燃气轮机透平叶片传热和冷却研究：内部冷却

随着燃气轮机透平进口温度的不断提高,其换热与冷却问题已然成为现代高性能燃气轮机研发中亟待解决的核心关键技术之一.透平叶片的冷却可以分为内部冷却和外部冷却,结合作者近年的研究工作,详细综述了燃气轮机透平叶片内部换热与冷却问题的研究现状与进展,着重介绍了叶片内部蛇形通道冷却、叶片内部冲击冷却和前缘的旋流冷却及尾缘柱肋冷却,指出了它们各自在相关方面需要进一步开展的工作.其中：在蛇形通道冷却方面,需要进一步研究旋转状态下蛇形通道内流动与换热特性、发展高性能的扰流装置及通道弯头结构、设计新颖高效的叶顶内部冷却结构、获得带气膜孔或冲击孔的蛇形通道内的换热与冷却特性;在叶片前缘内部冲击冷却方面,需要研究不同曲率面上的冲击冷却换热特性、旋转条件下的冲击冷却以及冲击气膜复合冷却特性;在旋流冷却方面,需要对其结构参数的影响开展进一步的广泛研究,并开展旋转状态下旋流冷却特性的研究;在尾缘柱肋冷却方面,需要进一步研究复杂流场下柱肋阵列通道中的流动换热与众敏感因子之间的关系.     

旋转状态下燃气涡轮叶片内部冷却的研究进展

在现代高性能燃气涡轮发动机中,随着涡轮前燃气温度的不断提高,旋转涡轮叶片的冷却问题日益受到重视。在众多的冷却技术中,内部冷却具有明显的优势和较强的应用前景。综述了近年来旋转状态下燃气涡轮叶片内部冷却技术的研究成果,总结了光滑壁面旋转对流场和传热的影响、旋转对冲击冷却影响以及旋转扰流式肋片冷却介质通道传热的研究现状,阐述了旋转状态下内部冷却和气膜冷却相互影响的研究情况。最后指出进一步优化内流通道结构,研究旋转对扰流柱通道流动及换热的影响以及在旋转状态下深入探讨内部流动与外部气膜冷却相互影响的机理是今后工作的重点。     

基于OpenFOAM的带肋双通道扰流冷却大涡模拟

基于OpenFOAM平台,对带直肋W/H=1双通道在静止状态下的流动耦合传热特性进行大涡数值模拟,研究了静止时双通道的流动换热性能。可以得出:在静止状态下由于肋片的扰流、离心作用,弯管处及弯管后的第二通道的Nu数比值大于第一通道,Nu数比值最大值出现在肋片的顶端,旋涡结构明显的多于第一通道,故换热效果明显的好于第一通道。结果表明,基于OpenFOAM的大涡模拟能够较好地应用于带肋通道复杂流动和传热研究。     

涡轮叶片尾缘典型结构的流动与换热特性研究

针对涡轮叶片尾缘"冲击+扰流柱"复合典型冷却结构,通过分析内部流场和换热特性,揭示"冲击+扰流柱"冷却结构中流动发展的过程以及冲击对压力分布和流场分布的影响,揭示涡轮叶片尾缘区内射流冲击扰流柱排通道内换热机理,详细分析了冲击下各个表面的换热情况。结果表明,压比的增大能够有效改善冷却通道端壁的换热性能,但同时增大了压力损失;在两种冲击距离下,n=3d换热效果优于n=6d,但是n=6d的下游换热覆盖效果优于n=3d。顺排时,冲击孔的平均换热系数大约是扰流柱的1.5倍;叉排时,冲击孔的平均换热系数大约是扰流柱的3倍,而其它部位的平均换热系数受排列方式的影响很小。因此,"冲击+扰流柱"冷却结构的匹配,对于优化涡轮叶片尾缘区域的换热及其重要。     

燃气轮机高温叶片内部冷却技术概述

综述了燃气轮机典型的内部冷却结构和设计手段.通过文献分析,提出内部冷却典型强化换热手段包括带肋通道冷却、扰流柱冷却和冲击冷却,重要设计手段包括一维管网和三维数值优化.管网计算基于实验总结的经验公式,计算效率高,关键在于动量方程的求解算法;三维数值优化可以降低设计对人工经验的依赖,关键在于合理选择优化目标和优化算法.分析表明,旋流等新的强化传热形式、微型冷却等新的叶片冷却模式、旋转和真实通道几何对内部冷却详细传热和流场的影响都将得到进一步研究,叶片设计技术将由人工经验性的设计逐渐向计算机自动化方向发展.     

