International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

doi: 10.14355/ijes.2014.0403.04

www.ijesci.org

The Application of 3D Blading and NonAxisymmetric Hub Endwall Contouring in a

Dual-stage Axial Flow Counter-Rotating
Compressor
Zhiyuan Cao*1, Bo Liu2, Xiaodong Yang3, Min Li4
School of Power and Energy, Northwestern Polytechnical University
NO. 159 Mail Box, NO. 127 West Youyi Road, Xian, 710072, P. R. China
*1

zylast@126.com; 2liubo704@nwpu.edu.cn; 3yangxiaodong1986@163.com; 4limin2749433@163.com

Received 27 August 2013; Accepted 9 September 2013; Published 16 April 2014

2014 Science and Engineering Publishing Company

Abstract
3D blading and non-axisymmetric endwall contouring
technologies are effective ways to control secondary flows in
cascades. 3D blading can effectively reduce the secondary
flows near the blade surface, but it has little impact on the
endwall region. Non-axisymmetric endwall contouring is
widely used in the control of endwall secondary flows in
turbines. However, the use of non-axisymmetric endwall
contouring in compressors is rarely. The effect of nonaxisymmetric endwall contouring on compressors is not
clear.
The research object of the report is an axial flow dual-stage
counter-rotating compressor. In order to further improve the
performance of the compressor and to explore the method of
reducing secondary flow loss, the two rotor blade rows and
the hub endwall of the secondary rotor row are redesigned
by 3D blading and non-axisymmetric endwall contouring
technologies based on optimization algorithm. The flow
fields of original compressor and redesigned compressor are
also compared. After 3D blading optimization, the secondary
flows near the suction surface of the rotor blades are
obviously reduced and the efficiency of the optimization
point increases. Nonetheless, the secondary flows at the hub
endwall improve scarcely any.
Based on the 3D blading optimization, the second row rotor
hub endwall are parameterization designed, and nonaxisymmetric endwall contouring is designed by
optimization algorithm. After non-axisymmetric endwall
contouring optimization, the hub endwall consist of a hill
near the rotor pressure surface and a valley near the
suction surface. The contouring reduces the pressure
gradient at 0~40% axial chord near the hub. And the
secondary flow loss is reduced effectively. This paper
successfully combines the advantages of both 3D blading

and non-axisymmetric endwall contouring technologies; the

performance of the counter-rotating compressor is improved
effectively.
Keywords
Counter-rotating
Compressor;
Three
Dimension
Optimization Design; Non-axisymmetric Endwall

Blade;

Introduction
High efficiency, high stage load are the objectives of
the aero turbomachinery designers all the time.
Separation and secondary flows are inevitable as the
stage
load
increases.
The
efficiency
of
turbomachineries decreases as the separation and
secondary flows increase.
3D swept and lean blades have been widely used
because of its advantages of controlling internal flows
and improving the performance of compressors, such
as E3E engine, PW4084 and PW6000 [1~2]. In the 1960s,
Professor Wang Zhong-qi puts forward the leaned
blades, which can effectively weaken the secondary
flows in blade tip and hub [3]. Afterwards, researchers
found that leaned blades can control the radial
secondary flows on the blades and the transverse flows
near the endwall. Swept blades are used to weaken
shock intensity and to improve the stability margin of
the transonic compressors [4]. Recent research
demonstrates that the swept blades can also improve
the performance and the stability margin of subsonic
compressors. C. Xu and R. S. Amano find that swept
blade redistributes the flow reducing the secondary
loss depending on the baseline, and forward swept can
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International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

