Browsing by Author "Tunstall, Richard"

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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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    Development of a research model to study the operability of a variable pitch fan aero engine in reverse thrust
    (Global Power and Propulsion Society, 2020-09-09) Rajendran, David John; Bentley, David; Azamar Aguirre, Hasani; Tunstall, Richard; Pachidis, Vassilios
    A rationale for the level of model fidelity required to provide the most representative flow field information to ascertain the feasibility of using a Variable Pitch Fan (VPF) in a modern high bypass ratio aero engine to generate reverse thrust is described in this paper. This is done by comparing the 3D RANS flow field solution for a newly developed reverse flow VPF design from two research models: i) isolated engine model in which the bypass duct, guide vanes, splitter and VPF are wrapped in an axisymmetric nacelle and placed in a generic far-field domain and b) integrated model in which the engine is installed to an airframe in landing configuration through a pylon and placed in a far-field domain bound by a rolling runway. The flow field solution obtained at an aircraft landing speed of 80 knots indicates that even though both models can predict the general flow patterns, there are substantial differences in parameters such as the amount of reverse stream, circumferential distribution of flow properties and flow development downstream of the engine. These differences impact the levels of reverse thrust generated, flow distortion entering the core engine and resultant airframe forces. This study makes the case that it is necessary to use an integrated model that includes a full engine nacelle installed on an airframe, to answer design questions for engineering the VPF system to generate reverse thrust.
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    Estimation of resultant airframe forces for a variable pitch fan operating in reverse thrust mode
    (American Society of Mechanical Engineers, 2022-10-28) Rajendran, David John; Tunstall, Richard; Pachidis, Vassilios
    The resultant forces with a reverse thrust Variable Pitch Fan (VPF) during the aircraft landing run are computed from the installed reverse thrust flow field obtained from an airframe-engine-VPF research model. The research model features a reverse flow capable VPF design in a future, geared, high-bypass ratio 40000 lbf engine as installed onto a twin-engine airframe in landing configuration, complete with a rolling ground plane to mimic the runway. The reverse thrust flow field during the aircraft landing run is obtained from 3D RANS/URANS solutions of the model. The evolution of the installed dynamic reverse thrust flow field is characterized by the interaction of the VPF induced reverse flow with the free stream. Several flow features like reverse flow wash-down by the freestream, external swirling helical flow development, pylon flow obstruction, 180° flow turn into the engine, subsequent separated flows, wake interactions and multi-pass recirculating flows are observed. The resultant airframe forces due to the reverse thrust flow field is estimated by adaptations of momentum based far-field and near-field methods. In the active thrust reverser engagement regime of 140 to 40 knots, the VPF generates a sufficient axial airframe decelerating force in the range of 45% to 8% of maximum take-off thrust. A drag decomposition study and a notional ‘blocked-fan’ analysis are described to understand the stack-up of the axial decelerating force. Additionally, the resultant force has a landing speed dependent lateral force component because of the pylon obstruction induced flow non-uniformity. A beneficial downforce component due to upward deflection of streamlines is also observed. The quantification of the resultant forces from the baseline installed airframe-engine-VPF reverse thrust flow field is a necessary step to explore the feasibility of the VPF reverse thrust system for future efficient turbofan architectures, understand force generation mechanisms and to identify areas for subsequent design improvement.
