A physics-based framework for online surface roughness assessment for high-pressure turbines

Surface roughness is a critical health parameter of a turbine blade due to its implications on blade surface heat transfer and structural integrity. This paper proposes a physics-based online framework for Gas Turbine Engines (GTE), in order to assess the blade surface roughness in a high-pressure turbine without engine shutdown. The framework consolidates Gas Path Analysis (GPA) based performance monitoring models and meanline turbomachinery analysis, using a novel GPA-meanline matching process. This extracts meaningful performance deviation trends from GPA, while addressing the uncertainties associated with the measurements and modelling. To relate efficiency loss to surface roughness severity, a meanline-based system-identification process has been developed to establish the meanline representation of the turbine stage, and to incorporate the empirical surface roughness loss correlations. The roughness loss correlations have been evaluated against recent transonic test data in the literature. A modification to the compressibility correction factor has been made according to the evaluation outcome, which improved loss predictions compared to the experimental measurements. The framework was tested on the three-year operational data of a cogeneration GTE, and the results verified the framework's potential for online surface roughness monitoring. The predicted surface roughness showed agreement in both trend and the magnitude-level with the measurements reported in the literature.     

进口探针支杆尾迹诱发压气机转子叶片共振的数值研究

为了探究包含支杆直径10mm进口探针的压气机罕见地出现第一级转子叶片动应变超限报警的产生机理,以更换直径8mm+3mm的探针后报警解除的情况作为对比方案,开展了进口探针支杆诱发压气机转子叶片振动的流动机理研究。以试验压气机为研究对象,利用ANSYS APDL命令流语言使用载荷步文件法对该压气机转子叶片进行了单向瞬态流固耦合数值计算。结果表明,两类探针支杆尾迹影响下,压气机转子叶片都发生了共振;引起叶片共振的激振力频率来源于支杆尾迹诱导频率与支杆通过频率的叠加,其中支杆尾迹诱导频率是由支杆尾迹涡脱落与转子叶片通过非同相位所诱导产生;支杆直径减小,支杆尾迹引起的叶片表面激振力减小,使叶片振动应变相应降低。     

涡轮盘低循环疲劳的概率设计

基于涡轮盘结构的低循环疲劳设计流程,将概率设计理念融入设计过程中,提出了涡轮盘低循环疲劳的概率设计流程。首先进行涡轮盘结构的优化分析,其中以确定性设计准则作为约束条件;以优化结构方案为基础,考虑参数的随机性,对涡轮盘低循环疲劳进行可靠性分析;以低循环疲劳寿命的可靠度为概率设计准则,对涡轮盘进行反复的设计和计算验证,通过修改结构尺寸完成涡轮盘低循环疲劳的概率设计。同时,根据灵敏度分析结果,讨论了设计变量的分散性对涡轮盘寿命的影响,为进一步提高结构的可靠性提供了新的研究思路。结果表明,按照概率设计观点确定的涡轮盘结构兼顾性能和可靠性,在满足可靠度的前提下降低涡轮盘的重量。同时该概率设计流程简单方便,易于工程的推广应用。     

粉末冶金涡轮盘裂纹扩展寿命分析

采用J积分方法建立了断裂力学有限元模型,对FGH95粉末高温合金标准紧凑拉伸(CT)试样的裂纹扩展试验结果进行了数值模拟,分析了材料的裂纹扩展规律。计算结果与试验结果吻合很好,表明了分析方法的准确性及可行性。将该方法加以拓展,建立了含有不同尺寸缺陷的粉末盘断裂力学有限元模型,并对其裂纹扩展寿命进行了评估。与传统预测方法相比,该方法将给出更为实际的结果,可应用于复杂构件裂纹扩展特性的工程分析。     

