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Abstract
The present study investigated the film cooling performance on the pressure side surface of
the nozzle guide vane with the optimized film cooling hole arrangement. An annular sector
transonic turbine cascade test facility in Korea Aerospace Research Institute was used. The
mainstream and the secondary air for cooling are supplied by 500hp and 50hp compressors,
respectively. To measure the film cooling effectiveness on the surface, a transient measurement
method was used with the FLIR infrared camera system and the mainstream temperature was
maintained 15 to 20C above the secondary flow temperature using 300kW heater. Five nozzle
guide vanes were installed in the test section. The configuration with the cooling hole
arrangement proposed by the optimization procedure was tested and compared with the
baseline configuration. For the cooling hole arrangement optimization, nine design variables are
taken into account for a single objective function of film cooling effectiveness on the pressure
side surface. Design of Experiment, Kriging surrogate model and Genetic Algorithm are used for
the optimization. The tests were conducted at the mainstream exit Reynolds number based on
the chord of 2.2x106 and the total coolant mass flow rate was set to be 10% of the inlet main
flow. The flow periodicity in the cascade passage was ensured by the surface static pressure
measurements. The results showed that considerable improvement of the film cooling
effectiveness is observed in the whole region with the optimized configuration, which gives the
possibility of coolant mass flow reduction.
Keywords
Annular Turbine Cascade Film Cooling Optimized Hole Arrangement
1
Korea Aerospace Research Institute, Daejeon, Republic of Korea
2
Turbomachniery Laboratory, University of Notre Dame
3
Department of Mechanical and Aerospace Engineering, Seoul National University, Seoul, Republic of Korea
*Corresponding author: rhee@kari.re.kr
Three rows of the cooling holes are named as PS1, PS2 and
PS3, respectively as shown in Fig. 2. The first row, PS1, has
an injection angle of 34 with respect to the surface while PS2
and PS3 have 30. The chordwise location of each row for
the baseline configuration is described in Table 2.
Table 5. Effective blowing ratio at hole exit for the baseline The test models shown in Fig. 8 are manufactured by 3D
configuration printer, CMET EQ-1, which uses a stereo-lithography method.
Meffective based on The solid properties of the test model, such as density,
Meffective based on
Position the pitchwise specific heat and thermal conductivity were carefully
the inlet main flow
averaged main flow measured for a transient test data reduction. Two
PS1 1.38 1.17 thermocouples were embedded on the surface from the
PS2 1.33 0.52 inside of the cooling channel cavity and are used as the
reference temperature for the in-situ calibration. In addition,
PS3 2.51 0.54 the models with the pressure taps were manufactured for the
static pressure measurements.
2
= 1 exp ( 2
) (
) (1)
Figure 7. Typical example of mainstream temperature variation during The solid properties (, k) in Eqn. (1) were obtained from
the transient test the separate property measurement test. The initial
temperature, Ti and the surface temperature, Tw on the
pressure side surface are measured during the test using an
IR camera at a sampling rate of 12Hz.
To calibrate the measured value from the IR camera, an in-
situ calibration was conducted in the test section for various
mainstream temperature conditions. As mentioned above,
the data from two thermocouples were used as the reference
temperature.
The mainstream temperature was controlled by 300kW
heater and the calibration data were taken when the steady
(a) baseline state was assured. Figure 9 presents the calibration curve of
IR camera data showing a quite linear pattern. Then, two
unknown variables, hf and Tf can be obtained from the data
at two different time frames in a single experiment. The
details of the data reduction procedure follow the reference
given by Ekkad et al. [17]. In this study, the nominal test
duration is within 60 seconds and the data of two time frames,
for example 5 and 30 seconds, are taken from the surface
temperature measurement results. The film cooling
effectiveness is then calculated from Eqn. (2). The recovery
(b) optimized configuration temperature is used as a reference temperature of the
Figure 8. Photographs of test nozzle guide vanes mainstream in Eqn. (2). The definition of the recovery
temperature is presented in Eqn. (3). In Eqn. (3), recovery
factor, r, is set to be Pr1/3 and the incoming Mach number (Min)
of the mainstream is used for this study. The mainstream
static temperature (Ts) is measured upstream of the center
nozzle and the coolant temperature (Tc), the temperature
inside the coolant plenums, is measured by four
thermocouples inside the plenums during the test.
