Innovative Centrifugal Compressor Design

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1 Innovative Centrifugal Compressor Design L. Tarnowski TURBOMECA groupe SAFRAN

2 INTRODUCTION SP2 : IRA (Intercooled Recuperative Aero-engine) Task HP Centrifugal Compressor Design The challenge is : to improve significantly the efficiency of a 2D flanked milled blades of a state of the art centrifugal compressor with a high hub to tip radius ratio. to maintain the initial stability range.

3 OVERVIEW OF THE IRA CONCEPT The new design approach is applied to the last stage of compression (HP) of the IRA engine concept HP centrifugal compressor

4 PARTNER INVOLVED in Task PBS PBS and Turbomeca advanced studies are complementary : Centrifugal compressor with a low hub to tip radius ratio. Main work : - Study of the rotor stator interactions. - Focusing on an optimisation of the geometrical definition of the radial diffuser captation zone.

5 TECHNICAL APPROACH STEPS of DESIGN Conventional 2D design of the centrifugal stage : rotor and stators Advanced 3D design of the rotor (unchanged stators) : - Identical meridional definition of the flow path - Identical throat area - Identical leading edge and trailing edge radius - Modification of the rotor blade angle - Modification of the rotor blade thickness Goals: - To increase the efficiency of the 2D design by 0.8 pts - To keep the stability of the 2D design - To comply with the mechanical criteria

6 1D DEFINITION OF THE CONVENTIONAL DESIGN Type of compressor: HP compressor following an intercooler. High hub to tip radius ratio of 0.8 (leading edge hub radius / Leading edge tip radius). Aerodynamic design point: Based upon the engine conditions: the mid-cruise flight. HPC inlet pressure HPC inlet temperature HPC PR HPC inlet mass flow kpa K - kg/s

7 1D DEFINITION OF THE CONVENTIONAL DESIGN Designed at ambient inlet conditions Aero-thermodynamic data HPC inlet pressure HPC inlet temperature kpa K Complementary data to estimate the efficiency Rotational speed rpm Technological data Radial and axial tip gap Roughness Blade to hub radius Geometrical data Inlet hub radius Maximum outer radius Radial extension mm µm mm mm mm (compressor cover) 0.4 (rotor inducer) 0.8.(rotor exducer)

8 DEFINITION OF THE CONVENTIONAL DESIGN Efficiency and stability targets of the conventional design (1D estimate) Isentropic efficiency pts 82.1 Surge margin (Kp (*) ) pts 10 (*)Kp=(π/ π/w) surge point /(π/ π/w) aero design point with W the corrected mass flow and π the total pressure ratio of the compressor stage. 3D view of the 2D flanked milled rotor and its associated diffuser

9 3D DEFORMATIONS The 2D blades geometry is modified step by step from hub to tip and along the blade to blade channel. The level of deformation from hub to tip, controlled by Bezier curves, is directly applied to the blade surfaces. This allows deformations as lean, bowed shapes, strong local curvatures, The thickness of the blade is controlled under the same principles. Bowed Leading Edge Types of Deformations Strong curvatures at the Leading Edge

10 ASSESMENTS : 3D CFD calculations The performances and the surge margin are estimated with 3D CFD calculations. Numerical features: 3D NS CFD code called elsa developed by ONERA. Low Reynolds Number model for the boundary layer. Code Name Grid Size Kind of Grid Turb Model Elsa (ONERA) 3*10 6 nodes Block structured K-l Smith (2-eq)

11 CFD RESULTS According to numerical predictions the final design is on target. With a factor of achievement of 0.5, the efficiency is improved by 0.8 pts. This is achieved at comparable surge margin pts

12 CFD RESULTS Cross section views of the entropy distribution : about 50% down stream the leading edge of the splitters «State of the art» impeller «Advanced 3D» impeller These pictures show the reduction of loss generation between the state of the art design and the 3D improved version of the impeller by the reduction of secondary flows (see the red circles).

13 TEST RIG View of the fully instrumented test rig Air Exit Air Intake

14 TEST RIG Manufacture of the test rig parts : Pictures of the instrumented diffuser Diffuser of the centrifugal compressor stage Trailing edge of the 2D axial diffuser

15 TEST RESULTS Main test results with 3D impeller : Increase of pressure ratio as predicted by CFD (+4% at given mass flow) Increase of efficiency (+0.9 pt at nominal speed, +1.5 at part speed), pretty consistent with CFD prediction (factor of achievement varying between 0.6 to 1.0) Slight deterioration of surge margin corresponding to the increase of choke mass flow. Baseline surge line can be recovered without any penalty on peak efficiencies by matching the radial diffuser Sensitivity to running clearances unchanged

16 TEST RESULTS «3D design» vs «State of the art design» : measured improvement of efficiency 2,5 Isentropic efficiency gai in (pts) 2 1,5 1 0, N' (%)

17 CONCLUSION & OUTLOOK Changing the way of design with massive use of 3D CFD calculations has allowed to generate 3D blades for the rotor which brought an improvement in efficiency better than the initial target (0.8 pt). A tuning of the radial diffuser section has to be considered to get back to the initial surge line. Further investigation are necessary to understand the interaction between the rotor and the stator to increase further more the overall efficiency of the compressor stage. Unsteady calculations will certainly be required to capture the flow features and allow a more efficient design of the rotor and the stator.

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