Analysis of upstream,double-row,cylindrical holes on primary and secondary effects of endwall flow and film cooling

Flow features and film cooling performance of five configurations of double-row, cylindrical holes, upstream of an E3 vane, in a linear cascade are numerically investigated. This simulation is completed using a verified turbulence model at four blowing ratios (M = 0.5, 1.0, 1.5, 2.0). The first three configurations have two rows of cylindrical holes, each row with the same compound angle (β=-45°, 0° or 45°), while the other two have two rows with opposite compound angles (β=-45°, 45° and β=45°, -45°), which are also referred to as double-jet film cooling (DJFC) holes. The primary effects on the downstream endwall and the secondary effects on the nearby airfoil of the cooled passage are analyzed and discussed in detail. Results show that at low blowing ratios the movement of the coolant is denominated by the interaction between the jets and vortices resulting in similar film coverage on both the endwall and airfoil. The effect of vortices is reduced at high blowing ratios. It is also shown that the movement of the coolant is determined by the initial velocity direction, as well as the film cooling configuration.     

Effects of injection angle orientation on concave and convex surfaces film cooling

The present study employs a transient liquid crystal thermography to measure film cooling performance over constant curvature of concave and convex surfaces. This work investigates detailed distributions of both film cooling effectiveness and heat transfer coefficient on concave and convex surfaces with one row of injection holes inclined stream-wise at 35° at four blowing ratios (0.5, 1.0, 1.5 and 2.0) on four test pieces with different hole configurations. All test models have a row of discrete holes with a stream-wise injection angle (γ of 35° and a pitch-to-diameter ratio (P/d) of 3. The current work examines four different injection configurations, one with simple and three with 8° forward-expanded holes. Three compound angles of 0, 45 and 90° with air (ρ_c/ρ_m = 0.98) as coolants are tested under the mainstream Reynolds number (Re_d) of 2300 on concave surface, and 1700 on convex surface. Measured results of the concave surface show that both the span-wise averaged heat transfer coefficient and film cooling effectiveness increase with blowing ratios for all tested models. Higher heat transfer levels induced by large flow disturbance of compound-angle injection also lead to poorer overall film cooling performance, especially at high blowing ratio and large span-wise injection angle. Present results show that the best surface protection on the concave surface over the widest range of M can be provided by the forward-expanded holes with β = 0° (Model-B), followed by the forward-expanded holes with β = 45° (Model-C). Convex surface results show that the compound-angle injection indicates increases in both film cooling effectiveness and heat transfer at moderate and high blowing ratios. The forward-expanded hole with simple-angle injection provides the best film performance because of high film cooling effectiveness and low heat transfer coefficient at blowing ratio of 0.5.     

Film cooling effectiveness from trenched shaped and compound holes

This paper presents a comparative-numerical investigation on film cooling from a row of simple and compound-angle holes injected at 35° on a flat plate with four film cooling configurations: (1) cylindrical film hole; (2) 15° forward diffused film hole; (3) trenched cylindrical film hole; (4) trenched 15° forward-diffused film hole. All simulations are at fixed density ratio of 1.6, blowing ratio of 1.25, length-to-diameter L/D = 4 and pitch-to-diameter ratio of 3.0. The effect of length-to-diameter ratio on film cooling has been also investigated using L/D in the range of 1–8. Computational solutions of the steady, Reynolds-averaged Navier–Stokes equations have been obtained using a finite volume method. It has been found that the shape of the hole and the trenched holes can significantly affect the film cooling flow over the protected surface. Further, it has been shown that the film cooling effectiveness by trenched shaped holes is higher than all other configurations both in spanwise and streamwise specially downstream of the injection. Also, a trenched compound angle injection shaped hole produces much higher film cooling protection than the other configurations investigated in the present paper. The length-to-diameter ratio of trenched holes was found to have a significant effect on film cooling effectiveness and the spread of the coolant jets.     

Film cooling and heat transfer with air injection through two rows of compound angle holes.

