Nasa Axial 35 CFD
Nasa Axial 35 CFD
U.S. ARMY
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jai
RESEARCH LABORATORY
Michael D. Hathaway
U.S. Army Research Laboratory, Glenn Research Center, Cleveland, Ohio
Jen-Ping Chen
The Ohio State University, Columbus, Ohio
May 2009
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NASA/TM—2009-215604 AIAA–2009–1059
U.S. ARMY
®
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jai
RESEARCH LABORATORY
Michael D. Hathaway
U.S. Army Research Laboratory, Glenn Research Center, Cleveland, Ohio
Jen-Ping Chen
The Ohio State University, Columbus, Ohio
May 2009
This work was sponsored by the Fundamental Aeronautics Program
at the NASA Glenn Research Center.
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Michael D. Hathaway
U.S. Army Research Laboratory
Glenn Research Center
Cleveland, Ohio 44135
Jen-Ping Chen
The Ohio State University
Columbus, Ohio 43210
Abstract
Two recent research endeavors in turbomachinery at NASA Glenn Research Center have focused on
compression system stall inception and compression system aerothermodynamic performance. Physical
experiment and computational research are ongoing in support of these research objectives. TURBO, an
unsteady, three-dimensional, Navier-Stokes computational fluid dynamics code commissioned and
developed by NASA, has been utilized, enhanced, and validated in support of these endeavors. In the
research which follows, TURBO is shown to accurately capture compression system flow range—from
choke to stall inception—and also to accurately calculate fundamental aerothermodynamic performance
parameters. Rigorous full-annulus calculations are performed to validate TURBO’s ability to simulate the
unstable, unsteady, chaotic stall inception process; as part of these efforts, full-annulus calculations are
also performed at a condition approaching choke to further document TURBO’s capabilities to compute
aerothermodynamic performance data and support a NASA code assessment effort.
Introduction
Turbomachinery generates power and propulsion for a wide variety of applications. Regardless of
application, it is imperative that the turbomachinery perform reliably and efficiently. A major focus of
research within NASA’s Fundamental Aeronautics Program concerns efficient, highly-loaded
turbomachinery. An essential part of the research is the development and validation of high-fidelity
computational design and analysis tools. Many computational tools have been commissioned, developed,
and validated by NASA, and an effort has been undertaken to assess these various tools.
Concurrent with NASA’s Fundamental Aeronautics goal for efficient, highly-loaded turbomachinery,
the Army Research Laboratory (ARL) has a vested interest in reliable, efficient turbomachinery for the
power plants used within the Army’s helicopters, tanks, and uninhabited aerial vehicles, inter alia.
Reliable, efficient performance of the gas turbine power plant depends on reliable, efficient performance
of the turbomachinery compression system. In pursuit of this goal, ARL has conducted extensive research
in compression system stall inception and stall control, both experimentally and computationally.
In support of NASA and ARL objectives, an extensive research effort has been performed on the
NASA Stage 35 single-stage transonic axial compressor. Physical experiments have been performed on
Stage 35 at Glenn Research Center, and computational research has advanced using several computational
fluid dynamics codes developed by NASA. In the research which follows, the TURBO code is applied to
simulate three-dimensional, full-annulus, unsteady, time-accurate simulations of Stage 35, with the
NASA/TM—2009-215604
inclusion of a temporally accurate, spatially precise sliding interface as well as gridded rotor tip
clearances. Such simulations—expending tremendous quantities of computational resources for long
periods of time—are necessary when attempting to capture the three-dimensional, unsteady, aperiodic
flow preceding and undergoing rotating stall. In other research efforts supporting these NASA and ARL
objectives, these large-scale TURBO simulations have provided valuable insight into the stall inception
process, though never intended to explicitly replicate the stalling process of Stage 35 per second. This
research documents TURBO’s performance in capturing mass-flow and pressure-ratio performance of the
Stage 35 transonic axial compressor for flow conditions from choke to stall, with additional investigation
of aerothermodynamic performance approaching choke.
