La caractérisation des mécanismes de transfert entre un écoulement fluide incompressible et une structure solide constitue l’objectif principal de ce présent mémoire. A partir d’un solveur développé au sein de l’équipe, les travaux se sont plus particulièrement focalisés sur les stratégies de couplage avec un solveur solide, afin de traiter à la fois les échanges énergétiques et les mouvements de la structure. Dans notre approche, le modèle traitant la partie solide est le solveur ASTER et une attention particulière a été portée sur la stratégie de couplage à mettre en place.Dans la partie couplage fluide/structure, des cas de référence ont été réalisés avec une complexité croissante et l’intégration de la problématique des frontières immergées a été étudiée. En effet, alors que la modélisation avec des frontières immergées semble ne pas perturber les traitements côté fluide, les changements d’état de la topologie induit par le mouvement du solide dans le domaine de calcul génèrent des discontinuités dans les forces fluides estimées sur la structure. Ces dernières peuvent être plus ou moins amorties par l’introduction de techniques hybrides dans les traitements aux frontières immergées.Malgré ses quelques limitations, le solveur est capable de traiter de grande déformation assurant un fonctionne robuste et rapide pour la caractérisation des mécanismes fortement couplés. Pour le souligner, une application sur des écoulements anisothermes au sein d’une cavité représentant une cellule frigorifique a été réalisée dans le cadre du projet de recherche OSEO. A notre connaissance, les traitements réalisés ont pour la première fois permis de quantifier l’effet des ouvrants (dans les phases d’ouverture et fermeture des portes de la cellule) sur les écoulements et les échanges thermiques. Une telle modélisation permet alors de proposer des améliorations de la géométrie en cours d’analyse. / Characterization of heat transfer mechanisms between an incompressible fluid flow and solid structure is the main objective of the proposed work. From a solver developed within the team, we particularly focused on strategies for coupling with a solid solver to address both energy and structure motion. In our approach, the model treating solid part is the solver ASTER and specific attention was paid to the coupling strategy. In the fluid / structure coupling part, reference cases were performed with increasing complexity and immersed boundaries was investigated. The change in topology for the Immersed Boundary Method enhances here and there some numerical instability and the latter can be more or less damped by hybrid techniques in the treatments to submerged borders.Despite such limitations, the solver is able to handle large deformation ensuring robust and fast analysis for the characterization of strongly coupled mechanisms. To emphasize such a point, isothermal flow in a cavity representing a cold-cell was conducted as part of the research project OSEO. To our knowledge, the processing performed for the first time quantified the effect of opening (in the opening and closing of the doors of the cell phases) on the flow and heat exchange. Such modeling is then used to suggest improvements to the geometry being analyzed.

A thermal tip clearance control system provides a robust and flexible means of manipulating the closure between the casing and the rotating blade tips in a jet engine, reducing undesirable tip leakage flows. This may be achieved using an impingement cooling scheme on the external casing of the engine in conjunction with careful thermal management of internal over-tip seal segment cavity. For a reduction in thrust specific fuel consumption, the mass flow rate of air used for cooling must be minimised, be at as low a pressure as possible and delivered through a light weight structure surrounding the rotating components in the turbine. This thesis first characterises the effectiveness of a range of external impingement cooling arrangements in typical engine casing closure system. The effects of jet-to-jet pitch, number of jets, inline and staggered alignment of jets, arrays of jets on flange, on an engine representative casing geometry are assessed through comparison of the convective heat transfer coefficient distributions in a series of numerical studies. A baseline case is validated experimentally. The validation data allowed the suitability of different turbulence closure models to be assessed using a commercial RANS solver. Importantly for each configuration the thermal contraction of an idealised engine casing is predicted using thermo-mechanical finite element models, at a series of operating conditions representing engine idle to maximum take-off conditions. Cooling is provided by manifolds attached to the outside of the engine. The assembly tolerance of these components leads to variation in the standoff distance between the manifold and the casing. For cooling arrangements with promising performance, the study is extended to characterise the variation in closure with standoff distance. It is shown that where a sparse array of non-interacting jets is used the system can be made tolerant of large build misalignments. The casing geometry itself contributes to the thermal response of the system, and, in an additional study, the effect of casing thickness and circumferential thermal control flanges are investigated. Restriction of the passage of heat into the flanges was seen to be dramatically change their effectiveness and slight necking of the flanges at their root was shown to improve the performance disproportionally. High temperature secondary air flowing past the internal face of the engine casing tends to heat the casing, causing it to grow. Experimental and numerical characterisation of a heat transfer within a typical over-tip segment cavity heat transfer is presented in this thesis for the first time. A simplified modelling strategy is proposed for casing and a means to reduce the casing heat pickup by up to 25 % was identified. The overall validity of the modelling approach used is difficult to validate in the engine environment, however limited data from a test engine temperature survey became available during the course of the research. By modelling this engine tip clearance control system it was shown that good agreement to the temperature distribution in the engine casing could be achieved where full surface external heat transfer coefficient boundary conditions were available.

