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Proceedings of ASME Turbo Expo 2006

Proceedings
Power for Land,ofSea,
GT2006
and Air
ASME Turbo Expo 2006:May 8-11,
Power for2006, Barcelona,
Land, Spain
Sea and Air
May 8-11, 2006, Barcelona, Spain

GT2006-90105

GT2006-90105

A TURBOMACHINERY DESIGN TOOL FOR TEACHING DESIGN CONCEPTS FOR


AXIAL-FLOW FANS, COMPRESSORS, AND TURBINES

Mark G. Turner Ali Merchant Dario Bruna


University of Cincinnati MIT University of Genoa, Italy
mark.turner@uc.edu merchant@mit.edu dario.bruna@unige.it

ABSTRACT A recent effort at Lund University [3,4] is a turbine


A new turbomachinery design system, T-AXI, is described analysis code available from within MATLAB. One needs to
and demonstrated. It is intended primarily for use by educators know MATLAB to run it, and this software is not available for
and students, although it is sophisticated enough for actual a compressor.
designs. The codes, example cases and a users manual are Because of these limitations, a new turbomachinery design
available through the authors web sites. The design system system, T-AXI, was created from some tools that had been used
can be used to design multistage compressors and turbines from by Merchant to create high pressure ratio aspirated fan designs
a small number of physical design parameters. Students can [5,6]. This new design system can create a new multistage
understand the connection between these physical parameters compressor or turbine from a table of design parameters. In
such as Mach number and flow angles to the cross sectional addition, the performance of an existing compressor or turbine
area and angular momentum. There is also a clear connection can be approximated. A built-in loss model is applied that has
between the angular momentum, work and blade loadings. most loss sources accounted for. A geometry generator is also
Loss models are built-in and results are compared against available so that an initial geometry can be created to jump-
tested geometries. The code also has a built-in blade geometry start a mixed inverse blade-to-blade design tool, estimate
generator and the geometry can be output for running the weights, or create a 3D blade that can be visualized or analyzed
MISES blade-to-blade solver on each section or visualizing the in 3D.
blades. This paper is intended to describe and demonstrate this
A single stage compressor from the US Air Force Stage new turbomachinery design system, T-AXI, for gas turbine
Matching Investigation rig, the 10 stage NASA/GE EEE high educators as well as undergraduates and graduate students
pressure compressor and the NASA/GE EEE 5 stage low studying gas turbines. Executable versions of the codes
pressure turbine have been used to validate T-AXI as a design making up this new design system are available from the
tool. authors web sites along with the examples shown in this paper
and a users manual. Although this design system is aimed for
INTRODUCTION educational use in the context of this paper, it is sophisticated
There are very few non-proprietary turbomachinery enough for creating actual designs.
design tools available for teaching fan, compressor or turbine
design. Mattingly [1,2] provides the codes COMPR and NOMENCLATURE
TURBN as part of a CD in ref. [1]. The algorithms for these
codes are described in [2], and this method of design has been a Speed of sound
extended in this paper. One of the issues with this software is c chord
that bleed and blockage cannot be analyzed, and only one value h Static enthalpy or blade height
of solidity can be specified for the entire machine. Blade gaps m& Mass flow
are also hard-coded. In addition, the loss in a blade row must q Meridional velocity magnitude
be specified in order to get an answer, and is not calculated.

1 Copyright 2006 by ASME


r Radius the blade row trailing edge, the rotation speed, blockage, and
s Entropy number of airfoils.
A Area T-AXI is an axisymmetric solver. Most axisymmetric
Cp Specific heat at constant pressure solvers use a streamline curvature method as described by
Smith [7] and Novak [8]. The method employed in the T-AXI
DR Diffusion ratio solver is more like the MISES algorithm [9,10]. Loss models
H Total enthalpy are applied at each spanwise section depending on whether it is
M Mach number a compressor or turbine. To increase the robustness of the
P Pressure calculation, the loss is smeared out just downstream of the
R gas Gas constant trailing edge. This has the effect of spanwise mixing described
Blade spacing, S = 2r / N blades
by Adkins and Smith [11] with an extremely simple approach.
S
The input walls and stack files can be created by hand
T Temperature for a general calculation. Detailed knowledge of the code non-
U Rotor wheel speed dimensionalization and formatting are needed to do this.
V Absolute velocity Alternatively, the compressor design code T-C_DES, the
W Rotor relative velocity turbine design code T-T_DES, or the turbine set-up code T-2-T-
Y Turbine loss coefficient AXI, can be used to automate the calculations based on design
Z Zweifel oefficient parameters. Straight leading and trailing edges are used
without contouring as well as a free-vortex assumption. A
Greek fourth approach to creating the input files for T-AXI is to
Absolute flow angle extract the axisymmetric geometry, trailing edge angular
Relative flow angle momentum and rotation rates from a 3D simulation. This
Blockage source approach has been used for the SMI example case, but is too
specific to make available for general use.
* Boundary layer displacement thickness
The input to T-C_DES is an init file, a stage file, and
Ratio of specific heats an optional igv file. If the igv file does not exist, it is
Blockage coefficient assumed that there is no igv in the design. These files provide
Tangential direction tabular input to the code that is similar to COMPR developed
Density by Mattingly [1]. The clearance ratio is the clearance divided
Solidity by radius. This is the tip radius for a rotor and hub radius for a
Rotor angular velocity stator. For a preliminary compressor layout, this one clearance
Compressor loss coefficient to radius number was felt to be more constant than a
clearance to height or clearance to chord ratio. The input to T-
T_DES is an init, stage, and an optional ogv file that are
Subscripts
similar to the T-C_DES input, but tailored for a turbine. The
h hub
input to the turbine set up code is an init file, a geometry file
t tip
(cgeo) with leading edge and trailing edge coordinates at the
x axial
hub and casing, and a file that describes the number of blades
Q Heat Transfer
and angular momentum for each blade row (cvth). Files that
S Secondary flow
can be edited have been used as code input. These could also
T Total
be accessed by an optimizer so that the T-AXI system could be
W Work
part of an overall compressor or turbine optimization system.
Tangential direction
The output of the T-AXI solver is a tabular listing of the
1 Leading edge
profiles of aerodynamic quantities at each leading and trailing
2 Trailing edge
edge. Profiles of loss, loading, and geometry are tabulated for
each blade row. Average loss, total pressure and temperature
ANALYSIS
ratio, and efficiency are calculated for each blade row as well
Figure 1 is a schematic of the T-AXI Turbomachinery
as the entire component. Given a maximum thickness to chord
Design System. It is made up of the T-AXI solver described in
ratio at the hub and casing, a blade shape is created for 5
detail later in this section, as well as the compressor and turbine
spanwise sections. This can be viewed as a 3D solid with a
design modules and the turbine set-up module. The T-AXI
Blade Viewer, or the volume and mass of a blade can be
solver works with non-dimensional input. The walls file
calculated. The 5 sections are also output as files consistent
defines the hub and casing geometry, and the stack file
with a MISES calculation [9,10]. A blade-to-blade solution can
includes the details needed for each blade row including the
therefore be obtained for this geometry including a coupled
leading and trailing edge geometry, the angular momentum at
boundary layer solution. MISES has been used by industry to