This paper describes the results of an experimental investigation into the film cooling effectiveness and the heat transfer characteristics of two staggered rows of compound angle holes. The effects of hole spacings and turbulence intensity on film cooling and heat transfer characteristic are investigated for three blowing rates; 0.5, 1.0 and 1.7. An attempt has been made to correlate the film cooling effectiveness results using a two dimensional correlation group. The increase of spanwise hole spacing results in a reduction in the film cooling effectiveness and an increase in the Stanton number. Increasing the freestream turbulence intensity has caused a significant reduction in the local film cooling effectiveness but increased the Stanton number, especially at blowing rate of 0.5.     

Numerical investigation of the influence of incidence angle on asymmetrical turbine blade model showerhead film cooling effectiveness

The influence of various incidence angles on film cooling effectiveness of an axial turbine blade cascade with leading edge ejection from two rows of cooling holes is numerically investigated. The rows are located in the vicinity of the stagnation line. One row is located on the suction side and the other one is on the pressure side. The predicted pressure field for various blowing ratios (M = 0.7, 1.1 and 1.5) is compared with available experimental results at the design condition. Moreover, the effect of various incidence angles (?10°, ?5°, 0°, 5° and 10°) at three blowing rates is investigated by analyzing the results of both laterally averaged and area averaged values of adiabatic film cooling effectiveness. Numerical results indicate that the incidence angle can strongly affect the thermal protection of the blade at low blowing ratio but becomes less dominant at high blowing ratio. In fact, for the low blowing ratio, a small change in the incidence angle that relates to the design condition can deeply affect the thermal protection of the blade, which is evident from the laterally and area averaged film cooling effectiveness distributions.     

Film cooling on a convex surface: influence of external pressure gradient and Mach number on film cooling performance

 The film cooling performance on a convex surface subjected to zero and favourable pressure gradient free-stream flow was investigated. Adiabatic film cooling effectiveness values were obtained for five different injection geometries, three with cylindrical holes and two with shaped holes. Heat transfer coefficients were derived for selected injection configurations. CO₂ was used as coolant to simulate density ratios between coolant and free-stream close to gas turbine engine conditions. The film cooling effectiveness results indicate a strong dependency on the free-stream Mach number level. Results obtained at the higher free-stream Mach number show for cylindrical holes generally and for shaped holes at moderate blowing rates significant higher film cooling effectiveness values compared to the lower free-stream Mach number data. Free-stream acceleration generally reduced adiabatic film cooling effectiveness relative to constant free-stream flow conditions. The different free-stream conditions investigated indicate no significant effects on the corresponding heat transfer increase due to film injection. The determined heat flux ratios or film cooling performance indicated that coolant injection with shaped film cooling holes is much more efficient than with cylindrical holes especially at higher blowing rates. Heat flux penalties can occur at high blowing rates when using cylindrical holes. Received on 29 May 2000     

Numerical modelling of film cooling from converging slot-hole

This paper presents a numerical prediction of a new 3D film cooling hole geometry, the converging slot-hole or console. The console geometry is designed in order to improve the heat transfer and aerodynamic loss performance of turbine vane and rotor blade cooling systems without loosing the mechanical strength of a row of discrete holes. The cross section of the console changes from a circular shape at the inlet to a slot at the exit. Previous successful application of a new anisotropic DNS based two-layer turbulence model to cylindrical and shaped hole injections is extended to predict film cooling for the new console geometry. The suitability of the proposed turbulence model for film cooling flow is validated by comparing the computed and the measured wall-temperature distributions of cylindrical hole injections. The result shows that the anisotropic eddy-viscosity/diffusivity model can correctly predict the spanwise spreading of the temperature field and reduce the strength of the secondary vortices. Comparative computations of the adiabatic film cooling effectiveness associated with the three geometries tested in the present study (cylindrical, shaped, and console) show that the new console film-cooling hole geometry is definitely superior to the other geometries as shown by the uniform lateral spreading of the effectiveness with a slight enhancement downstream of the intersection of the two consoles.     

