aerodays 2006 vienna - trimis · 2019-06-03 · control device for super aggressive ducts testing...

Volvo Aero, Aerotherm. dpt., S. Baralon2006-06-19, Slide 1

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Priority 4 Aeronautics & SpaceSpecific Targeted REsearch Project

AST3-CT-2003-502836Aggressive Intermediate Duct Aerodynamics for Competitive & Environmentally Friendly Jet Engines

Aerodays, 2006, Vienna

©2006 Volvo Aero Corporation

Aggressive Intermediate Duct Aerodynamicsfor Competitive & Environmentally Friendly Jet Engines

Coordinator & contact person: Stéphane Baralon, Volvo Aero, Sweden

AERODAYS 2006Vienna


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The engine and its intermediate ducts

Compressor

Intermediate

ducts

Turbine

Intermediate

duct


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Making Intermediate Ducts more Aggressive …

•Area ratio•dR/L•h/L

Compressor Duct Turbine Duct


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New integrated duct/vane design

concepts validated against

high quality engine realistic

measurementsts




measurementsts

Improved aerodynamic simulation tools through

code calibration and validation against high quality engine realistic

measurements



measurements

Derivation of new design

rules for aggressive and super aggressive

ducts



ducts

Validated and calibrated

optimisationmethods for aggressive duct design



5% reduction in aeroenginedevelopment cost

10% reduction in aeroenginetime-to-market



Reduction in component design

iterations


iterations

AIDA

Exploitable

Outcomes

6th FrameworkProgramme

Area

Engine

Significance

Reduction in overall engine design iterations


Component

Significance

1.3.1.1 a,g 1.3.1.1 a,g 1.3.1.1 a,g1.3.1.1 a,g 1.3.1.1 a,g1.3.1.1 a,g

Strengthening Competitiveness

Objective 1

Improved understanding of aggressive duct physics through combined use of experiments and simulation tools


Testing and CFD modelling

of passive control device

for super aggressive

ducts




ducts

20 % increase in compressor duct radial offset


20 % increase in turbine duct radial offset


20 % shorterducts

20 % shorterducts

1% reduction in engine SFC


1 % increase in downstream

turbine efficiency


turbine efficiency

1-2 % reduction in engine weight


0.5 % increase in compression

system efficiency


system efficiency

Reduction in risk for multi-component

integration problems



Reduced part count due to

increased blade loading



2.5 % improvement in airline operating margin for longhaulaircrafts, 2% reduced fuel burn.