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    Estimation of resultant airframe forces for a variable pitch fan operating in reverse thrust mode
    (American Society of Mechanical Engineers, 2022-10-14) Rajendran, David John; Tunstall, Richard; Pachidis, Vassilios
    The resultant forces with a reverse thrust variable pitch fan (VPF) during the aircraft landing run are computed from the installed reverse thrust flow field obtained from an airframe-engine-VPF research model. The research model features a reverse flow capable VPF design in a future, geared, high-bypass ratio 40,000 lbf engine as installed onto a twin-engine airframe in landing configuration, complete with a rolling ground plane to mimic the runway. The reverse thrust flow field during the aircraft landing run is obtained from the three-dimensional RANS/URANS solutions of the model. The evolution of the installed dynamic reverse thrust flow field is characterized by the interaction of the VPF-induced reverse flow with the freestream. Several flow features like reverse flow wash-down by the freestream, external swirling helical flow development, pylon flow obstruction, 180 deg flow turn into the engine, subsequent separated flows, wake interactions, and multipass recirculating flows are observed. The resultant airframe forces due to the reverse thrust flow field are estimated by adaptations of momentum-based far-field and near-field methods. In the active thrust reverser engagement regime of 140 to 40 knots, the VPF generates a sufficient axial airframe decelerating force in the range of 45% to 8% of maximum takeoff thrust. A drag decomposition study and a notional “blocked-fan” analysis are described to understand the stack-up of the axial decelerating force. Additionally, the resultant force has a landing speed-dependent lateral force component because of the pylon obstruction-induced flow nonuniformity. A beneficial downforce component due to upward deflection of streamlines is also observed. The quantification of the resultant forces from the baseline installed airframe-engine-VPF reverse thrust flow field is a necessary step to explore the feasibility of the VPF reverse thrust system for future efficient turbofan architectures, understand force generation mechanisms, and to identify areas for subsequent design improvement.
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    Gas turbine sub-idle performance modelling : groundstart altitude relight, and windmilling
    (Cranfield University, 2013-01) Grech, Nicholas; Pachidis, Vassilios; Zachos, Pavlos K.; Rowe, Arthur; Brown, Steve; Tunstall, Richard
    Engine performance modelling is a major part of the engine design process, in which specialist solvers are employed to predict, understand and analyse the engine’s behaviour at various operating conditions. Sub-idle whole engine performance synthesis solvers are not as reliable and accurate as design point solvers. Lack of knowledge and data result in component characteristics being reverse-engineered or extrapolated from above-idle data. More stringent requirements on groundstart and relight capabilities, has prompted the need to advance the knowledge on low-speed engine performance, thereby requiring more robust sub-idle performance synthesis solvers. The objective of this study, was to improve the accuracy and reliability of a current aero gas turbine sub-idle performance solver by studying each component in isolation through numerical simulations. Areas researched were: low-speed and locked-rotor com- pressor characteristics, low-power combustion efficiency, air blast atomizer and combustor performance at sub-idle, torque-based whole engine sub-idle performance synthesis, and mixer performance at far off-design conditions. The observations and results from the numerical simulations form the contribution to knowledge of this research. Numerical simulations of compressor blades under highly negative incidence angles show the complex nature of the flow, with the results used to determine a suitable flow deviation model, a method to extract blade aerodynamic char- acteristics in highly separated flows, and measure the blockage caused by highly separated flow with operating condition and blade geometry. The study also concluded that the use of Blade Element Theory is not accurate enough to be used at such far off-design con- ditions. The linearised parameter-based whole engine performance solver was converted to used torque-based parameters, which validated against engine test data, shows that it is suitable for low-power simulations with the advantage of having the potential to start engine simulations from static conditions. A study of air-blast atomization at windmilling relight conditions has shown that current established correlations used to predict spray characteristics are not suitable for altitude relight studies, tending to overestimate the atomization quality. Also discovered is the highly influential interaction of compressor wakes with the combustor and atomizer under altitude relight conditions, resulting in more favourable lighting conditions than previous assumptions and models have shown. This is a completely new discovery which will result in a change in the way combustors are designed and sized for relight conditions, and the way combustion rig tests are conducted. The study also has valuable industrial contributions. The locked-rotor numerical data was used within a stage-stacking compressible flow code to estimate the compressor sub- idle map, of which results were used within a whole engine performance solver and results validated against actual engine test data. The atomization studies at relight were used to factor in the insensitivity of current spray correlations, which together with a newly de- veloped sub-idle combustion efficiency sub-routine, are used to determine the combustion efficiency at low-power settings. The interaction of compressor wakes with the atomizer showed that atomizer performance at relight is underestimated, resulting in oversized combustors. By using the knowledge gained within this research, combustor size can be reduced, resulting in lower NOx at take-off and a smaller and lighter core, with a com- bustor requiring less cooling air. The component research has advanced the knowledge and modelling capability of sub-idle performance solvers, increasing their reliability and encouraging their use for future aero gas turbine engines.