reduce the tip loading [5]. Reference [6] indicates that

swept blades have the similar effects on the endwall
flow fields as leaned blades in subsonic compressors.
In 1994, Rose put forward the new concept of nonaxisymmetric endwall [7]. Non-axisymmetric endwall
contouring can effectively control the transverse
pressure gradient between pressure surface and
suction surface near the endwall, hence decreases the
secondary loss. Literature [8] investigates the
secondary flows in a turbine cascade with and without
the implementation of endwall profiling. G. Brennan
redesigns the HP turbine of the Trent 500 engine by
using non-axisymmetric endwall, and improves the
HPT by 0.4% in efficiency [9]. T. Germain designs the
endwalls using automatic optimization algorithm, and
the results confirm that non-axisymmetric endwall
profiling can improve turbine efficiency [10]. Na
Zhenzhe optimizaiton designs the non-axisymmetric
end wall in a high pressure turbine. The isentropic
efficiency increases by 0.456% [11].
The main objectives of the report are to reduce the
radial secondary flows on the rotor blades and the
transverse secondary flows near the endwall of the
dual-stage axial flow counter-rotating compressor by
using 3D blading and non-axisymmetric endwall
technologies. The swept law and lean law of the
stacking line of the two rotor blade rows are optimized
designed firstly. And the hub endwall of the secondary
rotor blade row are optimization designed. Whats
new in this report is that the 3D blading is found
having little effect on the transverse flows near the hub
endwall, and the compressor is optimized combined
by 3D blading and non-axisymmetric endwall
contouring technique. That is rarely found in existing
literatures.
Investigated Compressor
The dual-stage axial flow counter-rotating compressor
is from Northwestern Polytechnical University of
China [12]. FIG. 1 shows a picture of the compressor.
The compressor mainly consists of an inlet guide vane
row (IGV), a first rotor row (R1), a second rotor row
(R2), an outlet guide vane row (OGV). The meridional
channel of the counter-rotating compressor is shown in
FIG. 2. The external diameter of the compressor is
400mm. The compressor is designed with a rotating
speed of 8000rpm, and the mass flow is 6.4Kg/s at the
design point and the efficiency is 0.89. Table 1 shows
the main parameters of the compressor. In order to
save time, the investigation of the report only focuses
on the two rotor blade rows.

92

Rotor 1

Rotor 2

OGV

FIG. 1 The picture of the dual-stage axial flow counter-rotating

compressor

FIG. 2 The meridional channel of the compressor

TABLE 1 MAIN PARAMETERS OF THE COMPRESSOR

IGV

R1

R2

OGV

22

19

20

22

Tip clearance

0.5mm

0.5mm

Hub-tip ratio

0.485

0.641

Design rotatingspeed

8000
rpm

-8000
rpm

Blade number

Numerical Model
The AUTOGRID model in NUMECA FINE/TURBO
commercial software package has been employed for
grid generation. The total grids number is about 0.71
million. The minimum orthogonality of the mesh is
17.19. The investigation in this paper is based on this
mesh. FIG. 3 to FIG. 5 show the mesh of blade and hub
endwall surface, S1 surface at the mid span, and the
leading edge of R1 hub. This report utilizes
FINE/TURBO to compute the flow fields. The FavreReynolds averaged Navier-Stokes equations are
discretized by a cell-center explicit finite volume
scheme according to Jameson et al. The temporal
discretization scheme used for the computation is an
explicit multi-stage Runge-Kutta scheme. The spatial
resolution is Jamesons finite volume scheme. The
mixing plane is used between the two rotors. Full
multigrid technology is used for convergence.
Turbulence effects are modeled using the SpalartAllmaras model. Inlet absolute total pressure, inlet
total temperature, inlet flow angle, and outlet static
pressure are presented for the boundary conditions.

International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

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1.3

Calculation
Experiment

Total Pressure Ratio

1.25

1.2

1.15

1.1

1.05

FIG. 3 The grids of blade and hub endwall surface

5.5

6.5

7.5

Mass Flow(kg/s)

FIG. 8. Total pressure ratio-mass flow performance

Optimization Design Method

Design Methods of 3D Blading

FIG. 4 The grids of S1 surface at the mid span

FIG. 5 The grids of the leading edge of R1 hub

As the experiment was done on the whole compressor,

the performance of the whole compressor is numerical
simulated firstly with the purpose of verifying the
validity of the mesh and the numerical method. The
mesh of R1 and R2 is the same with that of FIG. 3. And
the numerical method is the same, too. The mesh of the
whole compressor is shown in FIG. 6. The results of
numerical simulation and experiments at design
rotating-speed are provided in FIG. 7 and FIG. 8. The
comparison shows that the calculation results agree
well with the experiment results. As a result, the
numerical model is reasonable and practicable.

