To reduce the secondary flow loss of the high-pressure turbine caused by the tip leakage flow, the design of the composite honeycomb tip has been experimentally and numerically examined in this study. The arrangement angle of the composite honeycomb is defined and optimized using the radial basis function and genetic algorithm. The tip flow field of the high-pressure turbine blade with a 2.128 mm clearance is simulated by CFX 18.0, and the arrangement angle of the composite honeycomb is optimized to obtain a lower loss. Moreover, the flat tip, basic honeycomb tip, and optimized honeycomb tip are tested in a low-speed cascade test facility. The results show that the vortices and radial velocity induced by the honeycomb structure cavity increase the kinetic energy loss of the leakage flow and reduce the leakage flow rate. Compared with the basic honeycomb, the optimized honeycomb has a supplemental blocking effect on the tip leakage flow by reducing the crosswise pressure gradient in the blade tip. The optimized honeycomb also changes the outlet angle of the leakage flow in the tip clearance, reduces the leakage vortex, and the total pressure loss is further reduced by 2.5%.
BindonJP. The measurement and formation of tip clearance loss. J Turbomach1989; 111(3): 257–263.
2.
YamamotoA. Interaction mechanisms between tip leakage flow and the passage vortex in a linear turbine rotor cascade. J Turbomach1988; 110: 329.
3.
TianYTMaHWMaR. Stereoscopic PIV measurements of the flow field in a turbine cascade. J Therm Sci2017; 26(1): 89–95.
4.
LordWKMac MartinDGTillmanTG. Flow control opportunities in gas turbine engines. In: Fluids 2000 Conference and Exhibit, Denver, CO, USA,2000. AIAA2000-2234.
5.
CheonJHLeeSW. Tip leakage aerodynamics over the cavity squealer tip equipped with full coverage winglets in a turbine cascade. Int J Heat Fluid Flow2015; 56: 60–70.
6.
LiuYZhangTLZhangM, et al.Numerical and experimental investigation of aerodynamic performance for a straight turbine cascade with a novel partial shroud. J Fluid Eng2016; 138(3): 031206.
7.
SaxenaVNasirHEkkadSV. Effect of blade tip geometry on tip flow and heat transfer for a blade in a low-speed cascade. J Turbomach2004; 126(1): 130–138.
8.
El-GhandourMShatatMMENakamuraY. On the physics of vortex formation at the tip of a turbine blade[C]//ASME turbo expo 2012. In: Turbine technical conference and exposition: New York, NY. American Society of Mechanical Engineers, 2012, pp. 1647–1654.
9.
LeeSWChaeBJ. Effects of squealer rim height on aerodynamic losses downstream of a high-turning turbine rotor blade. Exp Therm Fluid Sci2008; 32(8): 1440–1447.
10.
AmeriAASteinthorssonERigbyDL. Effects of tip clearance and casing recess on heat transfer and stage efficiency in axial turbines. J Turbomach1999; 121(4): 683–693.
11.
NiuMZangS. Experimental and numerical investigations of tip injection on tip clearance flow in an axial turbine cascade. Exp Therm Fluid Sci2011; 35(6): 1214–1222.
12.
HamikMWillingerR. An innovative passive tip-leakage control method for axial turbines: linear cascade wind tunnel results. In: ASME turbo expo 2004: power for land, sea, and air. New York, NY: American Society of Mechanical Engineers, 2008. ASME paper GT2008-50056.
13.
PesciniEDe GiorgiMGSumaA, et al.Separation control by a microfabricated SDBD plasma actuator for small engine turbine applications: influence of the excitation waveform. Aero Sci Technol2018; 76: 442–454.
14.
DeyDCamciC. Aerodynamic tip desensitization of an axial turbine rotor using tip platform extensions. New York, NY: American Society of Mechanical Engineers, 2001.
15.
LeeSWCheonJHZhangQ. The effect of full coverage winglets on tip leakage aerodynamics over the plan tip in a turbine cascade. Int J Heat Fluid Flow2014; 45(5): 23–32.
16.
CamciCDeyDKavurmaciogluL. Aerodynamics of tip leakage flows near partial squealer rims in an axial flow turbine stage. J Turbomachinery-Trans Asme2005; 127(1): 14–24.
17.
BunkerRS. A review of turbine blade tip heat transfer. Ann N Y Acad Sci2001; 934: 64–79.
18.
GaoJZhengQ. Effect of squealer tip geometry on rotor blade aerodynamic performance. Acta Aeronautica Astronautica Sinica2013; 34(2): 218–226.
19.
El-GhandourMIbrahimMKDoiK, et al.Effects of tip cavity depth, width, and location on the leakage flow in an axial turbine cascade. J Fluid Sci Technol2010; 5(3): 558–573.
20.
