j. a,cos~a · 2015-05-06 · dynamometer and power supply as can be seen in f;g. 1, the dynamometer...
TRANSCRIPT
![Page 1: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/1.jpg)
D.epartment of the Navy Bureau of Ordnance Contr<ict ,NOrd 9(>12
Iteport on Design · and tonstruction of ,.
THE AXIAL FLCW PUMP TEST FACILITY
T. W. FullE"r
and
· A '. J. A,cos~a
Hydrodynamics Laboratory California l11sti.tute of Technology
Pasadena, California
Report No. E -12.1J June 1953
' \
Approved by A. Hollander
![Page 2: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/2.jpg)
CONTENTS
Introduction
Objectives
De scription of Facility
General Description
Test Unit
Dynamometer and Power Supply
Instrumentation
Blade -Making Technique
Master Blade and Attachment Segment
Mold Making
Casting Procedure
Preliminary Operation
Acknowledgment
Page
1
2
3
3
4
5
5
7
8
9
10
11
12
![Page 3: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/3.jpg)
![Page 4: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/4.jpg)
INTRODUCTION
In studies concerned with the application of pumps to underwater jet
propulsion, it has been pointed out that cavitation may be avoided or sup
pressed by enclosing the pump {or propeller) in a suitably shaped shroud!:'
The advantages of avoiding cavitation are clear; namely, the elimination of
much noise, damage and vibration in addition to increasing the allowable
speed. However, a general discussion of the various flow processes which
lead to cavitation is not yet possible. For propellers, cavitation is observ
ed in helical trailing vortices and also on the blade surface proper, but for
other types of propulsion sy!..items, notably pump jets, neither is the location
known nor the cause completely understood. Roughly speaking, cavitation
will occur when local pressures reach the vapor pressure of the flowing liq
uid, however, the magnitude and location of these local underpre s sure s de
pend upon the complete history of the flow as it passes through the machine.
Consequently, minimum pressures may occur in the free stream in some
cases, or upon the blade surface itself in others. ·Thus, in order to study
cavitation phenomena, it is first necessary to investigate the detailed be
havior of the flow.
Apart from cavitation and noise, there are also other problems of
considerable importance in rotating axial flow machinery. Among the most
prominent of these is the behavior of the fluid in the boundary layer near the
rotor and stator blade tips, and the off design performance in the region of
f;talled flow. These questions are of great concern in the de sign and appli
cation of axial flow compressors and, as long as compressibility effects
are negligible, they may be investigated just as well in water as in air.
Moreover, inasmuch as the kinematic viscosity of air to that of water is
thirteen to one {at atmospheric conditions), machines can be made to oper
ate in water at the same Reynolds numbers as in air at 1nuch reduced speeds,
sizes, power consumptions and blade stresses, and as a result of these facts
the inst<:.llation and ope rational costs are also lower than for the comparative
air machine. The cost of th~ blading of a compressor is a major portion of
the total cost of the machine 2.nd, therefore, the high expense of installing
different blade designs for research purposes prohibits extensive
,~
r Wislicenus, G. F.' "Fluid Mechanics of Turbomachinery, II
McGraw Hill, 194 7, p. 409.
![Page 5: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/5.jpg)
-2-
investigation. In 1951 the Hydrodynamics Laboratory at the California Insti
tute of Technology developed a m e thod of making inexpensive precision lead
alloy blades for axial flow pump test impelh:rs. As a result of this work,
interest was expressed by personnel of the Naval Ordnance Test Station and
staff members of the Institute in the application of such blade -making tech
niques for air compressor c.nd underwater propulsion research. It was
estimated that blades could be made for about one -eighth of the cost per
blade row of those in a research compressor currently operating at the
Institute. This attractive estimate lead to the consider2.tion of an axial flow
compressor run in water as a pump at relatively low speeds so that research
on cavitating and noncavitating flow could be done without prohibitive expense.
Under this contract, NOrd 9612, an axial flow pump with its enclosed circuit
was constructed and preliminary tests on a single stage of blading were run
by the first week of November, 1952. It is the purpose of this report to des
cribe the installation and show its usefulness for research.
