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Proceedings of Global Power and Propulsion Society ISSN-Nr: 2504-4400
Beijing Conference 2019 16th – 18th September, 2019
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GPPS-BJ-2019-0109
ANALYSIS OF FLOW CHARACTERISTICS AND OVERALL COOLING EFFECTIVENESS OF ULTRA-HIGH IMPINGEMENT DISTANCE HEAT
SHIELD
Zhou Jianjun Shenyang Aero-engine Institute of Aero Engine
Corporation of China Shenyang, China
Xie Long Northwest University of Technology
[email protected] Xi’an, China
Liu Cunliang Northwest University of
Technology
[email protected] Shenyang, China
ABSTRACT
Computational investigations is reported on a flat plate
subjected to combined impingement and film cooling.
Conjugate heat transfer and 3-D steady RANS approach with
the k-ω SST turbulence model were used for analysis of the
impingement and film cooling plates. The flow dynamic
features of impinging jets and the coolant-mainstream
interaction in presence of heat shield are described. The
discharge coefficients are presented at blowing ratio M = 0.2
to 0.8 and Reynolds number Re 9300 to 75000 respectively.
A comparison between the conventional heat shield and
ultra-high impingement distance heat shield shows that the
discharge coefficients values for the new heat shield are
higher. The value of overall cooling effectiveness for the new
heat shield is lower than the conventional structure at low
blowing ratio, but at high blowing ratio, the values of overall
cooling effectiveness for both the heat shields are almost
equal. As the blowing ratio is increased from 0.2 to 0.8, the
overall effectiveness values show an increasing trend for
both the heat shields.
INTRODUCTION
An afterburner is a key component for the modern
engines. The thrust augmentation provides by afterburning or
reheating is critical for takeoff, maneuverability and
acceleration. Therefore, there has been ongoing demand of
higher temperature ratio to meet the goal of maximum thrust.
As a consequence, the afterburner outlet temperature for
recent high-performance engines exceeds 2200K (Stephen,
1960), which is far beyond the melting point of the
afterburner cylinder.
The original flat-plate heat shield is a housing for
enclosing the afterburner tube and receiving the coolant from
the compressor for delivery along the tube, which is
composed of several cylindrical cylinders. The cooling air
can flow out from the joint between the cylinders, forming a
film on the hot gas side wall and protect the surface from the
hot exhaust gas (Stephen, 1960; Gérard et al, 1991). This
structure has a low film cooling effectiveness so that requires
a large quantity of cooling air to protect the wall.
(Donald et al, 1986) and (Howard et al, 1990) proposed
a new structure of the liner that contains a plurality of double
wall elements. Each element is generally annular and extends
from a first axial part to a second axial part. The second axial
part is placed inwardly towards the geometric center line of
the afterburner duct, and both the two axial part have holes
attached. This structure includes both impingement and film
cooling techniques, which makes full use of cooling air.
However, it is complicated and difficult to process and
maintain.
Later, the transverse corrugated heat shield has been
proposed. The wave axis of the latitudinal corrugated liner is
parallel to the streamwise direction. This structure can
effectively absorb the radial high frequency oscillation
energy of 1000-2000HZ, which is mostly used in the turbojet
afterburner. There remains a recirculation zone between its
peaks and troughs, which can make full use of the cooling air
and enhance heat transfer. (Zhang et al, 2000) analyzed the
temperature distribution of the transverse corrugated liner
under experimental and numerical simulation conditions.
2
Concluded that along the flow direction, the temperature of
the wave wall gradually increases and has a certain range of
temperature fluctuations. (Qu et al, 2016) analyzed the
influence of blowing ratio, corrugation wavelength and
corrugation amplitude on the cooling efficiency of the
transvers corrugated heat shield. The results show that with
the increase of the blowing ratio, the average adiabatic film
cooling effectiveness increases, and there is an optimal
blowing ratio M=0.2. Both the corrugation wavelength and
the corrugation amplitude have a little influence on the
average adiabatic film cooling effectiveness.
Today’s turbofan afterburner with low frequency energy
of 100-500HZ has a large radial dimension. Therefore it is
better to use the longitudinal ripple heat shield that can
absorb the low frequency oscillation energy. The wave axis
of longitudinal ripple heat shield is perpendicular to the
streamwise direction. (Funazaki, 2001) came up with a
longitudinal corrugated heat shield with certain range of hole
diameter and hole pitch, which only drill holes in the
downstream waves. They show that this structure can make
the distribution of cold air more uniform and reduce the
consumption of cold air. (Thomas, 1993) proposed a
corrugated wall with uniformly hole and introduced a low
cost manufacturing method for making the combustor liners.
