ft/sec) tip speed, and a high power loading of 301 kW/sq m (37.5 shp/sq ft). Each model had its own integrally designed area-ruled spinner, but used the same specially contoured nacelle. These features reduced blade-section Mach numbers and relieved blade-root choking at the cruise condition. No adverse or unusual low-speed operating conditions were found during the test with either the straight blade SR-2 or the 45 deg swept SR-3 propeller. Typical efficiencies of the straight and 45 deg swept propellers were 50.2 and 54.9 percent, respectively, at a takeoff condition of Mach 0.20 and 53.7 and 59.1 percent, respectively, at a climb condition of Mach 0.34

Model Engine Performance Measurement From Force Balance Instrumentation

A large scale model representative of a low-noise, high bypass ratio turbofan engine was tested for acoustics and performance in the NASA Lewis 9- by 15-Foot Low-Speed Wind Tunnel. This test was part of NASA's continuing Advanced Subsonic Technology Noise Reduction Program. The low tip speed fan, nacelle, and an un-powered core passage (with core inlet guide vanes) were simulated. The fan blades and hub are mounted on a rotating thrust and torque balance. The nacelle, bypass duct stators, and core passage are attached to a six component force balance. The two balance forces, when corrected for internal pressure tares, measure the total thrust-minus-drag of the engine simulator. Corrected for scaling and other effects, it is basically the same force that the engine supports would feel, operating at similar conditions. A control volume is shown and discussed, identifying the various force components of the engine simulator thrust and definitions of net thrust. Several wind tunnel runs with nearly the same hardware installed are compared, to identify the repeatability of the measured thrust-minus-drag. Other wind tunnel runs, with hardware changes that affected fan performance, are compared to the baseline configuration, and the thrust and torque effects are shown. Finally, a thrust comparison between the force balance and nozzle gross thrust methods is shown, and both yield very similar results

Effect of reduced aft diameter and increased blade number on high-speed counterrotation propeller performance

Performance data of 0.17-scale model counterrotation pusher propeller configurations were taken in the NASA Lewis 8- by 6-Foot Supersonic Wind Tunnel at Mach numbers of 0.66, 0.71, 0.75, and 0.79. These tests investigated the aerodynamic performance of the unducted fan (UDF) demonstrator propeller engine developed in a joint program by General Electric and NASA. Data were recorded to show the effect on counterrotation propeller cruise efficiency of two takeoff noise-reduction concepts. These two concepts are reduced aft blade diameter and increased forward blade number. The four configurations tested were a baseline (F1/A1 8/8) configuration, a reduced aft diameter (F1/A3 8/8) configuration, an increase forward blade number (F1/A1 9/8) configuration, and a combination of the latter two (F1/A3 9/8) configurations. Data were collected with a complex counterrotation propeller test rig via rotating thrust and torque balances and pressure instrumentation. Data comparisons documented the power differences between the baseline and the reduced aft diameter concepts. Performance comparisons to the baseline configuration showed that reducing the aft blade diameter reduced the net efficiency, and adding a blade to the front rotor increased the net efficiency. The combination of the two concepts showed only slightly lower net efficiency than the baseline configuration. It was also found that the counterrotation demonstrator propeller model (F7/A7 8/8) configuration outperformed the baseline (F1/A1 8/8) configuration

Experimental investigation of the subsonic high-altitude operation of the NASA Lewis 10- by 10-foot supersonic wind tunnel

An experimental investigation was conducted in the NASA Lewis 10- by 10-Foot Supersonic Wind Tunnel during subsonic tunnel operation in the aerodynamic cycle to determine the test section flow characteristics near the Advanced Turboprop Project propeller model plane of rotation. The investigation used an eight-probe pitot static flow survey rake to measure total and static pressures at two locations in the wind tunnel: the test section and the bellmouth section (upstream of the two-dimensional flexible-wall nozzle). A cone angularity probe was used to measure any flow angularity in the test section. The evaluation was conducted at tunnel Mach numbers from 0.10 to 0.35 and at three operating altitudes from 2,000 to 50,000 ft. which correspond to tunnel reference total pressures from 1960 to 245 psfa, respectively. The results of this experimental investigation indicate a total-pressure loss area in the center of the test section and a static-pressure gradient from the test section centerline to the wall. These total and static pressure differences were observed at all tunnel operating altitudes and diminished at lower tunnel velocities. The total-pressure loss area was also found in the bellmouth section, which indicates that the loss mechanism is not the tunnel flexible-wall nozzle. The flow in the test section is essentially axial since very small flow angles were measured. The results also indicate that a correction to the tunnel total and static pressures must be applied in order to determine accurate freestream conditions at the test section centerline

Comprehensive Report of Fan Performance From Duct Rake Instrumentation on 1.294 Pressure Ratio, 806 ft/sec Tip Speed Turbofan Simulator Models

