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Experimental and numerical investigation

of secondary flow on compressor blades


A. Hergt*, R. Meyer*
German Aerospace Center (DLR);
Institute of Propulsion Technology; Dept. of Turbulence Research;
Mller-Breslau-Str. 8; D-10623 Berlin; Germany
e-mail: alexander.hergt@dlr.de
K. Engel
MTU Aero Engines GmbH;
Dachauer Str. 665; D-80995 Munich
Abstract
An experimental and numerical investigation on the flow separation in the corner between a wall and a vane in a
highly loaded compressor cascade was performed. A large part of the total losses of a compressor stage is caused
by this separation. The objective of the investigation is to understand the fluid mechanic mechanism of corner
separation and to detect reference results for developing a flow control technique to avoid this flow separation. The
experiments with a compressor cascade were carried out at a high-speed test facility at the DLR in Berlin. The
experiments were done at Reynolds numbers up to Re = 0.6 x 10-6 (based on 40 mm chord) and Mach numbers up
to Ma = 0.7. The profile of this blades represents the 10 % cut of vane length distance from the hub of the guide
vanes of the single stage axial compressor of the Technical University of Darmstadt. For the assessment of the
total pressure losses of the cascade (caused by the corner separation) a pressure measuring technique was used. To
detect the separation area on the vane a flow visualisation technique was used. Different kind of flow control
devices are intended to influence the corner separation. In order to optimize the devices for an application in
turbomachines, an experimental study is currently ongoing, which investigates the use of such devices to reduce
the losses of an aerodynamically highly loaded compressor cascade. In addition to the experiments, numerical
computations were carried out with TRACE, a parallel Reynolds-Averaged Navier-Stokes flow solver, which has
been developed for the simulation of turbomachinery flow. The computations were carried out with the same
geometry as the experiments, including the measured inflow boundary layer conditions at the side walls.

Keywords: corner separation, secondary flow, compressor cascade


Nomenclature
Flow parameter:
Ma
[-]
Re
[-]
pt
[Pa]
p
[Pa]
q
[Pa]

[kg/m3]

[-]
cf
[-]
TF
[-]

Geometric parameter:
1
[]
incoming flow angle
2
[]
out going flow angle
S
[]
stagger angle
t
[m]
pitch
c
[m]
vane chord
h
[m]
vane height
x
[m]
axial coordinate
u
[m]
circumferential coordinate
z
[m]
vane height coordinate

Mach number
Reynolds number
total pressure
static pressure
dynamic pressure
density
total pressure loss coefficient
skin friction coefficient
transition coefficient

* Scientist, Turbulence Research Group


Head, Compressor Aerodynamic
1

Introduction
A better knowledge about the flow phenomena in turbomachine cascades is necessary to improve the efficiency.
The basic for experimental investigations of the phenomena is the two dimensional cascades. This cascade is a
simplification as a result of a coaxial cylinder barrel cut of a three dimensional cascade. Since the 1950s,
systematic studies of the flow in two dimensional cascades were performed with the mainly objects of the
influence of compressibility, Mach number, Reynolds number and turbulence on cascade flow [7], [9].
Furthermore secondary flow phenomena and cascade losses were investigated. Especially in the 1960s the
attention were turned to profile loss investigation to decrease the total losses of a compressor stage. Additional
investigations of secondary flow phenomena were performed in the early 1990s. [3], [6], [11].
Another major source of losses in a compressor cascade is the separation between the side wall and the vane
(i.e. corner separation) caused by the interference between the wall and vane boundary layer and the high
positive pressure gradient in flow direction. The current experiments were performed with the objective of
understanding the fluid mechanic mechanism of corner separation and of detecting reference results to permit
more investigations in order to improve the efficiency. In addition to the experiments, numeric computations
were carried out with the aim of better visualization and understanding of the flow. Due to the small dimension
of the test section and the influence of probes in the flow the accessibility for measurements are limited. By
means of CFD we obtained more information about flow parameters e.g. the pressure distribution at the vane
and the comparison between computed and measured results allowed us to validate the used flow solver also.

Setup of the Cascade Experiments


The High Speed Cascade Wind Tunnel
The experimental investigations were carried out at the high-speed wind tunnel of the DLR (Institute of
Propulsion Technology, Department of Turbulence Research) in Berlin (figure 1). The channel has a rectangular
cross section of 40 mm width and 90mm height at the exit of the nozzle which has a contraction rate of 1:218.
Thus flow velocities of Ma = 0.7 with a Reynolds number of 600000 can be obtained [5].

