Design and Performance Analysis of A 3-D Supersonic Impulse
Design and Performance Analysis of A 3-D Supersonic Impulse
Design and Performance Analysis of A 3-D Supersonic Impulse
1
by an increase in the mass flow rate for the same
stagnation conditions upstream.
Though the research on impulse blade profile with
minimum losses have been proposed from late 1960’s as
seen above, there has been no research lately to either
improve or understand the effects of changes in certain
parameters of the impulse blade. In this regard, this
report attempts to utilize and improve the Stratford and
Sansome design methodology for rotor profile design.
The effect of the parameters - transition arc angle and
passage width was studied to obtain optimum rotor
profile. The study is carried out in 2 stages: Firstly, Fig. 1 Stator blade to have convergent-divergent nozzle
different impulse 2-D blade profiles were studied for profile (Stratford, 1962a); all dimensions in mm
their relative performance. Secondly, full admission 3-D
analysis was carried out with the impulse blade profile Impulse Blade
shortlisted for better performance. The design procedure elaborately explained in
Stratford (1962b) was adopted to design the impulse
blade profile. According to the design procedure, for
NOMENCLATURE
Cp specific heat capacity in kJ/kgK rotor inlet Mach number M0, is defined as
follows:
M Mach number
µo= Sin-1 (1)
Ptot total pressure in Pascal
radius of curvature of convex surface in mm From the results acquired through tunnel test
experiments, Stratford concluded that the values obtained
radius of curvature of concave surface in mm from Eq. (2) should be reduced by 20% to 30% for
practical applications. In this paper, M0 is taken as 2.4
radius of curvature of passage centre line, mm which is also the exit flow Mach number of the stator
used. Hence the value obtained from Eq. (2) for this case
w passage width in mm is 0.9091. Including the reduction of 20% to 30% as
mentioned by Stratford and Sansome, should be
α Nozzle angle in deg
maintained between 0.72728 and 0.63637 respectively.
β Impulse blade angle in deg
Table. 1 Parameters of impulse blades modelled
µ0 Mach angle in deg
w as w
% of (mm) (mm) (mm) (mm)
transition arc angle in deg pitch
21.80 1.9674 4.128 6.096 5.112 0.6771 0.3848
k turbulent kinetic energy 24.29 2.1860 3.916 6.102 5.009 0.6417 0.4364
27.33 2.4600 3.649 6.109 4.879 0.5973 0.5042
ω turbulent dissipation rate 29.14 2.6232 3.490 6.113 4.802 0.5709 0.5463
ρ density in kg/m3
Subscripts
w
0 stator outlet, rotor inlet
1 Nozzle exit
2 Impulse blade inlet
in rotor inlet
out rotor outlet
DESIGN OF BLADES
The stator was designed referring to Stratford Fig. 2: Impulse blade profile; all dimensions in mm
(1962a) design method to obtain a shock free supersonic
flow with Mach number of 2.4 at the stator exit. The For every passage width shown in Table 1, a series of 2-
pitch and chord of stator passage is 14mm and 12mm D impulse blade profiles were obtained for transition arc
respectively. A Convergent–Divergent nozzle passage angle of 100, 110, 120, 130 and 150 which resulted in
designed with throat width of 1.105 mm at mean twenty impulse blade profiles. The chord of all these
diameter, exit to throat area ratio of 2.962 and nozzle exit impulse blades was maintained as 11.979 mm. The pitch
angle of 140 was obtained for 2-D cascade. Figure 1 and total turning angle of these impulse blade passages
shows the layout of the nozzle passage. was fixed at 9 mm and 1440 respectively.
2
A 2-D cascade CFD analysis was carried out for all Grid
the configurations mentioned above. Fig. 3 illustrates the
2D cascade model used for the analysis. 2-D grid. Quadrilateral elements were used
Pressure inlet throughout the 2D cascade flow domain. Successive ratio
of 1.05 was maintained for the meshes normal to the
stator and rotor walls to accurately capture the viscous
effects and flow separation as indicated in enlarged view
of rotor passage of Fig. 4. The 2D cascade flow domain
had a total of 49650 cells.
Periodic boundary
Pressure outlet
3D DESIGN
The 2D CFD analysis (discussed under 2D results)
Fig. 4 Meshed 2D cascade with enlarged view of rotor
showed that the profile with a passage width of 2.186
passage having a successive ratio of 1.05
mm and transition arc angle of 120 was a suitable choice
for optimum performance. This impulse blade profile 3-D grid. Unstructured tetrahedral elements were
was therefore used to design a 3-D impulse turbine of used in the stator and rotor domain of the 3D model,
mean diameter 60 mm. The design parameters are while hexahedral elements were used in the duct domain.
tabulated in Table. 2. The 3D mesh contains a total of 4.147 million cells. This
was reduced to around 1.45 million cells after the
Table. 2 Specifications of stator and impulse rotor blades tetrahedral cells were converted to polyhedral cells in
for 3D model Fluent because the latter reduces the computational time
and cell skewness while increasing orthogonality.
Profile Stator Rotor
Height (mm) 8 8
Chord (mm) 12 11.979
Pitch (mm) 14.03 9
α1 14 0
-
β2 - 18.40
Throat (mm) 1.105 2.186
Quantity 13 21
NUMERICAL ANALYSIS
The numerical analysis was carried out using the Fig. 5 Meshed 3D turbine model with stator, rotor and
commercially available software Ansys Fluent. duct domains from left to right.
3
that of an ideal gas, Cp is defined as a piece-wise
polynomial function of temperature defined between
temperatures 250K and 1400 K. The viscosity co-
efficient and thermal conductivity of water vapour are
also defined as functions of temperature as available in
Fluent.