OBJECTIVES
The principal objectives of this installation are the de sign of a suitable
facility to observe and study cavitation and cavitation noise phenomena, and,
furthermore, the development of blade -making techniques so that stage char
acteristic measurements can be obtained on a variety of blade types rapidly
and inexpensively. In general, in experimental work on turbomachines, two
types of information are sought. The first is the determination of over-all
performance, i.e. , flow rate, head, torque and efficiency; the second is
the knowledge of the internal flow details, for example profiles of internal
velocity, pressure and direction. Hence, in order to provide for a maxi
mum utilization of the facility, arrangements were made for obtaining both
kinds of information.
Apart from these considerations, wherever possible emphasis was put
on obtaining a highly flexible installation so that work would not be restricted
to any particular de sign.
In order to show some of the advantages obtained by water operation of
an axial flow turbomachine, the following table was prepared:
![Page 6: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/6.jpg)
-3-
TABLE I
Ratio of water to air machine parameters at the same Reynolds number, blade solidity and for similar characteristic curves. The last case (with the asterisk) represents the design of the test facility described h e rein.
No. of Diameter Spe,ed Power Blades
l. 00 0.08 0.39 1. 00 0 . 28 1. 00 1. 40 1. 00 0 . 39 0.54 1. 00 1. 00
l. 00 0.04 0.05 0 . 50 0.20 1. 00 0.25 0.50 0 . 05 16 . 00 l. 00 0.50
0 . 39 ~' 0.27 0. 15 0.53
DESCRIPTION OF FACILITY
G e ne r al Description
The foregoing objectives led to the des i gn of a vertically mounted test
unit installed in a simple closed hydraulic circuit using water as the working
fluid. The rotor i s externally driven and provides the only power for flow
circulation
The circuit it s elf consists of the test pump which discharges into a
vaned elbow and thenc e into a diffusing section . Anothe r vaned elbow
di re cts the flow through a s e cond diffusor and hence into an internal "lattice"
type throttling d e vice . The circuit is closed through two more vaned elbows
and a 6:1 contr a ction nozzle. The component parts, i. c., diffusers, elbow,
etc., are fabricated from 1/4-in. galvanized plate . All e lbows are con
structed with 90° turning vanes which have a spacing chord ratio of 0. 46.
The first two elb ows have contoured vanes, i.e., of varying thickness,
whe r e as the last two have vanes rolled from 3/16-in. stock.
The test unit and dynamometer are mounted separately on rigid steel
bas e s grouted to a concrete wall. Auxiliary pressurizing and evacuating
circuits are provided so that the ambient pressure in the circuit can be
arbitrarily fixed between 25 psi and 20 in. Hg of vacuum. The test unit is
![Page 7: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/7.jpg)
~· :
-4-
about 40 in. long and 14 in. inside diameter, and can accommodate up to
three stages of blading. Although rotative speeds of about 600 rpm are ob
tainable with the power available , speeds as low as 200 rpm may be used
and still obtain Reynolds numbers based on blade chord of about eighty
thousand. A general view of the test flow and pumping circuit is shown in
Figs. 1, 2, and 3.
Te s t Unit
The test unit is vertically mounted and is split longitudinally in halves,
as can be seen in Fig. 3. The general de sign features are shown in Fig. 4.
One -half of the pump case is bolted and dowelled to the mounting plate and
the other half is removed by a roll-a-way jig assembly which is permanently
attached to the structure . The same jig is also used for the removal of the
rotor assembly . The removable casing-half contains a lucite viewing win
dow which runs the full length of the rotor and extends over 45 ° of the blade
tip circumference. Flow surveying ports are also installed in the remov
able casing-half behind each of the four stationary blade rows as well as a
single surveying hole behind each of the rotor row po s itions. Static piezom
eter take-offs are located in the fixed casing-half between every blade row.
The stationary blades (i.e. , entrance, stator and s traightening) are
attached to 2-in. wide circular segments which are fastened into grooves
machined in the casing halves with countersunk screws. There are eigh
teen stationary blades per row and sixteen rotating one s. The rotor blades
are attached by means of segrr1ents in the sarne manner as the stator blades.
