Design and Analysis of Annular Combustion Chamber For A Low Bypass Turbofan Engine in A Jet Trainer Aircraft
Design and Analysis of Annular Combustion Chamber For A Low Bypass Turbofan Engine in A Jet Trainer Aircraft
Design and Analysis of Annular Combustion Chamber For A Low Bypass Turbofan Engine in A Jet Trainer Aircraft
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ORIGINAL ARTICLE
a
Department of Aerospace Engineering, Karunya University, Coimbatore, T.N., India
b
A.E.R.D.C., Hindustan Aeronautics Ltd., Bangalore, KA, India
KEYWORDS Abstract The design of an annular combustion chamber in a gas turbine engine is the
backbone of this paper. It is specifically designed for a low bypass turbofan engine in a jet
Aerodynamic design;
Annular combustion trainer aircraft. The combustion chamber is positioned in between the compressor and turbine.
chamber; It has to be designed based on the constant pressure, enthalpy addition process. The present
CFD (computational methodology deals with the computation of the initial design parameters from benchmarking of
fluid dynamics) analy- real-time industry standards and arriving at optimized values. It is then studied for feasibility
sis; and finalized. Then the various dimensions of the combustor are calculated based on different
Gas turbine engine; empirical formulas. The air mass flow is then distributed across the zones of the combustor.
Optimization; The cooling requirement is met using the cooling holes. Finally the variations of parameters at
Real-time model different points are calculated. The whole combustion chamber is modeled using Siemens NX
8.0, a modeling software and presented. The model is then analyzed using various parameters
at various stages and levels to determine the optimized design. The aerodynamic flow
characteristics is simulated numerically by means of ANSYS 14.5 software suite. The air-fuel
mixture, combustion-turbulence, thermal and cooling analysis is carried out. The analysis is
performed at various scenarios and compared. The results are then presented in image outputs
and graphs.
& 2016 National Laboratory for Aeronautics and Astronautics. Production and hosting by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
n
Corresponding author.
E-mail address: [email protected] (C. Priyant Mark).
Peer review under responsibility of National Laboratory for Aeronautics and Astronautics, China.
2212-540X & 2016 National Laboratory for Aeronautics and Astronautics. Production and hosting by Elsevier B.V. This is an open access article under the
CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
http://dx.doi.org/10.1016/j.jppr.2016.04.001
98 C. Priyant Mark, A. Selwyn
1. Introduction for ease of use. Silva [4] has discussed a consolidated design
methodology for an automotive turbocharger utilizing a
Gas turbine engine evolved as a critical part and the most micro gas turbine combustor. It gives a brief report along
efficient propulsion unit for aircrafts. It is now used in with heat-transfer analysis. Generally, the computational
almost all of the passenger aircrafts worldwide with fluid dynamics (CFD) analysis of a combustor is carried
different variations. Military aircraft made the debut in out based on different combustion models [5]. Few models
using the turbojet engine. As the technology progressed, such as Westbroor-Dryer one step model and Westbroor-
high performance military aircraft began using low bypass Dryer two step model hold good for laminar combustion
turbofan engines due to its advanced capabilities, efficiency simulation. Likewise K-epsilon model, K-omega model and
and reliability, even at supersonic speeds. K-omega shear stress transport (SST) model hold good for
Low bypass turbofans have a bypass ratio of around 1:1 turbulent combustion simulation. The present paper discusses
or less [1]. A high specific thrust/low bypass ratio turbofan mainly about designing a gas turbine combustor at a scale of
normally has a multi-stage fan, developing a relatively high a jet trainer aircraft engine using the most straightforward
pressure ratio and, thus, yielding a high (mixed or cold) and transparent approach. It also focuses on reducing the
exhaust velocity. The core airflow needs to be large enough development time and gives ample support for refining the
to give sufficient core power to drive the fan. A smaller core design at every phase. The paper also presents a computer
flow/higher bypass ratio cycle (for the fan operation) can be aided design (CAD) model designed using the same princi-
achieved by raising the high pressure (HP) turbine rotor ples to show the practicality in using the design. For an
inlet temperature. The temperature rise of the airflow from accurate CFD analysis result of a gas turbine combustion
the intake to the nozzle of the engine is also less, which chamber, it needs to simulate combustion and turbulence
results in a reduced fuel flow leading to a better specific fuel simultaneously. This paper gives a detailed CFD analysis
consumption (SFC) for the same pressure ratio. Thus, a low report of the designed combustor based on the combustion-
bypass turbo fan would add to the efficiency of the engine. turbulence interaction model.
