叶尖小翼控制压气机叶顶间隙流动的研究
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摘要
叶顶间隙流动对压气机性能和稳定性都有着极其重要影响,如何通过合理控制叶顶间隙流动,调控叶尖各旋涡之间的相互作用,对于提高燃气轮机的气动性能和稳定性有着重要意义。近年来,叶尖小翼技术在叶轮机械领域也受到广泛关注,对其作用机理进行详细深入的研究,可以为提高叶尖小翼技术在实际压气机中应用的可靠性、有效性及广延性奠定基础。
本文采用实验测量并结合数值模拟,针对叶尖小翼控制压气机矩形叶栅和压气机转子间隙流动进行研究,揭示了叶尖小翼对压气机叶栅和转子气动性能的影响规律。通过改变间隙尺寸、来流冲角及小翼几何形状,研究了以上诸因素对叶尖小翼控制间隙泄漏效果的影响。
本文第一部分首先实验研究了叶尖泄漏与压气机叶栅三维角区分离之间的相互作用机制,而后研究了近零冲角和不同负冲角条件下不同安装方式叶尖小翼对叶栅间隙流场的影响。结果表明适当大小的叶顶间隙引入的泄漏流阻止了端壁二次流动与叶片吸力面附面层之间的相互作用,消除了三维角区分离,改善了叶栅性能。吸力面小翼使得泄漏涡涡核更靠近叶栅流道中部,上通道涡受泄漏涡的挤压作用迁移至相邻叶片压力面侧,叶顶泄漏涡、上通道涡及集中脱落涡之间的相互作用减弱。压力面小翼使得叶尖泄漏流切向动量减弱,泄漏涡涡核向叶片吸力面/端壁角区侧迁移。泄漏涡对上通道涡的抑制作用减弱,上通道涡的作用范围扩大。组合小翼方案中存在着吸力面小翼和压力面小翼的双重作用,受其叶顶较宽及带来的附加摩阻较大的影响,在大负冲角时叶片端壁/吸力面角区处泄漏涡造成的高损失显著降低,近端壁区气流欠偏转程度减弱。
第二部分实验研究了带不同宽度叶尖小翼叶栅的变间隙特性和变冲角特性。结果表明,小间隙时不同宽度叶尖小翼均使得叶栅损失增加,中等间隙和大间隙时不同宽度的吸力面小翼均使得泄漏涡强度减弱且作用范围减小,通道涡更靠近相邻叶片压力面且作用范围缩小,叶栅总损失降低。最大宽度的压力面小翼降低了50%-80%叶高的叶片尾迹区损失,叶栅总损失较其他叶栅为最低,但会使得叶栅出口气流角沿展向分布的不均匀性增强。在较大的正冲角条件下不同宽度的叶尖小翼仅弱化了间隙中后部的泄漏流强度,减少了其对泄漏涡的补充作用。
第三部分首先利用数值模拟方法研究了融合式叶尖小翼对叶栅间隙流场的影响,结果表明不同安装方式的融合式叶尖小翼都可以有效降低叶顶泄漏流速,削弱泄漏涡强度,叶尖小翼改变了叶尖负荷及泄漏涡运行轨迹,进而影响了叶尖流场各涡系之间的相互作用。其次研究了端壁相对运动对叶栅间隙流动的影响,发现端壁相对运动时叶栅通道内出现刮削泄漏涡,上通道涡及叶顶分离涡受到抑制,叶尖负荷增大,间隙泄漏流量增加。接着探讨了融合式叶尖小翼对压气机低速孤立转子气动性能的影响,融合式吸力面小翼使得转子中泄漏涡轨迹更远离叶片吸力而,减弱了其对叶片吸力面附而层的卷吸吸作用,导致叶片吸力面附面层分离程度加剧。压力面小翼使得泄漏涡轨迹更靠近叶片吸力面,抑制了转子叶片吸力面的附面层分离,可以在效率略有降低的情况下有效拓宽压气机转子的流量范围。接着针对某跨音压气机级详细分析了影响其失速稳定性的关键因素,压气机级在设计转速工作时,动叶中激波/叶尖泄漏涡相互作用产产的阻塞区和附面层径向涡引发的附面层分离阻塞区及它们所导致的下游静叶附面层分离是影响压气机级失速的关键因索。最后研究了融合式叶尖小翼对跨音速压气机转子动性能的影响,发现吸力面小翼使得泄漏涡较早地与通道激波作用并发生破裂,造成叶片通道上游压力面侧形成的低速区范围较原型动叶显著增大,诱发跨音速转子较早失速。压力面小翼方案中，通道激波位置较原型更远离叶片前缘,同时受从转子前缘叶尖发出的泄漏流强度减弱的影响,泄漏涡与通道激波作用后产生的阻塞区缩小,推迟了跨音转子失速的发生。
第四部分详细介绍了跨音速压气机级试验系统的组成,设计了带叶尖小翼的压气机级试验件,给出了跨音速压气机级常规性能的测量方案及数据处理方法设计了三维PIV可视化流场测量方案,为下一步开展带叶尖小翼的的跨音速压气机级试验验证奠定了基础。
It is well known that tip clearance flow is detrimental to the pressure rise capability, stability and efficiency of the compressor. To improve the performance and reliability of gas turbine, it is important for the researchers to understand how to control the tip clearance flow and corporate the interaction of the vortices. Recently, blade tip winglet controlling gap flow technique has also been concerned in the field of turbomachinery. In order to enhance the reliability, validity and universality of tip winglet technique application, it is necessary to investigate the action effect of winglet and its mechanism.
