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A Review of Inlet-Fan Coupling Methodologies
A Review of Inlet-Fan Coupling Methodologies
GT2017
June 26-30, 2017, Charlotte, NC, USA
GT2017-63577
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A REVIEW OF INLET-FAN COUPLING METHODOLOGIES
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celle designers are working on slimmer and shorter inlet geome- (1997) [11] describes distortion propagation through fan stage
tries. As a result, the next generation of turbofan will experience in order to accurately elaborate a multiple segment parallel com-
stronger inlet-fan interactions. Besides, innovative concepts such pressor model. He points out a phase difference between acoustic
as boundary layer ingesting (BLI) propulsion systems [1, 2, 3] and particle paths across the fan stage. More recently, Lesser and
will be subjected to even more critical inlet-fan interactions. In- Niehuis (2014) [12] have performed CFD simulations in order
deed, BLI disruptive distortions are not only encountered during to analyze the transfer of a circumferential stagnation pressure
special flight conditions (e.g. cross-wind, high angle of attack distortion through a compressor stage. They highlight the fan
(AoA), etc.) but throughout the entire aircraft envelope including decoupling effect described by Mazzawy and present a thorough
cruise. It is therefore necessary to include inlet-fan interaction in analytical explanation of different parameters transfer (stagna-
future design process. tion pressure and temperature, flow angle, axial velocity, etc.).
Unfortunately, fully coupled unsteady simulations, although Both analytical discussion and numerical results emphasize that
relatively well adapted to capture inlet-fan interactions, are still the fan tends to spread the distortion sector and thus bring to light
computationally too expensive and time-consuming for every- a critical distortion angle above which the fan stage suffers sig-
day design iterations. Alternative approaches are thus necessary. nificant loss in stability margin. Those results are consistent with
To address this issue, this paper presents low-cost CFD methods those of Reid (1969) [13], who was the first to introduce criti-
in order to account for inlet-fan interactions. The first fan model- cal distortion angles. Impact of stagnation pressure distortion on
ing method presented relies on the use of actuator disc boundary fan performance and stability has also been highlighted by many
conditions. The second method is a body-force modeling (BFM), studies. Cousins et al. (2003) [14] have tested two distortion
which consists in replacing the bladed region by an axisymmet- screens respectively of 180◦ 1/rev and 90◦ 2/rev on a turbofan
ric volume where source terms are applied in order to reproduce engine. While both distortion screens resulted in lowered sta-
fan stage effects [4]. Both fan modeling methods are compared bility limits, the 90◦ 2/rev showed the strongest decrease, con-
to isolated nacelle simulations and experimental data. tradictory this time to Reid’s investigations. Fidalgo et al. [15]
have simulated the transfer of a 120◦ 1/rev stagnation pressure
This paper includes a literature review, a description of
distortion pattern through the NASA rotor 67. Comparisons with
the test case, methodologies and numerical set-up. Follow
experimental data has demonstrated the validity of the U-RANS
results and discussion including comparisons between experi-
methods to study inlet distortion transfer. Among many findings,
ments, standard and low-cost simulations.
they have pointed out that the fan may locally operate beyond
the stability limit without actually observing stall or surge de-
pending on the inlet reference plan. The fan is seen to operate
LITERATURE REVIEW
within stability margins only by taking the reference section just
Inlet distortion has for long been identified as a major con-
upstream of the fan leading edge, which shows the importance
cern regarding fan performance and stability. However, inlet-fan
of inflow redistribution upstream of the fan. Fan local operating
interaction is quite complex as one may encounter difficulties
points can then be understood by considering both mass flow and
quantifying inlet distortion impact on fan performance, stability
swirl distortion.
and aeromechanics if using turbomachinary standards.
