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Axial Compressors 2: - Blade Design - Preliminary Design of A Seven Stage Compressor
Axial Compressors 2: - Blade Design - Preliminary Design of A Seven Stage Compressor
Blade design
• We want:
– blade must achieve required turning at
maximum efficiency over a range of
rotational speeds
• Correlated experiments are very
valuable to estimate performance
– tests on single blades (effect of
adjacent blades must be estimated)
– tests on rows of blades - so called
cascades Annular cascade
• Linear cascades (rectilinear cascade).
Mechanically simpler than annular to
build. Flow patterns are simpler to Linear cascade
interpret. More frequent.
• Annular. Many root tip ratios would
be required. Does not satisfactorily
reproduce flow in actual compressor
Chalmers University of Technology
Blade design
• For a test camber angle θ, chord c and pitch s will be fixed
and the stagger angle ζ is changed by the turn table.
• Pressures and velocities are measured downstream and
upstream by traversing instruments
Chalmers University of Technology
Blade design
• Measurements are recorded
as pressure losses and
deflection
• Incidence is varied by
turning the turn-table
• Mean deflection and loss
are computed
p01 p02
loss
1
V12
2
deflection 1 2
incidence 1 1
Chalmers University of Technology
Blade design
• Selecting more than 80%
of stall deflection means
risk of stalling at part load
• Select 0.80 S
*
Annulus dimension
Continuity gives the compressor inlet area:
rr2
m 1 ACa1 1 rt 1 2 Ca1 ,
2
C1 No IGV Ca1 150 m/s
rt
A
( 1)
C1 m RT01 1 2 2 ( 1)
M1 0.45 M 1 1 M1 0.5000
T1 P01 A1 2
C 2
R 288 1
2c p
A1 0.120 m 2
Chalmers University of Technology
Annulus dimension
A single stage turbine can designed to drive this compressor if a
rotational speed of 250 rev/s is chosen (Chapter 7). N = 250 rev/s gives:
Assume root tip ratio 0.5 0.2261 U t 2 rt 355.2 m / s
A
rt
rr2
1 2
rt
rm 0.1696
Considering the relatively low Ut centrifugal stresses in the root will
not be critical and the choice of a root-tip ratio of 0.5 will be considered
a good starting point for the design. Recall the approximative formula:
b 2
b 2 rr
2
ct max
t
ar r
ardr ... U t 1
2 rt
rr
root tip ratio
rt
Chalmers University of Technology
Annulus dimension
U t2 Ca21
• A check on the tip Mach number gives: M rel ,tip 1.165
RT
This is a suitable level of Mach number. Relative Mach numbers over
about 1.2-1.3 would require supercritical (controlled diffusion blading).
Too low values would result in a low stage temperature rise.
• The compressor exit temperature is estimated assuming a polytropic
efficiency, η c,polytropic, of 90%, which gives the exit area:
1 1
P c ,
T02 T01 02 452.5, C1 Ca Cexit 150 m / s
P01
( 1)
Cexit mexit RT0,exit 1 2 2 ( 1)
M exit 0.356 M exit 1 M exit 0.391 A exit 0.044 m 2
Texit
P0,exit A 2
C
2
R 452.5 exit
2c p
Chalmers University of Technology
Annulus dimension
• The blade height at exit can now be calculated
Aannulus Atot Aroot rt 2 rr2 rt rr rt rr
2 rt rr
rt rr
2hrm h 0.0413 m
2
h
rm
rt 0.1902
rr 0.1489
A constant mean diameter
design is assumed
Chalmers University of Technology
Design goal
• Stage 1 and stage 7 are somewhat less loaded to allow for:
– Stage 1: highest Mach numbers occur in first stage rotor tip => difficult
aerodynamic design. Inlet distortion of flow may be substantial. Less
aerodynamic loading may alleviate these difficulties
– Stage 7: it is desirable to have an axial flow exiting the stator of the last
stage => a higher deflection is necessary in this stage which may be
easier to design for if a reduction in goal temperature rise is allowed for
• This gives the following design criteria (assuming a typical
work done distribution)
Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7
ΔT=20 ΔT=25 ΔT=25 ΔT=25 ΔT=25 ΔT=25 ΔT=20
λ=0.98 λ=0.93 λ=0.88 λ=0.83 λ=0.83 λ=0.83 λ=0.83
Chalmers University of Technology
Cw 2 Cw1
C3 C1 1 0.856
2U
• Since the root-tip ratio of the first stage is the lowest, the greatest
difficulties with low degrees of reaction will be experienced in
the first stage rotor. Thus, a good margin to 0.50 has to be
accepted.
