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Tip clearance flow in axial flow compressor is unavoidable and responsible for pressure losses and noise generation and influences the stability of the compressor. However, necessary flow measurement in the blade tip region is a great challenge due to the small gap width as well as the structure limitation. In this paper, a polyvinylidene fluoride (PVDF) piezoelectric-film sensor array is developed to capture the dynamic pressure field over the blade tip in an axial flow compressor. The PVDF sensor array with 40 evenly distributed sensing points is fabricated directly on a 30 μm thick aluminum-metalized polarized PVDF film through photolithography. Dynamic calibration of the sensor is accomplished using acoustic source as excitation and a microphone as a reference. The test pressure range is up to 3.5 kPa and the sampling frequency is 20 kHz. The sensor presents a high signal-to-noise ratio and good consistency with the reference microphone. Sensitivity, frequency response, linearity, hysteresis, repeatability as well as the influence of temperature are also investigated through the calibration apparatus. The calibration gives credence to the relevance and reliability of this sensor for the application in dynamic pressure field measurement. The sensor is then applied to an actual measurement in a compressor. The output of the PVDF sensor array is also compared with the results of common pressure transducers, and the features of the dynamic pressure filed are discussed. The results indicate that the PVDF sensor array is capable of the dynamic pressure field measurement over the blade tip, and superior to the conventional approaches in installation, spatial resolution, frequency response, and cost. These advantages indicate its potential broad application in pressure measurement, especially for the complex spatial surface or thin-walled structure, such as the blade surface and the thin casing wall of the compressor.

When a compressor is throttled to the near stall point, rotating instability (RI) is often observed as significant increases of amplitude within a narrow frequency band which can be regarded as a pre-stall disturbance. In the current study, a single compressor rotor row with varying blade tip clearance (1.3%, 2.6% and 4.3% chord length) was numerically simulated using the zonal large eddy simulation model. The mesh with six blade passages was selected to capture the proper dynamic feature after being validated in comparison to the measured data, and the dynamic mode decomposition (DMD) approach was applied to the numerical temporal snapshots. In the experimental results, RIs are detected in the configurations with middle and large tip gaps (2.6% and 4.3% chord length), and the corresponding characterized frequencies are about 1/2 and 1/3 of the blade passing frequency, respectively. Simulations provide remarkable performance in capturing the measured flow features, and the DMD modes corresponding to the featured RI frequencies are successfully extracted and then visualized. The analysis of DMD results indicates that RI is essentially a presentation of the pressure wave propagating over the blade tip region. The tip leakage vortex stretches to the front part of the adjacent blade and consequently triggers the flow perturbations (waves). The wave influences the pressure distribution, which, in turn, determines the tip leakage flow and finally forms a loop.

Inducers play a critical role in pump operation by providing a preliminary pressure boost to suppress cavitation. The size of the tip clearance directly influences a pump’s operational efficiency. To investigate the impact of tip clearance on a pump’s hydraulic performance and its behavior under cavitation conditions, this study combines experimental and numerical simulation approaches. Numerical computations of the full flow field, including the inducer and a two-stage impeller, were performed for five liquefied natural gas (LNG) cryogenic inducers with different tip clearances. The accuracy of the numerical simulation results was validated by comparing them with the experimentally obtained hydraulic performance curves. The results yield cavitation performance curves, pressure distributions at incipient cavitation, vapor volume fraction contours, and leakage flow streamlines for various tip clearances. The impact of tip clearance on the overall hydraulic performance and cavitation behavior of the LNG inducer was systematically examined, with particular attention given to the microscopic evolution of the Tip Leakage Vortex (TLV) during the initial stages of cavitation. The experimental results indicate that for every 0.2 mm increase in the inducer tip clearance, the pump head decreases by approximately 1 m, the efficiency drops by about 0.2%, and the tip leakage flow rate increases by approximately 5 m3/h. Furthermore, under cavitation conditions, the cavitation area expands as the tip clearance increases. A critical clearance value, δ, exists within the range of 0.4 mm to 0.6 mm, which governs the development pattern of the TLV. When the clearance is smaller than δ, the TLV forms more rapidly, and cavitation development is significantly more sensitive to increases in tip clearance. Conversely, when the clearance exceeds δ, the formation of the TLV is delayed, and cavitation progression becomes less responsive to further increases in tip clearance.

In this paper, an experimental study was carried out on the rotating instability in an axial compressor subjected to inlet steady paired swirl distortion. In order to deepen the understanding of the rotating stall mechanism under inlet steady paired swirl distortion, the dynamic-wall static pressure near the rotor tip was monitored to characterize the flow in the rotor tip region at different circumferential stations. In the experiment, the dynamic characteristics of the rotor tip flow field at a stable operating point and during the process from the stable point to complete stall were measured. The results indicated that for the compressor with a 2 mm rotor tip clearance, the inlet paired swirl distortion induced rotating instability (RI) near the stall point, causing the compressor to enter stall in advance. Compared with the RI intensity of the clean inlet, the distortion with a swirling blade stagger angle (αst) of ±20° increased the RI intensity up to 69.8%, while for αst equal to ±40°, the RI intensity increased at most by 135.8%. As the rotor tip clearance increased to 3 mm, the co-rotating swirl in the paired swirl distortion inhibited the appearance of RI, while the counter-rotating part aggravated the development of RI. At the beginning, the process of the compressor rotating stall involved the alternation of short-scale disturbance and long-scale disturbance. The co-rotating swirl weakened the perturbation propagated from the counter-rotating swirl sector. Once the inhibition was no longer present, the short-scale disturbance rapidly developed into a long-scale disturbance and then entered the rotating stall.

