<b>Expanding the Scope of Isolated Unsteady Diffuser Computational Modeling</b>
Creators: name: Holtmann, Benjamin Lukas
Publisher: name: Purdue University Graduate School
Year: 2024
Subjects: classificationCode: 401204
subject: Computational methods in fluid flow, heat and mass transfer (incl. computational fluid dynamics)
classificationCode: 401201
subject: Aerodynamics (excl. hypersonic aerodynamics)

description: Increased scrutiny from customers and regulators to design aeroengines that are more efficient and environmentally friendly has pushed the need to investigate new engine architectures, manufacturing techniques, and computational fluid dynamic methods. This has led to the development of the CSTAR Gen. 2.5 centrifugal compressor, which uses an additively manufactured diffusion system and investigates the aerodynamic performance of an axi-centrifugal aeroengine. Additionally, an isolated unsteady diffuser computational model was previously developed that seeks to significantly reduce the computational cost of unsteady CFD in the diffuser.The research presented in this paper is part of an ongoing attempt to utilize the capabilities of isolated unsteady diffuser modeling and rapid prototyping enabled through additive manufacturing in CSTAR Gen. 2.5 to develop a design framework that allows for quick computational and experimental analysis of diffusion systems in centrifugal compressors. Specifically, the scope of isolated unsteady diffuser modeling, which was previously only implemented in CSTAR Gen. 1 and at a single loading condition, is expanded by analyzing computational instabilities when applying the methodology to CSTAR Gen. 2.5 and analyzing results from four loading conditions (high loading, design point, low loading, and near choke) along a speedline.Computational instabilities in the CSTAR Gen. 2.5 isolated diffuser models were determined to be caused by the decreased vaneless space compared to Gen. 1, which led to less “mixed” flow at the impeller outlet and a stronger diffuser potential field affecting the inlet profile. A boundary profile correction approach was developed which slightly increased very low total pressure near the diffuser shroud and negative radial velocity regions near the shroud and pitchwise locations of the diffuser vane leading edges while minimizing the overall affected area. The correction was successfully validated using 3D flow structure and minimum, average, and maximum total pressure, absolute velocity magnitude, and pressure comparisons at the diffuser inlet between an isolated and full-stage model.Prediction capabilities of 3D flow structures and 1D performance parameters by isolated unsteady diffuser models were validated with results from full-stage unsteady models at each loading condition. The analysis indicated consistent performance by the isolated unsteady diffuser model at all loading conditions. An overall agreement in 3D flow structures was found, and trends in the full-stage unsteady models along the speedline were tracked well by the isolated unsteady model. At all loading conditions, there was a consistent over-representation of the separation region along the diffuser vane pressure side in the diffuser passage, overprediction of total pressure magnitude at the core of the flow at the diffuser outlet, and over- or underprediction of total pressure loss and static pressure recovery respectively. The similarity in the results between full-stage and isolated unsteady models, tracking of trends along the speedline, and consistent differences in 3D flow structure predictions and 1D performance parameters validates the isolated unsteady diffuser methodology for use at loading conditions from surge to choke.