The original geometry of the compressor is given by

discrete points. But the optimization design is a
parameterization optimization design process. The
blade sections are firstly parametric fitted by high
order Bezier curves of 8 control points. The stacking
lines are defined by meridional position (swept) and
tangential position (lean). We use leading edge
stacking method to stack the S1 blade element. Both
swept and lean lines are fitted by high order Bezier
curves (7 control points, the control point at the blade
hub is fixed), which is shown in FIG. 9. In the
optimization design process, individual blade sections,
hub line and shroud line remain unchanged. Only
'swept' law and 'lean' law of the stacking lines are
modified in the design process.

(a) Swept law

FIG. 6 The mesh of the whole compressor
1

Calculation
Experiment

Isentropic Efficiency

0.9

0.8

0.7

0.6

0.5

5.5

6.5

7.5

Mass Flow(kg/s)

FIG. 7. Isentropic efficiency-mass flow performance

(b) Lean law

FIG. 9 Parametric stacking line

Design Methods
Contouring

of

Non-axisymmetric

Endwall

The optimization design object is a single period of the

hub endwall. The original hub endwall curved surface
is expressed by some simple control parameters. The
parameters are adjusted in the design process in order
that the non-axisymmetric endwall curved surface is
obtained. FIG. 10 shows the method of nonaxisymmetric
endwall
contouring.
The
non-

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International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

axisymmetric endwall region is limited to Inlet

and Outlet shown in the figure. Axisymmetric hub
endwall is defined by period boundary curve and
tangential profile. Both the period boundary curve and
meridional profile are defined by a high order Bezier
curve which has 7 control points. Through adjusting
the value of the control points, all the superposition of
R along radial direction is obtained. Finally, the nonaxisymmetric hub endwall is obtained. All the control
points are modified at last.

function and the optimized variables, and uses the

genetic algorithm to find the optimal value of target
function.
In this report, as the structure changes small, we only
consider the aerodynamic performance. There are no
mechanical constraints and the throat area is also not
considered. The work of the 3D blading and nonaxisymmetric endwall optimization lasted for 21 days
in all.
Results and Analysis
The surge margin of the compressor is defined as
follows:

FIG. 10 Non-axisymmetric endwall contouring method

Optimization Methods
The numerical simulation indicates that the radial
secondary flows near the blade surfaces and the
transverse flows near the hub endwall are obvious at
the near stall condition. So we select near stall
condition for optimization condition. The optimization
object is to improve the efficiency of the whole
compressor. In the optimization process, the same
condition is defined as with the same boundary
conditions described in NUMERICAL MODEL.
Based on artificial neural network, approximate
function and genetic algorithm, the optimization
methods of 3D blading design is the same with nonaxisymmetric endwall contouring design. A database
is generated before the optimization process by using
the DATABASE_GENERATION model in NUMECA
FINE/TURBO software. This paper utilizes discrete
layer sampling method to generate samples. The
sampling method divides the geometric constraint into
some region in order to guarantee the generating
samples having globally representative. Little changes
for the values of the objective function are obtained
during the process. As a result, a total of 150 samples
for 3D blading and 80 samples for non-axisymmetric
endwall
contouring
are
generated.
The
OPTIMIZATION model is employed in the
optimization process. The object for the optimization is
improving the efficiency of the compressor, with the
mass flow not decreasing. The optimization method
utilizes artificial neural network technology to
establish the relationship between the objective