Jet fighters as well as trainers are high performance
aircraft that use the most powerful engines for producing
thrust. The process of upgrading military hardware has 2. Aerodynamic design
initiated the race to develop even more powerful engines.
By increasing power, the engines require more fuel input, 2.1. Preliminary design procedure
thereby resulting in fuel guzzling engines. This directly
points to an inefficient engine in terms of fuel consumption. The procedure purposed by Melconian and Modak
Fuel consumption efficiency is required even in military (1985) [6] to design a combustor is described in Figure 1.
aircraft as it can aid in increasing the range. For improving The equations utilized in the design procedure is presented,
efficiency, the very fundamentals lie in the combustion which is sufficient for the reader to understand the design
chamber. An efficient combustion chamber is the answer methodology idea.
for better performance.
The most commonly used type of combustor is the fully
annular combustor, the others being tubular and tuboannu- 2.2. Initial design parameters
lar combustor. Annular combustors [2] do away with the
separate combustion zones and simply have a continuous The initial design parameters are mostly the compressor
liner and casing in a ring (the annulus). There are many exit and turbine inlet constraints, which is usually absorbed
advantages to annular combustors, including more uniform for any combustion chamber design. Others include custo-
combustion, shorter size (therefore lighter), and less surface mer specifications, constants, experimental values and
area. Additionally, annular combustors tend to have very limits. Table 1 shows the initial parameters used for the
uniform exit temperatures. They also have the lowest design, which were obtained from real-time data.
pressure drop of the three designs (on the order of 5%).
The annular design is also simpler, although testing gen-
erally requires a full size test rig. Most modern engines use
annular combustors; likewise, most combustor research and 3. Dimensions
development focuses on improving this type. This paper
deals with designing an efficient annular combustion 3.1. Casing area
chamber for use in jet trainer aircrafts.
Conrado [3] has discussed a design methodology which Eq. (1) calculates the reference area [7].
follows a similar approach for designing a micro gas turbine " 2 #0:5
R m_ 3 T 0:5 ΔP3 4 ΔP3 4 1
combustor. It also showcases an example and further Aref ¼ 3
ð1Þ
automating the same approach using a computer program 2 P3 qref P3
Design and analysis of annular combustion chamber of a low bypass turbofan engine in a jet trainer aircraft 99
The combustor sectional area (AL) can be calculated by The annulus area Aan, is the difference between Aref and
Eq. (2) [6]. AL and can be calculated from Eq. (3).
AL ¼ 0:66Aref ð2Þ Aan ¼ Aref AL ð3Þ
100 C. Priyant Mark, A. Selwyn
PF ¼ 0:25
m_ 3 28.7103 kg/s
LL ¼ 0:15719 m
T3 743.352 K
P3 2083450 Pa
m_ f 0.25818 kg/s 3.7. Primary zone length
Inlet m_ 3 100
Recirculation zone/snout m_ RZ 20
Swirler m_ SW 12
Dome cooling m_ Dcool 8
Annulus m_ an 80
Primary zone m_ PZ 20
Secondary zone m_ SZ 10
Dilution zone m_ DZ 10
Cooling air m_ cool 40
Figure 4 Front end geometry of combustor.
5. Diffuser dimensions
The diffuser, swirler and the recirculation zone geometry
is presented in Figure 4.
Figure 3 Airflow apportioning. The snout outer area Ao is calculated assuming the air
velocity in this sectional area is equal to Aan air velocity,
then use Eq. (9) [3].