Pas de résumé / No abstract

Les simulations numériques représentent un élément central du processus de conception d’un avion complétant les tests physiques et essais en vol. Elles peuvent notamment bénéficier de méthodes innovantes, telle que l’intelligence artificielle qui se diffuse largement dans l’aviation. Simuler une mission de vol complète pour plusieurs disciplines pose d’importants problèmes à cause des coûts de calcul et des conditions d’opérations changeantes. De plus, des phénomènes complexes peuvent se produire. Par exemple, des chocs peuvent apparaître sur l’aile pour l’aérodynamique alors que le mélange entre les écoulements du moteur et de l’air extérieur impacte fortement l’aérothermie autour de la nacelle et du mât. Des modèles de substitution peuvent être utilisés pour remplacer les simulations haute-fidélité par des approximations mathématiques afin de réduire le coût de calcul et de fournir une méthode construite autour des données de simulations. Deux développements sont proposés dans cette thèse : des modèles de substitution utilisant l’apprentissage automatique pour approximer des calculs aérodynamiques et l’intégration de modèles de substitution classiques dans un processus aérothermique industriel. La première approche sépare les solutions en sous-ensembles selon leurs formes grâce à de l’apprentissage automatique. En outre, une méthode de reéchantillonnage complète la base d’entrainement en ajoutant de l’information dans des sous-ensembles spécifiques. Le deuxième développement se concentre sur le dimensionnement du mât moteur en remplaçant les simulations aérothermiques par des modèles de substitution. Ces deux développements sont appliqués sur des configurations avions afin de combler l’écart entre méthode académique et industrielle. On peut noter que des améliorations significatives en termes de coût et de précision ont été atteintes. / Numerical simulations provide a key element in aircraft design process, complementing physical tests and flight tests. They could take advantage of innovative methods, such as artificial intelligence technologies spreading in aviation. Simulating the full flight mission for various disciplines pose important problems due to significant computational cost coupled to varying operating conditions. Moreover, complex physical phenomena can occur. For instance, the aerodynamic field on the wing takes different shapes and can encounter shocks, while aerothermal simulations around nacelle and pylon are sensitive to the interaction between engine flows and external flows. Surrogate models can be used to substitute expensive high-fidelitysimulations by mathematical and statistical approximations in order to reduce overall computation cost and to provide a data-driven approach. In this thesis, we propose two developments: (i) machine learning-based surrogate models capable of approximating aerodynamic experiments and (ii) integrating more classical surrogate models into industrial aerothermal process. The first approach mitigates aerodynamic issues by separating solutions with very different shapes into several subsets using machine learning algorithms. Moreover, a resampling technique takes advantage of the subdomain decomposition by adding extra information in relevant regions. The second development focuses on pylon sizing by building surrogate models substitutingaerothermal simulations. The two approaches are applied to aircraft configurations in order to bridge the gap between academic methods and real-world applications. Significant improvements are highlighted in terms of accuracy and cost gains

<p dir="ltr">A fast model of a Rotating Detonation Combustor (RDC) is developed based on the Method of Characteristics (MOC). The model provides a CFD-like solution of an unwrapped 2D RDC flow field in under 10 seconds with similar fidelity as 2D Reacting URANS simulations. Parametric studies are conducted using the simplified model, and the trends are analyzed to gain insight into the underlying physics of rotating detonation combustors. A methodology to assess the performance of operation with multiple waves is presented. The main effect of increasing waves is found to be the increase in the exit Mach number of the combustion chamber. The design process of a mixer component is also presented. The mixer lies downstream of a channel-cooled RDC with subsonic exit and upstream of a Rolls-Royce M250 helicopter engine in open-loop configuration. The mixer dilutes the RDC exhaust with approximately 250% air to condition the flow for the M250 turbine at steady state operation, while also acting as an isolator with a choked throat to prevent back propagation of pressure waves. The mixer aerodynamic design was completed using 2D axisymmetric RANS simulations, and the mechanical design was evaluated using Ansys Mechanical FEA and was found to be able to survive the high thermal stresses present both during the transient heating and steady state operating condition.</p>