2 Copyright 2006 by ASME


igv.xxx
cvth.xxx ogv.xxx

init.xxx stage.xxx init.xxx cgeo.xxx init.xxx stage.xxx

Compressor Turbine Turbine


design code T-C_DES T-2-T-AXI Set-up code T-T_DES design code

ttdes-results.xxx
tcdes-results.xxx

walls.xxx stack.xxx
bladedata-xxx.dat

3D mesh
+ T-AXI Mises files Mises
Solution Blade Design

Compressor
or Turbine
Blade Viewer
Feedback
3D RANS blade3d.brx To T-AXI
Blade Volume
Figure 1. Schematic for T-AXI Turbomachinery Design System.

optimize airfoils as shown in references [12,13]. A mixed-


inverse option is also available so that an improved pressure
distribution can be specified, and a new blade shape Tt
T = (1)
determined. The ability of the design system to create a 1+ [( 1) /2]M 2
starting geometry can then be used to generate more optimum
blade sections. The output of MISES can also be used to Pt
P = /( 1) (2)
{1+ [( 1) /2]M 2}
update the loss and turning in the stack file to be fed back
into T-AXI. MISES is currently freely available for
educational use, and can be obtained from Mark Drela through
P
the ACDL website at http://raphael.mit.edu. For commercial
use it must be obtained through the MIT Technology Licensing
= (3)
RgasT
Office.
a = RgasT (4)
T-C_DES Compressor Flow Path Creator
The compressor design code T-C_DES is similar to V = Ma (5)
COMPR described by Mattingly [1,2]. The analysis presented
in reference [2] is similar except that a blockage term has been V x = V cos (6)
added that is often used by compressor designers to define the
build up of wakes and endwall boundary layers as well as other V = V sin (7)
non-uniform flow circumferentially. In addition, the input
allows for bleed, a unique solidity for each blade row, and the m&
flowpath for each stage is smoothed at the end of the design. A = (8)
The following equations can be applied from the given input. V x

3 Copyright 2006 by ASME


where is the blockage. In reality this blockage is a term that and the blade row gap parameters can be specified after each
represents the area reduction due to endwall boundary layers, nozzle and rotor. These additional input parameters allow for a
wakes, and other circumferential non-uniformities. For the T- very general turbine design capability.
AXI solver with the coupled boundary layer turned on, some of Eulers Turbomachinery equation is used for the turbine to
this blockage affect will be calculated. define the change in tangential velocity across the rotor just as
The cross sectional area is then: it was for the compressor. The equations used are similar,

(
A = rt rh
2 2
) (9)
except that the turbine loss coefficients are normalized by the
trailing edge dynamic pressure.
Pt 2 Pt1
A hub, tip or midspan radius is given. From this and the area, Y= (15)
the flowpath radii can be defined. It should be realized that the Pt 2 P2
design aspect of turbomachinery is to determine how the In addition, the Zweifel coefficient [14] is used to set the
flowpath area varies. This is the real output of this design number of blades in a blade row.
code, and is the critical quantity in an optimum compressor
S
design.
Z = 2 tan 1 tan 2 cos 2 2 (16)
The loss coefficient is specified as an input. The total
pressures in the following equation are relative total pressure if
cx
applied for a rotor. for a nozzle, and relative flow angles are used in Equation (16)
Pt 2 Pt1 for a rotor. The blade spacing S = 2r / N blades .
= (10)
Pt1 P1
T-AXI Solver
The average loss coefficient is also calculated in the T-AXI The T-AXI inviscid solver is based on the multiple
solver. The input loss coefficient can be updated, or viewed as interacting streamtube Euler equation formulation that is the
a parameter that is used along with the other parameters to foundation of several design codes developed by Drela and
create the flowpath area of the compressor. If the loss is not Giles [9] and Youngren and Drela [10]. In T-AXI, the
updated, the other specified parameters such as the Mach axisymmetric equations are discretized in a strong conservative
number and angles will not be set precisely, but will vary form on a meridional streamline grid. In contrast to typical
depending on the actual loss calculated. streamline curvature codes, T-AXI has no inherent limitation at
Eulers Turbomachinery equation is used to define the total high subsonic Mach numbers, and can be used in subsonic as
enthalpy rise due to stage work as well as supersonic flow regimes.
H W = d (rV ) (11) The streamwise momentum equation has the form:
V
Equation (11) can be applied across the rotor dp + qdq + [d (rV ) V dr ] +
( ) r (17)
H 2 H 1 = C p (TT 2 TT 1 ) = r2V 2 r1V 1 (12)
pd (s ) d (H W ) = 0
The free vortex assumption is applied where
rV = const Here, p is the pressure, is the density, and q is the
(13)
across the span of the blade row. The velocity triangle relations meridional velocity given by V x2 + Vr2 . The differentials d()
are: are applied at each grid point along each streamtube, including

