Paper 24 Basawaraj02
Paper 24 Basawaraj02
ISSN: 1001-4055
Vol. 44 No.4 (2023)
Abstract: This paper deals with the Design, Analysis and optimizing a single stage axial transonic compressor.
The recent trend to increase the capacity of modern heavy duty gas turbine compressors requires high
performance transonic rotors with increasing tip Mach numbers. When developing a transonic compressor, an
important subject is to design an airfoil shape which gives good performance in transonic flow region. NACA-
65 aerofoil is best suitable for subsonic regime. While Multi Circular Arc (MCA) airfoil design and DCA
aerofoil design are suitable in transonic regimes. Therefore an attempt is made to design and study the
aerodynamic characteristics of a transonic compressor stage with NACA-65, MCA and DCA aerofoil
combinations.CF-turbo is used to design the aerofoil and computational analysis is carried out in Ansys CFX.
The air mass flow rate is considered of 5kg/sec at 10,000 RPM, blade tip speed 454 m/sec rotor hub to tip speed
ratio=0.7. Overall performance of all the combinations were inlet totalpr =1 atm. Comparatively good having
the isentropic efficiency ranging from 77.9 % to 84.8% having MCA-DCA combinations the lowest & NACA-
MCA being the highest but overall pr.ratio is observed to be 1.244 in MCA-MCA and MCA-DCA combinations
while NACA-MCA is only 1.23. Flow coefficient and head coefficient being the highest in MCA-MCA &
MCA-DCA combinations of 24.87 and 13.62 respectively. Blade loading co efficient is observed as -8.7 and it
is nearly flat over the upper surface of rotor as well as stator in MCA-DCA combinations, while NACA-MCA
having uneven behavior of -7.86. Thereby through my study i conclude that NACA-65 aerofoil with MCA for
the rotor and NACA-65 with DCA for stator as the best combination among all the different cases studied in
this attempt.
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Figure 1.1:General Electric J85 Cutaway with Axial Flow Compressor [2]
1.2Construction and Working of Axial Flow Compressor
A typical axial flow compressor sucks the air axially and increases its pressure energy level by passing
air through the two main elements rotorand stator. Each consecutive pair of rotor and stator is referred as a
stage. Rotor is the rotating element having blades fixed on the spindle or drum. These blades, turning at high
speed, takes the air at the inlet and impel torque to the air along the axial path similar to propeller because of its
airfoil shape and pitch angle. Now the stator is the stationary blades mounted on the stator casing slows down
the air velocity and convert the circumferential component of air into pressure. Stator blades are arranged to
form the diverging passage to act as the diffusers at every stage, partially converting kinetic energy to pressure.
Pressure ratio increases with the number of stages. Each stage has the ability of achieving the compression ratio
of approximately 1.25:1.Most aircraft engines consists of up to 16 stages in order to fulfill higher pressure ratio
requirements.
Figure 1.2:Velocity and Pressure variation over rotor and stator in axial flow compressor[2]
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Vol. 44 No.4 (2023)
An extra row of fixed vanes called inlet guide vanes are placed at the inlet of the compressor to guide the air to
the first row of rotating blades as shown in figure 1.2. These compressors are highly efficient and are capable of
handling large flow rates with respect to their size. They offer the most compact and light weight design for
large flow rate applications. In every stage the gap between the rotor and stator must be as close as possible for
efficient flow. Designing length of the blade with minimal tip clearance is a challenging task. The height of the
blades is reduced over successive stages so as to compensate the reduction in fluid volume and contribute to rise
in pressure. Thus the axial flow velocity is maintained constant throughout the compressor. [1]
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Losses experienced in axial flow compressors are grouped under the following types: [1]
1. Profile loss:arises due to the peculiarity of their blade aerofoil design. In other words, arises due to the boundary
layer growth and its subsequent separation over the blade.
2. Skin Friction loss:also known as Annulus loss or viscous loss. This accounts up to 50% of the total losses. This
arises due to axial growth of boundary layer.
3. Secondary Flow loss: arises due to the secondary flow occurrence in the passages formed between curved
blades.
4. Tip Leakage loss:arises due to the gap between the rotor blades and the casing.
1.7 Comparison between Centrifugal Compressor and Axial Flow Compressor
[3]
Table 1.1: Comparison between centrifugal compressor and axial flow compressor
Sl.
Parameters Centrifugal Compressor Axial Flow Compressor
No.
Axial flow (parallel to the axis of
1 Direction of flow Radial flow
rotation)
Pressure ratio per
2 4.5:1 1.25:1
stage
3 Isentropic efficiency 80-82% 86-88%
4 Frontal area Large Small
Mass flow rates Low High
Wide range of operational speeds Narrow range of operational speeds
5 Operation between chocking and surging limits. between chocking and surging limits.
Part load performance is better. Part load performance is poor.
6 Starting power Needs low starting torque Needs higher starting toque.
Almost insensitive to deposit Sensitive to deposit accumulation on the
7 Deposits
accumulation on the blade surfaces. blade surfaces.
Construction
8 Simple and relatively cheap. Complex and costly
complexity and cost
Suitability for
9 Slightly difficult Suitable for multi staging
multistage
Supercharger in IC engine, air
Jet engines, large marine gas turbine
10 Applications conditioner, low pressure
engines.
refrigerators.