A large scale model representative of an advanced ducted propulsor-type, low-noise, very high bypass ratio turbofan engine was tested for acoustics, aerodynamic performance, and off-design operability in the NASA Glenn 9- by 15-Foot Low-Speed Wind Tunnel. The test was part of NASA s Advanced Subsonic Technology Noise Reduction Program. The low tip speed fan, nacelle, and un-powered core passage were simulated. As might be expected, the effect of stall management casing treatment was a performance penalty. Reducing the recirculating flow at the fan tip reduced the penalty while still providing sufficient stall margin. Two fans were tested with the same aerodynamic design; one with graphite composite material, and the other with solid titanium. There were surprising performance differences between the two fans, though both blades showed some indication of transitional flow near the tips. Though the pressure and temperature ratios were low for this fan design, the techniques used to improve thermocouple measurement accuracy gave repeatable data with adiabatic efficiencies agreeing within 1 percent. The measured fan adiabatic efficiency at simulated takeoff conditions was 93.7 percent and matched the design intent

Takeoff/approach noise for a model counterrotation propeller with a forward-swept upstream rotor

A scale model of a counterrotating propeller with forward-swept blades in the forward rotor and aft-swept blades in the aft rotor (designated F39/A31) has been tested in the NASA Lewis 9- by 15-Foot Anechoic Wind Tunnel. This paper presents aeroacoustic results at a takeoff/approach condition of Mach 0.20. Laser Doppler velocimeter results taken in a plane between the two rotors are also included to quantify the interaction flow field. The intention of the forward-swept design is to reduce the magnitude of the forward rotor tip vortex and/or wakes which impinge on the aft rotor, thus lowering the interaction tone levels. A reference model propeller (designated F31/A31), having aft-swept blades in both rotors, was also tested. Aeroelastic performance of the F39/A31 propeller was disappointing. The forward rotor tip region tended to untwist toward higher effective blade angles under load. The forward rotor also exhibited steady state blade flutter at speeds and loadings well below the design condition. The noise results, based on sideline acoustic data, show that the interaction tone levels were up to 8 dB higher with the forward-swept design compared to those for the reference propeller at similar operating conditions, with these tone level differences extending down to lower propeller speeds where flutter did not occur. These acoustic results are for a poorly-performing forward-swept propeller. It is quite possible that a properly-designed forward-swept propeller would exhibit substantial interaction tone level reductions

The Effect of Bypass Nozzle Exit Area on Fan Aerodynamic Performance and Noise in a Model Turbofan Simulator

The design of effective new technologies to reduce aircraft propulsion noise is dependent on identifying and understanding the noise sources and noise generation mechanisms in the modern turbofan engine, as well as determining their contribution to the overall aircraft noise signature. Therefore, a comprehensive aeroacoustic wind tunnel test program was conducted called the Fan Broadband Source Diagnostic Test as part of the NASA Quiet Aircraft Technology program. The test was performed in the anechoic NASA Glenn 9- by 15-Foot Low Speed Wind Tunnel using a 1/5 scale model turbofan simulator which represented a current generation, medium pressure ratio, high bypass turbofan aircraft engine. The investigation focused on simulating in model scale only the bypass section of the turbofan engine. The test objectives were to: identify the noise sources within the model and determine their noise level; investigate several component design technologies by determining their impact on the aerodynamic and acoustic performance of the fan stage; and conduct detailed flow diagnostics within the fan flow field to characterize the physics of the noise generation mechanisms in a turbofan model. This report discusses results obtained for one aspect of the Source Diagnostic Test that investigated the effect of the bypass or fan nozzle exit area on the bypass stage aerodynamic performance, specifically the fan and outlet guide vanes or stators, as well as the farfield acoustic noise level. The aerodynamic performance, farfield acoustics, and Laser Doppler Velocimeter flow diagnostic results are presented for the fan and four different fixed-area bypass nozzle configurations. The nozzles simulated fixed engine operating lines and encompassed the fan stage operating envelope from near stall to cruise. One nozzle was selected as a baseline reference, representing the nozzle area which would achieve the design point operating conditions and fan stage performance. The total area change from the smallest to the largest nozzle was 12.9 percent of the baseline nozzle area. The results will show that there are significant changes in aerodynamic performance and farfield acoustics as the fan nozzle area is increased. The weight flow through the fan model increased between 7 and 9 percent, the fan and stage pressure dropped between 8 and 10 percent, and the adiabatic efficiency increased between 2 and 3 percent--the magnitude of the change dependent on the fan speed. Results from force balance measurements of fan and outlet guide vane thrust will show that as the nozzle exit area is increased the combined thrust of the fan and outlet guide vanes together also increases, between 2 and 3.5 percent, mainly due to the increase in lift from the outlet guide vanes. In terms of farfield acoustics, the overall sound power level produced by the fan stage dropped nearly linearly between 1 dB at takeoff condition and 3.5 dB at approach condition, mainly due to a decrease in the broadband noise levels. Finally, fan swirl angle survey and Laser Doppler Velocimeter mean velocity and turbulence data obtained in the fan wake will show that the swirl angles and turbulence levels within the wake decrease as the fan nozzle area increases, which helps to explain the drop in the fan broadband noise at all fan speeds