A first well established inlet-fan interaction property is the Although authors, particularly those mentioned above, have
fan action on inlet flow that works to bring forward reattach- investigated quite thoroughly inlet-fan interactions, very few
ment [5, 6], either in terms of mass flow and wind velocity for have attempted to provide good practices for fan design with inlet
cross-wind cases [7, 8] or in terms of Mach number and AoA distortion. Hall (2016) [16] has used BFM to study the impact of
for climb phase cases [9]. Thus, neglecting fan effects prevents different parameters on distortion intensity. The parameters con-
from over-constraining the design space by excluding short in- sidered are radial loading distribution, rotor-stator spacing and
let. Peters (2014) [10] has undertaken a parametric study on the non-axisymmetric stator geometry (by applying an exit flow an-
inlet length to fan diameter ratio L/D , using CFD simulations gle cosine function). One of the main conclusions of the study
with BFM to represent fan work of a nacelle turbofan at cruise is that non-axisymmetric stator geometry can provide significant
and under AoA. It indicates that design could be push toward distortion mitigation. Cao et al. (2016) [9] have studied inlet-
L/D = 0.25 without having fan efficiency penalties offsetting fan aerodynamics at high AoAs. In particular, they performed a
benefit from reduced nacelle drag, which remains far less than parametric study on the fan axial position using BFM. It shows
current turbofan standards (L/D ≈ 0.6). that the fan induces an inflow acceleration. The study points out
Impact of inlet distortion on fan performance and stability that the closer the fan to the inlet the stronger the acceleration,
Blade Number 18
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Bypass ratio ≈9
Specific Mass Flow (kg.s−1 .m−2 ) ≈ 220
Nominal Pressure Ratio ≈ 1.6
Inlet Length to Fan Diameter ≈ 0.6
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(i) mesh size is significantly reduced as fan blades are modeled
and not meshed within the computational domain and
(ii) steady approach can be applied, enabling the use of stan-
dard convergence acceleration techniques.
Their performance relies on their ability to reproduce fan effects.
These approaches can provide a good representation of the mean
fan effects on the nacelle flows. They seem valuable to estimate
large pattern inlet distortion. However, the application is limited
to short length scale phenomena that can appear between succes-
sive blades or between two blade rows. Also, these techniques
are not able to capture unsteady flow effects such as rotor/stator
interactions.
Actuator Disc
The actuator disc (AD) model consists in substituting the
meshed fan by an axial sector through which stagnation pressure
and enthalpy rises and flow deviation are added. The first AD
methodology considered in this study is described in [20]. It was
originally implemented for propeller configurations and is based
on the Glauert theory [21]. In short, downstream conditions of
the disc depend on upstream conditions and are evaluated by us-
FIGURE 3. Radial Distribution of Stagnation Pressure and Tempera-
ing pre-formatted tables. Tables are composed of lists of angle,
ture Ratios for the MASCOT2 fan and the Glauert formulation Actuator
stagnation pressure and temperature variations over a range of
Disc at Maximum efficiency and 50 % of the nominal shaft rotation
radii that covers the distance hub-to-shroud and thus for several
speed
values of AoA α and Mach number M. In practice, for every
cell face of the disc, a bilinear interpolation of the input flow
conditions (i.e. M, α) is conducted at each iteration to provide and ∆α) matching those specific values is determined
output flow variations (i.e. ∆pi , ∆Ti and ∆α). Tables were set up by an additional interpolation using radial basis function
in order to reproduce fan stagnation pressure and temperature at based on the field of results generated in steps 1 and 2.
maximum efficiency. FIGURE 3 shows that the model is quite
successful at reproducing targeted stagnation pressure and tem- Compared to the previous approach, this methodology is richer
perature ratios. These ratios are based on stagnation pressure and as it requires a large number of reference simulations.
temperature of the domain reference state.
Another actuator disc methodology was also tested. This Body-force Modeling
time, instead of relying on the Glauert theory (which is question-
Body-force approaches consist in replacing the bladed re-
able for fan applications), tables are created via an interpolation
gion by an axisymmetric volume where blockage, momentum
process over RANS simulation results covering the performance
and energy source terms are applied within each cell. Source
map. The interpolation process can be described by three steps.
terms are a combination of external and flow data so as to repro-
step 1 : Two axial stations, upstream and downstream of the fan duce the effect of the blades (cf. FIGURE 4). Force components
volume, are selected. RANS results are extracted at can be decomposed following Marble’s equations [22]. Within
these stations and averaged over the circumference. the flow plane, components are respectively a force perpendic-
step 2 : Results are then translated at the station which defines ~ . In this
ular fn and parallel f p to the flow relative velocity W
the actuator disc using basic mass flow rate, momentum decomposition, f p is proportional to entropy gradient which can
and energy conservation properties. be associated with stagnation pressure losses while fn refers to
step 3 : Tables are composed of only several specific input Mach fan load and deviation. The appropriate formulations of fn and
numbers and AoAs over which the bilinear interpolation f p must then be found. This can include flow values but also
is performed during computation. Output data (∆pi , ∆Ti external data such as geometric or calibration coefficients de-
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has been shown to improve agreement with the RANS simula-
tions near stall. However, it decreases robustness. In order to
guarantee simulation convergence and stability, the body-force
simulations presented in this paper were calibrated with the val-
ues βs = π/2 which corresponds to C(βs ) = 0.86.