94

*
Ks

mas
=
1 100%
SM *
Ko

mao

*
m
Ks
as the

total pressure ratio and mass flow at

the near surge point;
*
m
Ko
ao the

total pressure ratio and mass flow at

the highest efficiency point.
Results of 3D Blading
After 3D blading optimization, the efficiency of the
compressor improves by 0.5% and the mass flow sees
an increase of 2.84%, while the total pressure ratio
remains unchanged. FIG. 11 and FIG. 12 show the
shape of R1 and R2 after 3D blading optimization
separately. FIG. 13 and FIG. 14 compare the lean law
and swept law of the stacking line for R1 and R2 before
and after 3D blading optimization.
The performance character of the original compressor
and 3D blading optimized compressor are shown in
FIG. 15 and FIG. 16. Because we define the same outlet
static pressure condition as the same condition during
the optimization process, the mass flow after 3D
blading optimization increases. So, although the
efficiency increases and the total pressure ratio
remains unchanged at the same condition, the
efficiency character shows little increase, but the total
pressure ratio character increases. The mass flow at the
near surge point decreases from 5.049kg/s to 4.872kg/s.
The surge margin increases from 27.03% to 30.90%.
FIG. 17 and FIG. 18 show the limited streamlines at the
suction surface of the original compressor and 3D
blading compressor. The radial secondary flows are

International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

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discovered at the suction surface of R1 and R2 of the

original compressor. The area of the secondary flow
region is about 25% of the suction surface. The radial
secondary flow is one of the main sources of flows loss.
After 3D blading optimization, the area of the radial
flow decreases, especially with R2. And it has a
positive role to improve the performance of the
compressor.

FIG. 15 Isentropic efficiency performance

FIG. 11 3D blading shape of R1

FIG. 16 Total pressure ratio performance

FIG. 12 3D blading shape of R2

Origin
Lean law

Swept law

3D blading

FIG. 17 Suction surface limited streamline for R1

FIG. 13 The stacking line of R1

Lean law

Swept law

FIG. 14 The stacking line of R2

Origin

3D blading

FIG. 18 Suction surface limited streamline for R2

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International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

FIG. 19 and FIG. 20 show the limited streamline and

static pressure contour at the hub of R1 and R2. The
blades' load at the optimization point is high, so the
hub of R1 shows transverse flow clearly. But as the
bending of R2 is less than R1, the blade load is lower
than R1. So the transverse flows of R2 hub are not as
obvious as R1. However, because the attack angle of
R2 hub is high at the near stall condition, the air flow
stagnation point is near the pressure surface, so the
static pressure at the leading edge of pressure surface
is much higher than that of suction surface. So the
pressure gradient at R2 inlet is higher than at the
middle and the outlet of the blade passage at R2 hub.
And the transverse flows are more obvious at the
leading edge of R2 hub. As the lean law and sweep law
changes small in the hub region, the 3d-blading in this
paper has little influence in the hub region.

Origin
3D blading
FIG. 19 Hub endwall limited streamline/static pressure contours of
R1

96

Origin
3D blading
FIG. 20 Hub endwall limited streamline/static pressure contours of
R2

FIG. 21 and FIG. 22 show the static pressure

distribution of R1 and R2 with original compressor
and optimized compressor. 3D blading has little
influence on the hub and middle blade span of R1 and
R2. The distribution curves of original and optimized
compressor are almost the same. 3D blading has more
influence on the tip span static pressure distribution.
The static pressure in the suction surface decreases in
0~20% axial chord of R1, and static pressure in the
pressure surface increases in 0~10% axial chord of R1.
Thus the load decreases at the leading edge of R1. But
at about 15%~100% axial chord of R1, the blade load
increases. The static pressure of R2 is similar to R1,
while the load increases higher at about 10%~100%
axial chord of R1.