Chalmers University of Technology
Stage-by-stage design
• Due to the increase in root-tip ratio for the second stage we
hope to be able to use a Λ of 0.70:
UCa
T0 tan 1 tan 2
cp
Ca
tan 1 tan 2
2U
• Solving the two simultaneous equations for
β 1 and β 2 gives: 57.70
1
2 42.19
• α 1 and α 2 are then obtained from (obtaining α 1 means that the
design of the first stage is complete):
U Ca tan 1 Ca tan 1 1 11.06
U Ca tan 2 Ca tan 2
2 41.05
Chalmers University of Technology
• The de Haller
number in the
stator is:
Ca
C3 cos 3
0.907
C2 Ca
cos 2
Chalmers University of Technology
Ca
tan 1 tan 2
2U
• Solving the two simultaneous equations for β 1 and β 2 gives
β 1=51.24 and β 2=28.00. This gives a to low de Haller number
which can be dealt with by reducing the temperature increase over
the stage to 24K. Repeating the calculation gives:
1 50.92
2 28.63
• which is produces an ok de Haller number. α 1 and α 2 are
obtained from symmetry which is obtained when Λ = 0.50.
Chalmers University of Technology
• The de Haller
number in the
stator is:
Ca
C3 cos 3
0.859
C2 Ca
cos 2
Chalmers University of Technology
Ca
tan 1 tan 2
2U
• Since λ is 0.83 for the remaining stages, the stages 4, 5 and 6 are
all designed with the same angles. Again the stage temperature
rise is reduced to 24 K to maintain the de Haller number at an
high enough number. Solving the two equations give:
1 2 51.38
2 1 27.71
Chalmers University of Technology
• The de Haller
number in the
stator is:
Ca
C3 cos 3
0.712
C2 Ca
cos 2
Chalmers University of Technology
• Stage 4, 5 and 6 are repeating stages, except for the stator outlet
angle of stage 6 which is governed by the design of stage 7.
Chalmers University of Technology
• The de Haller
number for the
stators are:
Ca
C3 cos 3
0.705
C2 Ca
cos 2
Chalmers University of Technology
Ca
tan 1 tan 2
2U
• The pressure ratio of the seventh stage is set by the overall
requirement of an rc = 4.15. The stage inlet pressure is 3.56 bar,
which gives the required pressure ratio and temperature increase
according to:
P03 4.192
1.177
P01 7 3.560
Stage TStage 1
1 1.177
T01
T0 22.8 K
Chalmers University of Technology
• Exit guide
vanes can be
incorporated to
straighten flow
before it enters
the burner
Chalmers University of Technology
Annulus shape
• The main types of annulus
designs exists
– Constant mean diameter
– Constant outer diameter
– Constant inner diameter
• Constant outer diameter
– Mean blade speed increases with
stage number
– Less deflection required => de
Haller number will be greater
– U1 and U2 will not be the same!!! It U 2Cw2 U 1Cw1
T0
will be necessary to use: cp
Chalmers University of Technology
rm
Cw 2,r Cw 2,m 111.4 m/s
rr
rm
C w 2 ,t C w 2 , m 58.7 m/s
rt
Chalmers University of Technology
Compressibility effects
• Fan tip Mach numbers of more than 1.5
are today frequent in high bypass ratio
turbofans
• At some free-stream Mach number a
local Mach number exceeding 1.0
will occur over the blade
– This Mach number is called the critical
Mach number Mcr.
– A turbulent boundary layer will separate
if the pressure rise across the shock
exceeds that for a normal shock with
an upstream Mach number of 1.3
(Schlichting 1979). Keep this in mind!!!
Chalmers University of Technology
dV dA
( M 1)
2
V A
Supercritical blading
Chalmers University of Technology
Learning goals
• Know how to determine a multistage
compressor design for a certain
specification.
– This includes making assumptions design
parameters
• Have an understanding of how
compressor design must be adjusted for
high Mach number effects.