Flow Solver
TURBO is a physics-based simulation tool for multistage turbomachinery. The solver computes the
fluid conservation laws without ad hoc modeling of any flow phenomena other than models required for
turbulence. This code solves the unsteady Reynolds-averaged Navier-Stokes equations and a decoupled
k-g turbulence model developed by Zhu and Shih (Ref. 1). To facilitate the rotor-stator interaction studied
in this effort, TURBO employs a sliding interface technique implemented by Chen and Barter (Ref. 2) in
which conservative variables are interpolated across blade row interfaces. The code is implemented in a
portable, scalable form for distributed-memory parallel computers using MPI message passing. The
parallel implementation employs domain decomposition and supports general multiblock grids with
arbitrary grid-block connectivity. The solution algorithm is a Newton iterative implicit time-accurate
scheme with characteristics-based finite-volume spatial discretization. The Newton subiterations are
solved using a concurrent block-Jacobi symmetric Gauss-Seidel (BJ-SGS) relaxation scheme. Because all
of the fundamental fluid mechanics are computed, the code is capable of capturing the nonlinear
characteristics of the flow fields of interest. With the actual modeling of the grid movement of the blade
rows in relative motion, this code is capable of computing the unsteady interactions between blade rows.
Details of the flow solver are given by Chen and Whitfield (Ref. 3). The approach to parallelization for
large-scale, complex problems is discussed by Chen and Briley (Ref. 4).
Computational Grid
This effort follows previous TURBO research studies on Stage 35 by Hathaway et al. (Ref. 6) and
Chen et al. (Refs. 7 and 8). For this effort, following the previous TURBO stall inception research on
Stage 35, three blade rows are gridded. In addition to the rotor and the stator of the turbomachinery
compression system, an inlet row precedes the rotor here. This inlet row allows for the activation of
injectors to introduce additional (air) flow for purposes of stall control. In this study, the “injectors” are
inactive, and the inlet blade row merely provides valuable additional ducting volume to better, but not
completely, replicate the geometry of the physical Stage 35 test rig.
NASA/TM—2009-215604 2
TABLE 1.—STAGE 35 DESIGN PARAMETERS
Rotor speed at 100 percent speed 17188.7 rpm
Tip speed at 100 percent speed 454.456 m/s
Hub/tip radius ratio 0.7
Rotor aspect ratio 1.19
Stator aspect ratio 1.26
Rotor blade count 36
Stator vane count 46
NASA/TM—2009-215604
Full Annulus Grids
From experimental research on the Stage 35 test rig, Bright et al. (Ref. 9) concluded that, “... our
high-speed stage under normal stalling condition is considered a “modal” machine, since modal
instabilities dominate the pre-stall behavior with some added “pip” instabilities present just before stall.”
Near the stall boundary, the flow field becomes inherently three-dimensional, unsteady, and aperiodic.
The physical machine stalls in response to both long-wavelength circumferential modes and higher-
frequency perturbations. Consequently, Stage 35 is resolved herein using full annulus grids. These full
annulus grids are depicted in Figure 3; a clearer picture of the grids for single inlet/injector, rotor, and
stator passages follows in Figure 4.
NASA/TM—2009-215604 4
Tip Clearance Grids
Differentiating this work from prior research by Chen et al. (Refs. 7 and 8) and Hathaway et al.
(Ref. 6) is the inclusion of gridded rotor tip clearance regions here. Previous stall inception research on
Stage 35 using TURBO has employed modeled, periodic rotor tip clearance models like those described
by Kirtley et al. (Ref. 10) Much previous research has shown tip clearance flow phenomena to be highly
relevant to the stall inception process for many compression systems, and this has motivated gridding
these regions to better resolve their flow characteristics. However, limited computational resources and
previous software infrastructure issues have effectively prohibited gridding these regions in previous
research efforts. The rotor tip clearance grids used in this study are pictured in Figure 5 (plan view of
leading edge), Figure 6 (plan view of trailing edge), and Figure 7 (plan view of mid-chord). A summary
of Stage 35 grid parameters is provided in Table 2.
NASA/TM—2009-215604
TABLE 2.—STAGE 35 CFD GRID PARAMETERS
Entity NI NJ NK Axial partitions Quantity
Inlet/injector 51 71 166 2 12
Rotor passage 151 71 56 2 36
Rotor tip clearance 81 11 13 2 36
Stator passage 141 71 79 3 46
In the previous Stage 35 stall inception work using TURBO, boundary-layer near-wall packing was
employed on grids near the casing. When gridding volume in the tip clearance region “below” the casing
and “above” the blade tip, the previously-appropriate unidirectional boundary-layer near-wall packing
must be altered. The pitchwise view of the tip clearance grids, shown in Figure 8, reflects the revised grid
spacing, with the outer eight grids equally spaced to accommodate tip clearance grids for the downstream
stator and the next two grids then (independently) equally spaced above the rotor tip.
Solution Parameters
Throughout this study, second-order temporal accuracy and second-order spatial accuracy are applied.