V V r r r the blade rows. s is the prescribed entropy change in the
; V = x ; V = W + U
= tan 1

Vx cos streamtube that is a result of losses from various sources. The
entropy s is defined as
W

W = V U ; W x = V x ; = tan 1 p 1
Wx s ln inlet
h (18)
p hinlet
Wx
W= (14)
cos Here, h is the static enthalpy and p is static pressure. The total
enthalpy rise due to stage work is defined using Equation (11),
T-T_DES Turbine Flow Path Creator the Eulers Turbomachinery Equation. The angular
The turbine design code T-T_DES is similar to T-C_DES momentum, rV , is prescribed as an input along with the
described above and TURBN described by Mattingly [1,2]. rotational speed, , of the blade row. Therefore, the enthalpy
There are several advantages over the TURBN code: an change due to a compressor or turbine rotor is explicitly
average meanline radius can be specified for each blade row; available. The energy equation is also not explicitly solved, but

4 Copyright 2006 by ASME


the enthalpy at every point along a streamtube is calculated captures the effect of meridional velocity changes across a
using blade row and due to variations in the flowpath. While this
formulation does not model many of the effects seen in
1 2
H = h+ q + H W + H Q (19) turbomachines [15], it was found to add an adequate amount of
2 blockage and loss to the endwalls to capture most of the
endwall effects. In particular, it was found that for a multistage
The last term in the above equation accounts for any total compressor, the endwall boundary layer evolution captures the
enthalpy change due to heat addition or removal to the trend seen on repeating blade row machines.
streamtube, and is also explicitly specified. The definition of
the enthalpy can be combined with the streamwise momentum Loss Models
equation to produce the entropy-advection equation with Loss is introduced into the streamtubes using the entropy
imposed source terms due to heat addition and adiabatic loss source term described above. Different loss models are used for
pds + pd (s) + d (H Q ) = 0 (20) compressors and turbines determined by the operating mode.
The T-AXI code is modular enough to support implementation
This equation can be used in all or parts of the flow field to of custom loss models or databases, and not restricted to the
replace the momentum conservation equation with the benefit models described below. An important distinction on using
of reducing spurious entropy generation due to numerical these models in T-AXI when compared to a meanline code is
errors. that relatively accurate flow information in terms of Mach
Finally, conservation of mass is imposed internally due to numbers, velocities, angles, etc. are available to use as inputs to
the streamline grid, and in addition mass can be discretely the loss models.
added or removed from each cell of a streamtube Compressor
dm& + d (m& f ) = 0 (21) a) Diffusion Loss: The loss due to boundary layers on the
blade is estimated using a correlation for momentum thickness
where m
&f is the prescribed bleed or injection flow. using the blade diffusion ratio as the driving parameter. The
blade diffusion ratio defined as the ratio of the peak velocity to
Conservation of mass also takes into account circumferential
the trailing edge velocity is estimated using an assumption of a
area change referred to as blockage in the context of this paper.
roof-top profile with the roof-top extending to 40% of blade
The meridional speed is calculated from the definition of mass
chord.
flow at a point in the streamtube
DR = f (r1 , r2 , 1 , 2 , W1 , W2 , , t / c) (24)
m& The inputs are the radii, relative flow angles, and relative
q= (22)
A velocities at the inlet and exit, and the solidity and thickness to
chord ratio. The momentum thickness is estimated using the
A is the flow area of the streamtube and is the blockage correlation by Fottner [15] modified to account for low
defined as a reduction in flow area Reynolds numbers effects.
b) Shock Loss: The shock loss is estimated by assuming

= 1 (23)
that the loss is entirely generated by a normal shock at the inlet
2r relative Mach number. While this is a simple assumption, it is
shown to be adequate for many compressors [16]. The relative
Here, could be a result of metal blockage due to the blades, Mach number input to the loss model is limited to 1.5, with the
boundary layers, or tip clearance flows, and other sources assumption that appropriate blade design will limit the Mach
arising from non-uniformities in the flow. number to values that do not cause excessive flow separation.
The discrete equations described above are arranged in a c) Clearance Loss: Hub and tip clearance losses are
form where the unknowns are the change in density and estimated based on the model described by Denton [17]. The
streamline positions, and the non-linear system is solved using model calculates the mass flow through the clearance gap
a global Newton method [9]. A particular advantage of this driven by the pressure difference across the blade. This is
approach is that the streamline positions are simultaneously estimated from the velocity components available in the
calculated as part of the solution and no explicit iteration is axisymmetric calculation. A discharge coefficient value of 0.8
required to update the streamline positions as in traditional is used. This same model is also used for shrouded stators
streamline curvature codes making T-AXI computationally even though the physics are different.
inexpensive and extremely robust. d) Endwall Loss: The end wall loss is directly estimated
Endwall boundary layer development is calculated using from the integral boundary layer calculation on the hub and
the two-equation integral boundary formulation [9]. These casing walls. The displacement and momentum thickness are
equations are coupled with the inviscid equations described readily available and used to calculate the entropy rise that is
above and solved simultaneously. The endwall boundary layer added to the overall loss.

