Efficient CFD based aero-thermo-mechanical modelling for aircraft engine design.

In this thesis, improved and faster CFD based aero-thermo-mechanical methods that can be used to optimize engine configurations early in the design process are described. Axisymmetric models of 3D non-axisymmetric features such as protrusions, holes and honeycomb liners are developed for use in this context, and 3D unsteady CFD is used to investigate the flow physics. Initially, the research focussed on modelling of a rotor-stator disc cavity. Steady CFD validations for a plane disc and for a disc with protrusion were carried out and a simplified body force model was developed for including the 3D effects of rotating and stationary bolts into the axisymmetric CFD models. The simplified rotor bolt model was verified and validated by comparing the results with Sussex Windage rig test data and 3D CFD data. The simplified stator bolt model was verified using 3D CFD results. The simplified rotor bolt model was found to predict the drag and windage heat transfer with reasonable accuracy compared to 3D sector CFD results. However, 3D sector CFD under-predicts the high core flow swirl and the adiabatic disc surface temperature inboard of the bolt, compared to experimental data. In the second part of the study, unsteady Reynolds averaged Navier-Stokes (URANS) calculations of the rotating bolts cases were performed in order to better understand the flow physics. Although the rotor-stator cavity with bolts is geometrically steady in the rotating frame of reference, it was found that the rotor bolts generate unsteadiness which creates time-dependent rotating flow features within the cavity. A systematic parametric study is presented giving insight into the influence of the bolt number and the cavity geometric parameters on the time dependent flow within the cavity. The URANS calculations were extended to a high pressure turbine (HPT) rear cavity to show possible unsteady effects due to rotating bolts in an engine case. Following this, the body force model was adapted to model the rotating hole velocity changes and flow through honeycomb liners. The honeycomb and hole models were verified by comparing the results with available experimental data and 3D CFD calculations. In the final part of the study, coupled FE-CFD calculations for a preliminary design whole engine thermo-mechanical (WETM) model for a transient square cycle was performed including the effects of non-axisymmetric features. Six cavities around the HPT disc were modelled using CFD. The coupled approach provides more realistic physical convective heat transfer boundary conditions than the traditional approach. The unvalidated baseline thermo-mechanical model results were verified using the high fidelity coupled FE-CFD solution. It was demonstrated that the FE-CFD coupled calculations with axisymmetric modelling of 3D features can be achieved in a few days time scale suitable for preliminary engine design. The simplified CFD based methods described in this thesis could reduce the computational time of transient coupled FE-CFD calculations several orders of magnitude and may provide results as accurate as 2DFE-3DCFD coupled calculations