Conceptual Design of a Two Spool Compressor for the NASA Large Civil Tilt Rotor Engine

This paper focuses on the conceptual design of a two spool compressor for the NASA Large Civil Tilt Rotor engine, which has a design-point pressure ratio goal of 30:1 and an inlet weight flow of 30.0 lbm/sec. The compressor notional design requirements of pressure ratio and low-pressure compressor (LPC) and high pressure ratio compressor (HPC) work split were based on a previous engine system study to meet the mission requirements of the NASA Subsonic Rotary Wing Projects Large Civil Tilt Rotor vehicle concept. Three mean line compressor design and flow analysis codes were utilized for the conceptual design of a two-spool compressor configuration. This study assesses the technical challenges of design for various compressor configuration options to meet the given engine cycle results. In the process of sizing, the technical challenges of the compressor became apparent as the aerodynamics were taken into consideration. Mechanical constraints were considered in the study such as maximum rotor tip speeds and conceptual sizing of rotor disks and shafts. The rotor clearance-to-span ratio in the last stage of the LPC is 1.5% and in the last stage of the HPC is 2.8%. Four different configurations to meet the HPC requirements were studied, ranging from a single stage centrifugal, two axi-centrifugals, and all axial stages. Challenges of the HPC design include the high temperature (1,560deg R) at the exit which could limit the maximum allowable peripheral tip speed for centrifugals, and is dependent on material selection. The mean line design also resulted in the definition of the flow path geometry of the axial and centrifugal compressor stages, rotor and stator vane angles, velocity components, and flow conditions at the leading and trailing edges of each blade row at the hub, mean and tip. A mean line compressor analysis code was used to estimate the compressor performance maps at off-design speeds and to determine the required variable geometry reset schedules of the inlet guide vane and variable stators that would result in the transonic stages being aerodynamically matched with high efficiency and acceptable stall margins based on user specified maximum levels of rotor diffusion factor and relative velocity ratio

Heat Transfer in a Superelliptic Transition Duct

Local heat transfer measurements were experimentally mapped using a transient liquid-crystal heat transfer technique on the surface of a circular-to-rectangular transition duct. The transition duct had a length-to-diameter ratio of 1.5 and an exit-plane aspect ratio of 3. The crosssectional geometry was defined by the equation of a superellipse. The cross-sectional area was the same at the inlet and exit but varied up to 15 percent higher through the transition. The duct was preheated to a uniform temperature (nominally 64 C) before allowing room temperature air to be suddenly drawn through it. As the surface cooled, the resulting isothermal contours on the duct surface were revealed using a surface coating of thermochromic liquid crystals that display distinctive colors at particular temperatures. A video record was made of the surface temperature and time data for all points on the duct surfaces during each test. Using this surface temperature-time data together with the temperature of the air flowing through the model and the initial temperature of the model wall, the heat transfer coefficient was calculated by employing the classic one-dimensional, semi-infinite wall heat transfer conduction model. Test results are reported for inlet diameter-based Reynolds numbers ranging from 0.4x106 to 2.4x106 and two grid-generated freestream turbulence intensities of about 1 percent, which is typical of wind tunnels, and up to 16 percent, which may be more typical of real engine conditions

Effects of Gas Turbine Component Performance on Engine and Rotary Wing Vehicle Size and Performance

In support of the Fundamental Aeronautics Program, Subsonic Rotary Wing Project, further gas turbine engine studies have been performed to quantify the effects of advanced gas turbine technologies on engine weight and fuel efficiency and the subsequent effects on a civilian rotary wing vehicle size and mission fuel. The Large Civil Tiltrotor (LCTR) vehicle and mission and a previous gas turbine engine study will be discussed as a starting point for this effort. Methodology used to assess effects of different compressor and turbine component performance on engine size, weight and fuel efficiency will be presented. A process to relate engine performance to overall LCTR vehicle size and fuel use will also be given. Technology assumptions and levels of performance used in this analysis for the compressor and turbine components performances will be discussed. Optimum cycles (in terms of power specific fuel consumption) will be determined with subsequent engine weight analysis. The combination of engine weight and specific fuel consumption will be used to estimate their effect on the overall LCTR vehicle size and mission fuel usage. All results will be summarized to help suggest which component performance areas have the most effect on the overall mission

Gas Turbine Characteristics for a Large Civil Tilt-Rotor (LCTR)

In support of the Fundamental Aeronautics Program, Subsonic Rotary Wing Project; an engine system study has been undertaken to help define and understand some of the major gas turbine engine parameters required to meet performance and weight requirements as defined by earlier vehicle system studies. These previous vehicle studies will be reviewed to help define gas turbine performance goals. Assumptions and analysis methods used will be described. Performance and weight estimates for a few conceptual gas turbine engines meeting these requirements will be given and discussed. Estimated performance for these conceptual engines over a wide speed variation (down to 50 percent power turbine rpm at high torque) will be presented. Finally, areas needing further effort will be suggested and discussed

DBD Plasma Actuators for Flow Control in Air Vehicles and Jet Engines - Simulation of Flight Conditions in Test Chambers by Density Matching