In this paper, a detailed experimental and numerical study was conducted to investigate the influences of blade tip winglet on tip clearance flow control in compressor cascade and rotors, and reveal the mechanism of the winglets. Results for a variation of the tip clearance size, incidence and winglet geometry are presented.
First of all, detailed experimental investigations were carried out to uncover the interaction of the tip clearance flow with three-dimensional separation in the corner region of a compressor cascade and the influences of three different winglet geometries, suction side winglet, pressure side winglet and double-side winglet. The results show that the three-dimensional separation on the blade suction surface is largely removed by the clearance flow for a proper tip clearance size and the aerodynamic performance of the cascade is improved. For the suction side winglet case, the tip leakage vortex is shift toward the core of the passage and pushes the passage vortex near the tip toward the pressure side of the adjacent blade, the strength of the interaction between tip leakage, passage vortex and concentrated shed vortex is reduced. For the pressure side winglet case, the tangential momentum of tip leakage flow is reduced; the pressure side winglet manages to displace the tip leakage vortex to the left, or toward the tip/outer casing corner of the suction side. For the double side winglet case with a high ratio of blade thickness to tip clearance height, the strength of tip leakage flow is reduced clearly due to more friction resistance between the blade tip and the endwall, and the flow undergoes a less underturning near the easing.
Extensive traverse measurements were made of the three dimensional flows in a low speed linear cascade with tip winglet of different widths for various tip clearance si- zes and for various cascade inlet flow angles. It is found that the winglets increase aerodynamic loss of the cascade for small tip gap height. For middle and large tip clearance sizes, the suction side winglets reduce loss in the tip leakage vortex region and passage vortex region. The pressure side winglet with the largest width can reduce the aerodynamic loss of the wake in50%-80%span region noticeably. At large incidence conditions, the winglets can only reduce the strength of the rear part tip clearance flow.
A numerical study was conducted to explore the effects of three different blended tip winglet geometries on tip clearance flow field of compressor cascade. The current results show that a significant tip leakage velocity and strength of tip leakage vortex reduction is possible by using blended winglet. The blade loading near the tip and the tip leakage vortex trajectories are changed by the tip winglets, thus the interaction between passage vortex and tip leakage vortex is also changed. The effect of endwall movement on the3D flow field in a compressor cascade with different tip clearances was studied; the simulation results show that when relative movement of endwall exists, the scrapped tip leakage vortex appearing in the cascade passage will move toward the pressure surface of adjacent blade; both the upper passage vortex and tip separation vortex are to be inhibited; the load near the tip region will rise which may result in tip leakage mass flow rate increased. Two types of blended tip winglet were investigated to control tip clearance flow in an isolated axial compressor rotor. The suction side blended tip winglet shifts the tip vortex trajectory toward the pressure side of adjacent blade, which results in the corner separation on the suction surface becoming seriously. For the pressure side winglet case, the presence of a tip leakage vortex near the suction surface induces spanwise flow towards the blade tip and helps to wash away the corner separation zone on the blade surface, and this type of winglet is found to increase the compressor rotor stall margin with a little loss in efficiency.3D numerical simulation was conducted for a single transonic compressor Stage37. It is found that the low energy zones due to breakdown of the tip leakage vortex, radial vortex and corner separation of the stator are the factors leading to flow instability at design speed. Based on an improved understanding of compressor rotor tip leakage flow development from CFD simulations, two kinds of blended tip winglet have been designed for a transonic compressor rotor and numerical simulation of three dimensional flows in the rotor were carried out to verify the designed winglet. For the case with suction-side winglet, the breakdown of the tip leakage vortex occurs due to the interaction of shock/tip leakage vortex appeared early than datum rotor, thus leading to more low energy fluid accumulated near the pressure side of the rotor tip passage. For the pressure-side winglet case, the passage choke caused by fluid of low energy and tip leakage flow can be improved, thus the compressor rotor surge point can be effectively delayed.