Figure 1: High speed wind tunnel connected to compressor cascade test section
2

The test section of the channel with the connected cascade as shown in figure 2 has some special features, which
permit the variation of several parameters.

Figure 2: Test section with cascade

The incoming flow angle 1 can be adjusted separately from the stagger angle S. This allows the usage of
different blade geometries, with the same cascade.
Boundary layer suction at all four channel walls is possible and can be adjusted separately (figure 2). The
suction at the upper and bottom walls allows the adjustment of the static pressure over the channel height.
Thereby a homogeneous inflow according to an infinite blade cascade is achieved.
Another special feature of this particular test-section is the adjustable boundary layer thickness of the side
walls. The boundary layer thickness can be reduced by suction at the side walls. To increase the boundary layer
thickness the optional spoiler section can be used.

Compressor Cascade and Measurement Equipment


The cascade used for the investigations consisted
of 5 blades with a chord length of 40 mm. The
profile of this blades represents the 10 % cut of
vane length distance from the hub of the guide
vanes of the single stage axial compressor of the
Technical University of Darmstadt. The main
geometrical parameters and design flow
conditions are shown in figure 3 and table 1.
Ma1
1
S

= 0.66
= 132
= 105.2

c
t/c
h/c

= 40 mm
= 0.55
=1

Table 1: Geometrical and design flow conditions

Figure 3: The compressor cascade


3

The aspect ratio (ratio of blade height and chord)


is 1. This value is typical for modern highly
loaded compressors and was selected in order to
let the secondary flow effects dominate. The
cascade is mounted in the test section as shown
in figure 4. Due to the boundary layer suction at
the upper and lower wall (also shown in figure 4)
a homogeneous inflow at the center blade
(blade 3) of the cascade could be achieved.
This was necessary, since the measurement
focused on the determination of the total pressure
losses of a passage in an infinite cascade. The
local total pressure loss coefficient is defined in
equation 1 [2],[10].

(u , z ) =

p t 1 p t 2 (u , z )
q1

(1)

In addition all presented loss results are mass


flow averaged. The main inflow conditions and
the total pressure distribution behind the cascade
must be determined to compute the coefficient.
Figure 4: Cross section of the mounted cascade with
Hence, the static inlet pressure, the total inlet
reference coordinates system
pressure and the total temperature in the settling
chamber were measured. Furthermore the total
pressure distribution was measured with two
wake rakes 40% of chord length c behind the trailing edge of the cascade blades, which can be traversed in
circumferential direction. One rake consists of 26 total pressure probes in line from one side wall to the other
side wall of the cascade. The other consists of one static pressure probe and 4 Conrad probes in order to detect
the outflow angle at 4 vane height positions [5]. Thereby it is possible to compute the mass flow averaged local
total pressure loss distribution and total pressure loss in vane height direction of a cascade passage. To detect the
separation area on vane a flow visualization technique was used.

Cascade Losses
The total pressure loss coefficient ges of a cascade
passage is computed by integration of total
pressure loss coefficient distribution (z) in vane
height direction, which is composed of three parts
of losses, as shown in figure 5 and equation 2: The
side wall boundary layer losses BL, the profile
losses P caused by the friction of flow around the
vane profile with infinite aspect ratio and the
losses due to corner separation SP [1], [4], [8].

ges = P + BL + SP

(2)

Experimental Errors
Systematic errors of the experimental setup can be
assessed. During the experiments only pressure
and temperature were measured. The pressure
measurement chain consists of probes, transducer
and voltmeter. The total pressure probe error

Figure 5: Total pressure loss parts


4

caused by probe inflow angle divergence of 10 amounts to max 0.5% [13], the transducer error to 0.05%
and the voltmeter error is negligible. Thereby a max measurement chain error of the total pressure downstream
of the cascade of 0.55% is possible. Upstream of the cascade the total and static pressure probes error is
negligible, since the inflow angle divergence is less than 5. Hence, the total pressure loss coefficient error
amount to 0.65%. The temperature measurement chain consists of Pt100 Sensor with an error of 0.3K and
Voltmeter with negligible error. Differences caused by wire length will be eliminated by four wire
measurement.