The casing is grooved at each end to receive the rotor bearing sup
ports but, when in operation, the rotor shaft is supported by means of the
drive line from the lower dynamometer motor bearing, the two bearing
supports in the casing merely acting as guides for the rotor. The rotor 1s
keyed onto the hollow shaft and held against thrust by a snap washer. The
upper end of the rotor shaft is connected to a universal joint. The drive
shaft then pas s es through a guide sleeve in the first elbow where leakage is
prevented by a mechanical seal.
Streamline ogival sections are mounted in front of and behind the hub
section .
![Page 8: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/8.jpg)
-5-
Immediately preceding the test unit is a loose spool piece and packing
assembly for easy removal of the case-half. A surveying plate is provided
immediately downstream of the contraction nozzle so that the flow distribu
tion entering the test unit can b-= determined.
Both rotor and case are cast in red brass. All shafting is of stainless
steel and all bearing surfaces are hard chrome plated and ground. The
bearing guides are of lead-bronze and are water lubricated. The test unit
can be disassembled with the rotor removed in about three man hours.
Dynamometer and Power Supply
As can be seen in F;g. 1, the dynamometer is vertically mounted about
three feet above the pun1p. The dynamometer motor is supported from below
by a large, dl ep-groove helicopter bearing and is guided at the top by a self
aligning ball tearing. Through an 18-in. arm fastened to the motor body
torque may be measured by balancing the reacti on with pan weights support
ed by a wire and pulley system. Electrical contacts on the torque arm indi
cJ.te motion of 0. 005 in. or so, and for accurate balance a Statham electri
cal strain gage is used . The sensitivity of the torque measuring system is
about 0. l in. lbs.
The motor is rate d at 30 hp at 1750 rpm, 230 volts de, corresponding
to 1,100 in. lbs torque. Power is supplied by a 30 kw thyratron rectifier.
A diffeJ.cntial gear box, supplied by Boller and Chivens vf South Pasadena,
is used to establish speed in unit rpm increments from about 150 rpm
through the full range. With this controller speed regulation is maintained
to within one part in ten thousand on the average.
Ins trume nta tion
The me.::..suremcnt o torque and speed has o.. lready been mentioned.
The other over-all quantiLcs which must be determined are the flow rate
and head. The pressure drop across the contraction nozzle upstream of
the tesi. unit p1.·ovidcs a convenient signal for determination of the system
flow rc..te. The nozz le is calibrated by means of a velocity survey taken at
its exit section (Fig. 4). As an aid in determining over-all head rise, total
head rakes with nine pr ob~ s each are set flush and faired into each of the
three legs of the downstream bearing support. A n1ultitube manometer bank
![Page 9: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/9.jpg)
-6-
is then used to measure the total head rise across the complete machine.
The details of the internal flow may also be measured through the sur
veying ports installed in the casing. Each of the ports, or slots, behind the
station~ry blade rows extends approximately over two blade passages so that,
if necessary, minutely detailed surveys of the stationary blade wakes could
be obt;;ti.ned. However, in the interest of simplicity and in order to avoid
scaling problems, the probing instruments are located by a plug, which fits
i.nto the : slot and which has holes drilled in it in radial increments of 4°.
The plug is so machined that when it is rotated 180° the radial holes are
shifted by 2°, hence allowing surveys to be made in 2° angular increments
:1cross the two blade passages. When not in use, the holes in the plug are
filled ,M"ith insert pieces, and blank plugs are used to fill the remaining ports.
A specjq.l probe holding device was made so that the probe could be position
ed ra<Ua.lly and angularly to within 1/64 in. and 1/4°, respectively. The
probe holder, probe and plug assembly ready for installation into the sur
veying Jport are shown in Fig. 5. The probe holder may also be mounted in
a surv.te;;ying station behind each of the rotor blade rows. An assortment of
various types of probing instruments has been made, i.e., a venturi-type
total he:ad probe (Kiel), boundary layer probe, static pressure probe, and
a cl3.w-type direction measuring probe. The direction and static probes
are c2.l~brated in the discharge jet of a large ratio contr3.ction nozzle using
air as the medium. These probes are shown in Fig. 6.
FC?r the determination of the pressure signals from the probing de
vices a 1-psi liquid service, Statham differential pressure, electric strain
gage is used in conjunction with a Baldwin-Southwark strain gage bridge.
