Search

The present work reports an experimental study of the leakage flow in a low-speed fan ring. Existing 2D Particle Image Velocimetry (PIV) measurements taken in a meridional plane in front of the rotor gap have been further processed and analyzed by means of the Proper Orthogonal Decomposition (POD). Three values of the dimensionless pressure rise across the rotor have been investigated. Namely, attention has been focused on the intermediate case—the one for which a strong radial oscillation in the leakage flow has been observed: POD results have shown that, in this condition, the leakage flow exhibits periodic radial oscillations that are not correlated to the periodic blade passing. Moreover, such coherent motions have been found to promote turbulence transport at different radial positions, whereas rotor-related oscillations have a negligible effect in this sense. The present POD procedure can be generally applied to turbomachinery flows to characterize their unsteady behavior beside the classical phase-averaging methods based on rotor-related quantities. The present approach is novel for the study of leakage flow dynamics in axial fans.

Three-dimensional blading is an efficient technique in compressor aerodynamic design, and its function mechanism in the cantilevered stator needs to be addressed. This paper focuses on the sweep and dihedral in the cantilevered stator and seeks to expose their effects through detailed flow field analysis. Results show that the forward sweep could alleviate the corner flow separation by preventing the accumulation of the secondary flow toward the corner region, resulting in stronger flow separation at the blade trailing edge; in summary, forward sweep with appropriate parameters could increase static pressure rise by 14.3%. The positive dihedral will carry the endwall flow to the upper-span sections, thereby reducing blade corner separation; hence, as much as 23.5% improvement in static pressure rise could be obtained with the appropriate dihedral. Moreover, the combination of a relatively large sweep height and a moderate sweep angle with a low dihedral height and a moderate sweep angle provides optimum aerodynamic performance; the static pressure rise coefficient sees an increment of 25.5% at the near stall point. An experiment is then performed to further validate the theory, which shows a 2% improvement in efficiency of 3D blading at small mass flow rates. However, the secondary leakage should be given attention at high mass flow coefficients, while the corner separation needs further elimination at small mass flow rates.

Axial-flow turbomachinery is widely used in low head water transfer and electricity generation projects. As there is a gap between the impeller and casing of the tubular flow unit, the fluid will cross the gap to form tip leakage flow, which may induce intense pressure pulsation, noise and mechanical vibration, and even threaten the safe operation of the unit. In order to ensure the efficient and stable operation of hydropower units, the influence factors of tip clearance flow and its formation and development mechanism have been deeply studied in this paper. In this paper, the impact of gap width, angle of attack and inlet velocity on tip leakage flow of hydrofoil with clearance are studied by orthogonal experiment method. The results suggest that the gap width has the greatest influence on tip clearance flow, the incidence angle takes the second place, and the inlet velocity has the least effect on tip clearance flow. Then the fractal characteristics of tip leakage vortices with different gap widths are studied. The results demonstrate that the fractal dimension of tip leakage vortices in large gaps was significantly larger than that in small gaps; The fractal dimension of the leakage vortex decreases gradually along the flow direction.

Both the compressor performance and the 3D flows inside the stator passage are significantly impacted by the stator hub gap. The interplay between leakage flow and corner separation within a cantilevered stator of a highly loaded, low-speed axial compressor with a succession of stator hub gaps was examined numerically in this paper. Firstly, the simulated results were compared with the measured results, including the compressor characteristics, the 3D flow structures, and the flow fields at the stator outlet. The results revealed that the used CFD solver, as well as the corresponding setup, can reproduce the flow not only in terms of the trend along with the stator hub gap, but also in terms of the specific scale of the 3D flow structure. Hence, it is feasible enough to be applied in the present investigation. Secondly, the flow mechanisms of the interplay between the corner separation and the leakage flow with different stator hub gaps were analyzed. It was found that the velocity of the leakage flow is the key parameter that dominates the flow structures as well as the compressor performance. Additionally, a simple metric was proposed to be used to choose the optimum stator hub gap. By comparing our results with those from published research, this metric was proven to be feasible. Finally, it is also discussed how the stator hub gap affected the stator inlet flow and rotor performance. It is demonstrated that the stator passage flow blockage can affect the upstream flow field. As a result, the performance of the rotor tends to vary in the opposite direction to that of the stator.