大负荷低压涡轮叶型分离转捩流动的大涡模拟

应用动力模式大涡模拟数值方法,对来流无扰动、不可压、雷诺数为5×104(基于进口速度和轴向弦长),定常来流条件下大负荷低压涡轮叶型(Pak B)叶型吸力面非定常分离转捩流动进行了三维数值模拟。在与相关实验数据的对比基础之上,对非定常流动物理信息进行了详细的分析讨论,揭示了计算来流状态下的Pak B叶型吸力面非定常分离转捩流动机理。结果表明,由无粘Kelvin-Helmholtz机制产生的、空间线性增长的初始二维不稳定性在分离剪切内诱导展向旋涡形成并脱落,脱落过程中的展向涡在非线性增长的三维不稳定性作用下发生变形并最终破碎成湍流。计算得到的Kelvin-Helmholtz不稳定性特征频率处于相关实验测量范围内。     

叶片弯掠对多级风扇气动性能的影响

利用数值模拟的方法,研究了多级环境中叶片弯掠对风扇整体气动性能的影响。研究过程将弯、掠叶片分别应用于某三级风扇的第二、三级静叶,以对比性能变化并研究其内在的流场作用机制。结果表明,多级环境中弯掠叶片排可通过改变沿径向密流分布对其它叶排施加影响;弯和掠都能借助低能流体迁移控制端壁流动,但掠叶片同时具有对主流的迁移作用,这就使得掠叶片对沿径向密流分布的影响要大于弯叶片;随转速下降,弯叶片的流体迁移作用被增强,掠则相反。此外发现,在多级环境中单独使用时可获得性能改善的弯掠叶片,组合应用后并未获得双重的性能收益。     

涡轮叶片尾缘扰流柱通道流动换热计算

为了深入研究涡轮叶片尾缘扰流柱区域流动的工程计算方法,用开发的基于流体网络计算的一维工程算法,对工作叶片尾缘扰流柱通道进行了计算,并与实验结果进行了对比。计算结果表明:工程计算得出的弦向出流量分布、压力分布从规律和数值上与实验结果都吻合较好,工程算法能够比较准确地计算出扰流柱通道的流动;扰流柱区的气体流动方向基本为弦向,但也存在着一定的径向流动,所以有必要在流体网络计算中设置表示径向流动的流路。     

Identification of crystal orientation for turbine blades with anisotropy materials

A novel approach to identify the crystal orientation of turbine blades with anisotropy materials is proposed. Based on enhanced mode basis, with the main advantages of its efficiency, accuracy and general applicability, the blade vibration mode of each order is linearly constructed by several specified mode shapes, which are obtained from the considered turbine blade with specified crystal orientations correspondingly. Then, a surrogate model based on Kriging method is introduced for constructing the condensed perturbed matrix of stiffness in order to improve the efficiency even further. The constructed surrogate model allows to perform the modal analysis of turbine blades with arbitrary crystal orientations in higher efficiency, due to the fact that the elements of condensed perturbed matrix of stiffness are considered in construction of the surrogate model rather than concerning the perturbation of all the elements of the initial stiffness matrix for the blade. Genetic algorithm is finally employed to optimize the defined fitness functions in order to identify the crystal orientation angles of turbine blades. Several corresponding examples demonstrated the accuracy, efficiency and general applicability of the proposed method.     

Tip-leakage flow loss reduction in a two-stage turbine using axisymmetric-casing contouring

In order to reduce the losses caused by tip-leakage flow, axisymmetric contouring is applied to the casing of a two-stage unshrouded high pressure turbine（HPT） of aero-engine in this paper. This investigation focuses on the effects of contoured axisymmetric-casing on the blade tipleakage flow. While the size of tip clearance remains the same as the original design, the rotor casing and the blade tip are obtained with the same contoured arc shape. Numerical calculation results show that a promotion of 0.14% to the overall efficiency is achieved. Detailed analysis indicates that it reduces the entropy generation rate caused by the complex vortex structure in the rotor tip region, especially in the tip-leakage vortex. The low velocity region in the leading edge（LE） part of the tip gap is enlarged and the pressure side/tip junction separation bubble extends much further away from the leading edge in the clearance. So the blocking effect of pressure side/tip junction separation bubble on clearance flow prevents more flow on the tip pressure side from leaking to the suction side, which results in weaker leakage vortex and less associated losses.