Validation
A validation exercise was conducted in order to
determine the effectiveness of Fluent in calculating the
flow field parameters in high pressure gradient
supersonic flows within the impulse blade passages. For
this purpose, a 2-D cascade CFD analysis was carried out
for Stratford’s (1962b) impulse blade geometry and inlet
Mach number conditions. These results were compared
with the annular cascade experimental data from
Stratford and Sansome (1962b).
Stratford and Sansome conducted experimental study
for different impulse blade designs. For this validation,
the CFD analysis was performed for one specific blade
called 1st blade design in Stratford (1962b). Fig. 7 Total to total pressure ratio of rotor outlet and
Fig 6 shows the Mach number contour plot for the rotor inlet across w at mid span
same. It can be observed that there is mild flow
separation near the entrance and exit of the rotor which is 2D RESULTS
consistent with the results of Stratford and Sansome The CFD analysis of the impulse blade used in the
(1962b-pp26). available partial admission design for the boundary
conditions mentioned above showed significant flow
separation as indicated in Fig. 8 (Ravichandran, 2013).
Suitable modification to the impulse blade profile was
clearly necessary. To reduce the shock losses, flow
separation extent had to be minimized and the separation
point needed to be moved further downstream of leading
edge of convex surface.
4
1
5
Fig. 12 Absolute static pressure distribution on concave for θT = 150 for passage width of 2.46 mm but the
and convex surface of impulse blades with w of 24.29% entropy increment are almost the same for both 120 and
of pitch for of 100, 120 and 150 150.
It was observed that the impulse blade with θT = 120 Fig. 16 Contour plot of Mach number for w of 29.14% of
performed better compared to other transition arc angle pitch and θT = 120
for every passage width analyzed. The entropy increment
as a measure of efficiency across the impulse blade Thus the CFD analyses of the 2D cascade model for
passage plotted for various passage widths against various impulse blades designed showed an optimum
transition arc angle (Fig. 13) concurs well with the above performance for a transition arc angle of 12 0 and passage
observations. Only exception is with passage width of width of 24.29% of pitch. It was observed that the
1.967 mm where the performance is almost the same for impulse blades with transition arc angle of 120 performed
100, 110 and 120. In addition, flow separation was least better when compared to the transition arc angles 10 0,
6
110, 130 and 150 for all the passage widths analysed. The appropriate approach. The density based coupled solver
design of the 3D stage was accordingly based on the was used and the rotational speed was set to 30000 RPM.
shortlisted profile from 2D analysis. Numerical divergence encountered in the initial attempts
were overcome by ramping up the inlet stagnation
pressure gradually from 3 bar (the outlet pressure was
Grid Independence kept fixed at 1.75 bar) to 40 bar through 5, 8, 15, 25 and
The 2D cascade results were checked for grid 35 bar in sequence. For each of these inlet conditions the
independence. The profile chosen for this was the one solver was allowed to run until the convergence or for at
with maximum passage width of 29.14% of pitch (2.6232 least 200 iterations.
mm). This ensured that the ones with lesser passage
width had finer elements than this case. The grids were
varied in the direction perpendicular to the flow. The
velocity magnitude profile at the exit of the rotor was
chosen as the parameter to compare the different mesh
results. This was used because all the variations inside
the impulse blade passage would affect the profile of
velocity at the rotor exit and hence would give us the
idea of the reliability of the mesh to capture the shocks
and flow separation.
The mesh sizes of 40, 60 and 80 elements
perpendicular to flow were analyzed for the case of
impulse blade with 2.6232 mm passage width and
transition arc angle of 120. Figure 17 shows the profile Fig. 18 Contour plot of Mach number for the turbine at
of velocity magnitude at the rotor exit for all these 50% blade height (mean diameter of 60 mm) for 1st
variations in mesh sizes. design
The maximum deviation in the magnitude of velocity
was found to be 1.826% between grid of 80 elements and The 3-D full admission simulation showed that there
that of 60 elements. The maximum deviation of 2.2% was occurrence of unforeseen oblique shocks at the stator
was found between grids with 60 and 40 elements. The exit as shown in Fig. 18. This led to a subsonic flow for
60 grid mesh was found to be satisfactory in capturing most part the rotor passage and these shocks became
the characteristics of flow with modest computational predominant when approached closer to the stator hub.
requirements. Hence the rest of the analysis was carried
out for 60 elements mesh.
Stator
Fig. 17 Deviation of velocity magnitude at rotor exit for blade tip
different grids
3D RESULTS
The objective of 3-D analysis was to establish the
ability of the stage design to deliver the rated power Impulse
operating at 30000 RPM and for conditions of full blade tip
admission. Under the time constraints of academic
deadlines, it was decided that an inviscid analysis would Fig. 20a Velocity angle contour plot at the mean blade
serve the stated objective. A steady state analysis in the height when the blade tips are closer
MRF framework made available by Ansys Fluent was an
7
pitch. Thus, it can be concluded that the impulse blade
with passage width of 2.186 mm and transition arc angle
of 120 showed optimum performance among the various
passage widths analyzed. The 3D aerodynamic analysis
of this impulse blade under inviscid, full admission
conditions showed weaker oblique shocks near the
Stator trailing edge of stator, which was not observed in 2D
blade tip
cascade results. This turbine gives a torque output of
Impulse 25.95 Nm and power output of 81.49 kW. It is believed
blade tip that the power output would increase if the trailing edge
shocks are eliminated.
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CONCLUSION Sweden.
From the 2D cascade results, it can be inferred that
the losses are minimum for transition arc angle of 120 for
all the passage widths analyzed and the flow performance
of the impulse blade was superior when the passage
width was maintained between 21.8% and 25% of rotor