5 Copyright 2006 by ASME


Turbine Spanwise Mixing or Averaging
a) Profile Loss: Most profile loss calculation methods for The T-AXI code also includes a simple spanwise mixing
turbines are based on fitting experimental data and involve a model to capture the mixing of losses that occurs in multistage
look-up table approach. This was found to be much too compressors. The physical mechanisms of the mixing process
complex an approach for T-AXI with little sound physical are described by Adkins and Smith [11]. This is also required
basis. The approach that has worked well for compressors loss for numerical reasons to prevent accumulation of loss in the
in T-AXI is to assume a pressure distribution from which to streamtubes nearest to endwalls. The option used in T-AXIS is
estimate the profile loss. For sake of simplicity, the profile loss spanwise averaging of the losses, where entropy is mass
is estimated based on the idealized surface velocity distribution averaged over all the streamtubes. This makes T-AXI a quasi-
described by Denton [17]. The loss coefficient is given by meanline code, but the distinction is that the loss is calculated
W W based on the local spanwise conditions in a blade row.
Y = CD 2 +6 (tan 2 tan 1 ) (25)
W W Modes of operation
T-AXI is essentially a design code with rubber blade
Absolute velocities and angles are used for stationary blade
rows. The flow angles and velocity are available locally, and geometry. The design angular momentum downstream, rV ,
W is estimated from the local angular momentum change. of a blade row is prescribed and held fixed. With the T-C_DES
The dissipation coefficient C D is assumed to be 0.002 for or T-T_DES code, a free vortex assumption is used and a
constant value of rV is calculated behind each blade row. In
turbulent flow and 0.0056 Re1 / 6 for laminar flow. In addition
other design scenarios, the angular momentum can be obtained
to the base profile loss, a small additional loss is added based as a spanwise profile from a 3D CFD calculation or a quasi-3D
on the diffusion that occurs near the trailing edge on highly blade-to-blade calculation, where the objective is to design a
loaded turbines. The diffusion factor defined by Lieblein [18] is blade shape to meet the required conditions in T-AXI.
used to estimate this additional loss, and it is only applied when
A constant spanwise angular momentum, rV , in T-AXI is
the diffusion factor is positive.
b) Trailing Edge Loss: Mixing loss due to thick trailing a free vortex design. Other variations of angular momentum
edges commonly found on turbines is estimated using a stream can also be imposed creating a forced vortex design. At a
thrust calculation using the flow conditions at the trailing edge minimum, the hub and tip angular momentum values must be
of a blade row. A fixed value of base pressure drag coefficient prescribed.
C Pb = 0.15 is used in the momentum balance.
Blade Design
c) Trailing Edge Shock Loss: A small amount of shock The axisymmetric design solution provided by T-AXI is
loss is added when the relative flow exiting the turbine is rich enough to begin and rapidly explore blade designs that can
supersonic. This accounts for weak shocks that may occur near produce the desired performance. T-AXI is therefore equipped
the turbine trailing edge. The compressor shock loss model is with a blade generator that uses the flow solution as input to
used, but the Mach number in the loss model is limited to 1.2. generate blade sections as well as a complete 3D stacking of
d) Clearance Loss: The clearance model described above the blade. Blade sections and flow conditions on streamtubes
for compressors is also used for turbines. can be exported with blade shapes in the MISES [9,10] design
e) Endwall Loss: The endwall loss is calculated from the code format. The initial blade shapes provided by T-AXI can
endwall boundary layer parameters as described above for then be used to perform redesign in MISES.
compressors.
f) Secondary Flow Loss: The secondary flow loss is RESULTS
estimated using the equation given by Dunham: In order to demonstrate the capability of the T-AXI design
c cos( exit ) * system, the approach has been applied on a single stage
YS = f (C L ) g (26) compressor, a ten stage high pressure compressor (HPC), and a
h cos( inlet ) c 5 stage low pressure turbine (LPT). The single stage
YS is the total pressure loss normalized by the downstream compressor was designed for the Stage Matching Investigation
(SMI) rig for the US Air Force [20-22]. The 10 stage HPC and
dynamic head, c / h is the chord to span ratio, f (C L ) is the five stage LPT were developed by GE Aircraft Engines as
Ainleys parameter that depends on the lift or circulation of the part of the NASA Energy Efficient Engine (EEE) Program.
blade row, and g ( / c) is a function that depends on the
* Many of the design and test reports can be downloaded from
the web as pdf files. The web site is http://ntrs.nasa.gov. In
incoming boundary layer thickness. A fixed value of g=0.034 is
the search dialogue box, just put the Contract Report number
currently used in T-AXI. The relative flow angles are used for
and one can access the pdf files for references [23-26].
rotating blade rows and absolute for stationary blade rows. A
detailed description of this model can be found in [19].

6 Copyright 2006 by ASME


Single Stage Compressor Table 1. SMI Aerodynamic Design Parameters (from
The SMI rig as described by Chriss [20] has been analyzed Chriss [20]).
with T-AXI and designed with T-C_DES. Figures 2 and 3
Parameter Rotor Stator
show the rig cross section and the measured stage characteristic
respectfully. Table 1 lists the parameters that define this stage Number of airfoils 33 49
design. The 3D solution for the close wake generator Aspect Ratio - average 0.961 0.892
configuration was used to create the walls and stack file for the Inlet Hub/Tip Ratio 0.75 0.816
T-AXI calculation. The inputs for the one stage design in T- Flow/Annulus Area, lbm/sec/ft^2 40
C_DES are in Tables 2 and 3. These design parameters were Flow/Frontal Area, lbm/sec/ft^2 17.502
set based on the measured flow rate and wheel speed as well as Flow Rate, lbm/sec 34.46
comparing to the geometry of the actual hardware. The overall Tip Speed, Correcte (ft/sec) 1120
results are in Table 4. The T-AXI results assume a good design Mrel, LE Hub 0.963 0.82
execution. The comparison between the two T-AXI runs is
Mrel, LE Tip 1.191 0.69
very similar. It is not known why the measured efficiency was
PR, Rotor 1.88
so much lower than the T-AXI calculation.
Figure 4 shows the initial T-AXI grid for the one stage PR, Stage 1.84
design as well as the T-AXI screens during the different runs. D factor, Hub 0.545 0.502
The initial screen shows the input angular momentum. With D factor, Tip 0.53 0.491
Eulers Turbomachinery equation, the enthalpy rise is LE Tip Diameter, in. 19 19
calculated. LE Hub Diameter, in. 14.25 15.502
The boundary layers are turned on once the solution is
converged with the loss model. Table 2. Stage data for one stage design (stage.smi-
des).
Parameter Stage 1
Stage rotor inlet angle [deg] 0
Stage rotor inlet Mach no. 0.5635
Total Temperature Rise [K] 61.38
Rotor loss coef. 0.076
Stator loss coef. 0.04
Rotor Solidity 1.892
Stator Solidity 1.838
Stage Exit Blockage 1
Stage bleed [%] 0
Rotor Aspect Ratio 0.69
Stator Aspect Ratio 0.84
Figure 2. Stage Matching Investigation rig cross-
section (from Chriss [20]. Rotor Axial Velocity Ratio 0.863
Rotor Row Space Coef. 0.07
Stator Row Space Coef. 0.05