=
(2)
1 2
= (1 + ( 1) ) (3)
2
Figure 9. In-situ calibration curve of IR camera
Experimental Study of Film Cooling Performance on Turbine Guide Vane with Optimized Hole Arrangements in a Transonic Annular Sector Cascade - 6
PS3. When the regions downstream of PS3 are compared, means that the optimization procedure and its methodology
the levels of the effectiveness are similar. However the region are quite reasonable to use for improvement of the cooling
just downstream of PS3, especially the near-hub region, has performance.
much larger area of high effectiveness with the optimized
configuration. This is due to the coalescence of the coolant
resulting from smaller hole spacing with the upstream coolant
protection effect in that region.
Figure 12 shows the spanwise distributions of film cooling
effectiveness downstream of rows of holes. Downstream of
PS2 (Fig. 12(a)), the highest values of effectiveness are
around 0.7 for both cases. However, the regions between
holes have quite different values. This is due to the relative
position of the holes at PS1 and PS2 as mentioned earlier.
For the optimized configuration, PS2 moves upward in
spanwise direction and the hole spacing is rearranged, that
is, has a relatively small spacing near the hub. The
superposition of the coolant from PS1 and PS2 makes higher
(a) 3d downstream of PS2
and more uniform effectiveness values in the downstream
region of PS2. Similar patterns are observed in the
downstream region of PS3 as shown in Fig. 12(b). In the
region of z/H0.5, the effectiveness values between the holes
are much higher for the optimized case while the peak values
are almost the same. In the region upstream of the trailing
edge slot (Fig. 12(c)), the mean values become very close to
each other configuration showing effectiveness of around 0.5
in the overall region, but much better uniformity is obtained
with the optimized case.
Figure 13 shows the streamwise distributions of the
(b) 3d downstream of PS3
spanwise averaged film cooling effectiveness for the baseline
and the optimized configurations. The effectiveness around
PS1 shows the similar values for both the cases. However
the downstream regions of PS2 and PS3 are found to have
much higher effectiveness values with the optimized
configuration as expected from the contour and local plots.
This reveals that the optimization process modifies the
cooling design to strengthen favorable interaction of coolant
ejecting from the upstream and downstream rows. As a result,
for the optimized case, relatively high effectiveness values
are found even far downstream region of PS3.
(c) 6d upstream of the trailing edge cooling slot
The film cooling effectiveness contours downstream of the
Figure 12. Spanwise distributions of film cooling effectiveness on
first row obtained by the CFD are shown in Fig. 14. It is noted the selected positions
that the contour range is different from that of the
experimental results to show the coolant behaviors on the
surface more clearly. The CFD cases shows the elevated
level of effectiveness values when compared with the
experimental results. There are two things to be considered
on these results. First, the boundary conditions for the CFD
were based on the real engine condition as mentioned earlier,
which means the difference in density ratio of the coolant to
the mainstream. Second, due to the limitation of computing
resources, the grid quality, especially near the surface, is not
as good as that of fully dedicated three dimensional numerical
simulations having y+ value of around 1 for a single
calculation. These may cause over-predicted film cooling
effectiveness on the pressure side surface when comparing Figure 13. Streamwise distributions of spanwise averaged film
with the experimental results. However the overall patterns cooling effectiveness for different hole arrangements
are quite similar to those of experiments qualitatively. This
Experimental Study of Film Cooling Performance on Turbine Guide Vane with Optimized Hole Arrangements in a Transonic Annular Sector Cascade - 8
ACKNOWLEDGMENTS
(b) optimized configuration This project is funded by Ministry of Industry, Trade &
Figure 14. Contours of film cooling effectiveness from the CFD Energy through the Aerospace Component Technology
Development Program (grant No. KA000157)
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