They show that this kind of structure can effectively reduce
the radial temperature gradient and thermal stress, thus
improving the fatigue stress. Also, more complex studies
such as the influence of the cooling channel dimensionless
height, corrugated wall dimensionless height and
aerodynamic parameters on film cooling effectiveness have
been conducted, the results show that the distribution of
overall cooling effectiveness in the direction of streamwise is
uneven, so there is a hidden danger of excessive thermal
stress. (Nathan et al, 2016) used either crossflow,
impingement, or a combination of both to supply the film
cooling to investigate overall film cooling and impingement
cooling effectiveness. The results show that the heat transfer
coefficient generally increases with streamwise development,
and increase with increasing blowing ratio. (Li et al, 2018)
proposed a method to improve full-coverage effusion cooling
effectiveness by varying the cooling arrangements and wall
thickness. They found that adding impingement and pins to
film cooling, and decreasing wall thickness increase the
cooling efficiency significantly. (Sneha et al, 2018) provided
spatially-resolved distributions of adiabatic cooling
effectiveness for effusion surface and spatially-resolved
distributions of surface Nusselt numbers impingement
surface.
During the development of heat shield, its aerodynamic
parameters, cooling effectiveness and coolant consumption
have always been improved. However, its temperature non-
uniformity restricts its development. The author proposed a
impingement/film cooling apparatus with ultra-high
impingement distance, the distance from the impingement
surface to the effusion surface is 20 cH d . The porous heat
shield with an ultra-high impingement distance can
effectively limit the oscillating combustion of the afterburner
by generating the gas damping and turbulence. It also can
effectively improve the uniformity of discharge coefficient
and overall cooling effectiveness while maintaining a
relatively high level of overall cooling effectiveness.
ANALYSIS
Discharge Coefficient
The discharge coefficient of the orifice is defined as the
ratio of actual mass flow rate to that which should be pass
through the cross-sectional area (Huning, 2008). It can be
written in the form
d
id
mC
m
(1)
The ideal mass flow rate can be calculated:
2 1
* 2 21 * * *
1 1 1
2 1m
1 R
k k k
i
p pkp A
k T p p
(2)
Discharge coefficients CD of hole are impacted by
several different factors: Reynolds Number, length to
diameter ratio, cross flow at inlet and outlet, pressure ratio
(Huning, 2008). The inlet or outlet approaching flow inclined
to the orifice axis caused by crossflow is accompanied by
flow loss, which decreases the discharge coefficient. Rohde
et al (Rohde et al, 1969) experimentally investigated the
discharge coefficient with cross-flow near the entrance of
orifice. They considered the ratio of velocity head of the
orifice jet to the velocity head of the main flow as a function
of the discharge coefficient
* *= p pjet crop p
(3)
(Gritsch et al, 1998a; Gritsch et al, 2001) considered the
influence of both entry and exit crossflow near the holes on
the discharge coefficient. They plotted the discharge
coefficient vs the ratio of jet to internal or external flux
momentum. The formulas are:
2
2
2
2
jet
c
jet
g
u
jet inCr
u
u
jet extCr
u
I
I
(4)
The result shows that the discharge coefficient increases
with the increased in either jet inCrI or jet extCrI . The results
also indicated that the discharge coefficient with crossflow is
lower than that without crossflow at the low momentum flux
3
ratio. The influence of crossflow on the discharge coefficient
can be neglected when the momentum flux ratio exceed 2.
NUMERICAL SIMULATION APPROACH
Combined impingement and film cooling Geometries
The impingement and film holes are staggered
arrangement as shown in Fig. 1. As shown in Fig. 2, to
guarantee the complete development of the mainstream, the
test plate is extended for 30 cd on the upstream. To
eliminate the impact of back flow, the test is extended for 40
cd on the downstream. The length of cH is 20 cd for the
ultra-high impingement distance model (model 1) and 5 dc
for the conventional impingement distance model (model 2).
The length of cL is 200 mm. The value of Φ and b are
fixed. The hole number of the jet impingement holes and
film holes was shown in Fig. 3.