As has been done in prior research by Chen et al. (Refs. 7 and 8) and Hathaway et al. (Ref. 6), three
Newton subiterations are applied with six symmetric Gauss-Seidel sweeps per subiteration. Previous
research using these solution parameters has yielded valuable insight into the stall inception process in
somewhat reasonable (computational) time.
NASA/TM—2009-215604 6
Speedlines are plotted from three TURBO simulations/configurations a 328-block configuration with
periodic rotor tip clearance regions, a 234-block configuration with periodic rotor tip clearance regions, and
a 306-block configuration with gridded rotor tip clearance regions. The 328-block configuration, run first by
Chen and Hathaway on 328 processes, features boundary-layer near-wall grid packing along the casing wall,
as it was not originally intended to include gridded rotor tip clearance regions; this grid has exactly the same
unpartitioned computational extents as listed here in Table 2 but without gridded rotor tip clearances. The
234-block configuration run in this effort on 234 processes is based upon the 328-block grid of Chen and
Hathaway, but it is repartitioned into 234 blocks (to conform to smaller computational cluster queues) with
equal spacing between casing wall and rotor tips (to facilitate seamless addition of rotor tip clearance grids).
The 306-block configuration consumed equal process-time as the 234-block configuration while providing
the additional gridding in the rotor tip clearance regions; recent enhancements to the code enabled this
efficient computational performance with additional gridding.
Detailed information on TURBO executions near stall is listed in Table 3. In this table, Throttle Exit
BC provides the exit corrected mass flow in kg/s (corrected to exit total conditions); Casing Grid may be
Boundary Layer (casing-biased) or Evenly Spaced; Mass Flow is listed in kg/s; Seed Flow indicates the
initial flow condition used to initiate the flow field at the new throttle setting; Flow Condition may be
Stable, at the Precipice to Stall (i.e., mass flow and static pressure recovery are about to plummet at this
operational condition), or exhibiting potential of going Unstable.
NASA/TM—2009-215604 7
As shown in Figure 9, TURBO exhibits similar, but slightly higher, choking mass flow rates as
experiment. TURBO’s choking mass flow rate and choking pressure ratio are identical for the 234-block
simulations with periodic tip clearances and the 306-block simulations with gridded tip clearances. Chen
and Hathaway did not document as deep a choked condition. Throttling down from choke, the 306-block
gridded tip configuration of the present study shows a general trend toward very slight reductions in mass
flow and pressure ratio in comparison with the original 328-block periodic tip configurations of Chen and
Hathaway; these deviations represent nominal, minimal improvements in TURBO’s predictions versus
experiment. As the throttle is closed, the current 234-block simulation employing periodic rotor tip
clearances has point P1 lying nearly collinear between points C1 and C2 from the original 328-block
simulations, also employing periodic rotor tip clearances, implying that the enhanced code is maintaining
the numerical performance of the original code and that the slight differences in gridding near the case are
inconsequential at this stable flow condition. The current 306-block simulation employing gridded rotor
tip clearances has point G1 lying between C1 and C2 in mass flow but with slightly reduced—and slightly
closer to experiment—static pressure recovery.
In the original TURBO simulations of Stage 35 by Chen and Hathaway, the last stable point (C2)
exhibits a virtually identical mass flow rate with the last stable point observed in experiment (E1);
TURBO’s prediction of static pressure recovery is higher than experiment. In the present TURBO
simulations of Stage 35, no definitively stable operating condition is found near the stalling mass flow
rate of experiment (E1) and previous TURBO simulation (C2). The simulations yielding G2 (gridded tip)
and P3 (periodic tip) operate quasi-stably in this vicinity for quite awhile before weakening and stalling,
and the simulation yielding P2 appears to be weakening as the simulation is suspended due to time and
resources constraints. Points P2 and P3 of the current 234-block periodic tip simulations are showing
reductions in static pressure recovery in comparison with C2 and C3 from the previous 328-block
periodic tip simulations, presumably due to the differences in casing boundary layer gridding.
Though at a lower mass flow rate than experiment (E1), points G2 and P3 do show good agreement
with one another with regard to stalling mass flow and stalling pressure recovery. This inspires
confidence that the TURBO-predicted stalling condition for this compressor is unaffected by the slight
differences in handling of the rotor tip clearance regions. However, points P3 and G2 represent different
throttle settings and the lengths of their stall-inception transients differ. Additionally, point P2 has the
same throttle setting as G2, yet the different treatments of rotor tip clearance flow are clearly yielding
differing performances over time for these two simulations. For a given exit boundary condition
(prescribed exit corrected mass flow), the gridded tip clearance configurations tend to allow less
throughflow and facilitate less static pressure recovery, presumably due to additional blockage in the rotor
tip clearance region.