The present paper reports a 2D-PIV (particle image velocimetry) study of the effect of the operating point on the leakage flow in a low-speed ring fan. First, the flow pattern has been studied at 12 operating points covering the whole characteristic curve. At very low loading, the leakage flow streams along the rotor ring and is directly reingested; then, a separation bubble attached to the ring forms that, approaching the design point, modifies in a flow streaming radially outward. As the loading further increases, a separated flow region appears in the blade tip region that finally merges with the leakage flow. A further, more detailed study has been performed at eight operating points in the neighborhood of the design one. Very small loading variations may yield the leakage flow pattern modification, but no intermittence is present during the transition, as instantaneous flow patterns of any intermediate type continuously alternate. These results provide a consistent explanation for the ones of previous acoustic measurements.

The design of gear pumps and motors is focused on more efficient units which are possible to achieve using advanced numerical simulation techniques. The flow that appears inside the gear pump is very complex, despite the simple design of the pump itself. The identification of fluid flow phenomena in areas inside the pump, considering the entire range of operating parameters, is a major challenge. This paper presents the results of simulation studies of leakages in axial and radial gaps in an external gear pump carried out for different gap shapes and sizes, as well as various operating parameters. To investigate the processes that affect pump efficiency and visualize the fluid flow phenomena during the pump’s operation, a CFD model was built. It allows for a detailed analysis of the impact of the gears’ eccentricity on leakages and pressure build-up on the circumference. Performed simulations made it possible to indicate the relationship between leakages resulting from the axial and radial gap, which has not been presented so far. To verify the CFD model, experimental investigations on the volumetric efficiency of the external gear pump were carried out. Good convergence of results was obtained; therefore, the presented CFD model is a universal tool in the study of flow inside external gear pumps.

This paper presents a new universal programmable portable measuring device (PMD) as a complete, accurate, and efficient solution for monitoring and technical diagnostics of industrial fluid power systems. PMD has programmable functions designed for recording, processing, and graphical visualization of measurement results at the test stand or the place of operation of fluid power systems. PMD has a built-in WiFi communication module for transferring measurement data via Industrial Internet of Things (IIoT) technology for online remote monitoring of fluid power systems. PMD can be programmed for a variety of measuring tasks in servicing, repairing, diagnosing, and monitoring fluid power systems. For this purpose, the fluid dynamic quantity, mechanical quantity, and electrical quantity can be measured. The adjustment of the PMD to the indirect measurement of leakage flow rate in a compressed air system (CAS) is presented in detail. Measuring instruments and PMDs were connected to a branch of the pipeline. The tests used the measurement system to estimate the leakage flow rate through air small nozzles, as well as other CAS indicators.

To explore the flow mechanism and improve the performance of supersonic tandem rotor blades, the supersonic rotor Rotor37 is taken as the prototype and redesigned to an original supersonic tandem rotor. Then, based on the Kriging model, the physical programming method, and improved particle swarm optimization algorithm, a multi-objective optimization methodology is developed and applied to achieve the multi-objective optimization of the supersonic tandem rotor blades. Compared with Rotor37, the mass flow and surge margin of the original tandem rotor obviously increased. However, the efficiency of the original tandem rotor was slightly lower than Rotor37. After multi-objective optimization, compared with the original tandem rotor, the total pressure ratio and efficiency of the optimized tandem rotor significantly increased, and the efficiency increased by 1.6%. Further, the surge margin increased by 2.75%. The range and intensity of the high-loss region in the middle section of the optimized tandem rotor significantly decreased, and the range of the low-loss area in the middle region and tip region significantly increased, but the range and strength of the high-loss area in the tip region changed a little. The reason for the decrease of total pressure loss in the middle region and tip region is that the three-dimensional optimization of the blade significantly reduced the shock loss and boundary layer separation loss of the front blade. At the same time, the mixing loss between low energy fluid and the main flow in blade wake also reduced. Besides, the three-dimensional optimization of the blade had little impact on the leakage flow and the secondary flow generated by the mutual interference of the leakage flow and shock wave.