In order to carry out the experimental study of the stage aerodynamic performances of the original and redesigned transonic compressors in the next step, the structure of the compressor test rig was introduced firstly, and the single transonic compressor stage with tip winglet was design. The traditional average flow field measurements and instantaneous velocity measurements obtained with3D-PIV will make it a powerful technique to understand the flow field occurring within compressor with winglet.
本文采用实验测量并结合数值模拟,针对叶尖小翼控制压气机矩形叶栅和压气机转子间隙流动进行研究,揭示了叶尖小翼对压气机叶栅和转子气动性能的影响规律。通过改变间隙尺寸、来流冲角及小翼几何形状,研究了以上诸因素对叶尖小翼控制间隙泄漏效果的影响。
本文第一部分首先实验研究了叶尖泄漏与压气机叶栅三维角区分离之间的相互作用机制,而后研究了近零冲角和不同负冲角条件下不同安装方式叶尖小翼对叶栅间隙流场的影响。结果表明适当大小的叶顶间隙引入的泄漏流阻止了端壁二次流动与叶片吸力面附面层之间的相互作用,消除了三维角区分离,改善了叶栅性能。吸力面小翼使得泄漏涡涡核更靠近叶栅流道中部,上通道涡受泄漏涡的挤压作用迁移至相邻叶片压力面侧,叶顶泄漏涡、上通道涡及集中脱落涡之间的相互作用减弱。压力面小翼使得叶尖泄漏流切向动量减弱,泄漏涡涡核向叶片吸力面/端壁角区侧迁移。泄漏涡对上通道涡的抑制作用减弱,上通道涡的作用范围扩大。组合小翼方案中存在着吸力面小翼和压力面小翼的双重作用,受其叶顶较宽及带来的附加摩阻较大的影响,在大负冲角时叶片端壁/吸力面角区处泄漏涡造成的高损失显著降低,近端壁区气流欠偏转程度减弱。
第二部分实验研究了带不同宽度叶尖小翼叶栅的变间隙特性和变冲角特性。结果表明,小间隙时不同宽度叶尖小翼均使得叶栅损失增加,中等间隙和大间隙时不同宽度的吸力面小翼均使得泄漏涡强度减弱且作用范围减小,通道涡更靠近相邻叶片压力面且作用范围缩小,叶栅总损失降低。最大宽度的压力面小翼降低了50%-80%叶高的叶片尾迹区损失,叶栅总损失较其他叶栅为最低,但会使得叶栅出口气流角沿展向分布的不均匀性增强。在较大的正冲角条件下不同宽度的叶尖小翼仅弱化了间隙中后部的泄漏流强度,减少了其对泄漏涡的补充作用。
第三部分首先利用数值模拟方法研究了融合式叶尖小翼对叶栅间隙流场的影响,结果表明不同安装方式的融合式叶尖小翼都可以有效降低叶顶泄漏流速,削弱泄漏涡强度,叶尖小翼改变了叶尖负荷及泄漏涡运行轨迹,进而影响了叶尖流场各涡系之间的相互作用。其次研究了端壁相对运动对叶栅间隙流动的影响,发现端壁相对运动时叶栅通道内出现刮削泄漏涡,上通道涡及叶顶分离涡受到抑制,叶尖负荷增大,间隙泄漏流量增加。接着探讨了融合式叶尖小翼对压气机低速孤立转子气动性能的影响,融合式吸力面小翼使得转子中泄漏涡轨迹更远离叶片吸力而,减弱了其对叶片吸力面附而层的卷吸吸作用,导致叶片吸力面附面层分离程度加剧。压力面小翼使得泄漏涡轨迹更靠近叶片吸力面,抑制了转子叶片吸力面的附面层分离,可以在效率略有降低的情况下有效拓宽压气机转子的流量范围。接着针对某跨音压气机级详细分析了影响其失速稳定性的关键因素,压气机级在设计转速工作时,动叶中激波/叶尖泄漏涡相互作用产产的阻塞区和附面层径向涡引发的附面层分离阻塞区及它们所导致的下游静叶附面层分离是影响压气机级失速的关键因索。最后研究了融合式叶尖小翼对跨音速压气机转子动性能的影响,发现吸力面小翼使得泄漏涡较早地与通道激波作用并发生破裂,造成叶片通道上游压力面侧形成的低速区范围较原型动叶显著增大,诱发跨音速转子较早失速。压力面小翼方案中，通道激波位置较原型更远离叶片前缘,同时受从转子前缘叶尖发出的泄漏流强度减弱的影响,泄漏涡与通道激波作用后产生的阻塞区缩小,推迟了跨音转子失速的发生。
第四部分详细介绍了跨音速压气机级试验系统的组成,设计了带叶尖小翼的压气机级试验件,给出了跨音速压气机级常规性能的测量方案及数据处理方法设计了三维PIV可视化流场测量方案,为下一步开展带叶尖小翼的的跨音速压气机级试验验证奠定了基础。
It is well known that tip clearance flow is detrimental to the pressure rise capability, stability and efficiency of the compressor. To improve the performance and reliability of gas turbine, it is important for the researchers to understand how to control the tip clearance flow and corporate the interaction of the vortices. Recently, blade tip winglet controlling gap flow technique has also been concerned in the field of turbomachinery. In order to enhance the reliability, validity and universality of tip winglet technique application, it is necessary to investigate the action effect of winglet and its mechanism.
