Abstract
For the next generation of aero-engines, manufacturers are planning to increase the overall compressor pressure ratio from the existing values around 50:1 to values of 70:1. The requirement to control the tight clearances between the blade tips and the casing overall engine-operating conditions is a challenge for the engine designer attempting to minimize tip-clearances losses. Accurate prediction of the tip clearance requires an accurate prediction of the radial growth of the compressor rotor, which depends on the temperature distribution of the disk. The flow in the rotating cavities between adjacent disks is buoyancy-driven, which creates a conjugate heat transfer problem: the disk temperature depends on the radial distribution of the Nusselt number, which in turn depends on the radial distribution of disk temperature. This paper focuses on calculating the radial growth of a simplified compressor disk in isolation from the other components. Calculations were performed using steady one-dimensional (1D) theoretical and two-dimensional numerical computations (2D finite element analysis (FEA)) for overall pressure ratios (OPRs) of 50:1, 60:1, and 70:1. At each pressure ratio, calculations were conducted for five different temperature distributions; the distribution based on an experimentally validated buoyancy model was used as the datum case, and the results from this were compared with those from linear, quadratic, cubic, and quartic power laws. The results show that the assumed distribution of disk temperature has a significant effect on the calculated disk growth, whereas the pressure ratio has only a relatively small effect. Good agreement between the growth calculated by the 1D theoretical model and the FEA suggests that the 1D model should be useful for design purposes. Although the results were obtained for steady-state conditions, a method is outlined for calculating the growth under transient conditions.