The impact of varying the tip clearance of each rotor on the performance of a counter-rotating axial compressor has been investigated based on numerical simulations. The main purpose was to investigate the sensitivity to the tip clearance of each of the two individual rotors and the corresponding aerodynamic mechanisms associated with the performance variation in this compressor. The results indicated that both the total pressure ratio and the efficiency decreased as the tip clearance was increased, and the sensitivity curve for peak efficiency for both rotors was found to be an approximately linear negative relationship with increasing tip clearance. The variations of peak efficiency and stability margin of Rotor 2 were more sensitive to changing tip clearance than Rotor 1. An optimum combination of tip gaps existed for this compressor, i.e. 0.5τ for Rotor 1 and 0.25τ for Rotor 2 (where τ represents the nominal tip clearance value). At this optimum configuration, the peak efficiency and stability margin were improved by 0.63% and 29.4%, respectively. The location of the onset of the tip leakage vortex was found to be shifted downstream when the tip clearance increased. The nature of the tip leakage flow for each rotor was found to be influenced by the variation of tip clearance in the other rotor. Rotor 2 showed a more significant impact on Rotor 1. Additionally, varying the combination of tip clearances changed which of the two rotors was the first to stall.

A low-speed counter-rotating axial flow compressor (CRAC) with single circumferential grooved casing treatment (CT) was investigated numerically. Both steady and time-accurate numerical calculations were performed to study the effects of the single grooved CTs over the rear rotor on the stability enhancement and the unsteadiness of tip leakage flow (TLF) in the CRAC. Parametric studies indicate that the best position of the single groove should be located near about 20% axial tip chord in terms of the stall margin improvement (SMI). The coincidence of the effective CT locations and the high fluctuating region on blade pressure surface in the smooth wall case shows that the unsteadiness of TLF plays an important role in the stall inception process. Frequency analysis for the static pressure signals near the blade tip shows that both the disappearance of the low frequency components and the suppression of unsteady TLF are beneficial to the SMI. Detailed observation of the flow structures illustrates that the action of the grooves on the different parts of TLF is responsible for the difference of SMI in the CTs. It is more effective to improve the flow stability by controlling the critical TLF released from near the mid-chord.

Unsteady Reynolds-averaged Navier–Stokes simulations of an axial-flow pump for waterjet propulsion are carried out at model scale, and the numerical uncertainties are analyzed mainly according to the procedure recommended by the twenty-eighth International Towing Tank Conference. The two-layer realizable k-ε model is adopted for turbulence closure, and the flow in viscous sub-layer is resolved. The governing equations are discretized with second-order schemes in space and first-order scheme in time and solved by the semi-implicit method for pressure-linked equations. The computational domain is discretized into block-structured hexahedral cells. For an axial-flow pump consisting of a seven-bladed rotor and a nine-bladed stator, the uncertainty analysis is conducted by using three sets of successively refined grids and time steps. In terms of the head and power over a range of flow rates, it is verified that the simulation uncertainty is less than 4.3%, and the validation is successfully achieved at an uncertainty level of 4.4% except for the lowest flow rate. Besides this, the simulated flow features around rotor blade tips and between the stator and rotor blade rows are investigated.

In this paper, the tip clearance effects on the aeroelastic stability of a last-stage steam turbine model are investigated. Most of the unsteady aerodynamic work contributing to flutter of the long blades of the last-stage of a steam turbine is done near the tip of the blade. The flow in this region is transonic and sensitive to geometric parameters such as the tip clearance height. The KTH Steam Turbine Flutter Test Case was chosen as the test case, which is an open geometry with similar parameters to modern free-standing last-stage steam turbines. The energy method based on 3D URANS simulation was applied to investigate the flutter characteristics of the rotor blade with five tip gap height varying from 0–5% of the chord length. The numerical results show that the global aerodynamic damping for the least stable inter-blade phase angle (IBPA) increases with the tip gap height. Three physical mechanisms are found to cause this phenomenon. The primary cause of the variation in total aerodynamic damping is the interaction between tip clearance vortex and the trailing edge shock from the adjacent blade. Another mechanism is the acceleration of the flow near the aft side of the suction surface in the tip region due to the well-developed tip leakage vortex when the tip clearance height is greater than 2.5% of chord. This causes a stabilizing effect at the least stable IBPA. The third mechanism is the oscillation of the tip leakage vortex due to the blade vibration. This has a negative influence on the aeroelastic stability.

Using blade tip winglet to control the tip leakage flow has been concerned in the field of turbomachinery. Computational simulation was conducted to investigate the phenomenological features of tip clearance flow. The simulation results show that suction-side winglet can reduce leakage flow intensity. The tip winglet can also decrease tip leakage mass flow and weaken tip leakage flow mixing with the mainstream and therefore reduce the total pressure loss at the blade tip.

Abstract Three-dimensional unsteady calculations were performed to explore the unsteady nature of tip clearance flow and its possible linking with the spike stall inception. It was found that the interaction of the broken-down leakage vortex with the tip clearance flow formed another distinctive vortex, denoted as the tip separation vortex. It formed below the rotor blade tip section and propagated diagonally inward. This vortex propagated across the rotor passage from the pressure side to the suction side with its vortex core filled with low-energy fluid. The spike emergence during stall inception included the breakdown of the tip leakage vortex and the formation and movement of the tip separation vortex.