Dielectric Barrier Discharge (DBD) Plasma actuators for active flow control in aircraft and jet engines need to be tested in the laboratory to characterize their performance at flight operating conditions. DBD plasma actuators generate a wall-jet electronically by creating weakly ionized plasma, therefore their performance is affected by gas discharge properties, which, in turn, depend on the pressure and temperature at the actuator placement location. Characterization of actuators is initially performed in a laboratory chamber without external flow. The pressure and temperature at the actuator flight operation conditions need to be simultaneously set in the chamber. A simplified approach is desired. It is assumed that the plasma discharge depends only on the gas density, while other temperature effects are assumed to be negligible. Therefore, tests can be performed at room temperature with chamber pressure set to yield the same density as in operating flight conditions. The needed chamber pressures are shown for altitude flight of an air vehicle and for jet engines at sea-level takeoff and altitude cruise conditions. Atmospheric flight conditions are calculated from standard atmosphere with and without shock waves. The engine data was obtained from four generic engine models; 300-, 150-, and 50-passenger (PAX) aircraft engines, and a military jet-fighter engine. The static and total pressure, temperature, and density distributions along the engine were calculated for sea-level takeoff and for altitude cruise conditions. The corresponding chamber pressures needed to test the actuators were calculated. The results show that, to simulate engine component flows at in-flight conditions, plasma actuator should be tested over a wide range of pressures. For the four model engines the range is from 12.4 to 0.03 atm, depending on the placement of the actuator in the engine. For example, if a DBD plasma actuator is to be placed at the compressor exit of a 300 PAX engine, it has to be tested at 12.4 atm for takeoff, and 6 atm for cruise conditions. If it is to be placed at the low-pressure turbine, it has to be tested at 0.5 and 0.2 atm, respectively. These results have implications for the feasibility and design of DBD plasma actuators for jet engine flow control applications. In addition, the distributions of unit Reynolds number, Mach number, and velocity along the engine are provided. The engine models are non-proprietary and this information can be used for evaluation of other types of actuators and for other purposes

Heat Transfer in Conical Corner and Short Superelliptical Transition Ducts

Local surface heat transfer measurements were experimentally mapped using a transient liquid-crystal heat-transfer technique on the surface of two circular-to-rectangular transition ducts. One has a transition cross section defined by conical corners (Duct 1) and the other by an elliptical equation with changing coefficients (Duct 2). Duct 1 has a length-to-diameter ratio of 0.75 and an exit plane aspect ratio of 1.5. Duct 2 has a length-to-diameter ratio of 1.0 and an exit plane aspect ratio of 2.9. Test results are reported for various inlet-diameter-based Reynolds numbers ranging from 0.45 106 to 2.39 106 and two freestream turbulence intensities of about 1 percent, which is typical of wind tunnels, and up to 16 percent, which may be more typical of real engine conditions

Measurements and computational analysis of heat transfer and flow in a simulated turbine blade internal cooling passage

Visual and quantitative information was obtained on heat transfer and flow in a branched-duct test section that had several significant features of an internal cooling passage of a turbine blade. The objective of this study was to generate a set of experimental data that could be used to validate computer codes for internal cooling systems. Surface heat transfer coefficients and entrance flow conditions were measured at entrance Reynolds numbers of 45,000, 335,000, and 726,000. The heat transfer data were obtained using an Inconel heater sheet attached to the surface and coated with liquid crystals. Visual and quantitative flow field results using particle image velocimetry were also obtained for a plane at mid channel height for a Reynolds number of 45,000. The flow was seeded with polystyrene particles and illuminated by a laser light sheet. Computational results were determined for the same configurations and at matching Reynolds numbers; these surface heat transfer coefficients and flow velocities were computed with a commercially available code. The experimental and computational results were compared. Although some general trends did agree, there were inconsistencies in the temperature patterns as well as in the numerical results. These inconsistencies strongly suggest the need for further computational studies on complicated geometries such as the one studied

Heat Transfer Measurements on the Endwall of a Variable Speed Power Turbine Blade Cascade

Heat transfer measurements were obtained on the endwall of a 2-D section of a variable speed power turbine (VSPT) rotor blade linear cascade. Infrared thermography was used to help determine the transition of flow from laminar to turbulent as well as determine regions of flow separation. Steady state data was obtained for six incidence angles ranging from +15.8 deg to -51 deg, and at five flow conditions for each angle. Nusselt number was used as a method to visualize flow transition and separation on the endwall surface and showed the effects of secondary flows on the surface. Nusselt correlation with Reynolds number from multiple flow conditions was used to plot local values of the correlation exponent and indicated the state of the local boundary layer as the flow transitioned from laminar to turbulent as well as secondary flow features

Numerical and Experimental Examination of Turbulent Mixing of a Heated Jet in Crossflow

The injection of fully-developed turbulent heated air from a tube into a cooler turbulent duct flow is examined, as an analogy to film cooled turbine blades. A LES numerical model is developed and applied in which tube and duct turbulence inflow effects are emulated using a divergence-free synthetic eddy method (SEM). For direct comparison, a hot-wire experiment is conducted within the ERB test cell SW-6 at NASA Glenn Research Center. Results related to velocity, temperature, and heat flux are obtained numerically and experimentally for a blowing ratio of 1.2, involving a 36 K temperature difference. The relative effect on the solutions of tube and duct inflow turbulence is systematically evaluated. The impact of inherent low-pass filtering of temperature measurements and probe wire offset on the experimental results are addressed

Heat Transfer Measurements for a Film Cooled Turbine Vane Cascade

Experimental heat transfer and pressure measurements were obtained on a large scale film cooled turbine vane cascade. The objective was to investigate heat transfer on a commercial high pressure first stage turbine vane at near engine Mach and Reynolds number conditions. Additionally blowing ratios and coolant density were also matched. Numerical computations were made with the Glenn-HT code of the same geometry and compared with the experimental results. A transient thermochromic liquid crystal technique was used to obtain steady state heat transfer data on the mid-span geometry of an instrumented vane with 12 rows of circular and shaped film cooling holes. A mixture of SF6 and Argon gases was used for film coolant to match the coolant-to-gas density ratio of a real engine. The exit Mach number and Reynolds number were 0.725 and 2.7 million respectively. Trends from the experimental heat transfer data matched well with the computational prediction, particularly for the film cooled case