Experiment Results
The experimental investigation was performed to detect the location of corner separation at the selected vane
profile and to measure the value of total pressure losses of a cascade passage. The obtained results serve as
reference for developing appropriate flow control devices and for understanding the secondary flow phenomena.
In a first series measurements were carried out at the design Mach number of 0.66 and inflow angle at peak
efficiency and off design with an incidence of -6.In the presentation an example for positive incidence angle
will be also given. The results are shown in figure 6 and 7. No absolute numbers can be given, since the data
were obtained in cooperation with MTU Aero Engines. Nevertheless the main information can be obtained from
the figures. In figure 6 and 7 the local total pressure loss coefficient distribution (u,z) (mass flow averaged) in
the wake, the measured outflow angles and the total pressure loss distribution (z) in vane height direction are
shown. The red and magenta areas present high losses and the blue areas less losses.

lokal total pressure loss coefficient (mass flow averaged)

lokal total pressure loss coefficient (mass flow averaged)

relative cascade pitch u/t [-]

trailing
edge

pressure side
-0.5
0

0.2

0.4

0.6

0.8

0.2

0.4

0.6

0.8

0.8

outflow angle

[]

total pressure loss coefficient

outflow angle
total pressure loss coefficient

[]

pressure side
-0.5

relative cascade pitch u/t [-]

suction side 0.5

suction side 0.5

(upstream view)
(mass flow averared)

0.2

0.4

0.6

0.8

(upstream view)
(mass flow averared)

0.2

0.4

0.6

relative vane height z/h [-]

relative vane height z/h [-]

Figure 6: Measurement results at design


point (Ma1= 0.66)

Figure 7: Measurement results at incidence


of -6 (Ma1= 0.66)
5

The high loss areas in the corner between wall and vane (relative cascade pitch u/t = 0 is equivalent to trailing
edge position of the vane) in both figures present the losses caused by corner separation. An increase of profile
losses and the displacement of corner loss areas due to incidence from design point are identifiable too. The
profile loss increase is caused by the visible increase of the wake expansion at the pressure side (figure 7, upper
diagram). In the flow visualisation (figure 9, lower picture) a flow separation on the pressure side near the
leading edge can be seen, which also explain the loss increase.

Figure 8: Flow visualisation on the vane at


design point (Ma1= 0.66)

In a second series measurements were carried out


at varying incidence angles between -8 and +8
and three inflow Mach numbers (Ma1= 0.5 / 0.66 /
0.7) to obtain loss curves as shown in figure 10.
The peak efficiency of the cascade is identified at
the curve which presents a reference for further
measuring and development of flow control
devices.

ges

[-]

total pressure loss Ma = 0.7


total pressure loss Ma = 0.66
total pressure loss Ma = 0.5

By means of flow visualization (figures 8 and 9)


the typical corner separation on the rear part of
the suction side of the reference blades can be
detected. The displacement of separation areas
due to incidence from design point is detectable in
the flow visualization figures too. Furthermore a
separation bubble on the suction side is shown
which give us information about the transition on
the vane. Upstream of the bubble the boundary
layer of the blade is laminar and downstream it is
turbulent.

Figure 9: Flow visualisation on the vane at


incidence of -6 (Ma1= 0.66)

peak efficiency

- incidence +
inflow angle 1 []

Figure 10: Measurement results depending on inflow angle


for various Mach numbers

Numerical Investigation
The numerical investigations were performed at MTU Aero Engines in Munich. For the numerical simulation a
structured OCH grid [12] consisting of five blocks with 784000 nodes was generated. The computations were
carried out with TRACE, a parallel Reynolds-Averaged Navier-Stokes flow solver, which has been developed
for the simulation of turbomachinery flow[14].
leading edge

trailing edge

incoming
flow
area of
corner
separation

laminar separation

turbulent reattachment

Figure 11: Computed static pressure distribution and strike lines on suction side of the
vane at design point (Ma1= 0.66)

Numerical Results
The incoming flow parameters for the simulation
are based on cascade measurements at the DLR in
Berlin. For the stationary computation, which was
carried out at design point of the cascade the k-
turbulence model and the Drela modified Abu
Ghannam & Shaw transition model was used [14]
and the transition was allowed on the whole blade
surface. In figure 11 the computed pressure
distribution and strike lines on suction side of the
vane is shown whereas the blue area is equivalent
to peak suction. The laminar separation bubble on
the suction side as indicated in figure 8 is also
visible in figure 11. This interpretation is
confirmed by the skin friction coefficient cf and the
transition coefficient shown in figure 12. At the
point of laminar separation the skin friction
coefficient cf becomes negative and the transition

la m ina r se pa ra tion

0 .0 1

0 .0 2

CF

TF

tu rbu le n t re a tta ch m e n t

0 .0 3

P
CF
TF

le a ding e dg e

tra iling e d ge

Figure 12: Computed static pressure distribution P,


skin friction coefficient cf and transition
coefficient TF at mid span (at design point,
Ma1= 0.66)

During the measurement the


angle at four vane height
determined. The computed
outflow angles are shown in
coincide very well.

mean outflow
positions was
and measured
figure 13 and

outflow angle 2 []

coefficient TF increases from zero to one.