AIDA’s contribution to strengtheningcompetitiveness





measurementsts




measurementsts



measurements



measurements



ducts



ducts










iterations


iterations

AIDA

Exploitable

Outcomes


Area

Engine

Significance



Component

Significance

1.3.1.1 a,g 1.3.1.1 a,g 1.3.1.1 a,g1.3.1.1 a,g 1.3.1.1 a,g1.3.1.1 a,g

Strengthening Competitiveness

Objective 1






ducts




ducts





20 % shorterducts

20 % shorterducts




turbine efficiency


turbine efficiency




system efficiency


system efficiency














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AIDA

Exploitable

Outcomes


Area

Engine

Significance

Component

Significance

2 % reduction in aircraft fuel burn and 2% reduction of CO2

emissions


emissions





20 % shorterducts

20 % shorterducts




turbine efficiency


turbine efficiency

1 to 2 % reduction in engine weight



system efficiency


system efficiency






concepts validated against high quality

engine realistic measurements

ts




ts



ducts



ducts








ducts




ducts

1.3.1.2 a 1.3.1.2 a 1.3.1.2 a1.3.1.2 a

Optimal engine configuration for Ultra High Bypass Ratio


Enabling factor for future low noise engines


Large Fan diameterReduced Low Pressure

spool speed


spool speed

Improvement of environmental

impact

Objectives 1 & 2

AIDA’s contribution to the improvement of aircraft environmental impact


AIDA

Exploitable

Outcomes


Area

Engine

Significance

Component

Significance


emissions


emissions





20 % shorterducts

20 % shorterducts




turbine efficiency


turbine efficiency




system efficiency


system efficiency








ts




ts



ducts



ducts








ducts




ducts

1.3.1.2 a 1.3.1.2 a 1.3.1.2 a1.3.1.2 a






spool speed


spool speed


impact

Objectives 1 & 2

AIDA

Exploitable

Outcomes


Area

Engine

Significance

Component

Significance


emissions


emissions





20 % shorterducts

20 % shorterducts




turbine efficiency


turbine efficiency




system efficiency


system efficiency








ts




ts



ducts



ducts








ducts




ducts

1.3.1.2 a 1.3.1.2 a 1.3.1.2 a1.3.1.2 a






spool speed


spool speed


impact

Objectives 1 & 2




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AIDA … in figures …The largest European programme on interduct aerodynamics:

• 4 years project with 16 partners from 7 countries:8 aeroengine manufacturers3 research institutes5 universities

• Total elligible budget of 8221717 € with a max. EC financing of 5607325 €

• 7 WorkPackages

• 778 Person Months, equivalent to the effort of a team of 18 experts workingtogether full time during 4 years

• 7 state-of-the-art test facilities:1 single spool and 1 two spool low-speed compressor and 1 high-speed compressor (WP1+WP3)1 low-speed and 1 high-speed turbine (WP2)2 facilities for passive control devices (WP4)


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AIDA … the project structure …Work Packages Partners

WP1 Fundamental Investigation of Aggressive Compressor Ducts R-R, VAC, MTU, SNM, TM, UCAM-DENG, LU, FOI

WP2 Fundamental Investigation of Transition Ducts for Turbines

MTU, RRD, ITP, SNM, TM, VAC, Avio, Chalmers, TU-GRAZ, UCAM-DENG

WP3 New Concepts and Integrated Compressor Duct Design VAC, R-R, MTU, SNM, TM, UCAM-DENG, LU, FOI

WP4 Passive Flow Control and Shape Optimisation

RRD, R-R, VAC, MTU, SNM, TM, ITP, Avio, UGEN-DIMSET, UCAM-DENG, Chalmers

WP5 CFD Analysis of Aggressive Transition Ducts

SNM, VAC, R-R, MTU, ITP, RRD, Avio, LU, Chalmers, DLR, ONERA

WP6 Data Integration and New Design Rules ONERA+All Partners

WP7 Project Management VAC, R-R, MTU, RRD, SNM, ONERA


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AIDA … the spine …

WP1, WP2 and WP3 Logic:

Component/rig design

Pre-test predictions

Experiment planning, layout, manufacturing, assembly

Measurement campaign

Post-test analysis based on measured boundary conditions

Critical review of computational and experimental results

WP4

Passive Flow C

ontrol & O

ptimization

WP5

CFD

Validation and B

enchmarking

WP6: Data Integration & Design Rules


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After 27 months of activity, an outline of the project achievements

The first tests and CFD based agressive duct designs have revealed:

• The conservatism in conventional duct design due to lack of understanding

• The complexity of the duct flow physics for both compressors and turbines

• The major influence of the upstream turbomachinery component on the flowdevelopment in the duct

• The suitability of shape optimisation for strutted or unstrutted duct design

• The potential of Passive Flow Control Devices to reduce the risk for separation


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WP1 Compressor DuctsCambridge Low-Speed Two-Spool Compressor Rig for duct with axial flow

CFD Predictionof duct exit

Test facility layout


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WP1 Compressor DuctsLoughborough low-speed one-spool compressor rig

for duct with swirling flow

Detail of Loughborough Single Spool Compressor and Duct Measured strutted duct exit flowTotal Pressure


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WP2 Turbine DuctsChalmers low-speed turbine rig

HPT subsonic stage + duct + LPT vanes


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WP2 Turbine DuctsTU-Graz high-speed turbine rig

HPT transonic stage + duct + LPT vanes

Phase locked measurementsof rotor wakes


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WP4 Optimisation & Passive Flow Control Devices

Measurement of Wake development

through the super-aggressive s-shaped duct.