Table 3 Fuel/air ratio and equivalence ratio for the zones. m _3
Ao ¼ Aan ð9Þ
m_ an
Parameter Recirculation Primary Secondary Dilution
zone zone zone zone
Ao ¼ 0:03492 m2
Fuel/air ratio 0.0450 0.0150 0.0118 0.0090
Equivalence 0.6701 0.2234 0.1763 0.1340
ratio 5.2. Snout outer diameter
m_ RZ 1
AS ¼ Ao ð12Þ
m_ 3 Cds
AS ¼ 0:01075 m2
LRZ ¼ 2DSW ð15Þ
LRZ ¼ 0:04579 m
6.2. Snout diameter
The snout diameter is calculated from AS with the 7.2. Recirculation zone angle
calculations similar to liner diameter.
The recirculation zone angle can be obtained from Eq.
Do ¼ 0:00798 m (16) [3].
" pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi#
DL ðDL 2DSW Þ ðDL 4LRZ Þ DL 2 4DL DSW þ 4DSW 2 8DL LRZ þ 16LRZ 2
θRZ ¼ cos 1 ð16Þ
2DL 2 4DL DSW þ 4DSW 2 8DL LRZ þ 16LRZ 2
Ldome ¼ 0:03448 m
6.4. Swirler diameter
9.2. Calculation
For the average gas temperature calculations [3] inside The combustor is divided into four zones: recirculation
the liner at different zones, only the core air mass flow rate zone, primary zone, secondary zone and dilution zone. For
is considered. The core air mass flow excludes cooling air each zone, the local temperature is assumed to vary linearly
and other combusted byproducts. between the zone inlet temperature (Tin) and zone outlet
104 C. Priyant Mark, A. Selwyn
temperature (Tout). For every zone, the outlet temperature is For recirculation zone, Tin is assumed to be equal to T3
calculated by Eq. (18). and the inlet temperature for every other zone is the outlet
temperature of the preceding zone. ΔT is the temperature
T out ¼ T 3 þ ηcc ΔT ð18Þ rise from T3 to adiabatic flame temperature which is
Design and analysis of annular combustion chamber of a low bypass turbofan engine in a jet trainer aircraft 105
calculated from the chart [7] on Figure 5 for the fuel JP-5 11. Aerodynamic analysis
using the corresponding FAR values of each zone.
The computational aerodynamic analysis is carried out to
9.3. Theoretical results validate the theoretical results and to obtain a detailed
preview of the outcome of the design in real-time working
The calculated zone outlet temperatures [4] for each zone conditions. It was done using the commercially available
is presented as graph in Figure 6. CFD code ANSYS 14.5 CFX to get a quick report of the
computed data. The analysis was performed using the
design parameters from Table 1 as inlet and turbine inlet
10. Modeling data as outlet conditions. The initial setup data is given in
Table 5. The eddy dissipation combustion model which
10.1. CAD model uses Eq. (19) and (20) [10], in combination with the finite
rate chemistry model which uses Eq. (21) [10] was used in
The design was modeled using Siemens NX 8.0. The the analysis, which allows accurate simulation of the heat
views are presented in Figures 7 and 8. release and the distribution of the main chemical species.
This is a combustion-turbulence interaction model, which
10.2. Analyzable model significantly improves accuracy of analysis results.
Figures 10–14 give the results.
To analyze the created model and obtain quicker results, !
due to computing limitations, the model was simplified into 0 ϵ min YR
a 201 cut section for a single burner. The view is presented Ri;r ¼ νi;r M w;i Aρ 0 ð19Þ
κ R νR;r M w;R
in Figure 9.
106 C. Priyant Mark, A. Selwyn
13. Conclusions
The design was successfully calculated and modeled. The
required simpler model for analysis was also created. Then
the model was aerodynamically analyzed at design point
and the geometry was optimized based on the results. This
has delivered one of the most efficient combustion chamber
design that can be used in the Jet Trainer Aircraft.
Figure 17 The pressure loss.
Acknowledgments
0 ϵ ΣP Y P
Ri;r ¼ νi;r M w;i ABρ ð20Þ The authors are grateful to HAL, Bangalore for the
κ ΣNj ν″j;r M w;j contribution of resources to complete the design and
analysis successfully.
!
N 0 N 00
ηj;r ηj;r
R^ i;r ¼ Γ νi;r νi;r
00 0
k f ;r ∏ Cj;r kb;r ∏ C j;r References
j¼1 j¼1
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Proceedings of the 10th ENCIT 2004, paper no. 0316. 2000.
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