(a) R1 hub

(b) R1 mid
FIG. 21 Static pressure distribution of R1

(c) R1 tip

(a) R2 hub

(b) R2 mid
FIG. 22 Static pressure distribution of R2

(c) R2 tip

International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

FIG. 23 compares the radial distribution of efficiency

for original and 3D blading compressor. After 3D
blading optimization, the efficiency at 0~20% and
60%~90% span of R1 improves, while the efficiency of
other span remains the same. The efficiency at 0~60%
span of R2 decreases, while the efficiency at 60%~100%
span increases.
FIG. 24 compares the radial distribution of total
pressure ratio for original and 3D blading compressor.
After 3D blading optimization, the total pressure ratio
at 0~30% of R1 decreases, while the total pressure ratio
of other span increases. The total pressure ratio at
0~40% and 86%~100% span of R2 decreases, while the
total pressure ratio at 40%~86% span increases. The
reason that the efficiency of the whole compressor
increases is that the load redistributes along the blade
span.

optimization design, the efficiency of the whole

compressor improves by 0.343% than 3D blading
compressor, and is 0.843% higher than original
compressor. FIG. 25 shows the contour of R2 nonaxisymmetric hub. The non-axisymmetric endwall hub
is similar with common literatures [7~10], with a "hill"
near the pressure surface and a "valley" near the
suction surface.

FIG. 25 NON-AXISYMMETRIC HUB ENDWALL CONTOURING OF R2

The performance character of the original compressor,

3D blading compressor, and non-axisymmetric
endwall compressor are shown in FIG. 26 and FIG. 27.
The efficiency of the non-axisymmetric endwall
compressor is higher than that of the original
compressor in most of the efficiency performance
curve at design speed. The total pressure ratio is
higher than that of the 3D blading compressor and
original compressor. Surge margin is almost the same
with the original compressor.

R1
R2
FIG. 23 Efficiency radial distribution

R1

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FIG. 26 ISENTROPIC EFFICIENCY PERFORMANCE

R2

FIG. 24 Pressure ratio radial distribution

Results of Non-axisymmetric Endwall Contouring

The 3D blading of R1 and R2 has little influence on the
transverse flows of the hub. Thus, in order to further
improve the flow fields of the rotor hub and to
improve the efficiency of the compressor, the author
designs the R2 hub contouring by non-axisymmetric
endwall contouring technique based on 3D blading
compressor.
After

non-axisymmetric

endwall

contouring

FIG. 27 PRESSURE RATIO PERFORMANCE

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FIG. 28 and FIG. 29 compare the suction surface

limited streamline of 3D blading compressor and nonaxisymmetric hub endwall compressor. The figures
show little variation after non-axisymmetric endwall
optimization. Non-axisymmetric hub endwall has little
effect on improving the radial secondary flows near
the blade suction surfaces.

3D blading

Non-axisymmetric hub

FIG. 28 Suction surface limited streamline for R1

3D blading

Non-axisymmetric hub

FIG. 29 Suction surface limited streamline for R2

FIG. 30 and FIG. 31 compare limited streamline/static

3D blading

pressure contour near the hub endwall of 3D blading

compressor and non-axisymmetric hub endwall
compressor. The flow fields of R1 show little variation.
However, the transverse flows near the R2 leading
edge is reduced after non-axisymmetric endwall
optimization. The static pressure near the pressure
surface of R2 decreases and the flow fields are better.
FIG. 32 and FIG. 33 compare the static pressure
distribution of different spans of 3D blading
compressor and non-axisymmetric hub endwall
compressor. The figures indicate that the nonaxisymmetric hub endwall has little effect on R1 and
the upper blade span of R2 static pressure distribution.
The static pressure of R2 hub is influenced much by
non-axisymmetric hub endwall. The static pressure
gradient decreases at about 0~40% axial chord, and
increases at about 40%~100% axial chord. The change
of static pressure is corresponding with that of the flow
fields in FIG. 28.
FIG. 34 shows the efficiency radial distribution of
original compressor, 3D blading compressor and nonaxisymmetric hub endwall compressor. After nonaxisymmetric endwall contouring, the efficiency
distribution of R1 varies little compared with 3D
blading compressor. The efficiency of 20%~70 span of
R2 increases, while at other spans remain the same
with 3D blading compressor.