In the side-chambers of radial turbomachinery, which are rotor–stator cavities, complex flow patterns develop that contribute substantially to axial thrust on the shaft and frictional torque on the rotor. Moreover, leakage flow through the side-chambers may occur in both centripetal and centrifugal directions which significantly influences rotor–stator cavity flow and has to be carefully taken into account in the design process: precise correlations quantifying the effects of rotor–stator cavity flow are needed to design reliable, highly efficient turbomachines. This paper presents an experimental investigation of centripetal leakage flow with and without pre-swirl in rotor–stator cavities through combining the experimental results of two test rigs: a hydraulic test rig covering the Reynolds number range of 4 × 10 5 ≤ R e ≤ 3 × 10 6 and a test rig for gaseous rotor–stator cavity flow operating at 2 × 10 7 ≤ R e ≤ 2 × 10 8 . This covers the operating ranges of hydraulic and thermal turbomachinery. In rotor–stator cavities, the Reynolds number R e is defined as R e = Ω b 2 ν with angular rotor velocity Ω , rotor outer radius b and kinematic viscosity ν . The influence of circumferential Reynolds number, axial gap width and centripetal through-flow on the radial pressure distribution, axial thrust and frictional torque is presented, with the through-flow being characterised by its mass flow rate and swirl angle at the inlet. The results present a comprehensive insight into the flow in rotor–stator cavities with superposed centripetal through-flow and provide an extended database to aid the turbomachinery design process.

A mechanical heart valve (MHV) is an effective device to cure heart disease, which has the advantage of long life and high reliability. Due to the hemodynamic characteristics of blood, mechanical heart valves can lead to potential complications such as hemolysis, which have damage to the blood elements and thrombosis. In this paper, flowing features of the blood in the valve are analyzed and the cavitation mechanism in bileaflet mechanical heart valve (BMHV) is studied. Results show that the water hammer effect and the high-speed leakage flow effect are the primary causes of the cavitation in the valve. Compared with the high-speed leakage flow effect, the water hammer has a greater effect on the cavitation strength. The valve goes through four kinds of working condition within one heart beating period, including, fully opening stage, closing stage and fully closing stage. These four stages, respectively, make up 8.5%, 16.1%, 4.7% and 70.7% of the total period. The cavitation occurs on the fully closing stage. When the valve is in closing stage, the high pressure downstream of the valve lasts for about 20 ms and the high-speed leakage flow lasts for about 200 ms. This study systematically analyzes the causes of cavitation emerged in the process of periodic motion, which proposes the method for characterizing the intensity of the cavitation, and can be referred to for the cavitation suppression of the BHMV and similar valves.

The effect of rotational speed and pressure rise on the leakage flow noise radiated by a low-speed axial fan, provided with rotating shroud, has been systematically investigated. The flow in the gap region has been studied by means of particle image velocimetry (PIV) measurements taken in the meridional plane. At low blade loading, the leakage flow is restrained close to the rotor ring and, at higher loading, it forms a wide recirculation zone. In the latter conditions, an unsteady flow separation likely takes place in the blade tip region which may be observed in the instantaneous flow field only. The leakage flow noise generally increases with the blade loading, but is non-monotonic, as the overall sound pressure level (OASPL) growth is interrupted by local minima; such a trend is qualitatively independent of the rotational speed. As the loading increases, the sound pressure level (SPL) spectrum shows important modifications, since the characteristic frequency of the subharmonic narrowband humps related to the leakage noise decreases; furthermore, height and width of the humps vary non-monotonically. Such a complicated behavior is likely related to the modifications in the leakage flow pattern and also to the appearance of the flow separation at the blade tip.