Leading edge film cooling heat transfer with high free stream turbulence using a transient liquid crystal image method

This paper studies film effectiveness and heat transfer coefficients on a large scale symmetric circular leading edge with three rows of film holes. The film hole configuration focuses on a smaller injection angle of 20° and a larger hole pitch with respect to the hole diameter (P/d=7.86). The study includes four blowing ratios (M=1.0,1.5,2.0 and 2.5), two Reynolds numbers (Re=30,000 and 60,000), and two free stream turbulence levels (nominally Tu=1% and 20% depending on the Reynolds number). A transient liquid crystal (LC) image technique is employed to obtain the film effectiveness and heat transfer coefficient distributions with high spatial resolutions of 0.6 mm in both streamwise and spanwise directions. Results are presented for detailed and spanwise averaged values of film effectiveness and Frössling number. Turbulence intensity has an attenuation on film effectiveness as well as on Frössling number for all blowing ratios at Re=30,000. Under high turbulence conditions the film effectiveness and Frössling number increase as blowing ratio increases from 1.0 to 2.0 for both Reynolds numbers. Further increasing the blowing ratio results in reverse effect. Increasing the Reynolds number from 30,000 to 60,000 results in increases in both the film effectiveness and Frössling number at high turbulence except for M=2.5. The blowing ratio of two shows a spatial coupling of the stagnation row of film holes with the second row (21.5°) of film holes which results in the highest film effectiveness and also the highest Frössling numbers.     

Influence of coolant injector configuration on film cooling effectiveness for gaseous and liquid film coolants

An experimental investigation is conducted to bring out the effects of coolant injector configuration on film cooling effectiveness, film cooled length and film uniformity associated with gaseous and liquid coolants. A series of measurements are performed using hot air as the core gas and gaseous nitrogen and water as the film coolants in a cylindrical test section simulating a thrust chamber. Straight and compound angle injection at two different configurations of 30°–10° and 45°–10° are investigated for the gaseous coolant. Tangential injection at 30° and compound angle injection at 30°–10° are examined for the liquid coolant. The analysis is based on measurements of the film-cooling effectiveness and film uniformity downstream of the injection location at different blowing ratios. Measured results showed that compound angle configuration leads to lower far-field effectiveness and shorter film length compared to tangential injection in the case of liquid film cooling. For similar injector configurations, effectiveness along the stream wise direction showed flat characteristics initially for the liquid coolant, while it was continuously dropping for the gaseous coolant. For liquid coolant, deviations in temperature around the circumference are very low near the injection point, but increases to higher values for regions away from the coolant injection locations. The study brings out the existance of an optimum gaseous film coolant injector configuration for which the effectiveness is maximum.     

Improvement of film cooling effectiveness with a small downstream block body

The aim of this study is to predict the improvement in film cooling performance over a flat plate through a single row of cylindrical holes with different streamwise angles by using the Ansys CFX software package. In order to improve the film cooling effectiveness, a short crescent-shaped block is placed downstream of a cylindrical cooling hole. The numerical results of the cylindrical hole without the downstream short crescent-shaped block are compared with experimental data.     

A predictive model based on a 3-D computational approach for film cooling effectiveness over a flat plate using GMDH-type neural networks

A 3-D numerical solution is implemented for investigating incompressible turbulent flow and thermal fields of film cooling through a single row of inclined cylindrical holes over a flat plate model. The effects of parameters of interest on the film cooling performance have been simulated. The group method of data handling (GMDH)-type neural networks successfully employed for modeling and presenting a correlation for area-weighted average adiabatic film cooling effectiveness.     