Fan Noise Source Diagnostic Test: Rotor Alone Aerodynamic Performance Results

The aerodynamic performance of an isolated fan or rotor alone model was measured in the NASA Glenn Research Center 9- by 15- Foot Low Speed Wind Tunnel as part of the Fan Broadband Source Diagnostic Test conducted at NASA Glenn. The Source Diagnostic Test was conducted to identify the noise sources within a wind tunnel scale model of a turbofan engine and quantify their contribution to the overall system noise level. The fan was part of a 1/5th scale model representation of the bypass stage of a current technology turbofan engine. For the rotor alone testing, the fan and nacelle, including the inlet, external cowl, and fixed area fan exit nozzle, were modeled in the test hardware; the internal outlet guide vanes located behind the fan were removed. Without the outlet guide vanes, the velocity at the nozzle exit changes significantly, thereby affecting the fan performance. As part of the investigation, variations in the fan nozzle area were tested in order to match as closely as possible the rotor alone performance with the fan performance obtained with the outlet guide vanes installed. The fan operating performance was determined using fixed pressure/temperature combination rakes and the corrected weight flow. The performance results indicate that a suitable nozzle exit was achieved to be able to closely match the rotor alone and fan/outlet guide vane configuration performance on the sea level operating line. A small shift in the slope of the sea level operating line was measured, which resulted in a slightly higher rotor alone fan pressure ratio at take-off conditions, matched fan performance at cutback conditions, and a slightly lower rotor alone fan pressure ratio at approach conditions. However, the small differences in fan performance at all fan conditions were considered too small to affect the fan acoustic performance

Advanced Subsonic Technology (AST) 22-Inch Low Noise Research Fan Rig Preliminary Design of ADP-Type Fan 3

This report presents results of the work completed on the preliminary design of Fan 3 of NASA s 22-inch Fan Low Noise Research project. Fan 3 was intended to build on the experience gained from Fans 1 and 2 by demonstrating noise reduction technology that surpasses 1992 levels by 6 dB. The work was performed as part of NASA s Advanced Subsonic Technology (AST) program. Work on this task was conducted in the areas of CFD code validation, acoustic prediction and validation, rotor parametric studies, and fan exit guide vane (FEGV) studies up to the time when a NASA decision was made to cancel the design, fabrication and testing phases of the work. The scope of the program changed accordingly to concentrate on two subtasks: (1) Rig data analysis and CFD code validation and (2) Fan and FEGV optimization studies. The results of the CFD code validation work showed that this tool predicts 3D flowfield features well from the blade trailing edge to about a chord downstream. The CFD tool loses accuracy as the distance from the trailing edge increases beyond a blade chord. The comparisons of noise predictions to rig test data showed that both the tone noise tool and the broadband noise tool demonstrated reasonable agreement with the data to the degree that these tools can reliably be used for design work. The section on rig airflow and inlet separation analysis describes the method used to determine total fan airflow, shows the good agreement of predicted boundary layer profiles to measured profiles, and shows separation angles of attack ranging from 29.5 to 27deg for the range of airflows tested. The results of the rotor parametric studies were significant in leading to the decision not to pursue a new rotor design for Fan 3 and resulted in recommendations to concentrate efforts on FEGV stator designs. The ensuing parametric study on FEGV designs showed the potential for 8 to 10 EPNdB noise reduction relative to the baseline

The Alternative Low Noise Fan

A 106 bladed fan with a design takeoff tip speed of 1100 ft/sec was hypothesized as reducing perceived noise because of the shift of the blade passing harmonics to frequencies beyond the perceived noise rating range. A 22 in. model of this Alternative Low Noise Fan, ALNF, was tested in the NASA Glenn 9x 15 Wind Tunnel. 'Me fan was tested with a 7 vane long chord stator assembly and a 70 vane conventional stator assembly in both hard and acoustically treated configurations. In addition a partially treated 7 vane configuration was tested wherein the acoustic material between the 7 long chord stators was made inactive. The noise data from the 106 bladed fan with 7 long chord stators in a hard configuration was shown to be around 4 EPNdB quieter than a low tip speed Allison fan at takeoff and around 5 EPNdB quieter at approach. Although the tone noise behaved as hypothesized, the majority of this noise reduction was from reduced broadband noise related to the large number of rotor blades. This 106 bladed ALNF is a research fan designed to push the technology limits and as such is probably not a practical device with present materials technology. However, a low tip speed fan with around 50 blades would be a practical device and calculations indicate that it could be 2 to 3 EPNdB quieter at takeoff and 3 to 4 EPNdB quieter at approach than the Allison fan. 7 vane data compared with 70 vane data indicated that the tone noise was controlled by rotor wake-stator interaction but that the broadband noise is probably controlled by the interaction of the rotor with incoming flows. A possible multiple pure tone noise reduction technique for a fan/acoustic treatment system was identified. The data from the fully treated configuration showed significant noise reductions over a large frequency range thereby providing a real tribute to this bulk absorber treatment design. The tone noise data with the partially treated 7 vane configuration indicated that acoustic material in the source noise generation region may be more effective than similar material outside of the generation region