Regenerative pumps are characterized by a low specific speed that place them between rotary positive displacement pumps and purely radial centrifugal pumps. They are interesting for many industrial applications since, for a given flow rate and a specified head, they allow for a reduced size and can operate at a lower rotational speed with respect to purely radial pumps. The complexity of the flow within regenerative machines makes the theoretical performance estimation a challenging task. The prediction of the leakage flow rate between the rotating and the static disks has the greatest impact on the prediction of global performance. All the classical approaches to the disk clearance problem assume that there is no relevant circumferential pressure gradient. In the present case, the flow develops along the tangential direction and the pressure gradient is intrinsically non-zero. The aim of the present work is to develop a reliable approach for the prediction of leakage flows in regenerative pumps. A preliminary numerical simulation on a virtual model of a regenerative pump where the disk clearance is part of the control volume has been performed for three different clearance aspect ratios. The outcome of that campaign allowed the authors to determine the behavior of the flow in the cavity and choose correctly the baseline hypotheses for a mathematical-physical method for the prediction of leakage flows. The method assumes that the flow inside of the disk clearance is two-dimensional and can be decomposed into several stream-tubes. Energy balance is performed for each tube, thus generating a system that can be solved numerically. The new methodology was tuned using data obtained from the numerical simulation. After that, the methodology was integrated into an existing one-dimensional code called DART (developed at the University of Florence in cooperation with Pierburg Pump Technology Italy S.p.A.) and the new algorithm was verified using available numerical and experimental data. It is here demonstrated that an appropriate calibration of the leakage flow model allows for an improved reliability of the one-dimensional code.

Labyrinth seals are not usually included in the numerical models of hydraulic machinery to simplify the geometric modeling, and thereby reduce the calculation burden. However, this simplification affects the numerical results, especially in the load rejection process, because disc friction losses, volume losses, and pressure fluctuations in the seal ring (SR) clearance passage are neglected. This paper addresses the issue by considering all of the geometrical details of labyrinth seals when conducting multiscale flow simulations of a high head Francis turbine under a transient load rejection condition using the commercial software code. A comparison of the numerical results that were obtained with the experimental testing data indicates that the calculated values of both torque and mass discharge rate are 8.65% and 5% slightly less than the corresponding values that were obtained from experimental model testing, respectively. The obtained pressure fluctuations of the Francis turbine in the vaneless zone and the draft tube appear to more closely match with the experimental test data when including SR clearance. Moreover, the flow rates through SR clearance passages were very small, but the pressure fluctuations among them were significantly enhanced under the minimal load condition. The numerical model with SR clearance can more accurately reflect the fact that the water thrust on the runner only fluctuates from 800 N to 575 N during the load rejection process, even though the water thrust on the blades varies from −220 N to 1200 N. Therefore, multiscale flow study is of great significance in understanding the effect of clearance flow on the load rejection process in the Francis turbine.

Hydroelectric power plants are used worldwide to cover varying electricity demands. The Salime hydroelectric power plant, which is located at Asturias, Spain, has four hydro turbines with a total design capacity of 128 MW. Each turbine has a ball valve with two maintenance seals to ensure a closure as complete as possible when the group ceases to operate. Unfortunately, at some occasions the seals did not really perform their sealing function properly, but started to develop periodic vibrations of indefinite duration. This phenomenon generates periodic leakage flow as well as high amplitude pressure fluctuations in the penstocks, which are not acceptable. This phenomenon corresponds to the field of flow-induced vibrations, in particular to the type of self-excited vibrations. The purpose of the research now reported was to develop a simplified theoretical model that can explain the excitation mechanism for the seal vibrations and that can estimate the behavior of the hydro-mechanical system depending on the relevant geometrical and physical parameters. In order to calculate the pressure and flow rate fluctuations, the energy equation for unsteady, unidirectional, incompressible and viscous flow has been applied along each pipe of the hydraulic system, together with continuity considerations at each pipe junction and the seal equation of motion. The perturbation technique has been used to solve the system variables. The mathematical model was solved by means of a specially designed MATLAB code, which allows simulating the time evolution of the annular seal vibration as well as the unsteady flow and pressure induced throughout the system for different system configurations. The results show that the system stability depends on the behavior of the hydraulic pressure force acting on the seal and the gap flow rate after system disturbance. Besides, the results obtained support that, at standing group situation, seal vibrations are less prone to occur when operating at either low reservoir energy level or very large reservoir energy level.

