Browsing by Author "Pawsey, Lucas"

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    Aerodynamic performance of an un-located high-pressure turbine rotor
    (Cambridge University Press, 2017-07-13) Pawsey, Lucas; Rajendran, David John; Pachidis, Vassilios
    The rotor sub-assembly of the high-pressure turbine of a modern turbofan engine is typically free to move downstream because of the force imbalance acting on the disc and blades following an un-located shaft failure. This downstream movement results in a change in the geometry of the rotor blade, tip seals and rim/platform seals because of the interaction of the rotor sub-assembly with the downstream vane sub-assembly. Additionally, there is a change in the leakage flow properties, which mix with the main flow because of the change in engine behaviour and secondary air system dynamics. In the present work, the changes in geometry following the downstream movement of the turbine, are obtained from a validated friction model and structural LS-DYNA simulations. Changes in leakage flow properties are obtained from a transient network source-sink secondary air system model. Three-dimensional Reynolds-averaged Navier-Stokes simulations are used to evaluate the aerodynamic effect from the inclusion of the leakage flows, tipseal domains, and downstream movement of the rotor for three displacement configurations (i.e. 0, 10 and 15 mm) with appropriate changes in geometry and leakage flow conditions. It is observed from the results that there is a significant reduction in the expansion ratio, torque and power produced by the turbine with the downstream movement of the rotor because of changes in the flow behaviour for the different configurations. These changes in turbine performance parameters are necessary to accurately predict the terminal speed of the rotor using an engine thermodynamic model. Further, it is to be noted that such reductions in turbine rotor torque will result in a reduction of the terminal speed attained by the rotor during an un-located shaft failure. Therefore the terminal speed of the rotor can be controlled by introducing design features that will result in the rapid rearward displacement of the turbine rotor.
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    Characterisation of turbine behaviour for an engine overspeed prediction model
    (Elsevier, 2017-11-28) Pawsey, Lucas; Rajendran, David John; Pachidis, Vassilios
    This paper focuses on the characterisation of turbine overspeed behaviour to be integrated into an engine overspeed model capable of predicting the terminal speed of the high pressure turbine (HPT) in the event of a high pressure shaft failure. The engine considered in this study features a single stage HPT with a shrouded contra-rotating rotor with respect to the single stage intermediate pressure turbine (IPT). The HPT performance is characterised in terms of torque and mass flow function for a range of expansion ratios at various non-dimensional rotational speeds (NH), up to 200% of the design value. Additionally, for each HPT expansion ratio and NH, the change in capacity of the downstream IPT, for different IPT non-dimensional rotational speeds (NI), also needs to be characterised due to the extremely positive incidence angle of the flow from the upstream rotor. An automated toolkit is developed to generate these characteristic maps for both the HPT and IPT. An unlocated high pressure shaft failure will result in rearward movement of the rotor sub-assembly. This causes changes in the rotor tip and rim seal regions, and in the rim seal leakage flow properties. Therefore, in the present work, a high fidelity characterisation of turbine behaviour with the inclusion of tip and rim seals is carried out at three different displacement locations, 0 mm, 10 mm and 15 mm, to improve terminal speed estimation. Furthermore, there is a possibility of damage to the tip seal fins of the HPT rotor due to unbalance in the spool that may result in contact between the rotor aerofoil tip and the casing. Consequently, another set of characteristics are generated with damaged tip fins at each displacement location. It is observed from the characteristics that the torque of the HPT rotor decreases with increasing NH. The HPT mass flow function initially decreases and then increases with an increase in NH. The IPT mass flow function initially remains similar and then decreases with increase in NH above values of 150%. The HPT rotor torque and IPT mass flow function decrease with rearward movement of the HPT rotor sub-assembly for all values of NH. With worn tip seal fins all parameters mentioned previously are lower than in the nominal undamaged case. The high fidelity characterisation of turbines that follows the sequence of events after a shaft failure, as described in this work, can provide accurate predictions of terminal speed and thus act as a tool for testing design modifications that can result in better management and control of the over-speed event.