NASA/TM—2009-215604
choke also exhibits temporal and spatial variation, but to a much lesser degree; time-averaged solution
data for flow approaching choke is collected and analyzed here.
The speedline characteristics comparing TURBO versus Reid and Moore experiment on total-to-total
pressure ratio are shown in Figure 10. TURBO simulations are executed with exit boundary conditions of
20.00 kg/s corrected mass flow, yielding a mass flow similar to Reid and Moore’s point 4004. As shown in
Table 4, this TURBO simulation at near-choke is indeed very close to the experimental data point in terms
of mass flow, total temperature ratio, total pressure ratio and adiabatic efficiency. TURBO’s deviation in
this simulation is within the bounds of experimental uncertainty cited by Reid and Moore (Ref. 5).
Beyond the stator exit in the physical experiment, two combination probes were traversed
circumferentially among nine locations within the stator gap, while two wedge probes were separately
located and diametrically opposed at stator midgap. Four static pressure taps were mounted on the hub
surface, and an additional four static pressure taps were mounted on the casing surface beyond the stator
exit. Forward of the rotor, two combination probes were diametrically opposed, and one wedge probe was
used. As with the stator exit, four static pressure taps were placed on the hub and casing surfaces alike.
All combination and wedge probes were sequenced through nine radial positions to gather spanwise data
of total pressure, total temperature, and flow angle.
With TURBO, similar data may be extracted with much finer geometric precision: The TURBO grid
contains 70 volumes between hub and case (including 10 volumes spanwise in the tip gap) and
78 volumes between adjacent vane surfaces. As was done with the coarser grid from the experiment,
TURBO data is mass averaged to calculate appropriate aerothermodynamic performance parameters.
Total pressure data is plotted in Figure 11. As was the case for the overall total pressure ratio (across the
full inlet and exit planes), TURBO is again generally predicting somewhat low, but the trends of total
pressure ratio from hub to case are very well captured by TURBO; TURBO’s maximum deviation from
experimental point 4004 is about 2 percent.
NASA/TM—2009-215604 9
In Figure 12, stage total temperature ratio data is plotted. TURBO is predicting slightly lower total
temperature ratio than the experimental data purports. TURBO and experiment show different trends from
15 percent span to 30 percent span, where experiment revealed an increase in total temperature ratio
versus the near-hub regions but TURBO shows total temperature ratio to be rather constant in this region.
TURBO captures well the trend of total temperature ratio from 30 to 70 percent span. TURBO’s
maximum midspan deviation is about 1 percent.
Adiabatic efficiency is easily derived from total pressure ratio and total temperature ratio. The radial
distribution of stage adiabatic efficiency is shown in Figure 13. TURBO agrees very well with experiment
in magnitude and trend throughout the span, though TURBO is about 2.5 percent high at 50 percent span.
Results for Stator Exit Flow angle follow in Figure 14. TURBO is underpredicting flow angle by about 3 °
throughout the span; similar computational results have been demonstrated with other CFD codes,
prompting questions about the experimental results (measurements and post-processing). This flow angle
deviation exceeds the experimental uncertainty of ± 1 °.
NASA/TM—2009-215604 10
Conclusions and Recommendations
A two-pronged computational research endeavor has been completed with the TURBO code. For
each task, TURBO results have been compared and validated with relevant experiments. While
overpredicting static pressure recovery slightly, TURBO reveals a very accurate flow range from choke to
stall, and TURBO captures the unstable, temporally unsteady, spatially aperiodic flows associated with
stall inception in high-speed transonic compressors when such fidelity is required. In analyzing
fundamental aerotheromodynamic compressor performance at a near choke condition, TURBO only
slightly underpredicts total pressure ratio and total temperature ratio. TURBO’s predictions of adiabatic
efficiency are quite accurate for most of the span. TURBO’s underprediction of stator exit flow angle
corroborates similar results from other CFD codes; exceeding experimental uncertainty, this common
discrepancy should be investigated.
NASA/TM—2009-215604 11
The TURBO simulations, employing full annulus geometry, are quite computationally costly. These
simulations have proven reliable in investigating unsteady, aperiodic, chaotic, complicated flow physics;
these simulations have also proven nicely accurate for fundamental aerothermodynamic performance
analysis, though results of similar quality may be attained with other CFD codes at much reduced
computational cost.