With the use of this transducer, pressures can be measured to 1/1000 of
the full-scale reading, and the flow angle can be determined to within 1/2°.
A differential carbon tetrachloride -water manometer is used to measure
the pressure drop across the contraction nozzle and, for the determination
of system pressure, a rncrcury-water manometer is used.
In order to know accurately the rotor blade tip clearances as install
ed in the machine, four equally spaced holes are provided in the case at
the first and third rotor row locations for depth micrometer measurements.
A hydrophone tap for the detection of cavitation noise is situated be
hind the first rotor blade row. Acoustic equipment for listening in the
![Page 10: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/10.jpg)
-7-
range of 20 - 100 kc is available in the Laboratory.
An instrumentation feature which, although not novel to this facility,
is still quite unusual, is an arrangement for making flow surveys relative
to the moving rotor. These n'1easurements are made possible by the hol
low drive shaft. Pressure signals, i.e., total head, static, etc., are
transmitted through small tubing from the rotor through the drive shaft
to a manometer which is mounted on and runs concentric with the drive
shaft outside the machine (Fig. 1). The pres sure readings can then be
read with the aid of stroboscopic illumination.
One of the main features of this facility is the viewing window. This
window allows cavitation phenomena to be directly observed, and with
the injection of suitable flow tracers, the flow relative to either the rotor
or stator blades can be visualized, and with the use of suitable photographic
techniques quantitative data can be taken.
BLADE-MAKING TECHNIQUE
The test unit is designed for a maximum of three stages of blading.
The stationary blade rows have eighteen blades each, and the rotor rows
sixteen each. A maximum chord of about two inches is all that can be used
and, as a result, the blade aspect ratio is about 1-1/2 . The use of fewer
blades of lower aspect ratio than is common for compressor de signs results
in higher strength blades and lower cost per blade row as well. The use of
water as the working fluid allows the rotative speed to be about 200 - 300
rpm and yet obtain Reynolds numbers on the order of 80, 000 - 120, 000 and
at these speeds bending stresses in the blades are quite low so that mater
ials of low strength can be used for blade manufacture.
For this work an alloy of lead and bismuth was selected rather than
a plastic because of its superior dimensional stability 2.nd casting ease.
Inasmuch as information on fabrication of blading for such research ma
chines is not readily available, the following rather detailed description of
this blade-making process is included for those who wish to do similar work.
The blades are precision cast of commercially ::1vail2.ble, low melting
point a lloys (e. g . , "Cerro-cast", "Cerro-dent") in plaster molds. The
blade is cast onto a brass holding fixture in order to simplify the casting
![Page 11: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/11.jpg)
-8-
and attachment problems. The molds are made in two pieces 1 each half be
ing formed on an accurately machined ,brass master blade. One master
blade is provided for each of the four types of blades in the machine I i. e. 1
entrance 1 rotor 1 stator and straightening.
The design and layout of compressor and pump blades is generally done
in cylindrical coordinates. The maC'hining of master blades is then also done
in the same system in order to avoid, tedious coordinate transformations.
Master Blade and Attachment Segment
The rna ster blades are made exactly to size with no allowance for mold
or casting metal expansion or shrinkage. This procedure is possible be
cause the molds when warmed expand the same slight amount that the cast
metal shrinks in cooling.
The rotor blade for the stage de~ign chosen has considerable twist.
Consequently, the master blade is first roughed out approximately 0. 060 in.
oversize on a pantograph milling machine. However, for blades with little
twist this operation is not necessary. A double size plaster blade surface
is used as a pattern, and it is made by spotting the surface of a plaster
block with a pointed cutter on a milling machine and carving to shape (Fig. 7 ).
The master blade is then roughed out from brass stock (Fig. 8} and subse
quently positioned on a milling machine for the final spotting operation (Figs.
9 and 10}.
The blade twists about a radial line through the centroids of the vari
ous section profiles. The rough machined brass stock is set up on the ma
chine so that radial, angular and elevation coordinates are •..! stablished from
this line. For ease of the finish s~t>tting, a Bridgeport milling head attach
ment is tilted normal to the average chord angle of the blade. The radial
and elevation coordinates on the blade surface are obtained by using the
vertical and horizontal traverses of the milling machine and a rotary table
pt-ovides the angular coordinate.