In this paper, a detailed experimental and numerical study was conducted to investigate the influences of blade tip winglet on tip clearance flow control in compressor cascade and rotors, and reveal the mechanism of the winglets. Results for a variation of the tip clearance size, incidence and winglet geometry are presented.
First of all, detailed experimental investigations were carried out to uncover the interaction of the tip clearance flow with three-dimensional separation in the corner region of a compressor cascade and the influences of three different winglet geometries, suction side winglet, pressure side winglet and double-side winglet. The results show that the three-dimensional separation on the blade suction surface is largely removed by the clearance flow for a proper tip clearance size and the aerodynamic performance of the cascade is improved. For the suction side winglet case, the tip leakage vortex is shift toward the core of the passage and pushes the passage vortex near the tip toward the pressure side of the adjacent blade, the strength of the interaction between tip leakage, passage vortex and concentrated shed vortex is reduced. For the pressure side winglet case, the tangential momentum of tip leakage flow is reduced; the pressure side winglet manages to displace the tip leakage vortex to the left, or toward the tip/outer casing corner of the suction side. For the double side winglet case with a high ratio of blade thickness to tip clearance height, the strength of tip leakage flow is reduced clearly due to more friction resistance between the blade tip and the endwall, and the flow undergoes a less underturning near the easing.
Extensive traverse measurements were made of the three dimensional flows in a low speed linear cascade with tip winglet of different widths for various tip clearance si- zes and for various cascade inlet flow angles. It is found that the winglets increase aerodynamic loss of the cascade for small tip gap height. For middle and large tip clearance sizes, the suction side winglets reduce loss in the tip leakage vortex region and passage vortex region. The pressure side winglet with the largest width can reduce the aerodynamic loss of the wake in50%-80%span region noticeably. At large incidence conditions, the winglets can only reduce the strength of the rear part tip clearance flow.
A numerical study was conducted to explore the effects of three different blended tip winglet geometries on tip clearance flow field of compressor cascade. The current results show that a significant tip leakage velocity and strength of tip leakage vortex reduction is possible by using blended winglet. The blade loading near the tip and the tip leakage vortex trajectories are changed by the tip winglets, thus the interaction between passage vortex and tip leakage vortex is also changed. The effect of endwall movement on the3D flow field in a compressor cascade with different tip clearances was studied; the simulation results show that when relative movement of endwall exists, the scrapped tip leakage vortex appearing in the cascade passage will move toward the pressure surface of adjacent blade; both the upper passage vortex and tip separation vortex are to be inhibited; the load near the tip region will rise which may result in tip leakage mass flow rate increased. Two types of blended tip winglet were investigated to control tip clearance flow in an isolated axial compressor rotor. The suction side blended tip winglet shifts the tip vortex trajectory toward the pressure side of adjacent blade, which results in the corner separation on the suction surface becoming seriously. For the pressure side winglet case, the presence of a tip leakage vortex near the suction surface induces spanwise flow towards the blade tip and helps to wash away the corner separation zone on the blade surface, and this type of winglet is found to increase the compressor rotor stall margin with a little loss in efficiency.3D numerical simulation was conducted for a single transonic compressor Stage37. It is found that the low energy zones due to breakdown of the tip leakage vortex, radial vortex and corner separation of the stator are the factors leading to flow instability at design speed. Based on an improved understanding of compressor rotor tip leakage flow development from CFD simulations, two kinds of blended tip winglet have been designed for a transonic compressor rotor and numerical simulation of three dimensional flows in the rotor were carried out to verify the designed winglet. For the case with suction-side winglet, the breakdown of the tip leakage vortex occurs due to the interaction of shock/tip leakage vortex appeared early than datum rotor, thus leading to more low energy fluid accumulated near the pressure side of the rotor tip passage. For the pressure-side winglet case, the passage choke caused by fluid of low energy and tip leakage flow can be improved, thus the compressor rotor surge point can be effectively delayed.
In order to carry out the experimental study of the stage aerodynamic performances of the original and redesigned transonic compressors in the next step, the structure of the compressor test rig was introduced firstly, and the single transonic compressor stage with tip winglet was design. The traditional average flow field measurements and instantaneous velocity measurements obtained with3D-PIV will make it a powerful technique to understand the flow field occurring within compressor with winglet.
引文
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