Propellers, pumps, and turbines are widely applied in marine equipment, water systems, and hydropower stations. With the increasing demand for energy conservation and environmental protection, the high efficiency and the stable operation of pumps and turbine have been drawing great attention in recent decades. However, the tip clearance between the rotating impeller and the stationary shroud can induce leakage flow and interact with the main stream, introducing complex vortex structures. Consequently, the energy performance and the operation stability of pumps and turbines deteriorate considerably. Constant efforts are exerted to investigate the flow mechanism of tip-clearance flow and its induced influence on performance. However, due to various pump and turbine types and the complexity of tip-clearance flow, previous works are usually focused on a specific issue. Therefore, a systematic review that synthesizes the related research is necessary and meaningful. This review investigates related research in the recent two decades in the perspectives from fundamental physics to engineering applications. Results reveal the vortex types, trajectory, evolution, and cavitation behaviors induced by tip-clearance flow. It is concluded that the influence characteristics of tip clearance on energy performance are closely related to the machinery type. Tip-clearance size and tip shape are found to be crucial parameters for tip-leakage vortex (TLV). The proposed optimization schemes are also demonstrated to provide inspiration for future research. Overall, this review article provides a coherent insight into the characteristics of tip-clearance flow and the associated engineering-design applications. On the basis of these understandings, comments on conducted research and ideas on future research are proposed.

The dynamic characteristics and energy loss in a shifting control system is important and necessary in the performance improvement of an automatic transmission. The direct operating solenoid valve has been considered as a potential component applying in the shifting control system in vehicle. The previous method can solve only a specific physical field or use the test results of the magnetic force as input curve. The paper presents a numerical approach for solving the multi-domain physical problem of the valve. A precise model of the direct acting solenoid valve considering different physical field is developed. An experimental study is also performed to evaluate and confirm the simulation. Based on the model, the influences on the dynamic characteristics of the valve are analyzed by calculating forces acting on the valve. The systematic analysis of forces and energy loss characteristics are performed for three different flow conditions varying clearance height from 10 µm to 30 µm. The results demonstrate that the pressure response time can be improved with smaller clearance between the spool and the sleeve. Moreover, the leakage of the shifting control system employing the direct acting solenoid valve can be reduced by 60% compared to the conventional two-stage pilot valve in our previous product.

Francis turbine guide vanes have pivoted support with external control mechanism, for conversion of pressure to kinetic energy and to direct them to runner vanes. This movement along the support is dependent on variation of load and flow (operating conditions). Small clearance gaps between facing plates and the upper and lower guide vane tips are available to aid this movement, through which leakage flow occurs. This secondary flow disturbs the main flow stream, resulting performance loss. Additionally, these increased horseshoe vortex, in presence of sand, when crosses through the gaps, both the surfaces are eroded. This causes further serious effect on performance and structural property by increasing gaps. This paper discusses the observation of the severity in hydropower plants and effect of clearance gaps on general performance of the Francis turbine through computational methods. It also relates the primary result with the empirical relation for leakage flow prediction. Additionally, a possible method to computationally estimate thickness depletion has also been presented. With increasing clearance gap, leakage increases, which lowers energy conversion and turbine efficiency along with larger secondary vortex.