The jet hole pitch are the same in the X and Y directions
for both impingement holes and film holes, which can be
determined by:
2
2
4
4
4
4
st f sp f f f f st f sp f
f f f
st c sp c c c c st c sp c
c c c
A n n X Y b d n n
X Y db
A n n X Y b d n n
X Y d
(5)
Fig. 1 Schematic of the cooling pattern
Fig. 2 Geometry parameters of the computational model
Fig. 3 The number of impingement an film holes
Fig. 4 Boundary conditions of the computational domain
Boundary Condition and Numerical Approach The periodic boundary condition is assigned to the
sidewalls in Y direction as shown in Fig. 4. The top and
bottom of the effusion wall are set as couple wall. The
impingement wall is adiabatic wall. The mass inlet boundary
is applied at the inlet of mainstream and coolant. The
mainstream Reynolds number from 9300 to 75000 is
calculated based on the parameters of hot gas inlet. The mass
flux of coolant depends on both of the blowing ratio
f f g gM u u from 0.2 to 1 or the mainstream
Reynolds number. The variables in blowing ratio depend on
the aperture area of film holes and the parameters of coolant
inlet. The fluid is ideal gas, and its specific heat and thermal
conductivity depend on temperature. The fluid dynamic
viscosity is determined by Sutherland’s formula. The
commercial CFD software ANSYS Fluent 16.0 was
employed in solving the steady RANS equations. The SST k-ω turbulence model was applied, because the previous
numerical computation research (Dees, et al, 2012; Mensch
et al, 2014; Panda et al, 2012; Ramachandran et al, 2015;
Zhou et al, 2016; Dyson et al, 2014; Zhao et al, 2016)
indicated that better simulation results can be obtained by
4
using the SST k-ω turbulence model. The criteria of
convergence is that the residual value of energy is below 10-
9. As shown in Fig. 5, the value of y+ of the first cell layer on
the target wall was less then 1. To validate the numerical
model, the numerical results were compared with experiment
data, as shown in Fig. 6(Qu, et al, 2017).
Fig. 5 The value of Y+ on the target wall
Fig. 6 Laterally averaged overall cooling effectiveness
Grid Independence
Fig.7 grid of fluid and solid domains
The structured grids were used for discreting fluid and
solid domain and O-type grids were applied on all the holes,
which were generated by ANSYS ICEM as shown in Fig. 7.
(Deng et al, 2016) has demonstrated that the grid
number of solid domain has little influence on the simulation
result of conjugated heat transfer model. Thus the mesh
generation method of solid domain is similar to that of fluid
domain. Three different number of grids were generated to
validate the independence of the grid with the method of
“Grid Convergence Index” described in (Ji et al, 2008). The
three employed fluid domain grids have 7.8 million cells,
10.9 million cells,15.6 million cells, respectively. The values
of cooling effectiveness for gird 2 and gird 3 are almost
equal, so the gird 2 was employed for the computation of the
conjugate model.
RESULT AND DISCUSSION
Effect of Reynolds number on flow characteristic of impingement hole
The case 1 has a larger level of discharge coefficient
than case 2 as shown in Fig. 9. This is mainly due to the vena
contracta of the impingement hole. The impingement holes
has a small ratio of length to diameterc c
l d . To
investigate the vena contracta, it was represented by the
velocity contour. The number of contour levels was eight for
each Reynolds number. The smallest cross-sectional area of
high velocity region was applied to represent the vena
contracta as shown in Fig. 8. Increasing the Reynolds
number from 9300 to 42000 cause a large separation at the
hole entrance and the flow cannot reattach to the hole
sidewall, which reduces the vena-contracta area and actual mass flow rate. The line 2 and line 3 as shown in Fig. 8 are
almost coincide, which means that the Reynolds number
from 42000 to 75000 has less influence on vena contracta.
Fig. 9 also shows that the discharge coefficient of the
downstream hole is larger than that of the upstream hole.
This is due to the end of coolant plenum is closed and the
coolant will flow back, which reduces the intensity of
entrance crossflow.
Fig. 8 vena contracta
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Fig. 9 The discharge coefficient of impingement holes for Re = 9300, 42000, 75000, M = 0.3
Effect of Reynolds number on flow characteristic of effusion hole
Fig. 10 The discharge coefficient of film holes for Re = 9300, 42000, 75000, M = 0.3
The ratio of length to diameter of film hole is 0.75,
which is a short hole too. Fig. 10 shows that the discharge coefficient of the
upstream effusion holes is negative (use the value of zero to
represent) at Reynolds number Re = 9300. This is due to the
pressure of the front-end of chamber in X direction is lower
than the mainstream pressure. The impingement flow cannot
eject through the effusion hole, and even the mainstream
pour back into the chamber.
