UHBR Open-Test-Case Fan ECL5/CATANA

The application of composite fans enables disruptive design possibilities but increases sensitivity to multi-physical resonance between aerodynamic, structure dynamic and acoustic phenomena. As a result, aeroelastic problems increasingly set the stability limit. Test cases of representative geometries without industrial restrictions are a key element of an open scientific culture but are currently non-existent in the turbomachinery community. In order to provide a multi-physical validation benchmark representative of near-future UHBR fan concepts, the open-test-case fan stage ECL5 was developed at Ecole Centrale de Lyon. The design intention was to develop a geometry with high efficiency and a wide stability range that can be realized using carbon fibre composites. This publication aims to introduce the final test case, which is currently fabricated and will be experimentally tested. The fan blades are composed of a laminate made of unidirectional carbon fibres and epoxy composite plies. Their structural properties and the ply orientations are presented. To characterize the test case, details are given on the aerodynamic design of the whole stage, structure dynamics of the fan and aeroelastic stability of the fan. These are obtained with a state-of-art industrial design process: static and modal FEM, RANS and LRANS simulations. Aerodynamic analysis focuses on performance and shows critical flow structures such as tip leakage flow, radial flow migration and flow separations. Mechanical modes of the fan are described and discussed in the context of aeroelastic interactions. Their frequency distribution is validated in terms of resonance risk with respect to synchronous vibration. The aeroelastic stability of the fan is evaluated at representative operating points with a systematic approach. Potential instabilities are observed far from the operating line and do not compromise experimental campaigns.