The tips of unshrouded, high-pressure turbine blades are prone to significantly high heat loads. The gap between the tip and over-tip casing is the root cause of undesirable over-tip leakage flow that is directly responsible for high thermal material degradation and is a major source of aerodynamic loss within a turbine. Both must be minimised for the safe working and improved performance of future gas-turbines. A joint experimental and numerical study is presented to understand and characterise the heat transfer and aerodynamics of unshrouded blade tips. The investigation is undertaken with the use of a squealer or cavity tip design, known for offering the best overall compromise between the tip aerodynamics, heat transfer and mechanical stress. Since there is a lack of understanding of these tips at engine-realistic conditions, the present study comprises of a detailed analysis using a high-speed linear cascade and computational simulations. The aero-thermal performance is studied to provide a better insight into the behaviour of squealer tips, the effects of casing movement and tip cooling. The linear cascade environment has proved beneficial for its offering of spatially-resolved data maps and its ability to validate computational results. Due to the unknown tip gap height within an entire engine cycle, the effects of gap height are assessed. The squealer's aero-thermal performance has been shown to be linked with the gap height, and qualitative different trends in heat transfer are established between low-speed and high-speed tip flow regimes. To the author's knowledge, the present work is the first of its kind, providing comprehensive aero-thermal experimental research and a dataset for a squealer tip at engine-representative transonic conditions. It is also unique in terms of conducting direct and systematic validations of a major industrial computational fluid dynamics method for aero-thermal performance prediction of squealer tips at enginerepresentative transonic conditions. Finally, after recognising the highest heat loads are found on the squealer rims, a novel shaped squealer tip has been investigated to help improve the thermal performance of the squealer with a goal to improve its durability. It has been discovered that a seven percent reduction in tip temperature can be achieved through incorporating a shaped squealer and maximising the internal cooling performance.

The path to future aero-engines with more efficient engine architectures requires advanced thermal management technologies to handle the demand of refrigeration and lubrication. Oil systems, holding a double function as lubricant and coolant circuits, require supplemental cooling sources to the conventional fuel based cooling systems as the current oil thermal capacity becomes saturated with future engine developments. The present research focuses on air/oil coolers, which geometrical characteristics and location are designed to minimize aerodynamic effects while maximizing the thermal exchange. The heat exchangers composed of parallel fins are integrated at the inner wall of the secondary duct of a turbofan. The analysis of the interaction between the three-dimensional high velocity bypass flow and the heat exchangers is essential to evaluate and optimize the aero-thermodynamic performances, and to provide data for engine modeling. The objectives of this research are the development of engine testing methods alternative to flight testing, and the characterization of the aerothermal behavior of different finned heat exchanger configurations. A new blow-down wind tunnel test facility was specifically designed to replicate the engine bypass flow in the region of the splitter. The annular sector type test section consists on a complex 3D geometry, as a result of three dimensional numerical flow simulations. The flow evolves over the splitter duplicated at real scale, guided by helicoidally shaped lateral walls. The development of measurement techniques for the present application involved the design of instrumentation, testing procedures and data reduction methods. Detailed studies were focused on multi-hole and fine wire thermocouple probes. Two types of test campaigns were performed dedicated to: flow measurements along the test section for different test configurations, i.e. in the absence of heat exchangers and in the presence of different heat exchanger geometries, and heat transfer measurements on the heat exchanger. As a result contours of flow velocity, angular distributions, total and static pressures, temperatures and turbulence intensities, at different bypass duct axial positions, as well as wall pressures along the test section, were obtained. The analysis of the flow development along the test section allowed the understanding of the different flow behaviors for each test configuration. Comparison of flow variables at each measurement plane permitted quantifying and contrasting the different flow disturbances. Detailed analyses of the flow downstream of the heat exchangers were assessed to characterize the flow in the fins¿ wake region. The aerodynamic performance of each heat exchanger configuration was evaluated in terms of non dimensional pressure losses. Fins convective heat transfer characteristics were derived from the infrared fin surface temperature measurements through a new methodology based on inverse heat transfer methods coupled with conductive heat flux models. The experimental characterization permitted to evaluate the cooling capacity of the investigated type of heat exchangers for the design operational conditions. Finally, the thermal efficiency of the heat exchanger at different points of the flight envelope during a typical commercial mission was estimated by extrapolating the convective properties of the flow to flight conditions. / Villafañe Roca, L. (2013). Experimental Aerothermal Performance of Turbofan Bypass Flow Heat Exchangers [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/34774