Fig. 10 also shows that the discharge coefficient of the
downstream holes is higher than that of upstream holes. This
is due to the outflow at upstream thickens the downstream
boundary layer. The thick boundary layer reduces the flow
area and accelerates the velocity of the mainstream as shown
in Fig.8. According to the principle of mass conservation,
when the density is assumed to be constant, the increase of
velocity can reduce the pressuregp , therefore increases the
pressure ratio. Another reason is the film accumulation at the
downstream provides the protection for downstream holes.
The large low velocity region near the outlet of film holes
reduces the influence of the mainstream crossflow, resulting
in larger exit cross-sectional area compared with the
upstream film hole as shown in Fig. 12.
Fig. 11 Velocity contour for center plane of film holes
Fig. 12 Comparison of upstream and downstream hole cross-sectional area (left: upstream; right:
downstream)
Effect of blowing ratio on discharge coefficient of film hole
Fig. 13 The relation between discharge coefficient and blowing ratio for film holes
6
Fig. 14 The pressure ratio of film holes inlet and mainstream under different blowing ratio
Fig.11 shows the effect of blowing ratio on discharge
coefficient of film holes. With the increases of blowing ratio,
the discharge coefficient increase. This is because of the
enhanced suction of the film hole by the increased pressure
ratio, which causes more penetration into the mainstream.
For the case1 in Fig. 13, there are some holes with a
discharge coefficient of negative (use the value of zero to
represent). This is due to the pressure ratio of these holes is
less than 1 as shown in Fig. 14 and the insufficient pressure
cannot eject the impingement flow in chamber through the
film holes.
The impact of impingement distance on discharge coefficient of impingement holes
Fig. 15 Flow characteristic of impingement gap
Fig. 16 vena contracta of film hole
Fig. 17 Discharge coefficient of high impingement distance model and low impingement distance
model.
Fig. 15 shows a complex interaction between the
impingement jet and effusion jet air feed. There remains a
reverse flow in the impingement gap. The interaction of jet-
impacting flow causes a upwash flow. The upwash flow will
reattach to the impingement surface and form a crossflow.
The effect of the crossflow on the exit cross-section area
highly depends on the impingement distance. For the high-
impingement-distance chamber, there remains a larger
momentum loss for the upwash, and the larger the
momentum loss of upwash, the smaller the momentum of
crossflow. This means that for the higher impingement
distance chamber, the exit cross-section area of impingement
holes is larger as shown in Fig. 16. Therefore, the level of
discharge coefficient for model 1 (high-impingement-
distance gap) is larger by a factor of 0.02, compared to the
model2 (low-impingement-distance gap) as shown in Fig. 17.
The effect of impingement gap on discharge coefficient of film holes
Fig. 18 shows that the difference between model 1 and
model 2 is smaller at low blowing ratio M=0.2. With the
increased of blowing ratio, the difference becomes larger.
And for the most of film holes, the discharge coefficient of
model 1 is larger than model 2 at blowing ratio M=0.8. This
is due to the vortex near the effusion wall in chamber is
enhanced by the increase of blowing ratio, which washes
7
away the impingement jet that should have blown into the
film holes as shown in Fig. 19. And for model 2, the intensity
of the vortex is larger due to the low impingement distance,
which will cause less entrance than model 1.
From Fig. 18, we can also see that the distribution of
discharge coefficient is more uneven for model 2. This is due
to the impingement jet cannot be fully developed in small
space for model 2, which resulting in uneven inlet condition
for each hole.
Fig. 18 Discharge coefficient of the third row of film holes of model 1 and model 2 at the blowing ratio
of 0.2 and 0.8.
Fig. 19 The vortex in impingement gap with short impingement distance
The impact of impingement distance on overall cooling effectiveness
Overall cooling effectiveness is defined as follows:
g w
g c
T T
T T
(6)
Model 1
Model 2
Fig. 20 Contour of overall cooling effectiveness on interaction surface where the coolant interacts with
the mainstream (for M = 0.6)
Fig. 21 Laterally averaged overall cooling effectiveness
Fig. 20 show that as the impingement distance decreases
from 20d to 5d, the overall cooling effectiveness is
improved. The regions of high overall cooling effectiveness
are concentrated near the impingement area. For the model 2,
the spot area with high overall cooling effectiveness is more
obvious and thus generates a higher gradient of temperature.