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Figure 3.3:Meridional view (R v/s Z) of single stage transonic axial compressor, Case-1
Figure 3.4:Meridional view (Rθ v/s Z) of single stage transonic axial compressor, Case-1
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Vol. 44 No.4 (2023)
Figure 3.5:3D CAD model of single stage transonic axial compressor in CF Turbo
Rotor ( 36 Blades) Stator ( 46 Blades)
Particular
Hub Mean Tip Hub Mean Tip
Solidity 1.634 1.413 1.188 1.452 1.375 1.330
Pitch/Chord 0.612 0.708 0.842 0.689 0.727 0.752
Throat/Pitch 0.644 0.551 0.467 0.783 0.761 0.738
Inlet Angle - - -
42.520 44.669 46.818
(deg) 49.645 57.636 64.947
Exit Angle - - -
4.863 3.209 1.554
(deg) 23.284 43.319 53.820
Stagger - - -
23.706 23.917 24.142
Angle (deg) 36.495 50.486 59.384
Radius at
0.178 0.218 0.252 0.188 0.217 0.243
LE (m)
Radius at
0.188 0.218 0.245 0.191 0.217 0.240
TE (m)
Table 3.2: Blade geometry details of rotor and stator for Case-1 in CF Turbo
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Boundary Conditions
Rotating Domain Speed 10000 RPM
Figure 3.8:Boundary Conditions applied over the compressor stage in Ansys CFX
4. Results And Discussion
Computational results obtained, variation of Mach number contour and variation of static pressure contours over
the blade profile and velocity streamlines in the passage between the blades are reported case wise here in this
chapter. Discussions over the results obtained is made at the end of this chapter using comparison graphs of
blade loading, total pressure ratio, total temperature ratio, flow coefficient, head coefficient, blade loading
coefficient and isentropic efficiency of the stage.
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Figure 4.1 :Obliqueshock formation over DCA stator blade in Case 6 – (MCA-DCA)
Figure 4.3 :Coefficient of pressure variation over super critical airfoils across the chord length.[3]
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4.1 Blade Pressure Loading Chart over Rotor and Stator Blades of all 9 Cases
Figure 4.4:Blade pressure loading chart over rotor blades of all 9 cases.
Blade pressure loading distribution over the rotor blades in all the cases examined is shown above in figure 4.4.
As we have discussed earlier the blade pressure loading should be uniform throughout the maximum extent of
the blade chord length/surface. MCA and DCA rotor blades are showing comparatively flat results over the
blade’s upper surface, while the pressure loading is slightly increased in NACA 65 rotor blades near to the
trailing edge.
Figure 4.5 :Blade pressure loading chart over stator blades of all 9 cases.
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Blade pressure loading distribution over the stator blades in all the cases examined is shown above in figure 4.5.
As we have discussed in figure 4.4 over the rotor blades, MCA and DCA stator blades are also showing
comparatively flat results over the blade’s upper surface, while the pressure loading is slightly increased in
NACA 65 stator blades show a dip in the pressure loading at its mid chord and again it raises near the trailing
edge.
In comparison between MCA stator blade and DCA stator blade. DCA is showing good results as the pressure
loading is completely flat, while in MCA blades there is a slight rise in the pressure loads in the mid chord of the
blade.
4.2 Comparison of Total Pressure Ratio obtained in all 9 Cases
Total Pressure
CASE Airfoil Combination
Ratio
1 NACA_NACA 1.24058
2 NACA_MCA 1.23924
3 NACA_DCA 1.23923
4 MCA_MCA 1.24461
5 MCA_NACA 1.24432
6 MCA_DCA 1.24322
7 DCA_DCA 1.23566
8 DCA_NACA 1.23601
9 DCA_MCA 1.23639
Figure 4.6 :Bar Chart in comparison of Total Pressure Ratio obtained in all 9 Cases
Total pressure ratio obtained in all 9 cases are tabulated in table 4.1 and comparison is made in figure 4.6. Case
4, 5 and 6 are showing higher pressure ratios of about 1.24322 to 1.24461. Case 4 shows the highest total
pressure ratio of 1.24461 and the least is observed in case 7 of 1.23566.
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1 NACA_NACA 24.507
2 NACA_MCA 24.6495
3 NACA_DCA 24.5149
4 MCA_MCA 24.8714
5 MCA_NACA 24.6084
6 MCA_DCA 24.4005
7 DCA_DCA 24.0948
8 DCA_NACA 23.9279
9 DCA_MCA 24.1893
Blade Loading
CASE Airfoil Combination
Coefficient
1 NACA_NACA -7.96385
2 NACA_MCA -7.86814
3 NACA_DCA -7.9467
4 MCA_MCA -8.39066
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5 MCA_NACA -8.39502
6 MCA_DCA -8.70122
7 DCA_DCA -8.07832
8 DCA_NACA -8.07604
9 DCA_MCA -8.39215
Figure 4.8 :Bar Chart in comparison of Blade Loading Coefficient in all 9 Cases
Blade Loading Coefficient in all 9 cases are tabulated in table 4.3 and comparison is made in figure 4.8. Case 4,
5 and 6 are showing lowerblade loading coefficient of about -8.39066 to -8.70122. Case 6 shows the lowest
blade loadingcoefficient of -8.39066 and the highest is observed in case 2 of -7.86814.
4.5 Comparison of Isentropic Efficiency in all 9 Cases
Isentropic
CASE Airfoil Combination
Efficiency
1 NACA_NACA 84.2
2 NACA_MCA 84.8
3 NACA_DCA 83.4
4 MCA_MCA 81.2
5 MCA_NACA 81.0
6 MCA_DCA 77.9
7 DCA_DCA 81.4
8 DCA_NACA 81.6
9 DCA_MCA 78.6
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6. References
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