A sharp conical tool spots the werk by being extended against the spin
dle stop and then retracted out of the way while the machine is reset far the
next spot. Once one side of the blade has been finished, the work is rotated
180° about the centroidal radial line without changing the original tool setting
in order to locate the work for spotting the other side of the master. (The
![Page 12: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/12.jpg)
-9-
leading edge is up for spotting one side, down for the other.) For accuracy,
an indicator was used to establish the elevation dimensions rather than the
lead screw of the mill.
The spotted surface is carefully smoothed down by hand filing until the
last traces of the spots just disappear. Figure 11 shows this process in de
tail, and Fig. 12 shows the completely filed master blade assembled to a
s e gment of the rotor hub . An unmachined po r tion of the original stock
serves as a refe rence plane so that the blade may be accurately positioned
relative to the s e gme nt. The segment is made from a ring that fits into the
grooves cut into the rotor hub. Each segment is finished to size in a com
bination mill and drill jig, and is held and aligned in the rotor groove by two
counter sunk cap screws. The same jig is used also to locate the tapped holes
in the rotor shell to hold the segments. The segment attached to the master
blade is the same as all others except that it does not have the milled "cast
ing groove 11 shown in the segment at the right side, of Fig. 17.
Mold Making
A complete mold has three parts; two plaster halves which define the
blade surface and an attachment segment which ultimately bee orne s an inte
gral part of the finished blade. Each of the plaster parts receive an impre s
sion from the assemble d master blade and segment so that the attachment,
or holding piece, has the same alignment to the blade as does the tnaster
blade and segment assembly. Thus, blade alignment is determined in the
initial machining ste p and is carried through the operations of mold making,
casting and subsequent installation in a manner similar to that of production
jigging.
In detail, the mold making operation is as follows: Fig. 13 shows the
master blade and segment and the various parts that cornprise the mold box
partially assembled. The master blade , mold box bottom, two half sides
and two ends are as sembled . The blade and segment are held by the right
hand mold box e nd and clay is filled in under the blade and trimmed care
fully to the top of the mold box half sides and the leading and trailing edges
of the vane (Fig. 14). With the othe r two half side s a s s e mbled, the box is
filled with "Hydrocal B-11" plaster mix and vibrated (Fig. 15). After the
plaster has set, the original half sides, bottom and the cla y are removed
![Page 13: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/13.jpg)
-10-
(Fig. 16). A good parting agent (silicone or potter's soap) is then applied to
all exposed surfaces and wiped off to leave a finely lubricated surface. The
two original half sides of the mold box are re-assembled and then the sec
and mold half is poured. Figures 17 and 18 show the completed mold dis
assembled. The mold halves are drie d in an air circulating oven at 130° F.
for 72 hours, and then wiped claan of parting compound, dust and impuri
ties with carbon tetrachloride.
Casting Procedure
A wooden box replaces all of the mold box parts except the segment
holding end piece. The wooden box is so arranged that the mold halves
a re clamped together and the segment-holding end, containing the segment
with " c a sting groove", is clampe d in turn against the halves (Fig. 19).
This arrangement reduces parting line flash to a minimum.
The molds are heated to approximately 130° F. in an oven and then
placed on a centrifugal casting machine arm . A heated carbon crucible is
lined up with the mold pouring hole (Fig. 20). The alloy is melted and
pour e d into the crucible at 350° F. The arm of the casting machine is
quickly accelerated to about 300 rpm and the machine rotate d for about
fiv e minutes until the metal is se t. The mold and metal temp e ratures
must be varied d e pending on the shape, size and thickness of the blade un
t il a good casting is obtained. All blades are then cast using the s ame .
t e mpe ratures. It is desirable to use as cool a mold as possible to mini
mize the rmal expansion and to pr e serve the surface of the mold cavity.
One mold casts 15 to 20 blades before the reproduc e d surfac e s become
significantly les s smooth tha n the master blade.
With the exception of the str a ightening blades, all blades were cast -,
in "Cerrocast " since it appe ar e d to have the n1ost satisfactory strength · .rt r
char:1ctc ristic s of the low-m e lting point alloys available and, furth e rmor.:!, . s e ems to have sufficient corrosion re s istance for use in water.