PrakashCLeeCPCherryDG, et al.Analysis of some improved blade tip concepts. J Turbomach2006; 128(4): 529–533.
21.
GaoJZhengQYuG. Reduction of tip clearance losses in an unshrouded turbine by rotor casing contouring. J Propul Power2012; 28(5): 936–945.
22.
ChenSZhouZCuiT, et al.Effects of tip injection on tip clearance flow in a low-pressure turbine stator cascade. In: Proceedings of the ASME turbo expo 2014: turbine technical conference and exposition. Volume 2C: turbomachinery. Düsseldorf, Germany, 16–20 June 2014, ASME. V02CT38A004.
23.
MercanBDoganEOstovanY, et al.Experimental investigation of the effects of waveform tip injection in a low pressure turbine cascade. In: ASME Turbo Expo 2012. Copenhagen, Denmark, 2012. ASME. paper GT2012-69316.
24.
JieGQunZZhengW. Effect of honeycomb seals on loss characteristics in shroud cavities of an axial turbine. Chin J Mech Eng2013; 26(01): 69–77.
25.
GaoJZhengQLiYJ. Effect of labyrinth-honeycomb seal of shrouded rotor blades on the aerodynamic performance of the turbine stage. J Aero Power2012; 27(1): 160–168.
26.
AlizadehMNikkhahiBFarahaniAS, et al.Numerical study on the effect of geometrical parameters on the labyrinth–honeycomb seal performance. Proc Inst Mech Eng G J Aerosp Eng2018; 232(2): 362–373.
27.
FuYChenFYuJ, et al.Effective control of composite honeycomb structures on the tip leakage flow in turbine cascade. J Aero Eng2018; 31(6): 04018093.
28.
FuYChenFLiuH, et al.Experimental and numerical study of honeycomb tip on suppressing tip leakage flow in turbine cascade. J Turbomach2018; 140(6): 061006.
29.
ChenFFuYYuJ, et al.Effect of clearance height on tip leakage flow reduced by a honeycomb tip in a turbine cascade. Proceedings of the Institution of Mechanical Engineering Part G Journal of Aerospace Engineering2019; 233(10): 3564–3576.
30.
WangYSongYYuJ, et al.Effect of the injection orientation and position on the leakage flow in a honeycomb-tip turbine cascade. Int J Heat Mass Tran2019; 144: 118633.
31.
WangYSongYYuJ, et al.Numerical study of the effect of the cavity depth on the leakage control in a cooled honeycomb-tip turbine cascade. Appl Therm Eng2018; 138: 292–299.
32.
WangYYuJSongY, et al.Parameter optimization of the composite honeycomb tip in a turbine cascade. Energy2020: 117236.
33.
BianchiniCMicioMMaiuoloF, et al.Numerical investigation to support the design of a flat plate honeycomb seal test rig. Boston, MA: ASME Turbo Expo, 2013. GT2013-95612).
34.
BehrT. Control of rotor tip leakage and secondary flow by casing air injection in unshrouded axial turbines. Zurich, Switzerland: Swiss Federal Institute of Technology, 2007. Ph.D. thesis.
35.
FuYChenFJianyangY, et al.ASME turbo expo 2016: turbomachinery technical conference and exposition, 2016. GT2016-56907.Numerical study of the effect of honeycomb tip on tip leakage flow in turbine cascade[C].
36.
AmeriAASteinthorssonERigbyDL. Effect of squealer tip on rotor heat transfer and efficiency. J Turbomach1998; 120: 753–759.
37.
WalterBCoxMGHarrisPM. Evolution of the guide to the expression of uncertainty in measurement. Metrologia2006; 43(4).
38.
DivoEKassabAJ. An efficient localized RBF meshless method applied to FLuid flow and conjugate heat transfer. In: Proceedings of the ASME 2005 international mechanical engineering congress and exposition. Heat transfer, Part A. Orlando, Florida, USA, 5–11, November 2005, pp. 241–250.: ASME.
39.
SunFSuWWangM, et al.RBF-POD reduced-order modeling of flow field in the curved shock compression inlet. Acta Astronaut2021; 185: 25–36.
40.
XiaoDFangFPainC, et al.Non-intrusive reduced-order modelling of the Navier–Stokes equations based on RBF interpolation. Int J Numer Methods Fluid2015; 79: 580–595. DOI: 10.1002/fld.4066
41.
SunSHuangZKangJ, et al. Study of the influence of multiple factors on the boundary layer of a high-lift LPT with the RBF-GA method. Proc Inst Mech Eng G J Aerosp Eng. 2023; 238: 103–116.
42.
WangYSongYYuJ, et al.Effect of cooling injection on the leakage flow of a turbine cascade with honeycomb tip. Appl Therm Eng2018; 133: 690–703.