Table 3, Initial data for one stage design (init.smi-


des).
Number of Stages 1
Mass Flow Rate [kg/s] 15.631
Rotor Angular Velocity [rpm] 13,508.92
Inlet Total Pressure [Pa] 101,353
Inlet Total Temperature [K] 288.167
Alpha 3 - Last Stage [deg] -2.5
Mach 3 - Last Stage 0.458
Ratio of Specific Heats 1.4
Gas Constant [kJ/kg*K] 0.28704
Figure 3. SMI measured overall stage characteristic
for the clean inlet and 40 wake generator Clearance Ratio 0.00158
configurations (from Chriss [20]). Tip Radius [m] 0.2413

7 Copyright 2006 by ASME


momentum and the real leading and trailing edge shapes are
Table 4. Performance Data for SMI example. applied from the 3D solution.
Figure 7 shows how the T-C_DES design compares to the
T-AXI T-AXI
SMI calculation calculation for actual flowpath of the SMI stage.
Overall SMI "clean" with SMI free-vortex
Goal measurement flowpath design
Temperature
Ratio 1.213 1.213
Pressure
Ratio 1.84 1.8 1.865 1.863
Efficiency 87 91.53 91.37

a.) Initial T-AXI grid showing blade


edge stations.

b.) Initial screen

c.) Screen after convergence


Total enthalpy without boundary layers

Angular
momentum

Figure 5. 3D representation of the one stage design.


d.) Screen after convergence The Blade Viewer program can output all the blades
with boundary layers of a design.
entropy

NASA/GE EEE 10 Stage Compressor


The NASA/GE EEE high pressure compressor was
designed during the late 1970s using the best methods
available to industry at the time. A six stage build and two ten
stage builds were used to refine the design [23,24]. Figure 8 is
a cross section of the EEE HPC. This 10 stage design was
Boundary layer parameters scaled up in size to become the high pressure compressor for
Figure 4. T-AXI screens during the solution of the the GE90.
one stage design. Graphics are used to check input T-C_DES was used to create geometry similar to the actual
and some guidance on solution convergence. EEE flowpath. Reference [23] contains output from the GE
Angular momentum is the primary input downstream axisymmetric code, CAFD, which was used to construct the
of each blade row. It is uniform for this free-vortex actual EEE flowpath and blade row angular momentum
design. distributions. Table 5 was initially constructed from the
meanline data shown in Figures 10-14, and 17 in ref [23]. The
Figure 5 is a 3D representation of the stage design using throughflow information was used to get the axial velocity
the blade viewer. The max thickness to chord used is the same ratios. The individual stage total temperature rise values were
as for rotor 1 and stator 1 of the EEE described in the next adjusted to match the overall temperature ratio from the actual
subsection. Figure 6 shows the T-AXI screen after the loss is EEE T-AXI calculation. The losses were modified to get an
converged and the initial grid for the true SMI flowpath. From overall pressure ratio from T-C_DES of 25. The rotor inlet
these plots, it can be seen that the profiles of angular Mach number values were tweaked to get the stage rotor
leading edge hub locations to match up with the actual design.
The blockage was set based on the report that stated an inlet

8 Copyright 2006 by ASME


value of 0.97 and an exit value of 0.90 with an approximately
linear distribution. This blockage is a very important parameter
for compressor design. It is used for sizing the area through the
compressor, and the coupled boundary layer in T-AXI is used
to approximate it. The aspect ratios and blade row gaps were
set to get approximately the right axial extent of each blade row
and stage. The stage tip radii are the values from the rotor
leading edge of the actual flowpath. The bleed values were
those specified in the report, and applied as a negative blockage
in T-AXI. Finally the solidity values were set to get the same
airfoil count as the actual EEE design. Figure 8. GE EEE High Pressure Compressor.

The initial data and IGV data are in Tables 6 and 7


respectively and come from the design intent. The clearance
comes from the clearance goals for the front rotors. The ratio
of specific heat is treated as a constant in T-AXI. The value
used is the average of the value from the inlet TT and the
expected exit TT.
Figure 9 shows the T-AXI screens for the 10 stage design.
The distribution of angular momentum, total enthalpy, blockage
and entropy are shown. The angular momentum plots give a
quick picture to the user that the work and stator exit angles
have been input correctly. For the EEE, as mentioned in the
Angular momentum
design report, the large reduction in temperature drop in stage 6
shown in Table 6 is to reduce the loading of that stage since the
stator upstream is the last variable stator row. Although T-AXI
cannot be used for off-design calculations, these design
features can be built into the parameters to address stall margin
at part power. The distribution of rotor inlet angle (the same as
the upstream stator exit angle), also in Table 5, allows for a
gradual build-up of inlet rotor swirl for improved efficiency
a.) T-AXI screen after loss is converged,
but without boundary layers. and making sure the last stage stator or OGV is not too loaded.
Figure 10 shows the T-AXI screens for the actual EEE
HPC geometry. The edge stations for stage 10 demonstrate the
nonlinear edge stations for the actual design. Figure 11
compares the 10 stage design flowpath with the actual EEE
flowpath demonstrating that the parameters available within T-
C_DES are flexible enough to create a realistic flowpath.
b.) Initial T-AXI grid showing The thickness distributions in Table 8 have been applied to
blade edge stations.
the 10 stage design. They came from the actual EEE report
Figure 6. T-AXI screens during the solution of the [23]. Figure 12 demonstrates how the blade geometry
SMI case derived from the 3D simulation. This capability within T-AXI can be used. Fig. 12 a) shows a 3D
solution had contoured leading and trailing edges as solid of the airfoil, b) shows the converged MISES grid for the
well as profiles of angular momentum. mid-span section, c) shows the Mach number distribution, also
for the mid-span section. Fig. 12 d) is a contour plot of the
MISES Mach numbers and e) demonstrates how the Pressure
Editor capability in MISES, EDP, was used to smooth out the
suction side leading edge spike. A 3D representation of the 10
Actual 3D geometry stage design as output by the Blade Viewer is shown in Figure
13.
The overall performance calculations are shown in Tables
9 and 10. The efficiency goal of the EEE was 85.7%. The two
From T-C_DES
10 stage builds did not reach 100% speed, or that efficiency
goal. The T-AXI solution of the actual EEE flowpath with
Figure 7. Comparison of the one stage flowpath profiles of angular momentum calculates an efficiency of
generated with T-C_DES and the SMI geometry.
Also shown are the leading edge and trailing edge
stations.
9 Copyright 2006 by ASME
Table 5. Stage data for 10 stage design (stage.e3c-des).