After fabrication a few bla d e s W<:; re randomly selected for in spec- :.-J
tion. It was found tha t the cast blade s w e re within 0. 002 in. per in. and "
1/10 d e gree chord a ngle of the de sign calculations. The out s ide diamete.J(l
of the rotor blade s and inside diamete r of the stator blades are trimm~~.d
by m a chining a cornple t~ blad e row in a jig to give the desired running tipr
![Page 14: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/14.jpg)
-11-
clearances. The cost per blade including cost of the master, molds, casting,
and blade trimming is less than $2.0. 00. The original tooling, of course,
may be used to make new sets of blades. A new set of entrance, stator and
rotor blades can be completed in our shop within two months.
In the event that much higher rotative speeds are desired, e. g., 400
rpm and up, the blade root bending stresses exceed the allowable values for
these low melting point alloys so that it becomes necessary to employ other
bb.de -making m e thods. As a simple alternative, wax blades can be cast in
the molds made as previously described and used as expendable patterns in
an investment process to obtain aluminum , brass or beryllium copper blades.
How2:ver, in order to obtain the accuracy afforded by the foregoing method,
allowance must be made for the wax and metal shrinkages.
PRELIMINARY OPERATION
One stage of "free vortex" blading was manufactured by the process
described in the foregoing sections. The blade design is the same as that
used in a compressor research program at the California Institute of Tech-1
nology. The characteristics of this stage are:
design flow rate ~ = cm 2 /u 2 = 0.45, 1f = b.H = 0. 4
and the 50% reaction point is at a radius ratio of 0. 70, 0. 6 being the ratio of
the blade root to tip. The spacing/chord ratio is about unity at the 50% re
action point with a blade aspect ratio of about 1-1/2, the chord being about
2. in. The "as-installed" tip clearance on the rotor varies between . 007
and . 008 in. A detailed tabulation of the characteristics of this de sign may
b e found in Ref. l.
Profile measurements were made first across the exit section of the
contr2..ction nozzle in order to dett:rmine the volume flow rate through the
machine. Two velocity traver '?\0! s taken in mutually perpendicular dirzc
tions, shown in Fig. 2.2., indicate that the flow entering the test unit is fairly
1 Bowen, Sabcrsky and Rannie, "Theoretical and Experimental 1nvestigations of the Axia l Flow Compressor", California Institute of Technology, 1Viechanical Enginee ring Department, Parts 1, 2. and 3.
![Page 15: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/15.jpg)
-12-
uniform although there is about a 1/2-in. boundary layer at the walls. In
order to check the hydraulic design of the pump and circuit, and to evaluate
the usefulness o£ the instrumentation velocity, flow direction and total head,
traverses were made across the entrance, rotor and stator blade rows at
the de sign flow rate and are shown in Figs. 23 to 25. A more detailed in
vestigation of the internal flow and measurement of the over-all character
istics are deferred to a later date so that the present data should be re
garded as tentative. However,_ it is clear from these plots that there is
gener2..l agreement between this data and that of Ref. 1, from which this de •
sign was taken, even though some discrepancies do appear. Apart from any
effects of the differ~nt aspect ratio, these differences seem to be due to the
inlet boundary lay~r on the wall, which is about twice as thick as that of the
air machine, and the fact that the prewhirl vanes do more turning than do
those of Ref. 1. It is of interest to note that the potential flow calculations
of Hlavka (unpublished) afford a quite good estimate of the entrance vane
turning angles (Fig. 23).
The total head rise across the rotor is not a true, weighted power
aver ~.ge, but consists of an average head, weighted with c:..r2a.
For this work the Reynolds number based or.. blade, chord and axial
velocity was 80,000 while the rotative speed was only 200 rpm.
The maximum flow rate coefficient obtainable with the pre sent single
stage is 0. 53, which is adequate for all blade designs anticipated. The
n1echanical details, i. e. , throttling device, pressurizing and evacuating
controls all worked satisfactorily over the desired range of variables.
ACKNOWLEDGMENT
The authors would like to acknowledge their indebtedness to Profes
sors A. Hollander and W. D. Rannie for their advice, interest and sup
port of this project. They would also like to express their thanks to
Messrs. D. A. Rc.ins, G. M. Hotz and E. Daly, without whose aid the
design and construction would not have been possible; and lastly to Mr.