Furthermore the location and area of corner
separation is computed and is in good
agreement with the experimental results of the
flow visualization.

TRACE Computation
Measurement

The experimental results of the local total


0
0,1
0,2
0,3
0,4
0,5
pressure loss coefficient distribution (figure
14b) are compared with the computed values
relative vane height z/h [-]
(figure 14a). The red and magenta areas
present high losses and the blue areas less
Figure 13: Comparison of computed and measured outflow
losses. The position of high loss areas at the
angle distribution at design point (Ma1= 0.66)
measurement result are well reflected in the
computed result, only the shape of the high
loss area is showing slight differences. This
can be attributed to the linear eddy viscosity turbulence model since the simulation of the three dimensional
turbulent flow in the corner is difficult. Nevertheless, the comparison of computed and measured results (figures
14a and 14b) are in fair agreement.

Figure 14a: Computed local total pressure


loss coefficient distribution at
design point (Ma1= 0.66)

Figure 14b: Measured local total pressure


loss coefficient distribution at
design point (Ma1= 0.66)

Discussion of the Results


The experimental results as well as the numerical results allow a good assessment of the fluid mechanic
mechanism of corner separation. It is well known that this separation mainly caused by the interaction between
the wall and blade boundary layer and the high pressure gradient in flow direction. The low energetic boundary
layer flow is decelerated by the increasing pressure till separation. The numerical simulation yields detailed data
for the backflow areas in both corners which cannot be obtained easily by experiments. Furthermore the position
of separation relative to the pressure distribution is known. The experimental results have also shown that the
corner separation losses are an important part of the total losses of a cascade and they will serve as reference for
continuing measurements.
8

Conclusions
Experimental investigations of secondary flow on compressor cascade blades were performed. Thereby the

values of losses at different incidences and Mach numbers were determined.

In addition a numerical investigation was carried out. The comparison between computed and measured

results is showing a very good agreement. The numerical simulation yields more information about the
separating flow region and improves the understanding of the investigated flow phenomena substantially.

Finally a better understanding of structure and development mechanism of corner losses was achieved.

Acknowledgments
The investigations reported in this paper were performed within a cooperation project with MTU Aero Engines
in Munich. In this manner we would like to thank for the good cooperation.

References
[1]

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Gttingen, 1967

[2]

CUMPSTY N.A.: Compressor Aerodynamics, Krieger Publishing Company, 2004

[3] HBENER J.: Experimentelle und theoretische Untersuchung der wesentlichen Einflussfaktoren auf die
Spalt- und Sekundrstrmung in Verdichtergittern, PhD Thesis, Universitt der Bundeswehr Mnchen,
1996; Germany
[4] MEYER R., BECHERT D.W., HAGE W.: Secondary Flow Control on Compressor Blades to improve the
performance of axial turbomachines, 5th European Conference on Turbomachinery Fluid Dynamics and
Thermodynamics, Prague, March 2003
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[7]

SCHLICHTING H.: Recent Research on Cascade-Flow Problems,


Journal of Basic Engineering, ASME, 1966

[8]

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[9]

SCHOLZ N.: ber die Durchfhrung systematischer Messungen an ebenen Schaufelgittern, Zeitschrift fr
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[10] SCHOLZ N.: Aerodynamik der Schaufelgitter, Verlag Braun, 1965


[11] WATZLAWICK R.: Untersuchungen der wesentlichen Einflussfaktoren auf die Sekundrverluste in
Verdichter- und Turbinengittern bei Variation des Schaufelseitenverhltnisses, PhD Thesis, Universitt
der Bundeswehr Mnchen, 1991; Germany
[12] WEBER A.: 3D Structured Grids for Multistage Turbomachinery Applications based on G3DMESH, DLR
IB-325-05-04, Numerical Simulation Group, Institute of Propulsion Technology, DLR, Cologne, February
2004

[13] WUEST W.: Strmungsmetechnik, Vieweg & Sohn Verlag, Braunschweig, 1969
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