References
1. Zhu, J. and Shih, T.H., “CMOTT Turbulence Module for NPARC,” Tech. Rep. CR–204143, National
Aeronautics and Space Administration, Aug. 1997.
2. Chen, J.-P. and Barter, J., “Comparison of Time-Accurate Calculations for the Unsteady Interaction
in Turbomachinery Stage,” Tech. Rep. AIAA–1998–3292, American Institute of Aeronautics and
Astronautics, 1998.
3. Chen, J.-P. and Whitfield, D.L., “Navier-Stokes Calculations for the Unsteady Flowfield of
Turbomachinery,” Tech. Rep. AIAA–1990–0676, American Institute of Aeronautics and
Astronautics, 1993.
4. Chen, J.-P. and Briley, W.R., “A Parallel Flow Solver for Unsteady Multiple Blade Row
Turbomachinery Simulations,” Tech. Rep. 2001–GT–0348, ASME TURBO Expo, New Orleans,
Louisiana, 2001.
5. Reid, L. and Moore, R.D., “Performance of single-stage axial-flow transonic compressor with rotor
and stator aspect ratios of 1.19 and 1.26, respectively, and with design pressure ratio of 1.82,” Tech.
Rep. TP–1338, National Aeronautics and Space Administration, 1978.
6. Hathaway, M.D., Chen, J., Webster, R.S., and Herrick, G.P., “Time Accurate Unsteady Simulations
of the Stall Inception Process in the Compression System of a U.S. Army Helicopter Gas Turbine
Engine,” 2004 DoD High Performance Computing Modernization Program Users Group
Conference, Williamsburg, Virginia, June 2004.
7. Chen, J.-P., Webster, R.S., Hathaway, M.D., Herrick, G.P., and Skoch, G.J., “Numerical Simulation
of Stall and Stall Control in Axial and Radial Compressors,” Tech. Rep. AIAA–2006–0418,
American Institute of Aeronautics and Astronautics, 2006.
8. Chen, J.-P., Hathaway, M.D., and Herrick, G.P., “Pre-stall Behavior of a Transonic Axial Compressor
Stage via Time-Accurate Numerical Simulation,” Tech. Rep. 2007–GT–29627, ASME Turbo Expo
2007, May 2007.
9. Bright, M.M., Qammar, H.K., and Wang, L., “Investigation of Pre-Stall Mode and Pip Inception in
High-Speed Compressors Through the Use of Correlation Integral,” ASME Journal of
Turbomachinery, vol. 121, 1999, pp. 743–750.
10. Kirtley, K.R., Beach, T.A., and Adamczyk, J.J., “Numerical Analysis of Secondary Flow in a Two-
Stage Turbine,” Tech. Rep. AIAA–1990–2356, American Institute of Aeronautics and Astronautics,
1990.
11. Chen, J.-P., Hathaway, M.D., and Herrick, G.P., “Prestall Behavior of a Transonic Axial Compressor
Stage via Time-Accurate Numerical Simulation,” ASME Journal of Turbomachinery, vol. 130, 2008.
12. Weigl, H.J., Paduano, J.D., Frechette, L.G., Epstein, A.H., Greitzer, E.M., Bright, M.M., and
Strazisar, A.J., “Active Stabilization of Rotating Stall and Surge in a Transonic Single Stage Axial
Compressor,” ASME Journal of Turbomachinery, vol. 120, 1998, pp. 625–636.
NASA/TM—2009-215604 12
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Unsteady Full Annulus Simulations of a Transonic Axial Compressor Stage
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14. ABSTRACT
Two recent research endeavors in turbomachinery at NASA Glenn Research Center have focused on compression system stall inception and
compression system aerothermodynamic performance. Physical experiment and computational research are ongoing in support of these
research objectives. TURBO, an unsteady, three-dimensional, Navier-Stokes computational fluid dynamics code commissioned and
developed by NASA, has been utilized, enhanced, and validated in support of these endeavors. In the research which follows, TURBO is
shown to accurately capture compression system flow range-from choke to stall inception-and also to accurately calculate fundamental
aerothermodynamic performance parameters. Rigorous full-annulus calculations are performed to validate TURBO’s ability to simulate the
unstable, unsteady, chaotic stall inception process; as part of these efforts, full-annulus calculations are also performed at a condition
approaching choke to further document TURBO’s capabilities to compute aerothermodynamic performance data and support a NASA code
assessment effort.
15. SUBJECT TERMS
Turbomachinery; Compressor; Stage; Transonic; Rotor; Stator; Navier-Stokes; CFD; Unsteady; Full annulus
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