高温燃气发动机叶片的冲击冷却与气膜冷却的数值研究
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摘要
随着燃气发动机在航空飞行器的动力系统、海上轮船的推进系统以及陆地电厂的发电系统中应用越来越广泛,提高燃气发动机效率变得更加重要。根据燃气发动机工作的Brayton循环原理可知,发动机的热效率和输出功率随着发动机叶片入口温度的增高而增加。当前的F119-PW-100透平风扇发动定子前缘温度已达到1600℃,而为了满足研制更加先进发动机的需求,需要叶片入口温度达到约2200℃,这个温度远高于叶片的金属材料熔点。因此,为了让叶片在高温下持续可靠工作,需要使用新的耐热材料和引进先进叶片冷却技术。然而,相比于研制新的材料或者工艺,采用先进的冷却技术所带来的叶片入口温度的增加更外显著。而冲击冷却和气膜冷又是先进冷却技术中最为重要的两种方法,值得更多关注。本文将使用数值模拟计算分别讨论用于高温燃气发动机叶片上的内部层板结构的冲击气膜冷却和外部气膜冷却的流动与传热特性。内容主要包含：
第一部分层板结构的冲击气膜冷却
这里分析了应用于叶片冷却的多孔层板结构的冲击气膜冷却技术。进行数值分析时,先需要对计算模型进行验证。该验过程是通过将用不同模型计算得到的速度场与相同条件下PIV测量的速度场相对比。结果显示,以Shear Stress Transport k-ω (SST k-ω)湍流模型计算得到的速度场与实验测量数据最为接近。同时,将高温条件热像仪测量下测量的层板表面温度检测了SST k-ω模型计算传热的精度,结果满足工程计算要求。因此,SST k-co湍流模型将用被作层板冷却研究。在模型选取后,使用流固耦合传热计算方法,讨论冲击孔、扰绕流柱、气膜孔的数目比、流柱排列方式以及气膜孔的倾斜角度对多孔层板的冷却效率和阻力损失的影响。然后使用单向耦合计算方法,即假设由于热应力引起的结构变形不会影响层板上的温度分布以及层板内部和外部流场,将由CFD计算得到的层板温度作为体载荷,开始层板结构上的热应力分析。在完成应力计算后,使用Goodman-diagram方法进行层板疲劳寿命评估。最后,结合正交试验方法和数值计算,讨论影气膜孔角度、扰流柱直径、扰流柱排列方式、扰流柱高度以及气流吹风比的变化对层板的冷却效率以及阻力损失的影响趋势以及影响权重,为优化层板结构提供参考方案。
第二部分跨音速转子气膜冷却
在这一部分里,选取Pratt&Whitney公司研制的单级高性能发动机叶片来分析在叶片正常运行工况下发动机内定子和转子的相互作用对转子上的压力与气膜冷却特性的影响。由于叶片通道与层板结构内的流动特征显著不同,因此湍流模型需要重新验证。且因为缺少在实际工况下该叶片上的温度与压力测量数据,这里选取实验测量到的定子和转子叶栅通道的压力分布以及一个缩扩型喷管上的壁面压力分布参考,并与使用不同湍流模型得到的压力值进行对比,发现Realizable k-ε湍流模型计算得到的结果最接近实验值,因此,此模型作为研究跨音速叶片通道内流动和传热分析。开始时,使用该模型分析了转子尾槽注入冷却气冷却以及定子上气膜孔冷却特性。然后,以2D模型分析叶片的翼展方向的中间截面处,定子与转子的相互作用(包含定子尾缘的激波、定子尾缘尾迹以及通道内势流)对转子上压力分布和气膜冷却效率影响。最后以3D模型讨论了叶片的扭曲对转子通道内流场的改变,以及吹风比对扭曲转子上的气膜冷却效率影响。
With more and more gas turbines being widely used for aircraft propulsion, sea-based ship propulsion and land-based power generation, it is extremely important to increase the turbine thermal efficiency. Based on the principle of Brayton cycle for gas turbines, increase in turbine inlet temperature can increase turbine thermal efficiency and power generation. Currently, the turbine fan F119-PW-110has a turbine inlet temperature of about1600℃, but it is still far lower than the requirement of advanced turbines which require the temperature should be of about2200℃Considering the gas temperature is far beyond the allowable metal melting points, new thermal resistant material and advanced cooling technologies should be developed and applied. Compared with the contribution of raised turbine inlet temperature by developing new thermal resistant material, utilization of advanced cooling technology benefits more. Impingement cooling and film cooling are two of the most effective cooling ways. It deserves more attention. This thesis is using numerical methods to investigate the flow field and heat transfer characteristics of impingement and film cooling on a gas turbine blade working under high temperatures. It consists of two parts:
Part I Impingement cooling in laminated plates
In this part, the work was concentrated on the study of impingent cooling and film cooling in the laminated plates which are used in turbine blades and combustor liners. Prior to the numerical simulation, the best turbulence model was chosen through the comparison of the flow fields by numerical simulation with PIV results and further validated via the comparison of the surface temperature of laminated plates with Infrared measurements. It was found that the Shear Stress Transport k-co (SST k-ω) turbulence model agreed best with the experimental data. Hence, this model was adopted for the following laminated plate cooling analyses. Firstly, the fluid-thermal coupled calculation method involving both fluid and solid regions was applied to discuss the effects of factors including, number ratio of impingement holes to ribs to film holes, ribs arrangement and inclined angles of film hole on film cooling performance and press losses of laminated plates. Secondly, a one-way coupled method, with the assumption that the deformation of the plates caused by thermal stress