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    On hysteresis in a variable pitch fan transitioning to reverse thrust mode and back
    (American Society of Mechanical Engineers, 2024-06-24) Vitlaris, Dimitrios; Rajendran, David John; Tunstall, Richard; Whurr, John; Pachidis, Vassilios
    A novel hysteresis phenomenon during the transition to and back from the reverse thrust mode in a Variable Pitch Fan (VPF) is identified and characterised in this work. This is done by using a three-dimensional (3D) fully transient Unsteady Reynolds-averaged Navier-Stokes (URANS) with the transitioning fan blade aerofoils simulated by an adaptation of the mesh displacement method. A “real-time” simulation of the complete VPF hysteresis loop is achieved by specifying a blade wall motion through an Eulerian rotation matrix in differential, gradual steps, that is combined with a mesh probe-and-update routine for improved numerical accuracy and stability. The VPF is modelled to be transitioning in a modern 40000 lbf geared high bypass ratio turbofan engine architecture at “Approach Idle” engine power setting in a typical twin-engine airframe with the flaps, slats, and spoilers set for an aircraft touchdown airspeed of 140 knots. The transition to reverse thrust mode involves flow starvation into the engine, formation of recirculation zones in the bypass duct and the establishment of the reverse stream, all of which occurs in the opposing presence of the free stream flow at aircraft touchdown velocity. The transition back to forward flow mode involves the gradual re-establishment of the free stream which is opposed by the presence of the reverse stream within the engine. It is quantified that in the transition to reverse thrust, the blockage develops with a larger time delay than the disappearance of the blockage during the transition back due to the interplay of the temporal dynamics of fan blade motion and flow field response. The details of the changes in the flow field behaviour, the effect of engine power setting and aircraft touch down velocity on the hysteresis behaviour are explained in detail in the paper. Additional manifestations of the hysteresis phenomena at reverse thrust involving engine spool-up and down, and aircraft acceleration-deceleration manoeuvres are also explored. The hysteresis phenomena described in this work are critical in properly developing control schedules to adapt for potential bi-stable flow field development during the landing run. The study addresses another part of the puzzle in exploring the feasibility of reverse thrust capable VPF engines for future sustainable aircraft to reach aviation climate neutrality.
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    On the flow physics during the transition of a variable pitch fan from nominal operation to reverse thrust mode
    (American Society of Mechanical Engineers, 2023-12-01) Vitlaris, Dimitrios; Rajendran, David John; Tunstall, Richard; Whurr, John; Pachidis, Vassilios
    The flow field during the transition of variable pitch fans (VPFs) from nominal operation to reverse thrust mode at typical “Approach Idle” engine power setting and aircraft touchdown speed of 140 knots is described in this work. An integrated airframe-engine-VPF research model that features a future 40,000 lbf geared high bypass ratio engine installed on a twin-engine airframe in landing configuration is used to explore the flow field in a fully transient unsteady Reynolds-averaged Navier–Stokes (URANS) simulation with imposed wall motion. A novel methodology that implements an adaptation of a mesh displacement equation to mimic the fan blade airfoil rotation is developed. The implementation of this method with gradual, small-step deformation along with an automated mesh update routine enables a high quality, near “real-time” simulation of the complete transition. The flow field during transition is characterized by the evolution from full typical forward flow through the engine to the development of massive recirculation regions at the feather pitch setting and finally to development of a reverse flow from the bypass nozzle to the fan passages. In the paper, the transient development of the various flow features through different stations of the engine flow path apropos the fan blade airfoil rotation to reverse thrust mode are discussed in detail. Also, the temporal development of the mass flow ingested through the engine, airframe decelerating force, and distorted flow at the core engine inlet are described. A hitherto unresolved fan power peaking during the middle of the transition and higher power requirement at reverse thrust mode is captured. The effect of fan rotational speed in terms of engine power setting and the aircraft touchdown velocity on the transition flow physics is explored. A comparison of this fully transient approach with discrete steady-state runs for different stagger angle settings is presented. The flow physics during transition to reverse thrust mode as described in this study is critical in understanding the feasibility of using VPF for reverse thrust in future aircraft. The new capability to study the transition in a fully transient simulation can be used as a design development aid to define design and control characteristics of the reverse thrust VPF.