A broad reconsideration of anti-vortex film cooling method using numerical optimization and an improved heat-flux model

This paper represents the detailed results of an evolutionary optimization framework towards the exploration of vortex mechanisms leading to effective anti-vortex film cooling. In this regards, several arrangements of triple cooling holes were studied on flat and curved geometries using differential-evolution optimization algorithm and a modified Reynolds-stress based flow solver. Depending on the flow and geometric parameters, four distinct types of vortex interaction with different cooling mechanisms were identified. The vortex-trapping mechanism, observed in the optimized upstream arrangement acts through imposing a mild downwash over the main counter-rotating vortex pair and provides the best cooling effectiveness for the low injection angle (less than 30°) cases. The vortex-suppression and -balancing are the optimal possible solutions of the adjacent arrangement. The latter is the classic well-known type of anti-vortex cooling, while the former provides a sudden strong controlling potential for high blowing ratios (higher than 1.0) and high injection angle film cooling. For the non-flat surfaces the triple holes effectively perform up to blowing-ratio of 2.0. However, the reverse-vortex-trapping mechanism occurring in the downstream arrangement is recommended for convex surfaces, while the adjacent arrangement is the choice for concave regions. In general, there is a possibility of reducing the coolant consumption about 30% through increasing the pitch-to-diameter ratio, while the values of cooling-effectiveness still remain in an acceptable range.     

Numerical study on film cooling effectiveness from shaped and crescent holes

This paper presents a comparative numerical investigation on film cooling from a row of holes injected at 35° on a flat plate with three film cooling configurations, including cylindrical hole, 15° forward diffused shaped hole, and new crescent hole. All simulations are conducted at blowing ratio of 0.6 and 1.25, length-to-diameter ratio of four and pitch-to-diameter ratio of three. Computational solutions of the steady, Reynolds averaged Navier–Stokes equations are obtained using a finite volume method. Previous successful application of a two-layer turbulence model to cylindrical hole is extended to predict film cooling for the different hole geometries. It has been found that the film cooling effectiveness of cylindrical holes obviously declined along with increasing the blowing ratio. While the forward diffused shaped hole presents a marked improvement, with a higher effectiveness at the lateral area between adjacent holes. By comparison, the crescent hole exhibits the highest film cooling effectiveness among the three configurations both in spanwise and streamwise especially downstream of the intersection of the two holes. Also, the crescent hole can restrain the vortex intensity, and then enhance the film cooling effectiveness.     

A numerical investigation of new film cooling hole configuration at the leading edge of asymmetrical turbine blade: part A

The focus of the first part of this numerical study is to investigate the effects of two new configurations: (1) slot with cylindrical end and (2) slot with median cylindrical hole, generated by the combination between two film cooling configurations: cylindrical hole and uniform slot. Computational results are presented for a row of coolant injection holes on each side of an asymmetrical turbine blade model near the leading edge. For each configuration, three values of the radius are taken: R = 0.4, R = 0.8 and R = 1.2. The six cases simulations, thus obtained, are conducted for the same density ratio of 1.0 and the same inlet plenum pressure. A new parameter, Rc, is defined to measure the rate of blade coverage by the film cooling. Results show that, at the pressure side; for the two new configurations, the six studied cases exceed the case baseline in cooling effectiveness term with the best result obtained for R = 0.8 (case 2). For the suction side, only configurations with R = 0.4 (cases 1 and 4) provide an increase of film effectiveness compared to the case baseline. The following configuration: Cases 1 or 4 at the suction side and case 2 at the pressure side, gets the best thermal protection because of their higher coverage and strong cooling effectiveness.     

Effect of incidence angle with wake passing on a film cooled leading edge: A numerical study

This work presents the numerical study of a film‐cooled blade under the influence of wake passing at different incidence angles. The film cooling technology has been proven to be effective to increase the blade life of first turbine stages. However, the leading edge is affected by an high heat transfer rate and cooling this region is difficult. Moreover, separated regions downstream the coolant injection increases the local heat transfer coefficient and can have a detrimental effect in terms of airfoil life. This work analyses how the flow field is affected by the wake passing at different incidence angles (?5, 0, 5) and the impact on heat transfer coefficient. The test case is a linear cascade with two rows of cylindrical holes at the leading edge. Two different holes arrangements are compared in terms of film cooling structures, namely AGTB‐B1 and AGTB‐B2 with 0 and 45^° spanwise inclination. The numerical results show a good agreement with the experiments. A deeper investigation is carried out on AGTB‐B1. The results obtained show that the wake passing and the incidence angle have a strong effect on coolant jets. In particular, there is a significative impact on coolant redistribution near the leading edge. The wake passing has a stronger effect on pressure side, mainly at negative incidence. The predictive approach is based on an U‐RANS in‐house CFD solver using a conventional two‐equations closure. In order to avoid extra turbulence production, critical in the leading edge region, the turbulence model incorporates an extra algebraic equation that enforces a realizability constraint. The unsteady formulation is based on a dual time stepping approach with a sliding plane between the moving bars and the cascade. Copyright © 2009 John Wiley & Sons, Ltd.     