燃气轮机通道宽高比对换热特性的影响

采用结构化六面体网格和κ-ε湍流模型,求解三维N-S方程,对直冷却通道内置不同宽高比的W型扰流肋片在入口雷诺数为20 000时的空气流动与换热特性进行数值模拟。分析了不同肋片通道的宽高比对肋间壁面的换热效果和流动损失的影响,并对通道的宽高比进行全局寻优。结果表明,肋片通道的宽高比是影响带肋片直冷却通道的整体换热效果和综合冷却效率的主要因素,并存在一一对应的关系,整体换热效果最好时所对应的肋片宽高比为5,考虑热量损失的情况下换热效果最好时所对应的肋片宽高比为0. 48。     

孔_肋相对位置对通道各壁面换热影响

数值模拟了肋和气膜孔的相对位置对矩形通道4个壁面换热特性的影响,重点分析了通道4个壁面换热系数差别以及3种气膜孔位置换热.计算结果和实验数据吻合较好.结果表明:气膜孔位置对同时带肋和气膜孔的下壁面影响最大,孔在肋间上游换热最好,孔在肋中间换热次之,孔在肋间下游换热最差,气膜孔位置对光滑的左右壁面换热影响较小,对只带肋的上壁面几乎没有影响.肋的扰流和气膜孔抽吸使通道下壁面换热系数增幅最大,左右壁面次之,上壁面最小.沿着流动方向,肋扰流和气膜孔出流共同作用导致带肋壁面换热增强因子先增大后减小,光滑壁面换热增强因子先保持不变后减小.     

内部通道肋片结构对Mark Ⅱ叶片冷却性能影响的降维模型研究

一维冷却通道气热耦合计算是分层涡轮叶片冷却结构设计的重要方法。发展了以管道网络算法为核心的内部冷却特性计算程序,并与三维传热计算进行了耦合。通过与MarkⅡ叶片特定实验工况下的结果进行对比,验证了方法的有效性。此外,进一步将带肋结构流道传热特性相关经验公式集总在一维气热耦合算法中,分析了带肋通道改型的MarkⅡ叶片冷却性能。结果显示,带肋结构相比光滑流道能显著提升换热性能,在中径截面处较原方案温度下降15～30 K。     

截面形状对旋转扰流柱通道流动换热特性的影响

为合理设计航空发动机涡轮动叶尾缘冷却结构,采用ANSYS FLUENT软件模拟了四种扰流柱截面形状在旋转状态下的流动换热特性。对比分析了不同旋转数(Ro)和不同扰流柱截面形状时通道内部的三维流场分布、湍流动能分布、努塞尔数(Nu)分布以及阻力系数。其中扰流柱的截面形状包含圆形、菱形、矩形和椭圆形,Ro数包含0、0.2、0.4和0.6四种数值。模拟过程中通道入口雷诺数为7 000,壁面恒定热流为1 000 W/m²。结果表明,截面形状和旋转数对流动和换热状态有着显著影响,矩形扰流柱通道的换热系数和阻力系数最高;随着旋转数的增加,迎风面和背风面的换热系数差异逐渐增大;在旋转作用下,扰流柱尾缘区域出现了纵向二次流,该二次流显著破坏了壁面附近的边界层,有利于背风面换热增强。     

燃气涡轮内置W型肋片的流动与传热模拟研究

以内设W型扰流肋叶片的传热通道为模型,应用Ansys软件进行网格划分、条件设置及计算。以W型扰流肋叶片导流角α为研究变量,研究α的变化与通道模型整体换热效果及两相摩擦损耗的关系,并将研究结果应用Matlab软件进行寻优。结论如下,α为46.7°的内置W型肋片的通道整体换热效果最好,α为30°时的通道摩擦损耗最小。     

