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Research Papers

Advanced Nonaxisymmetric Endwall Contouring for Axial Compressors by Generating an Aerodynamic Separator—Part I: Principal Cascade Design and Compressor Application

[+] Author and Article Information
Christian Dorfner, Eberhard Nicke, Reinhard Moenig

 German Aerospace Center (DLR), Institute of Propulsion Technology, 51147 Cologne, Germany

Alexander Hergt1

 German Aerospace Center (DLR), Institute of Propulsion Technology, 51147 Cologne, Germanyalexander.hergt@dlr.de

1

Corresponding author.

J. Turbomach 133(2), 021026 (Oct 27, 2010) (6 pages) doi:10.1115/1.4001223 History: Received August 05, 2009; Revised September 03, 2009; Published October 27, 2010; Online October 27, 2010

Modern methods for axial compressor design are capable of shaping the blade surfaces in a three-dimensional way. Linking these methods with automated optimization techniques provides a major benefit to the design process. The application of nonaxisymmetric contoured endwalls is considered to be very successful in turbine rotors and vanes. Concerning axial compressors, nonaxisymmetric endwalls are still a field of research. This two-part paper presents the recent development of a novel endwall design. An aerodynamic separator, generated by a nonaxisymmetric endwall groove, interacts with the passage vortex. This major impact on the secondary flow results in a significant loss reduction because of load redistribution, reduction in recirculation areas, and suppressed corner separation. The first paper deals with the development of the initial endwall design using a linear compressor cascade application. A brief introduction of the design methods is provided, including the automated optimization and the 3D process chain with a focus on the endwall contouring tool. Hereafter, the resulting flow phenomena and physics due to the modified endwall surface are described and analyzed in detail. Additionally, the endwall design principal is transferred to an axial compressor stage. The endwall groove is applied to the hub and casing endwalls of the stator, and the initial numerical investigation is presented. For highly loaded operating points, the flow behavior at the hub region can be improved in accord with the cascade results. Obviously, the casing region is dominated by the incoming tip vortex generated by the rotor and still remains an area for further investigations concerning nonaxisymmetric endwall contouring.

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Figures

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Figure 1

Compressor cascade with cross flow visualization

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Figure 2

3D process chain of the automatic optimization

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Figure 3

Used endwall parameterization

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Figure 4

Novel endwall geometry

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Figure 5

Separation edge and aerodynamic separator

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Figure 6

Wall shear stress at the endwall

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Figure 7

Modified blade passage flow

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Figure 8

Streamlines: (a) blade passage; (b) suction side and endwall at trailing edge; and (c) trailing edge view

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Figure 9

Design point—radial distributions

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Figure 10

IDAC3—stator 3: endwall groove at hub and casing

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Figure 11

IDAC3—third stage: radial distributions

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