Aerodynamic performance of an annular cascade of film cooled nozzle guide vanes under engine representative conditions

This paper addresses two important issues relevant to efficiency measurements in film-cooled annular cascades: the definition of the ideal flow to be used in loss calculation, and the measurements that are necessary for such loss calculation. The paper also addresses the question of the correct parameterisation of coolant density effects, showing that the momentum flux ratio, rather than the blowing rate, is the most appropriate parameter. Experiments examining the effect of extensive aerofoil surface film cooling on the aerodynamic efficiency of an annular cascade of transonic nozzle guide vanes are reported. A dense foreign gas (SF₆/Ar mixture) is used to simulate engine representative coolant-to-mainstream density ratios, momentum ratios and blowing rates under ambient temperature conditions. Experiments are also conducted with air coolant to study the effect of density ratio on efficiency. The flowfield measurements have been obtained using a four-hole pyramid probe in a short duration blowdown facility which correctly models engine Reynolds and Mach numbers. This work compares the measured aerodynamic efficiencies of uncooled vanes with those which employ an extensive amount of cooling. The engine-representative cooling geometry investigated features 14 rows of cylindrical cooling holes, and a second geometry where 8 of these rows are replaced by holes having a fan-shaped exit. The effects of adding trailing edge slot ejection are also presented. By selectively blocking rows of holes, the cumulative effect on the mid-span efficiency of adding rows of cooling holes has also been determined. Experimental results are presented as area traverse maps (total pressure, isentropic Mach number and flow angles), from which the relative changes in efficiency due to film cooling have been calculated. These calculations reveal that the presence of foreign-gas coolant from the cylindrical-hole geometry increases the aerodynamic loss (relative to the uncooled baseline) by 6.7%; and coolant from the fan-shaped holes increases the loss by 15%. The effects of different assumptions for the coolant total pressure are shown to significantly change the measured loss; if the loss measurements are based on the mainstream total pressure, rather than the total pressure in the coolant cavity, the respective increase in loss (relative to the uncooled baseline) of cylindrical and fan-shaped holes is 4.5% and 12.5%. Experimental data is compared with loss predictions using a Hartsel model. Received: 4 December 1998/Accepted: 1 September 1999     

The effect of turbulence intensity on film cooling of gas turbine blade from trenched shaped holes

This paper reports a computational investigation on the effects of mainstream turbulence intensity on film cooling effectiveness from trenched holes over a symmetrical blade. Computational solutions of the steady, Reynolds-Averaged Navier–Stokes equations are obtained using a finite volume method with k − ε Turbulence model. Whenever possible, computational results are compared with experimental ones from data found in the open literature. Computational results are presented for a row of 25° forward-diffused film hole within transverse slot injected at 35° to AGTB symmetrical blade. Four blowing ratios, M = 0.3, 0.5, 0.9 and 1.3 are studied together with four mainstream turbulence intensities of Tu = 0.5, 2, 4 and 10%. Results indicate that the trenched shaped holes tend to give better film cooling effectiveness than that obtained from discrete shaped holes for all blowing ratios and all turbulence intensities. The trenching of shaped holes has changed the optimum blowing ratio and also the location of re-attachment of separated jet at high blowing ratios. Moreover, it has been found that the effect of mainstream turbulence intensity for trenched shaped holes is similar to that obtained for discrete shaped holes with the exception that the sensitivity of film cooling effectiveness to turbulence intensity has decreased for trenched shaped holes.     