An experimental investigation of the heat transfer in a ribbed triangular cooling channel

One of the most challenging aspects of gas turbine cooling is the cooling of the first stages of turbine blades. Here the highest external heat load is seen at the leading edge of the blade. The present study investigates the internal cooling in a triangular channel with a rounded edge as a model of a leading edge cooling channel for a gas turbine blade. A transient liquid crystal method is used to measure the heat transfer. Experimental results are reported for a number of new 3D rib configurations for Reynolds numbers between 50 000 and 200 000. From the experimental results it has been found that 60 deg. ribs provide in general higher heat transfer enhancements than 45 deg. ribs. However, this results in extremely high friction factors for the 60 deg. ribs. Taking the local and mean distributions of the heat transfer coefficients (as well as the increase in friction factors) into consideration, it was found that the most promising rib arrangement for leading edge cooling is a 3D rib with 45 deg. angle and double-sided fully overlapped ribs in the arc area. These ribs provide uniform heat transfer in the arc area as well as a high level of the heat transfer coefficients in the channel. The resulting friction factors are in an acceptable range for these ribs.     

Experimental Study of Heat Transfer and Pressure Loss in Channels with Miniature V Rib-Dimple Hybrid Structure

Abstract

In order to increase the thermal efficiency, the gas turbines are designed to operate at higher temperature, which requires highly efficient cooling structures for turbine blades. The dimples and ribs are effective surface structures to enhance the convective heat transfer in the gas turbine blade internal cooling. In the present study, a novel hybrid cooling structure with miniature V-shaped ribs and dimples is presented, and the heat transfer and pressure loss characteristics are obtained experimentally. The heat transfer performance of the rib–dimple structures, which include three different rib height-to-hydraulic diameter ratios of 0.017, 0.029 and 0.044 and one dimple configuration with the dimple depth-to-diameter ratio of 0.2, are studied by using the transient liquid crystal thermography technique for turbulent flow in rectangular channels within the Reynolds number range from 10,000 to 60,000. It is found that the miniature V-shaped ribs arranged upstream the dimples can significantly improve the heat transfer performance of the dimples, resulting in a more uniform heat transfer distribution on the surface. The V rib-dimple hybrid structure in the channel shows much higher heat transfer enhancement than the counterparts with only the dimples in the channels.     

Influence of internal channel geometry of gas turbine blade on flow structure and heat transfer

This paper presents the study of the influence of channel geometry on the flow structure and heat transfer,and also their correlations on all the walls of a radial cooling passage model of a gas turbine blade.The investigations focus on the heat transfer and aerodynamic measurements in the channel,which is an accurate representation of the configuration used in aeroengines.Correlations for the heat transfer coefficient and the pressure drop used in the design of internal cooling passages are often developed from simplified models.It is important to note that real engine passages do not have perfect rectangular cross sections,but include a comer fillets,ribs with fillet radii and a special orientation.Therefore,this work provides detailed fluid flow and heat transfer data for a model of radial cooling geometry which has very realistic features.     

基于流热耦合的燃气轮机透平叶顶冷却设计

燃气轮机透平叶顶区域存在复杂的流动和换热问题,承受很高的热负荷。为了降低透平动叶叶顶温度,在透平叶顶现有结构的基础上提出气膜冷却和气膜+内冷通道冷却两种叶顶冷却方案,并通过流热耦合计算分析冷却升级前后叶顶区域的换热和流动特性。研究发现：叶顶气膜冷却方案可有效降低叶顶温度,特别是叶顶前缘至中弦区域;而气膜＋内冷通道冷却方案基于外部气膜冷却,结合内部冷却通道设计,可进一步降低叶顶尾缘的温度;与原型叶片相比,气膜+内部冷气通道的复合冷却设计可以使叶顶尾缘最高温度降低24 K。     

Large eddy simulation of flow and heat transfer in a rotating ribbed channel

The internal cooling passage of a gas turbine blade equipped with ribs is modeled as a rotating ribbed channel. The flow and heat transfer in the ribbed channel have been investigated by conducting large eddy simulations with a dynamic subgrid-scale model. The Reynolds number considered is 30,000 and rotation numbers are 0, 0.1 and 0.3. The time-averaged results show good agreement with the experimental data. By comparing the present data with those of the smooth channel, it is observed that the vortices shed from the rib induce strong wall-normal motions, and they are augmented on the trailing-wall side by the rotation, resulting in a significant increase in the heat transfer due to rotation. It is also shown that the similarity between the streamwise velocity and temperature is significantly destroyed by both the rotation and the rib itself.     