Stage
Parameter 1 2 3 4 5 6 7 8 9 10
Stage rotor inlet angle [deg] 10.3 13.5 15.8 18 19.2 19.3 16.3 15 13.6 13.4
Stage rotor inlet Mach no. 0.59 0.51 0.475 0.46 0.443 0.418 0.402 0.383 0.35 0.313
Total Temperature Rise [K] 52.70 52.30 51.12 49.74 49.14 43.62 45.69 47.27 48.26 47.57
Rotor loss coef. 0.053 0.0684 0.0684 0.0689 0.069 0.069 0.069 0.069 0.069 0.07
Stator loss coef. 0.07 0.065 0.065 0.06 0.06 0.065 0.065 0.065 0.065 0.1
Rotor Solidity 1.666 1.486 1.447 1.38 1.274 1.257 1.31 1.317 1.326 1.391
Stator Solidity 1.353 1.277 1.308 1.281 1.374 1.474 1.379 1.276 1.346 1.453
Stage Exit Blockage 0.963 0.956 0.949 0.942 0.935 0.928 0.921 0.914 0.907 0.9
Stage bleed [%] 0 0 0 0 1.3 0 2.3 0 0 0
Rotor Aspect Ratio 2.354 2.517 2.33 2.145 2.061 2.028 1.62 1.417 1.338 1.361
Stator Aspect Ratio 3.024 2.98 2.53 2.21 2.005 1.638 1.355 1.16 1.142 1.106
Rotor Axial Velocity Ratio 0.863 0.876 0.909 0.917 0.932 0.947 0.971 0.967 0.98 0.99
Rotor Row Space Coef. 0.296 0.4 0.41 0.476 0.39 0.482 0.515 0.58 0.64 0.72
Stator Row Space Coef. 0.32 0.35 0.45 0.45 0.9 0.46 0.89 0.52 0.58 0.55
Stage Tip radius [m] 0.351 0.336 0.328 0.321 0.315 0.308 0.304 0.300 0.297 0.295

84.6% whereas the Build 2 adjusted peak efficiency was


84.8%. The 10 stage free vortex design solution has a
calculated value of efficiency of 85.6%. These comparisons
are excellent for these calculations. a.) Initial T-AXI grid showing blade edge
stations.

Table 6. Initial data for 10 stage design (init.e3c-des).


b.) Initial
screen c.) Screen after
Number of Stages 10
convergence
Mass Flow Rate [kg/s] 54.4 without
Rotor Angular Velocity [rpm] 12,299.49 boundary

Inlet Total Pressure [Pa] 101,325 Total enthalpy

Inlet Total Temperature [K] 288.15


Alpha 3 - Last Stage [deg] 0
Mach 3 - Last Stage 0.272 Angular
Ratio of Specific Heats 1.37836 momentum
Blockage
Gas Constant [kJ/kg*K] 0.287
Clearance Ratio 0.0015

Entropy
Table 7. IGV data for 10 stage design (igv.e3c-des).
Soldity 0.6776 d.) Screen after
Boundary layer convergence with
Aspect ratio 5.133 parameters boundary layers
Phi Loss Coef. 0.039
Inlet Angle 0
Figure 9. T-AXI screens during the solution of the 10
Inlet Mach 0.47 stage design. Graphics are used to check input and
Lambda 0.97 help guide solution convergence. Angular
IGV Row Space Coef. 0.4 momentum is the primary input downstream of each
IGV Tip Radius [m] 0.36211 blade row. It is uniform for this free-vortex design.

10 Copyright 2006 by ASME


Table 8. Maximum Thickness to chord data at hub
and casing for the GE EEE HPC applied to the 10
stage design.
Blade Row TM/C hub TM/C tip
a.) Initial T-AXI grid showing blade edge stations.
IGV 0.0850 0.0850
R1 0.0961 0.0250
S1 0.0599 0.1128
R2 0.0849 0.0260
Rotor 10 S2 0.0462 0.0958
Stator 10
R3 0.1085 0.0261
S3 0.0626 0.0898
R4 0.0813 0.0335
b.) Blow up of the Stage 10 grid showing details of the axisymmetric S4 0.0666 0.0998
shape of the leading and trailing edge stations. R5 0.0799 0.0340
S5 0.0703 0.0999
R6 0.0797 0.0359
S6 0.0730 0.1090
R7 0.0960 0.0390
S7 0.0671 0.0949
R8 0.0786 0.0380
S8 0.0799 0.1000
R9 0.0741 0.0390
S9 0.0799 0.1000
R10 0.0850 0.0435
S10 0.0601 0.0750
Angular momentum
Table 9. Comparison of the EEE efficiency goals and
measurements with the T-AXI calculation results.

