Research Papers: Gas Turbines: Aircraft Engine

Experimental Validation of the Aerodynamic Characteristics of an Aero-engine Intercooler

[+] Author and Article Information
Xin Zhao

Division of Fluid Dynamics,
Department of Applied Mechanics,
Chalmers University of Technology,
Göteborg SE-41296, Sweden
e-mail: zxin@chalmers.se

Mikhail Tokarev

Division of Fluid Dynamics,
Department of Applied Mechanics,
Institute of Thermophysics,
Novosibirsk, Russia
e-mail: mikxael@gmail.com

Erwin Adi Hartono

Division of Fluid Dynamics,
Department of Applied Mechanics,
Chalmers University of Technology,
Göteborg SE-41296, Sweden
e-mail: erwin-adi.hartono@chalmers.se

Valery Chernoray

Division of Fluid Dynamics,
Department of Applied Mechanics,
Chalmers University of Technology,
Göteborg SE-41296, Sweden
e-mail: valery.chernoray@chalmers.se

Tomas Grönstedt

Division of Fluid Dynamics,
Department of Applied Mechanics,
Chalmers University of Technology,
Göteborg SE-41296, Sweden
e-mail: tomas.gronstedt@chalmers.se

Contributed by the Aircraft Engine Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received April 15, 2016; final manuscript received August 29, 2016; published online November 22, 2016. Assoc. Editor: Riccardo Da Soghe.

J. Eng. Gas Turbines Power 139(5), 051201 (Nov 22, 2016) (10 pages) Paper No: GTP-16-1140; doi: 10.1115/1.4034964 History: Received April 15, 2016; Revised August 29, 2016

Porous media model computational fluid dynamics (CFD) is a valuable approach allowing an entire heat exchanger system, including the interactions with its associated installation ducts, to be studied at an affordable computational effort. Previous work of this kind has concentrated on developing the heat transfer and pressure loss characteristics of the porous medium model. Experimental validation has mainly been based on the measurements at the far field from the porous media exit. Detailed near field data are rare. In this paper, the fluid dynamics characteristics of a tubular heat exchanger concept developed for aero-engine intercooling by the authors are presented. Based on a rapid prototype manufactured design, the detailed flow field in the intercooler system is recorded by particle image velocimetry (PIV) and pressure measurements. First, the computational capability of the porous media to predict the flow distribution within the tubular heat transfer units was confirmed. Second, the measurements confirm that the flow topology within the associated ducts can be described well by porous media CFD modeling. More importantly, the aerodynamic characteristics of a number of critical intercooler design choices have been confirmed, namely, an attached flow in the high velocity regions of the in-flow, particularly in the critical region close to the intersection and the in-flow guide vane, a well-distributed flow in the two tube stacks, and an attached flow in the cross-over duct.

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Fig. 1

Intercooler geometry and installation on aero-engine

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Fig. 2

Building blocks of the intercooler concept

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Fig. 3

Photographs of the full intercooler rig and PIV setup for measurements in vertical planes of the crossover duct

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Fig. 4

Experiment schemes: (upper) full setup and (lower) flow distribution case

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Fig. 5

Four planes cutting through crossover duct for PIV

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Fig. 6

Computational domain (left) and mesh strategy (right) for the CFD simulations

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Fig. 7

Pressure distribution at the bottom of the inflow duct rear part (part 4)

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Fig. 8

Development of the four vortices after the inflow and outflow intersection (CFD result)

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Fig. 9

Comparison of the total pressure plot at the outlet of the intercooler: experimental result (left) and CFD result (right)

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Fig. 17

Illustration of the real tube stacks and porous model blocks

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Fig. 16

PIV record (up) and CFD result (down) of the flow velocity at the horizontal plane of the crossover duct

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Fig. 15

PIV records and CFD results of the flow velocities at the three vertical planes of the crossover duct: +15 mm (top), mid (middle), and −15 mm (down)

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Fig. 14

Normalized flow velocity for each tube of each column: experiment results (dot with line) and CFD results (red)

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Fig. 13

Pressure (up) and velocity vector (down) plots at the vertical midplane in the crossover duct

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Fig. 12

Normalized average flow velocity for each tube column of the inflow tube stack

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Fig. 11

Improved intercooler outlet total pressure profile with lifted intercooler inflow interface

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Fig. 10

Lifted intercooler inflow interface illustration



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