Flow structure and heat exchange analysis in internal cooling channel of gas turbine blade

This paper presents the study of the flow structure and heat transfer, and also their correlations on the four walls of a radial cooling passage model of a gas turbine blade. The investigations focus on heat transfer and aerodynamic measurements in the channel, which is an accurate representation of the configuration used in aeroengines. Correlations for the heat transfer coefficient and the pressure drop used in the design of radial cooling passages are often developed from simplified models. It is important to note that real engine passages do not have perfect rectangular cross sections, but include corner fillet, ribs with fillet radii and special orientation. Therefore, this work provides detailed fluid flow and heat transfer data for a model of radial cooling geometry which possesses very realistic features.     

大型燃气轮机透平第一级静叶表面温度分布的计算方法

利用附加源项法计算叶片外表面换热系数及温度分布,编制叶片内部冷却计算程序及壁面导热程序,应用该程序计算了某大型燃气轮机第一级静叶表面温度分布,对燃气涡轮叶片先进的内外部冷却系统设计方法的消化吸收奠定了基础。     

Enhanced Internal Heat Transfer on the Tip-Wall in a Rectangular Two-Pass Channel (AR = 1:2) by Pin-Fin Arrays

To improve gas turbine performance, the operating temperature has been increased continuously. However, the heat transferred to the turbine blade is substantially increased as the turbine inlet temperature is increased. Cooling methods are therefore much needed for the turbine blades to ensure a long durability and safe operation. The blade tip region is exposed to the hot gas flows and is difficult to cool. A common way to cool the tip is to use serpentine passages with a 180° turn under the blade tip cap taking advantage of the three-dimensional turning effect and impingement. Increasing internal convective cooling is however required to increase the blade tip life. In this article, enhanced heat transfer of a blade tip has been investigated numerically. The computational models consist of a two-pass channel with a 180° turn and arrays of pin-fins mounted on the tip-cap, and a smooth two-pass channel. Inlet Reynolds numbers range from 100,000 to 600,000. The computations are 3-D, steady, and incompressible. The detailed 3-D fluid flow and heat transfer over the tip surfaces are presented. The overall performance of the two models is evaluated. It is found that due to the combination of turning, impingement, and pin-fin crossflow the heat transfer coefficient of the pin-finned tip might be a factor of 1.84 higher than that of a smooth tip. This augmentation is achieved at the expense of a penalty of pressure drop around 35%. It is suggested that the pin-fins could be used to enhance blade tip heat transfer and cooling.     

具有新型双层壁结构的透平叶片流热耦合研究

多通道壁面射流冷却结构是一种新型的燃气透平动叶内部冷却结构,具有消耗冷气少、压力损失小等优点。本文构建了简化的壁面射流冷却叶片与GE-E3冷却结构叶片模型,采用流热耦合方法对比研究了其流动与换热特性。结果表明,壁面射流冷却通道内的狭小空间抑制了横流的产生,冷气在冷却通道中形成了流向涡;前缘冷气流道中的大量冷气流经吸力侧冷却区,并从出口压力更小、面积更大的尾缘排出,使得前缘气膜孔出流的冷气流量和动量较小,冷气在叶片外表面的气膜覆盖特性更好;离心力的影响导致前缘冷气流道中叶根处的压力较低,叶根附近的气膜孔出现燃气主流入侵现象。相比于GE-E3叶片,壁面射流冷却叶片的前缘温度和温度梯度都较小,因此多通道壁面射流冷却在前缘具有更优异的冷却特性。