Journal of Applied Fluid Mechanics (May 2024)
Fast-moving Mesh Method and Its Application to Circumferential Non-uniform Tip Clearance in a Single-stage Turbine
Abstract
The circumferential non-uniform tip clearance (CNTC) due to casing out-of-roundness adversely affects the turbine aerodynamic performance due to machining and assembly errors, thermal deformation, and improper active clearance control (ACC), etc. Moreover, the asymmetric computational domain caused by casing out-of-roundness presents difficulties for conventional numerical techniques that consider rotational periodicity. Since previous traditional methods using split computational domains have the disadvantages of high interpolation error and high time cost, an efficient fast-moving mesh (FMM) method based on an algebraic approach is proposed in this paper. This method is first validated by using a single-stage turbine with elliptical casing. The results show that the FMM has the advantages of high accuracy, high efficiency, and easy operation, which helps to solve the CNTC problem quickly in scientific research or engineering applications. Then, the effects of CNTC induced by the elliptical casing on the flow field and aerodynamic performance are investigated by using an in-house code that integrates the FMM method. Finally, the effect of stator row interference on the aerodynamic performance in the turbine stage with an elliptical casing is demonstrated. The results show that different types of elliptical casings have a significant effect on the aerodynamic performance. However, the variation law is not consistent (decreasing by 0.538% or increasing by 0.212%). Importantly, the novel finding of this paper is that this discrepancy is jointly determined by the interaction of multiple secondary flows (passage vortex, scraping vortex, etc.) at different spans, not just related to the variation of the tip leakage vortex (TLV) with tip size. Furthermore, this study is the first to indicate that the stator row interference can mitigate the extent of performance degradation due to elliptical casings by suppressing the development of secondary flows. These results may provide theoretical support for blade tip gap design and can also serve as a reasonable reference for the effective application of ACC in engineering. Finally, low-order harmonic components with high amplitudes are also innovatively found in the rotor row with a CNTC. These components may cause low-engine-order (LEO) resonances that endanger the safe operation of engines.
Keywords