- Cambridge -

Strut flow

CFD

Exp


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WP4 Optimisation & Passive Flow Control Devices

PIV measurements of flow field behind vortex generator- Genoa University -

Duct shape optimisation- Chalmers -


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AIDA … exploitation and dissemination prospects …Extensive exploitation in European engines and strengthened competitiveness of European industry is ensured as all European engine manufacturers are part of AIDA consortium,:

• Short term exploitable outcomes used in recent engine development programmes (787 engines, TP400, etc)

• Medium and long term exploitables outcomes in future engine development programmes to helpachieving the ACARE noise and emission reduction target

AIDA’s outcomes will act as enablers for the successful design of new promising engine configurationssuch as those proposed in FP6 European Engine Integrated Projects (VITAL, NEWAC) and FP7 JTIs & IPs

High quality fundamental and applied research (PhDs, Postdoctorates) at worldclass European Centers of Excellence ensures extensive dissemination in Journals and Conferences

AIDA’s work on passive control devices is expected to have an impact on a broad range of aerodynamic

engineering applications


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Backup slides


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The AIDA objectivesAIDA’s scientific & technical objectives:AIDA’s scientific & technical objectives:

•Improved understanding of the flow physics in aggressive intermediate ducts•System integration - Knowledge of how aggressive ducts interact with neighboring components•Development and tests of a new class of very aggressive intermediate ducts•Assessment of new advanced vane-duct integration concepts•Establishment of validated analysis methods and “CFD Best Practice Guidelines” for duct flows•Tests and modeling of novel passive separation control devices for super-aggressive ducts•Development of new numerical optimization techniques for intermediate ducts•Establishment of design rules and a validation database for aggressive intermediate ducts

•Improved understanding of the flow physics in aggressive intermediate ducts•System integration - Knowledge of how aggressive ducts interact with neighboring components•Development and tests of a new class of very aggressive intermediate ducts•Assessment of new advanced vane-duct integration concepts•Establishment of validated analysis methods and “CFD Best Practice Guidelines” for duct flows•Tests and modeling of novel passive separation control devices for super-aggressive ducts•Development of new numerical optimization techniques for intermediate ducts•Establishment of design rules and a validation database for aggressive intermediate ducts

AIDA’s impact on engine system optimisationAIDA’s impact on engine system optimisation

•1-2% reduced engine weight & length•0.5% increase in compression system efficiency•1% increase in low-pressure turbine efficiency•More optimal configuration for future low-noise ultra-high-by-pass-ratio jet engines•Reduced part-count in compressors and turbines due to increased loading•5% reduction of aero-engine development costs•10% reduction of aero-engine time-to-market

•1-2% reduced engine weight & length•0.5% increase in compression system efficiency•1% increase in low-pressure turbine efficiency•More optimal configuration for future low-noise ultra-high-by-pass-ratio jet engines•Reduced part-count in compressors and turbines due to increased loading•5% reduction of aero-engine development costs•10% reduction of aero-engine time-to-market

AIDA’s impact on duct designAIDA’s impact on duct design

•20% shorter ducts (with same radial offset and diffusion)•20% increase in duct radial offset (with same length and diffusion)•20% increase in duct diffusion rate (with same length and radialoffset)•50% reduction of duct design-time and design-iterations•50% reduced risk for late and serious duct related component integration problems

•20% shorter ducts (with same radial offset and diffusion)•20% increase in duct radial offset (with same length and diffusion)•20% increase in duct diffusion rate (with same length and radialoffset)•50% reduction of duct design-time and design-iterations•50% reduced risk for late and serious duct related component integration problems

AIDA’s impact on aircraft systemAIDA’s impact on aircraft system

•2% reduced fuel burn and C02 emissions•2.5% better operating margin for long-haul aircraft•A new class of low-noise engines

•2% reduced fuel burn and C02 emissions•2.5% better operating margin for long-haul aircraft•A new class of low-noise engines

aerodays 2006 vienna - trimis · 2019-06-03 · control device for super aggressive ducts testing...

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