is small and it has no effect on the temperature filed in the solid and no change to the flow fields in and around the plate, was adopted to calculate thermal stress distribution in the laminated plates using the temperature as the body load obtained directly from CFD. After that, a Goodman-diagram method is used to assess the fatigue characteristics of the plate. Lastly, the method of combining design of experiments and numerical simulation is used to analyze the influences of film hole inclined angle, diameter of rib, rib arrangement, height of ribs, and blowing ratio on the laminated cooling performance and pressure losses, which is valuable for helping design an optimal plate.
Part II Film cooling on transonic gas turbine rotors
In this part, a one-stage high load transonic turbine for high efficient energy engine made by Pratt&Whitney was chosen for investigating the effects of stator-rotor interaction on the aerodynamic characteristic and film cooling performance on the rotor under the turbine design condition. Since the flow features in the turbine passages are significantly different from thoese of laminated plates, it is again necessary to compare and choose an appropriate turbulence model. Due to the lack of experimental data of the blade at turbine representative conditions with film cooling, the static pressure distributions for flow passing through the stator and rotor cascades, and a convergent-divergent nozzle are referenced for comparison. Through the comparison, the Realizable k-s turbulence was chosen over other models And this model was applied to futher discuss the effects of trailing edge coolant injection on the flow field in a rotor cascade, and film cooling characteristics on the stator in the stator cascade. After that, a2D analysis of the effects of stator-rotor interaction on the pressure distribution and film cooling performance on the rotor at the turbine mid-span followed. And then it was concluded by discussing the effects of using twisted blade on the flow features in the rotor passage and film cooling performance on the rotor under three blowing ratios.
第一部分层板结构的冲击气膜冷却
这里分析了应用于叶片冷却的多孔层板结构的冲击气膜冷却技术。进行数值分析时,先需要对计算模型进行验证。该验过程是通过将用不同模型计算得到的速度场与相同条件下PIV测量的速度场相对比。结果显示,以Shear Stress Transport k-ω (SST k-ω)湍流模型计算得到的速度场与实验测量数据最为接近。同时,将高温条件热像仪测量下测量的层板表面温度检测了SST k-ω模型计算传热的精度,结果满足工程计算要求。因此,SST k-co湍流模型将用被作层板冷却研究。在模型选取后,使用流固耦合传热计算方法,讨论冲击孔、扰绕流柱、气膜孔的数目比、流柱排列方式以及气膜孔的倾斜角度对多孔层板的冷却效率和阻力损失的影响。然后使用单向耦合计算方法,即假设由于热应力引起的结构变形不会影响层板上的温度分布以及层板内部和外部流场,将由CFD计算得到的层板温度作为体载荷,开始层板结构上的热应力分析。在完成应力计算后,使用Goodman-diagram方法进行层板疲劳寿命评估。最后,结合正交试验方法和数值计算,讨论影气膜孔角度、扰流柱直径、扰流柱排列方式、扰流柱高度以及气流吹风比的变化对层板的冷却效率以及阻力损失的影响趋势以及影响权重,为优化层板结构提供参考方案。
第二部分跨音速转子气膜冷却
在这一部分里,选取Pratt&Whitney公司研制的单级高性能发动机叶片来分析在叶片正常运行工况下发动机内定子和转子的相互作用对转子上的压力与气膜冷却特性的影响。由于叶片通道与层板结构内的流动特征显著不同,因此湍流模型需要重新验证。且因为缺少在实际工况下该叶片上的温度与压力测量数据,这里选取实验测量到的定子和转子叶栅通道的压力分布以及一个缩扩型喷管上的壁面压力分布参考,并与使用不同湍流模型得到的压力值进行对比,发现Realizable k-ε湍流模型计算得到的结果最接近实验值,因此,此模型作为研究跨音速叶片通道内流动和传热分析。开始时,使用该模型分析了转子尾槽注入冷却气冷却以及定子上气膜孔冷却特性。然后,以2D模型分析叶片的翼展方向的中间截面处,定子与转子的相互作用(包含定子尾缘的激波、定子尾缘尾迹以及通道内势流)对转子上压力分布和气膜冷却效率影响。最后以3D模型讨论了叶片的扭曲对转子通道内流场的改变,以及吹风比对扭曲转子上的气膜冷却效率影响。
With more and more gas turbines being widely used for aircraft propulsion, sea-based ship propulsion and land-based power generation, it is extremely important to increase the turbine thermal efficiency. Based on the principle of Brayton cycle for gas turbines, increase in turbine inlet temperature can increase turbine thermal efficiency and power generation. Currently, the turbine fan F119-PW-110has a turbine inlet temperature of about1600℃, but it is still far lower than the requirement of advanced turbines which require the temperature should be of about2200℃Considering the gas temperature is far beyond the allowable metal melting points, new thermal resistant material and advanced cooling technologies should be developed and applied. Compared with the contribution of raised turbine inlet temperature by developing new thermal resistant material, utilization of advanced cooling technology benefits more. Impingement cooling and film cooling are two of the most effective cooling ways. It deserves more attention. This thesis is using numerical methods to investigate the flow field and heat transfer characteristics of impingement and film cooling on a gas turbine blade working under high temperatures. It consists of two parts:
Part I Impingement cooling in laminated plates
In this part, the work was concentrated on the study of impingent cooling and film cooling in the laminated plates which are used in turbine blades and combustor liners. Prior to the numerical simulation, the best turbulence model was chosen through the comparison of the flow fields by numerical simulation with PIV results and further validated via the comparison of the surface temperature of laminated plates with Infrared measurements. It was found that the Shear Stress Transport k-co (SST k-ω) turbulence model agreed best with the experimental data. Hence, this model was adopted for the following laminated plate cooling analyses. Firstly, the fluid-thermal coupled calculation method involving both fluid and solid regions was applied to discuss the effects of factors including, number ratio of impingement holes to ribs to film holes, ribs arrangement and inclined angles of film hole on film cooling performance and press losses of laminated plates. Secondly, a one-way coupled method, with the assumption that the deformation of the plates caused by thermal stress is small and it has no effect on the temperature filed in the solid and no change to the flow fields in and around the plate, was adopted to calculate thermal stress distribution in the laminated plates using the temperature as the body load obtained directly from CFD. After that, a Goodman-diagram method is used to assess the fatigue characteristics of the plate. Lastly, the method of combining design of experiments and numerical simulation is used to analyze the influences of film hole inclined angle, diameter of rib, rib arrangement, height of ribs, and blowing ratio on the laminated cooling performance and pressure losses, which is valuable for helping design an optimal plate.
Part II Film cooling on transonic gas turbine rotors
In this part, a one-stage high load transonic turbine for high efficient energy engine made by Pratt&Whitney was chosen for investigating the effects of stator-rotor interaction on the aerodynamic characteristic and film cooling performance on the rotor under the turbine design condition. Since the flow features in the turbine passages are significantly different from thoese of laminated plates, it is again necessary to compare and choose an appropriate turbulence model. Due to the lack of experimental data of the blade at turbine representative conditions with film cooling, the static pressure distributions for flow passing through the stator and rotor cascades, and a convergent-divergent nozzle are referenced for comparison. Through the comparison, the Realizable k-s turbulence was chosen over other models And this model was applied to futher discuss the effects of trailing edge coolant injection on the flow field in a rotor cascade, and film cooling characteristics on the stator in the stator cascade. After that, a2D analysis of the effects of stator-rotor interaction on the pressure distribution and film cooling performance on the rotor at the turbine mid-span followed. And then it was concluded by discussing the effects of using twisted blade on the flow features in the rotor passage and film cooling performance on the rotor under three blowing ratios.
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