Effect of tip clearance on non-synchronous propagating flow disturbances of compressor rotors under high aerodynamic loading conditions

Abstract

The complex tip flow instability and its induced non-synchronous vibration have become significant challenges, especially as aerodynamic loading continues to increase. This study investigates the effects of tip clearance on non-synchronous propagating flow disturbances of compressor rotors under high aerodynamic loading conditions by conducting full-annulus unsteady numerical simulations with three typical tip clearance values for a 1-1/2 stage transonic compressor. The non-synchronous aerodynamic excitation frequency, circumferential mode characteristics, and annular unstable flow structures are analyzed under near stall conditions. The results show that the total pressure ratio and normalized mass flow parameters first increase and then decrease as the tip clearance increases from 0.5%C (where C represents the tip chord length) to 2%C under high aerodynamic loading conditions, instead of constantly decreasing. For the 0.5%C tip clearance case, the traveling large-scale tornado-like separation vortices cause a low non-synchronous aerodynamic excitation frequency and severe pressure fluctuations. The periodic shedding and reattachment processes of the rotor blades separated by 2 – 3 pitches result in 19 dominant mode orders in the circumferential direction. As the tip clearance increases from 1%C to 2%C, the difference of tip flow structures in each blade passage is significantly weakened, and the dominant mode order of the disturbance is equal to the rotor blade-passing number. The pressure fluctuation is mainly caused by cross-channel tip leakage flow, and the aerodynamic excitation frequency exhibits evident broadband hump characteristics, which has been reported as a rotating instability phenomenon.