NUMERICAL SET-UP
CFD simulations are performed with the solver elsA devel-
oped by Onera on structured meshes [29]. Equations are dis-
cretized in space using a cell-centered finite volume method with
the Jameson scalar dissipation scheme preconditioned for adap-
tation to low speed dissipation fluxes [30]. The model of Spalart
FIGURE 4. Body-force Principle and Analogy with Blade Deviation Allmaras [31] ensures turbulence closure. Simulations are all
[16] steady and are performed with an implicit pseudo-time marching
method with backward Euler scheme. The grid was generated
using ANSYS ICEM CFD software [32] and is relatively coarse
riving from experiments or CFD simulations. The most proven with domain mesh size of approximately 8.7×106 elements. The
body-force formulation comes from Gong (1999) [4] who orig- meshing strategy was developed to limit the computational re-
inally developed this model for stall inception of compressor in sources while respecting good practices such as ∆y+ < 1 and
inlet distortion conditions. This model has been reworked by boundary layers discretized with at least 30 cells with a growth
several authors [23, 24]. Peters (2014) [25] has included lean rate kept below 1.1.
effects and improved parallel force f p behavior away from max-
imum efficiency. Blockage effects can also be taken into account
by including additional source terms as described by Kottapalli
(2013) [26] or Thollet et al. (2015) [27]. The model used in the
study uses blockage source terms and is highly inspired from the
one developed by Thollet et al. (2016) [28]. It is based on a
lift-drag analogy and is defined by :
2πσ 2
fn = W Fs (β , β0? , βs ) (2)
H
W2
f p = K p0 (x, r) + 2πσ (β − β0 (x, r))2 (3)
H
where W and β are respectively the local flow relative velocity FIGURE 5. Nacelle-Fan Numerical Boundary Conditions
and angle, σ = c/H is the local blade row solidity where c and
H respectively refer to the blade chord and he blade to blade
staggered spacing. K p0 , β0 and β0? are data extracted from a Boundary conditions are represented in FIGURE 5. Far field
mono-segment RANS computation of the fan at maximum ef- conditions are applied to the external boundaries by imposing
ficiency (cf. [28] for additional details). The only difference with stagnation pressure and temperature and flow Mach number and
the model of Thollet et al. is the function defined by (4) : angle. Cross-wind angle is set to 90◦ for different wind veloc-
ities. For the nacelle-engine configuration (cf. FIGURE 5 left
β − β0? (x, r)
zoom) internal outlets are defined with valve conditions respect-
Fs (β , β0? , βs ) = (β − β0? (x, r)) cos C(β s ) (4)
βs − β0? (x, r) ing radial equilibrium. Primary outflow targets a reference mass
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ṁn
p piv,n+1 = p piv,n + λ2 pre f −1 (5)
ṁre f
2
ṁn
p piv,n+1 = pre f + λ4 (6)
ṁre f
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been specifically conducted for this paper. Therefore, compar- additional sources of distortion (e.g. natural wind, IDC pressure
isons with experiment must be taken into perspective. For exam- rakes, etc.).
ple, one can contest the fully turbulent assumption as laminar-
turbulent transition is well known to play a major part in inlet Focus at 25 kts: FIGURE 8 offers a comparison of all con-
separation [7, 33]. figurations computed at 25 kts. Left side captions represent a
slice parallel to cross-wind velocity colored with absolute Mach
number. Right side captions show stagnation pressure distortion
upstream of the fan leading edge at the location indicated by the
dashed lines on the left side captions. In order to separate fan
from internal geometry effects, an additional simulation (whose
results are shown in FIGURE 8 (b)) was performed with the en-
gine mesh but without using fan modeling methods. Secondary
mass flow was imposed by a radial equilibrium following equa-
tion (5).
Remarkably, the interpolated actuator disc has little effects
on inlet separation (cf. FIGURE 8 (c)). Inflow and distortion pat-
tern are similar with those of configuration (b), while flow down-
stream of the actuator disc is close to the flow predicted with
the BFM simulation (d). It demonstrates a lack of downstream-
upstream coupling that is likely the result of the discontinuity
introduced by the actuator disc interface. The presence of a flow
discontinuity across the disc limits the inlet mass flow redistri-
bution. On the other hand, the body force case (d) is absent of
FIGURE 7. IDC vs. Cross-Wind Velocity
this discontinuity as source terms are added smoothly across the
fan zone. Thus, a real coupling between the inlet, the fan vol-
ume where source terms are effective and the outlet domain is
FIGURE 7 shows a comparisons of IDC values as functions
possible. As a result, separation almost disappears.