Non-axisymmetric hub

FIG. 30 Hub endwall limited streamline/static pressure contours of R1

(a) R1 hub

98

3D blading

Non-axisymmetric hub

FIG. 31 Hub endwall limited streamline/static pressure

contours of R2

(b) R1 mid
FIG. 32 Static pressure distribution of R1

(c) R1 tip

International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

(a) R2 hub

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(b) R2 mid
FIG. 33 Static pressure distribution of R2

R1

(c) R2 tip

R2
FIG. 34 Efficiency radial distribution

R1

R2
FIG. 35 Pressure ratio radial distribution

FIG. 35 shows the total pressure ratio radial

distribution of original compressor, 3D blading
compressor and non-axisymmetric hub endwall
compressor. The total pressure ratio at all different R1
span of non-axisymmetric endwall compressor
decreases compared with that of 3D blading
compressor, and at 20%~100% R1 span of nonaxisymmetric
endwall
compressor
decreases
compared with that of original compressor. The reason
why the total pressure ratio of R1 decreases is that the
mass flow increases after non-axisymmetric hub
optimization. So the load decreases when the mass
flow increase. However, because of the influence of
non-axisymmetric hub, the distribution of R2 is not the
same with R1, and the total pressure ratio of R2
increases instead. The total pressure ratio at all
different R2 span of non-axisymmetric endwall
compressor increases compared with that of 3D

blading compressor, while at 0~90% R2 spans of nonaxisymmetric endwall compressor increases compared
with that of original compressor. Non-axisymmetric
hub endwall can not only improve the flow fields of
R2 hub, but also redistribute the aerodynamic
parameter along the rotor span.
Conclusions
The report optimization designs the 'swept' law and
'lean' law of the stacking line of R1 and R2 separately
at the near stall condition. The effect of 3D blading on
the compressor performance and flow fields are
investigated. 3D blading optimization design indicates
that 3D blading have little influence on the hub flow
fields. So the hub endwall of R2 is optimization
designed by non-axisymmetric endwall technique
based on optimization algorithm with the purpose of
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International Journal of Energy Science (IJES) Volume 4 Issue 3, June 2014

further improving the compressor performance.

Experimental study is to be done on the platform in
order to verify the optimization methods of 3D
blading and non-axisymmetric contouring. The
conclusions are as follows,
(1) 3D blading can significantly improve the
performance of the dual-stage axial flow counterrotating compressor, the efficiency of the compressor
improves by 0.5%, the mass flow sees an increase of
2.84%, and the surge margin increases from 27.03% to
30.90%. The radial secondary flows are reduced by 3D
blading effectively. However, 3D blading has little
effect on the transverse flows near the hub endwall,
which is rarely found in existing literatures.
(2) 3D blading increases the load at the tip of R1 and
R2. But the load of the lower span of R1 and R2 varies
little. Efficiency and total pressure ratio distribution
along R1 and R2 radial are influenced by 3D blading.
And the reason that the performance of compressor
improves is the redistribution of aerodynamic
parameter along the rotor span.
(3) After non-axisymmetric endwall contouring
optimization design, the efficiency of the whole
compressor improves by 0.343% than 3D blading
compressor. The transverse flows at the hub of R2
improve significantly, and the loss near the hub
reduces.
(4) The static pressure distribution of R2 hub endwall
varies after non-axisymmetric endwall contouring.
The static gradient at about 0~40% axial chord
decreases, while at about 40~100% axial chord
increases. Non-axisymmetric endwall contouring can
not only improve the flow fields of R2 hub, but also
redistribute the aerodynamic parameter along the
rotor span. However, R2 non-axisymmetric hub
endwall has little effect on the static pressure
distribution of R1 and upper span of R2.
ACKNOWLEDGMENT

The work is funded by the natural science foundation

of China. The fund number is 51236006.
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