CFD Modeling of Particle Ingestion Damage and Accumulation and its Attendant Impact on Multistage Axial Compressor Performance

Project: Research project

Project Details

Description

A three-year research program is offered to develop, calibrate and apply a coupled 3DCFD+throughflow performance prediction methodology that captures the effects of operational particle ingestion damage and accumulation/blockage on the performance of high-speed axial compressors. The tool will be calibrated using ~ clean, ~ uncoated damaged, and, ~ coated damaged configurations to be studied in a series of T700 engine runs at NAVAIR-Pax. The tool and analysis process will be conformed to reliably predict compressor efficiency as it deteriorates with effectiveparticle exposure time. This research will establish confidence that the damage, roughness morphology and material buildup elements of systems operating in these environments can be assessed in the context of their performance ~ and attendant effect on TSFC/specific thrust ~ based on exposure time and other parameters including particle type, and mission profiles. This research can significantly benefit the DoD~s ability to predict gas turbine engine performance subject tovarious coating schemes and operational environments, thereby enabling significant fuel cost savings and optimization of maintenance protocols. Professor Robert Kunz of Penn State~s Department of Mechanical Engineering will serve as Principal Investigator (PI) of the project, and with a PhD student, lead the technical development of the tool and its calibration against the PAX T700 data, as well as clean aero-thermo performance validation against clean multistagecompressor data. Statement of Work~ Perform multi-stage CFD analysis for clean, uncoated-damaged, and coated-damaged T700 configuration. Couple 3D CFD model of individual blade rows with an axial through-flow model, to obtain polytropic compressor efficiency for three cases per T700 engine test protocol: 1) undamaged blading, 2) damaged uncoated blading, 3) damaged coated blading. Work closely with researchers and engineers at NAVAIR-Pax in obtaining the necessary inputs for our models. These include as-tested annulus and blade geometries (pre and post-test), test conditions, andperformance data. Use optical scans obtained at Pax or PSU to develop CFD suitable damaged (and perhaps undamaged) test blade geometry. Compare and calibrate as needed the CFD analysis with the Pax measurements.~ Compare compressor performance vs. exposure time for the coated and uncoated systems, and develop a polytropic efficiency vs. exposure time correlation for the T700. ~ Apply the tool to modeled damage fields based on notional coating schemes. I.e., with NAVAIRinvolvement, test localized coating schemes in-silico, to obtain estimates performance tradeoffs associated with coating different regions of the compressor. Update the polytropic efficiency vs. exposure time model with these results, leading to guidance on coating processes. ~ Apply the tool to a larger Navy relevant axial compressor. ~ Evolve the project towards more mechanistic prediction of particle damage. To achieve this goal, apply modern Eulerian multiphase CFD modeling, coupling the effects of particle impaction to damage models which capture particle size, morphology, mass fraction, velocity, trajectory, and damaged geometry (deformation, erosion). DeliverablesYear 1: ONR reporting/documentation, technical review attendance/presentation.Year 2: ONR reporting/documentation, technical review attendance/presentation, demonstrated progress on PhD thesis, conference and journal publications.Year 3: ONR reporting/documentation, technical review attendance/presentation, completed PhD thesis, conference and journal publications.

StatusActive
Effective start/end date4/1/19 → …

Funding

  • U.S. Navy: $341,508.00

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