Rudolph Lorman for the services of his exceptional instrument shop.
![Page 16: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/16.jpg)
'o
N
N
AX
IAL
F
LO
W
PU
MP
:'f?.'
O~f-:
s.'/i
-:!'.:·
-tit-------
lJI-
---.
.N
CO
NT
RA
CT
ION
N
OZ
ZL
E
I j T
HR
OT
TL
E
VA
NE
S
Fig
. 1
-S
ch
em
ati
c d
iag
ram
of
pu
mp
ing
cir
cu
it a
nd
in
stall
ati
on
.
Fig
. 2
-Assem
bly
vie
w o
f te
st
flo
or.
-VJ
![Page 17: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/17.jpg)
-14-
Fig. 3 - Machine open installed with one stage of blading showing the viewing window.
![Page 18: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/18.jpg)
TO
TA
L H
EA
D R
AK
[:."
'\
•
( TY
D.
3 P
Lt>
CE
;'j
QO
IOQ
. V
t>N
t.
(o
<0 I
0 <:!
CO
NT
QA
CT
\ON
~
,;~~
:~?~
~ENTQANC~
VA
N[:.
_5U
_I2.
V\2
:{_!
2_LA
-TE
~LOOP.
LE
VI;
L
~-
l ~~~--...,--~~-~
II I' li ,,
~
11'1
BE
A-Q
ING
11 ~
I
li li
lr~~~~~~~~~___,,
il~ll-
1 II
I -~
11
I ffit
A
r (\J I -
' V
IE\f\
IIN
G \
f\1\N
DO
IN
-_f
'f<
QB
E._
l:iQ
LQtc
:R ~
J:>L\
,JG
A55
E_l
0.
Fig
. 4
-A
ssem
bly
test
un
it.
ME
CI-1
AN
\CI'.
L 51
-1A,
I:T
SE
AL
EtJ
B
(HA
L I=
S\Z~
HV
OR
'OO
YN
AM
lCS
L
AB
OQ
A.\
Y
CA
L\F
OQ
.N.l,
b. ~~.~~ TE
.CH
I<.lO
LOG
Y
AX
IAL
F
LO
W
PU
MP
A-S
SE
MB
LY
ll<IJ.C..Cll~ 6·
18-~
I¥:A
l.ll
-Q..
JA0:
1E~'
tNOi
"ED
: ;j,
?f.-~J
N
-70
46
-Y
.......
\}1
![Page 19: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/19.jpg)
Fig
. 5
. P
rob
e h
old
er
wit
h p
rob
e i
n p
lug
.
Fig
. 7
-S
po
t m
ach
inin
g a
d
ou
ble
si
ze p
last
ic s
ur
face f
or
the p
an
tog
rap
h m
illi
ng
op
era
tio
n.
~1
'''1''
' li
1'1111
1 1'
1'1'
''11
I I
' .
1 i
I 2
. I 3
I.:
I 4'
i
--·
. ..t.._
__
. --
-~ ~-
--.-
-"
-.
,9 j
s ·1·1
1'11
111 ill
I .h
,L
'l!t
t H'
'
Fig
. 6
-M
iscell
an
eo
us
pro
be d
ev
ices
.
Fig
. 8
-R
ou
gh
mach
inin
g o
f ro
tor
maste
r o
n p
an
tog
rap
h m
ill.
I ......
0'
1
![Page 20: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/20.jpg)
Fig
. 9
-F
inis
h s
po
t rn
ach
ing
of
the ro
tor
rna s
te r
bla
de.
Fig
. 11
-
Han
d f
ilin
g m
aste
r b
lad
e t
o s
ize.
Fig
. 1
0 -A
no
ther
vie
w o
f th
e f
inis
h
spo
ttin
g o
pera
tio
n.
~ -:::
:!
-=1
I - -
:j=
Fig
. 1
2 -
Fin
ish
ed
maste
r b
lad
e a
ttach
ed
to
ho
ldin
g s
eg
men
t.
......
-..]
I
![Page 21: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/21.jpg)
-18-
Fig. 13 -Mold box partially assembled with master blade attached to end piece.