of cross-wind velocity between experiments and simulations of
both isolated nacelle and fan modeling methods. While ex-
Focus at 30 kts: FIGURE 9 presents similar comparisons of
perimental values were taken at iso-mass-flow rate, simulations
fan modeling methods AD (a) and BFM (b) at 30 kts cross-wind
were performed at iso-boundary conditions. It does not necessar-
velocity. Here, both inlet flow present a separation on the in-
ily guarantee conservation of mass-flow as separation increases
let lip exposed to cross-wind. However, models predict different
with cross-flow intensification. As a results, IDC disparity can
pattern of separation. This can be observed looking at distortion
emerge. In order to get rid of mass-flow influence on IDC val-
patterns on the right side captions of the FIGURE 9. In particu-
ues, the IDC is normalized by the normalized mass flow. Results
lar, it shows that the AD distortion pattern remains spread across
must then be interpreted as follow : near-zero IDC values reflect
almost half of the circumference. It also shows that the BFM
clean inlet configuration while non-zero values prove the pres-
source terms affect the inlet distortion pattern. The stagnation
ence of inflow separation.
pressure loss of FIGURE 9 (b) is concentrated on the left down
The simulations and experiments for the isolated configura- quarter and resembles what can be obtained with fully coupled
tion are in rather good agreement. Separation occurs in both sets simulations (cf. FIGURE 10 (a)) or with the distortion cartogra-
of data above 25 kts. IDC values then differs by approximately phy reconstituted from IDC mean probe values (cf. FIGURE 10
10%, which remains acceptable. (b)). FIGURE 11 offers a closer view of the separation evolution
Differences between the “isolated nacelle” and the “nacelle- through the fan area for both AD and BFM. In the configuration
engine” experiments illustrate well the fan’s effect on inlet sep- represented in FIGURE 11 (a), the separation reaches the actua-
aration. While the separation appears for the isolated nacelle at tor disc inlet face without being affected by the latter. The actu-
25 kts, the inlet remains clean up to 30 kts for the nacelle-engine ator disc condition mechanically interpolates over data stored in
configuration. This is the separation delay that fan modeling tables and provides output accordingly. On the other hand, when
methods and fully coupled simulations must capture. Accord- body-force source terms are applied, the separation is contracted
ing to results shown in FIGURE 7, only the use of BFM properly upstream of the fan zone.
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may lead to better results. Also, the body-force modeling method
still requires a complete validation process in order to be used
accurately for industrial purpose. In particular, comparisons with
fully coupled unsteady simulations are necessary. Other rotation
speed must also be considered to investigate the model’s ability
to address fan interaction with transonic phenomenon (ex. inlet
separation induced by shock). What has been presented in this
paper serves to highlight the potential of such method to provide
a complete inlet-fan interaction assessment in terms of both inlet
aerodynamics and fan performance.
Those preliminary results represent a first milestone to sup-
ply designers with suitable tools to address inlet-fan interactions.
Not only aerodynamics performance and operability must be
considered but also aeromechanics behaviors. Therefore, addi-
tional methods such as URANS have been identified. A global
strategy proposed is the use of body-force methods to provide
representative inlet distortion to be used as inflow boundary con-
FIGURE 14. Stagnation pressure ratio performance map. Compar- ditions in URANS computations for aeromachanics behavior as-
isons of performance orbits under 25 kts and 30 kts resulting from BFM sessments.
and AD. 50% of the nominal rotation speed
ACKNOWLEDGMENT
We would like to thank Safran Aircraft Engines for the fund-
CONCLUSION AND PERSPECTIVE ing, for the supporting and for sharing valuable experimental data
Applications of two fan modeling methods on nacelles in without which this research work would not have been possi-
cross-wind conditions have been presented. The first one is an ble. We also would like to thank Jean-Christophe Boniface and
actuator disc model based on pre-formatted tables. Those tables Robert Gaveriaux for their technical support along the working
are generated via an interpolation within the performance map. process. We are grateful to Yanis Sadoudi who shared results
The BFM relies on the work of Thollet et al. [28]. Both methods from his PhD thesis. Last but not least, we are greatly indebted
are successful in reproducing the fan performance map. How- to William Thollet and Guillaume Dufour who share with us their
ever, the AD model shows limited effect on nacelle inlet aero- knowledge in body-force modeling methods.
dynamics. Separation remains almost unchanged and the AD
must then work with the separation directly as an input condi-
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