The larger thermal stress caused by higher temperature
gradient will reduce the thermodynamic efficiency and the
service life of model 2. The Fig. 21 shows that with the impingement distance
decreases from 20d to 5d, the overall cooling effectiveness
increases by approximately 0.1. The difference of overall
cooling effectiveness φ between model 1 and model 2 is
smaller with the increase of blowing ratio. This is due to the
stronger impingement cooling at larger blowing ratio reduces
the influence of impingement distance. The Fig.18 also
shows that the difference of overall cooling effectiveness φ
between model 1 and model 2 is smaller at large fx d .
This is due to the accumulated film at the downstream is the
main factor affecting the cooling effectiveness.
8
CONCLUSION
Numerical study was applied to investigate the flow
characteristic and overall cooling effectiveness of
laminated configuration with high impingement distance.
This paper also compared the uniformity of temperature and
discharge coefficient of high and low-impingement-distance
heat shield.
Some conclusions are summary as follows:
Due to the short ratio of length to diameter c cl d of
impingement holes, with the increase of Reynolds number
from 9300 to 42000, the discharge coefficient decreases.
When the Reynolds number increases from 42000 to 75000,
the influence of Reynolds number decreases, thus the
increase of discharge coefficient mainly depends on the
pressure ratio. Due to the influence of crossflow in coolant
plenum, the discharge coefficient of the downstream
impingement hole is larger than that of the upstream hole.
The increase of Reynolds number of films holes has less
impact on the discharge coefficient at the hole number from
20 to 75 due to the higher difference of pressure ratio. The
mainstream crossflow at the exit of film holes is weakened
by the accumulation of film.
The discharge coefficient of impingement holes
increases with the increase of blowing ratio.
The discharge coefficient of film holes increases with
the increase of blowing ratio. At blowing ratio M=0.8, the
discharge coefficient value is on approximately the same
level, due to the overall increase in pressure ratio.
The overall cooling effectiveness increases with the
increase of blowing ratio. Because of the accumulation of
film at downstream, the overall cooling effectiveness is
larger at downstream.
The impingement-hole discharge coefficient of high
impingement model is larger than that of low impingement
model. And for the most of film holes, the discharge
coefficient of high impingement model is larger than that of
low impingement model.
The overall cooling effectiveness of conventional heat
shield is larger than that of ultra-high impingement distance
heat shield. But the overall cooling effectiveness of
conventional heat shield is poor and the temperature
gradient of model 2 is larger, which will reduce the
thermodynamic efficiency and the service life.
ACKNOWLEDGMENTS
The authors acknowledge gratefully the financial
support from the National Natural Science Foundation of
China (Grant No. 51776173) and the Fundamental Research
Funds for the Central Universities (Grant No.
3102017gx06006).
NOMENCLATURE
φ overall cooling effectiveness
l length of the hole
dc diameter of impingement hole, mm
df diameter of effusion hole, mm
Hc impingement distance, mm
Lc the length of test plate, mm
CD discharge coefficient (actual mass flow rate/ideal
mass flow rate)
m actual mass flow rate
idm
ideal mass flow rate
θ the ratio of velocity head of the orifice jet to the
velocity head of the main flow
p pressure
p* total pressure
I momentum flux ratio
M blowing ratio, c c g gU / U
Re
reynolds number based on hydraulic diameter of hot
gas inlet g g gU D /
δc Impingement wall thickness
δf film wall thickness
Φ porosity of impingement wall
X streamwise coordinate , m
Y coordinate normal to the test surface, m
Z spanwise direction, m
b aperture area ratio of film hole to impingement hole
n Holes number
Greek symbols
φ Overall cooling effectiveness
density, 3
kg m
molecular viscosity, 2Ns m
Subscripts
intCr crossflow at the hole entrance
extCr crossflow at the hole exit
g hot gas
c coolant
f film
1 entrance
2 exit
st streamwise direction
sp spanwise direction
id ideal
jet jet gas
cro crossflow
st-c streamwise direction of impingement wall
sp-c spanwise direction of impingement wall
st-f streamwise direction of effusion wall
sp-f spanwise direction of effusion wall
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