Fig. 14 - Mold box partially assembled Fig. 15 - Plaster mold half being poured. showing clay parting surface trimmed
at leading and trailing edges of the master blade.
![Page 22: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/22.jpg)
Fig. 16- Clay parting surface being removed from first mold hal£.
\
\
Fig. 18 - End piece ready for assembly with mold halves.
-19-
Fig. 17 - Completed plaster mold halves, mold box end and seg
ment with casting groove.
Fig. 19 -Clamping mold parts together prior to casting.
![Page 23: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/23.jpg)
-20-
Fig. 20 - Centrifugal casting setup showing metal being poured into crucible before
centrifuging into warmed mold.
Fig. 21 - Separation of mold halves showing cast blade,
![Page 24: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/24.jpg)
Cl z 0 (.) w
(f)
0:: w
a.
t- w
w
u. ~
>- t- - (.)
0 _J
w
>
_J
~
X
<l
4.0
3.0
2.0
1.0 0
wi~
09
~
®0
~
0®
0
· 0~ ~c ·0~0
®9
9 ·~
X X
X
NO
RT
H-S
OU
TH
T
RA
VE
RS
E
0 E
AS
T-W
ES
T
TR
AV
ER
SE
l
6 4
2 0
DIS
TA
NC
E
FR
OM
N
OZ
ZL
E
I I
2 4
CE
NT
ER
,
6
INC
HE
S
Fig
. 2
2
-V
elo
cit
y p
rofi
le a
t ex
it s
ecti
on
o
f co
ntr
acti
on
no
zzle
.
(f) w
w
0::
(!) w
Cl
(f) w
z <l >
w
(.) z <t
0::
t- z u:
r (!) ::::>
0 0:: r t- (!) z z 0::
::::>
t- ~
0 _J
u. ;....
30
28
26
24
22
20
18
) . .
16
6 5 A-
14
} .. 8
7
I
0 0 0 !:.
ST
AT
ION
5
ST
AT
ION
6
ST
AT
ION
7
ST
AT
ION
8
-----
CO
NS
TA
NT
'S
RU
LE
---C
AS
CA
DE
T
HE
OR
Y -----R
EF
ER
EN
CE
1
121-
------+
--------+
---------.----------
lOL--------------L------------~~------------~------------~
.6
.7
.8
.9
1.0
RA
DIU
S
RA
TIO
, t;r/r
2
Fig
. 2
3 -F
low
an
gle
beh
ind
en
tran
ce v
an
es.
T
he
soli
d l
ine i
s th
e m
ean
of
data
in
Ref
. l.
I N
1-'
I
![Page 25: J. A,cos~a · 2015-05-06 · Dynamometer and Power Supply As can be seen in F;g. 1, the dynamometer is vertically mounted about three feet above the pun1p. The dynamometer motor is](https://reader034.vdocuments.site/reader034/viewer/2022043016/5f38ffc312266c334b6b962b/html5/thumbnails/25.jpg)
-22-
.5 I I
-"'" ..r.\. /,MEAN (MEASURED)
r:? "' .I ..
... ::::l
' 0
u .4
-;- - r-~ r-- I · r-- ,-i-MEAN (INTEG RATED FROM CURVE)
0::: 0 1-
~ .3
0 z I w CD
>- .2 1-
l)
0 _J
w > ...J . I <[
X <[
0> C\J
' NN ::::l
' :I: ~
~
1-z w · -(.)
u. u. w 0 (.)
0 <[
w :I:
0 .6
. 5
.4
.3
.2
. I
0
f I
I I
.7 .B .9
RADIUS RATIO, '= r/r 2
Fig. 24 - Axial velocity profile behind rotor now at de sign flow rate .
I
~ AXIAL FLOW
..cr-- ~ REFERENCE / ./ 1--'~,
// /
K~ v //
¢
~ I
I _I
1.0
PUMP
I
/ "R \ 1\ I
1\ lw I-zl<t
(.!) a:
~~~ 0 0
,~ Re = 80,000
I N = 200 RPM
I
0 .I .2 .3 .4 .6 .7
FLOW C 0 E F F I C I EN T
Fig. 25 - Total pressure rise behind rotor row.