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    A characteristic-based 1D axial compressor model for stall and surge simulations
    (American Society of Mechanical Engineers (ASME), 2023-09-09) Kissoon, Sajal; Righi, Mauro; Pawsey, Lucas; Pachidis, Vassilios; Tunstall, Richard; Roumeliotis, Ioannis
    A low-order unsteady one-dimensional axial compressor and combustor model has been developed at Cranfield University as part of a larger unsteady gas turbine engine model, with the ability to simulate compressor stall and surge. The flow is resolved using the 1D unsteady Euler equations and source terms are used to model bleed extraction (and addition), pressure losses, and heat and work exchange. Species tracking is used in the combustor part of the model, using a semi-coupled approach, to keep track of the combustion products and unburnt fuel in the main gas path. The equations are solved using a Roe Approximate Riemann Solver, modified to handle the high magnitude, transient source terms necessary for this simulation. The performance of the compressor during the transient surge event is described by a set of compressor characteristics, including reverse flow and rotating stall regions, obtained from a validated 3D throughflow code, ACRoSS. To replicate the exact response of multi-stage compressors, stage-by-stage characteristics are used during reverse flow. The low-order method presented is successfully verified against ACRoSS for a high-power surge event of a coupled IPC and HPC configuration. The rate at which the total pressure at the outlet of the HPC collapses was calculated to be within 1%. This approach presents a faster alternative to high-fidelity CFD and can be used to investigate the compressor stall behaviour within minutes during the early design phase.
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    Multidisciplinary methodology for turbine overspeed analysis
    (Cambridge University Press, 2018-11-15) Eryilmaz, Ibrahim; Pawsey, Lucas; Pachidis, Vassilios
    In this paper, an integrated approach to turbine overspeed analysis is presented, taking into account the secondary air system dynamics and mechanical friction in a turbine assembly following an unlocated high-pressure shaft failure. The axial load acting on the rotating turbine assembly is a governing parameter in terms of overspeed protection since it governs the level of mechanical friction which acts against the turbine acceleration due to gas torque. The axial load is dependent on both the force coming from secondary air system cavities surrounding the disc and the force on the rotor blades. It is highly affected by secondary air system dynamics because rotor movement modifies the geometry of seals and flow paths within the network. As a result, the primary parameters of interest in this study are the axial load on the turbine rotor, the friction torque between rotating and static structures and the axial position of the rotor. Following an initial review of potential damage scenarios, several cases are run to establish the effect of each damage scenario and variable parameter within the model, with comparisons being made to a baseline case in which no interactions are modelled. This allows important aspects of the secondary air system to be identified in terms of overspeed prevention, as well as guidelines on design changes in current and future networks that will be beneficial for overspeed prevention.
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    Three-dimensional through-flow modelling of axial flow compressor rotating stall and surge
    (Elsevier, 2018-04-17) Righi, Mauro; Pachidis, Vassilios; Könözsy, László Z.; Pawsey, Lucas
    This paper presents a three-dimensional through-flow approach based on the cylindrical Euler equations incorporating a body force method. Blade performance is captured through a mixture of empirical correlations and a novel reverse flow treatment. The code is the first application of a physically correct Godunov solver to three-dimensional rotating stall and surge modelling. This solver ensures the accurate calculation of inter-cell fluxes unlike in typical modern CFD codes in which the non-linear convective terms are linearised. Validation consists of modelling a low speed three-stage axial compressor in all operating regions, recreating the reverse flow, rotating stall and forward flow characteristics with good agreement to experimental data. Additional comparisons are made against rotating stall cell size and speed, to which good agreement is also shown. The paper ends with some full surge cycle simulations modifying both the tank volume after the compressor and the level of inlet distortion applied. Both tank volume and level of distortion have been found to affect the type of instability developed. The development of this code is a step forward in compressor rotating stall and reverse flow modelling and allows recreation of a full compressor map at a significantly low computational cost when compared to commercially available 3D CFD codes.