Analysis of the influence of cooling hole arrangement on the protection of a gas turbine combustor liner

Numerical investigations of an industrial gas turbine combustor were conducted in this paper. The studied combustion chamber has a high degree of geometrical complexity related to the injection system as well as the cooling system which consists of thousands of small holes (about 3390 holes) bored on the liner walls. The main aim of this study was to propose modifications into the liner cooling system that can enhance the protection of this critical component. The calculations were carried out using the industrial CFD code fluent 6.3. It was shown that the addition of rows of cooling holes in the primary zone of the liner leads to a reduction of the maximum liner metal temperature of 33%. Nevertheless, this modification causes an increase of the maximum gas temperature at the outlet of the combustion chamber of 12% which could be harmful to the turbine vanes. It was also shown that this increase can be controlled by the suppression of rows of cooling holes in the dilution zone.     

Multi-objective optimization of discrete film hole arrangement on a high pressure turbine end-wall with conjugate heat transfer simulations

This paper discussed a method of combining a full automatic multi-objective optimization and conjugate heat transfer calculation to obtain optimal cooling layouts on a transonic high pressure guide vane under a realistic turbine working condition. The improvement in cooling design from the optimized models was analyzed in detail, along with a discussion of sensitivities of two objective functions to five design variables. The full automatic method comprises the process of geometry creation, mesh generation, numerical solution and post data analysis. The vane is solid and the end-wall is arranged in a linear cascade. On the end-wall, film holes are all cylindrical and classified in five regions, with region A near the leading edge of the vane, region B near the suction side, regions C and D near the pressure side, and region E for the rest. Five design variables are three pitch-to-hole ratios in regions B, D, E and two compound angles of film holes in regions A and D. Two selected objective functions are area averaged overall cooling effectiveness of the end-wall and aerodynamic losses in a cross-plane at x/C_ax = 1.06 just downstream of the outlet of the cascade. For the optimization process, the multi-objective genetic algorithm based on the Non-dominated Sorted Genetic Algorithm-II was applied. The Latin hypercube sampling method was used to choose 21 experimental design points in the design space, which are also the sources for constructing the surrogate models with the Kriging model. The results demonstrate that the method using full automatic optimization and conjugate heat transfer calculation has achieved an increase of 8.7%–9.5% in area-averaged overall cooling effectiveness and a reduction of about 4.8%–6.1% in aerodynamic losses. The highest increase in cooling effectiveness exists in the region near the pressure side with a mild increase in the middle of the passage. The largest heat flux reduction exists in the regions near the pressure side and the crown of the suction side. The change of compound angle in region A near the leading edge has a negligible influence on overall cooling effectiveness but a high impact on aerodynamic losses. It's advisable to maintain the compound angle and pitch-to-diameter ratio at low values in region D near the pressure side to obtain high cooling performance.     

Heat transfer in film-cooled turbulent boundary layers at different blowing ratios as affected by longitudinal vortices

Effects of embedded longitudinal vortices on heat transfer in film-cooled turbulent boundary layers at different blowing ratios are discussed. These results were obtained in boundary layers at free-stream velocities of 10 and 15 m/s. Film coolant was injected from a single row of holes at blowing ratios of 0.47–1.26. A single longitudinal vortex was induced upstream of the film-cooling holes using a half-delta wing attached to the wind tunnel floor. Heat transfer measurements were made downstream of injection using a constant heat flux surface with 126 thermocouples for surface temperature measurements. For all blowing ratios examined, the embedded vortices cause significant alterations to wall heat transfer and to film cooling distributions. Measurrments of mean temperatures and mean velocities in spanwise planes show that high wall heat transfer regions are associated with regions of high near-wall longitudinal velocity where very little film coolant is present. In addition to high heat transfer regions associated with the vortex downwash, there are also secondary heat transfer peaks. These secondary peaks develop due to shear layer mixing and interaction between the vortex and cooling jets and become higher in magnitude and more persistent with downstream distance as the blowing ratio increases from 0.47 to 1.26.