T-AXI
EEE Build 1 EEE Build 2 T-AXI calculation
Peak Adjusted Peak Adjusted calculation for 10 stage
Efficiency at Efficiency at for EEE Design with
EEE goal 97.5% speed 99% speed flowpath free-vortex
85.7 83.9 84.8 84.6 85.6
c.) T-AXI screen after loss is converged, but without boundary layers.

Figure 10. T-AXI screens during the solution of the NASA/GE EEE 5 Stage Low Pressure Turbine
EEE full geometry. This solution had contoured The NASA/GE EEE 5 stage low pressure turbine is used to
leading and trailing edges as well as profiles of demonstrate the turbine capability in T-AXI and the turbine
angular momentum as defined by the axisymmetric design capability of T-T_DES. In the first case, the Turbine set
output in the EEE report. up code T-2-T-AXI was used to create a walls and stack
file from the flowpath geometry, the initial data in Table 11,
and the blade row data in Table 12. The work split was
presented in the NASA report [26], and adjusted to get the
From T-C_DES
Actual 3D geometry overall temperature rise of 133.33 K as indicated by the design
point test reading 503. This work split and the nozzle exit
angles were used to get the angular momentum for each blade
row. This LPT case was also used by Reed and Turner [27] in
the validation of an entropy-based meanline code. Figure 14 is
Figure 11. Comparison of the 10 stage flowpath
a cross section of the 5 stage EEE LPT.
generated with T-C_DES and the EEE design. Also
Figure 15 shows the initial grid, and Figure 16 shows the
shown are the rotor 1 leading edge and stator 10
T-AXI screen after the loss is converged. The boundary layers
trailing edge.
are not applied for this turbine since the favorable pressure
gradient makes its impact minimal.

11 Copyright 2006 by ASME


b.) MISES grid of the Stator 7 mid-
span section,

a.) Stator 7 geometry generated with T-AXI.

Figure 13. 3D representation of the 10 stage design. The


d.) Stator 7 mid-span section Blade Viewer program can output all the blades of a design.
c.) Stator 7 mid-span section
analyzed with MISES. Mach number contours from
MISES solution.
Figure 17 is a 3D representation of the LPT analyzed. The
required input of max thickness to chord ratio was set to 5%.
The turbine design code, T-T_DES used the initial data in
Table 11 and the Stage data in Table 13 to create a 5 stage
design that matched the flowpath of the EEE as shown in
Figure 18 which is compared to the actual EEE flowpath.
Notice how the flexibility of these parameters can be used to
come very close to an existing design. Table 14 shows the
overall result of the two T-AXI runs compared to the test data.

Table 11. Initial Data for 5 stage EEE LPT matching


Reading 503 from Block II Configuration 5 (from
e.) Stator 7 mid-span section modified with Pressure Bridgeman [26]) (init.lpt-des).
Editor capability in MISES.

Figure 12. Blade design features. The output of Number of Stages 5


geometry and MISES files allows MISES to be run Mass Flow Rate [kg/s] 28.321
without changing files. With a small modification of Rotor Angular Velocity [rpm] 3214.57
the files, a coupled boundary layer can be run or a Inlet Total Pressure [Pa] 310,801.3
mixed-inverse can allow a blade row section to be Inlet Total Temperature [K] 417.94
redesigned. Nozzle 1 Leading Edge Mach Number 0.335
Inlet Duct Length/N1 Axial Width Ratio 1.441
Ratio of Specific Heats 1.39689
Table 10. Comparison of the EEE goals with the T- Gas Constant [KJ/(kg-K)] 0.287
AXI calculation results. Clearance Ratio 0.0009
T-AXI T-AXI calculation for
calculation for Design with free
EEE Goal EEE flowpath vortex
Temperature Ratio 2.686 2.686
Pressure Ratio 25 25.26 25.93

12 Copyright 2006 by ASME


Table 12. Number of blades and hub tangential
velocity (specifies angular momentum) for each blade
row.
Blade Number hub Vtheta
row of blades (ft/sec)
N1 72 800
R1 120 -388.214
N2 102 820 Figure 15. Initial grid for the 5 stage EEE LPT also
R2 122 -404.072 showing the leading and trailing edge stations.
N3 96 820
R3 122 -391.928
N4 114 780
R4 156 -247.716
N5 120 640
R5 110 -103.938

Figure 14. GE EEE LP Turbine Flowpath (from


Bridgemann [26]) .

Figure 16. T-AXI screen during the solution of the 5 stage


EEE LPT.

13 Copyright 2006 by ASME


generate a 3D model allows blade weights to be calculated, and
it is very rewarding to visualize the design in 3D.
From the design system that has been described, a student
can make the connection of key physical input parameters such
as Mach number and angle with the cross sectional area and
angular momentum. Because angular momentum is a primary
quantity, its connection to the work is made obvious, and the
ability of a blade-to-blade solver to be connected directly can
present the connection of loading with a change in angular
momentum. These concepts become second nature to those
experienced in turbomachinery, but it is useful when explaining
to students to have a design tool that makes these connections
more obvious.

