Multi-bladerow fan forced response predictions using an integrated three-dimensional time-domain aeroelasticity model

Abstract

A non-linear integrated aeroelasticity system to predict the forced vibration response of aero-engine fans is presented in this paper. The computational fluid dynamics (CFD) solver, which uses Favre-averaged Navier-Stokes equations on unstructured grids of mixed elements, is coupled to a modal model of the structure so that the effects of blade flexibility can be accommodated. The structural motion due to unsteady fluid forces is computed at every time step and the flow mesh is moved to follow the structure so that the resulting flow unsteadiness is determined in a time-accurate fashion. Two fan forced response case studies are reported in detail. The first one deals with a high-pressure ratio fan, the excitation being due to the upstream variable-angle inlet guide vanes (VIGVs). The unsteady flow analysis with blade motion was conducted using a sector of three VIGVs and four rotor blades. The wake predictions were found to be in good agreement with the corresponding laser measurements. The flow was observed to be completely separated for high VIGV angles and the excitation encompassed several harmonics. The predicted rotor blade vibration levels were generally found to be within 30 per cent of the measured values. The forced response to upstream obstructions was studied in the next fan case study. Three whole bladerows, consisting of 11 struts, 33 VIGVs and 26 rotor blades, were modelled in full. The model also included a prescribed inlet distortion pattern so that the combined effects of stator wakes and inlet distortion on the response of the rotor blades could be studied. The unsteady flow calculations were conducted using a time-accurate non-linear viscous flow representation. Blade motion was also included. Such an undertaking required about 4.2 million grid points to include all three bladerows in a complete stage calculation. To reduce the computational effort, a number of smaller computations were conducted by considering the stator and rotor domains separately: the outflow solution of the stator domain was used as an inflow boundary condition to the rotor domain. The results indicated that such isolated bladerow computations were likely to under-predict the response levels because of neglecting rotor-stator interactions. A number of low engine order (LEO) harmonics were identified from an inspection of the unsteady forcing created by the inlet distortions. Good agreement was obtained for cases where experimental data were available.