CONCLUSIONS AND CODE ACCESS


The turbomachinery design system, T-AXI, has been
presented and described with real multistage compressor and
turbine examples. Three test cases have been used to validate
the method and loss models with good results. With a small
amount of input, a design can be created that is similar to a real
design. The design is then defined by a small number of
Figure 17. 3D representation of the 5 stage LPT parameters which can be used to explore the design space.
analyzed. Blades were generated with 5% max This system is intended for use by educators and students to
thickness to chord ratio. explain turbomachinery concepts and for use in a design class.
The system is also sophisticated enough for actual design use.
USE AS A TEACHING TOOL Executable versions of the codes are available from the
The T-AXI suite of codes is meant to be used as part of a authors web sites in addition to the input from the examples
senior undergraduate or graduate level class, or as part of a presented and a users manual. The T-AXI web site URLs are:
research project. This paper has presented the overall theory of http://gtsl.ase.uc.edu/T-AXI,
the codes and the validation using a single stage transonic http://web.mit.edu/merchant/www/taxi.html, and
compressor, a 10 stage high pressure compressor and a 5 stage http://www.cfdg.unige.it/software.htm.
low pressure turbine. Although not extensive, this validation Table 13. Stage Parameters for 5 stage design using
provides a level of trust that the design system results can be T-T_DES (stage.lpt-des); the temperature drop per
used in a design process. The input files can be easily modified stage came using work splits from Table IV of
to quickly change a design. The tables can be read into a Bridgeman [26], and matching the overall
spreadsheet program such as Excel, modified and output. It temperature rise of Reading 503.
becomes a very easy process to add stages to create a 14 stage
HPC design, for example. The files output by Excel can then Stage
be read by the design codes T-C_DES or T-T_DES. As Parameter 1 2 3 4 5
demonstrated, the input parameters are flexible enough to Nozzle Exit Ang. [deg] 61 64.1 64.8 62.3 55.3
generate the flowpath for existing designs and therefore allow Nozzle Exit Mach No. 0.5806 0.588 0.58 0.544 0.5
for an almost unrestricted design space. Stage TT Drop [K] 27.53 29.797 30.944 26.474 18.583
The stage work input is easily specified through the Nozzle Zweifel Number 0.639 0.956 0.978 1.058 1.075
temperature rise or drop. Using many of the parameters for the
Rotor Zweifel Number 0.891 0.878 0.83 0.812 0.793
EEE cases for loss, aspect ratio, or blade row spacing builds on
Nozzle Loss Coef. 0.08 0.05 0.05 0.05 0.05
a successful design. A new design can be configured to meet a
design condition, or an existing design can be reverse- Rotor Loss Coef. 0.12 0.1 0.1 0.1 0.05
engineered and validated to add to the database of cases. It is Nozzle Aspect Ratio 1.8106 3.5 3.77 4.94 5.47
relatively easy to create a good design, and the codes could be Rotor Aspect Ratio 4.088 4.57 5.38 7.76 6.05
tied to an optimizer to create an optimum design. Rotor Axial Vel. Ratio 0.85 0.989 1.029 1.051 1
The ability to easily couple with a blade-to-blade solver Noz. Row Space Coef. 0.231 0.38 0.3 0.51 0.34
such as MISES can be used for more advanced classes or
Rotor Row Space Coef. 0.575 0.47 0.472 0.63 0.567
advanced projects. This allows for a complete demonstration
Noz. Mean Radius [m] 0.2466 0.2729 0.2939 0.3141 0.3223
of the process so that calculated blade pressure profiles can be
connected to the blade loading parameters. The ability to Rotor Mean Radius [m] 0.2631 0.2845 0.3071 0.3203 0.3199

14 Copyright 2006 by ASME


[6] Merchant, A., Epstein, A. H., and Kerrebrock, J. L., Compressors
45 with Aspirated Flow Control and Counter-Rotation, AIAA-2004-
2514, 2nd AIAA Flow Control Conference, Portland, Oregon, June 28-
40 1, 2004.
[7] Smith, L. H. Jr., The Radial-Equilibrium Equation of
35 Turbomachinery, J. of Engineering for Power, pp 1-11, Jan. 1966.
[8] Novak, R. A., Streamline Curvature Computing Procedures for
Radius (cm)

30
Fluid-Flow Problems, J. of Engineering for Power, pp 1-13, Jan.
1966.
25
[9] Drela, M. and M.B. Giles, Viscous-Inviscid Analysis of Transonic
and Low Reynolds Number Airfoils, AIAA Journal, 25(10):1347
20
1355, Oct 1987.
Hub EEE
Tip EEE
15 Hub T-T_DES [10] Youngren, H.H. and M. Drela, Viscous/Inviscid Method for
Tip T-T_DES
Preliminary Design of Transonic Cascades, AIAA-91-2364, 1991.
10 [11] Adkins, G. G., Jr., and L.H. Smith, Jr., Spanwise Mixing in
-5 0 5 10 15 20 25 30 35 40 45
Axial distance (cm) Axial-Flow Turbomachines, J. of Engineering for Power, Jan. 1982,
Vol. 104, pp.97-110, also ASME paper 81-GT-57.
Figure 18. Comparison of the flowpath generated
with T-T_DES using the stage input parameters [12] Koller, Ulf, Reinhard Monig, Bernhard Kusters, and Heinz-Adolf
compared with the actual EEE 5 stage flowpath. Schreiber, Development of Advanced Compressor Airfoils for
Heavy-Duty Gas Turbines--- Part I: Design and Optimization, Journal
of Turbomachinery Vol. 122, Issue 3, pp. 397-405, 2000. (Also ASME
Table 14. Performance comparison between reading 99-GT-95).
503 and the T-AXI calculations. [13] Ksters, B., Heinz-Adolf Schreiber, Ulf Kller, and Reinhard
Mnig, Development of Advanced Compressor Airfoils for Heavy-
T-AXI Duty Gas Turbines Part II: Experimental and Theoretical Analysis,
calculation Journal of Turbomachinery -- July 2000 -- Volume 122, Issue 3, pp.
Measurement EEE T-AXI calculation 406-414. (Also ASME 99-GT-96).
Reading 503 flowpath (T-T_DES design)
[14] Zweifel, O., The Spacing of Turbomachine Blading, Especially
Pressure Ratio 4.409 4.351 4.326 with Large Angular Deflection, Brown Boveri Review 32, 1945.
Temperature Ratio 1.468 1.464 1.463
[15] Hirsch, C.H. and J. D. Denton Editors, Axial Compressor
Efficiency 92.05 92.85 92.91
Performance Predictions, in Throughflow Calculations in Axial
Turbomachines, 1981. AGARD-AR-175.
[16] Koch, C.C. and L.H. Jr. Smith, Loss Sources and Magnitudes in
Axial Flow Compressors, Journal of Engineering for Power, pages
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15 Copyright 2006 by ASME


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16 Copyright 2006 by ASME

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