High Fidelity 3D Simulation of the GE90 Mark G. Turner, University of Cincinnati Andrew Norris, Ohio Aerospace Institute  Joe Veres, NASA Glenn Research Center The support received from the Aerospace Propulsion and Power Program at NASA Glenn Research Center under the Vehicle Systems Program is greatly appreciated.

Outline Background of NPSS Full Engine Simulation The GE90-94B APNASA Turbomachinery Solver National Combustor Code & NCC Results Simulation Procedure & Computer Timings Results Compared to Cycle Aerodynamic Blockage & Blockage Results Conclusions & Future Work

NPSS Full Engine Simulation { LPT HPT HPC booster Use the GE90 as the application for turbomachinery and combustion simulation efforts. Rigs { fan + OGV + booster S1 Combustor Components: { Turbine Core System: Discuss today = simulations completed Full Engine Complete, and In progress The Entire Engine Simulation has been Driven by Validation and Accuracy of the Solutions

GE90-94B Turbofan 94,000 pounds of thrust 120 inch diameter fan 8.4 Bypass Ratio

GE90-94B Turbofan First flight of the Boeing 777-200ER powered by two GE90-94B was on June 14, 2000.

GE90-94B Turbofan I’m 6 foot, 4 inches tall

GE90 Turbofan Simulation 49 blade rows of turbomachinery fan OGV 3 stage booster (7 blade rows) fan frame strut 10 stage HPC (21 blade rows) 2 stage HPT (4 blade rows) turbine mid-frame strut 6 stage LPT (12 blade rows) turbine rear frame strut Mach 0.25, sea level takeoff condition. Use cycle to bound solution.

GE90 Turbofan Simulation Combustor dual dome annular design reduced NOX emission levels reduced unburned hydrocarbon, carbon monoxide and smoke levels 30 pairs of fuel nozzles COMPRESSOR EXIT FUEL NOZZLE WITH AIR SWIRLER TURBINE DISK CAVITY PURGE AIR DILUTION HOLES TO HPT COOLING TO LPT COOLING DIFFUSER WITH SPLITTER

APNASA Turbomachinery Solver Physical Models ·Average Passage Formulation of Adamczyk and Generalized for Non-Pure H-Grids Wall Functions Rotor Tip Clearance Flow Compressor Bleed Air Blade Fillets at Rotor Hub Stator Button Geometry Turbine Cooling Flow Real Gas model Leakages   Numerical Details 4 Stage Runge-Kutta Explicit 3D Navier-Stokes Solver Local Time Steps Implicit Residual Smoothing Implicit k-e Turbulence Model Two Levels of Parallel Using MPI Message Passing  

National Combustor Code Parallel Unstructured Solver Explicit four-stage Runge-Kutta scheme Uses preconditioner to handle low Mach number flows k–e model with a high Reynolds number wall function or non-linear k-e model for swirling flows Linked to any CAD geometry via Patran files Gaseous fuel models (used in this simulation) Spray combustion model

NCC Results Total Pressure Total Temperature 1,100,000 Tetrahedra 24° Periodic Sector

Full Engine Simulation Execution qsb_fan Run APNASA in multi-block mode Fan, OGV and first stage booster stator Post process fan Pass block 1 profile to booster Fan, block 2 Fan, block 1 HPC Combustor Turbine, HPT & LPT Booster qsb_boost Run APNASA 4 stators, 3 rotors & strut Post process booster exit Pass profile to hpc qsb_hpc Run APNASA IGV, 10 rotors & 10 stators Post process hpc exit Pass profile to combustor of

Full Engine Simulation Execution qsb_hpc qsb_turb Run APNASA HPT is 2 nozzles and 2 rotors mid frame LPT is 6 nozzles and 6 rotors Exit Guide Vane strut stators Stop Run qsb_comb Run NCC 24 degree sector (pair of DAC nozzles) Post process combustor Pass combustor profile to hpt

Computer Timings

Comparison to Cycle fan P –0.8 T –0.6 W +0.5 turb P –0.7 T +2.8 turb comb P +5.18 T +2.0 W –1.0 turb P -0.0 T+4.8 W-3.9 turb T +4.6 W –4.5 hpc P -0.0 T +0.0 W –2.4 P –0.3 T +2.8 W –3.1 turb P +1.5 T +0.6 W –4.6 boost P +0.0 T +0.0 W +0.2 fan P -0.1 T W –2.1 comb P -4.4 T -0.3 W –3.3 hpc P +2.3 T +0.24 W –4.6 boost P +0.7 T +3.0 W –3.2 turb

Power Balance HPT HPC 1.409 1.295 LPT 1.016 Fan & Booster 1.0 Power from Fan is based on enthalpy rise. Power from HPC, HPT and LPT are based on pressure and skin friction torque. HPT 1.409 HPC 1.295 LPT 1.016 Fan & Booster 1.0 Power normalized by Fan and Booster. Power to pump cooling flows not subtracted from HPT. Work by HPC under-predicted..

Aerodynamic Blockage linear function of g with T Mass Average Area

Blockage Results booster stator 2 Fan Booster

Booster Stator 2

HPC Blockage HPC rotor 6

Turbine Blockage LPT Rotor 5 Vorticity Contours HPT LPT LPT Rotor 5 Secondary flow vortex LPT

Conclusions and Future Work A successful 3D simulation of the GE90-94B solution has been achieved Gains in parallel compute timings demonstrated Aerodynamic Blockage Shows 3D and Multistage Effects Isolates Shocks, Separation, Secondary flows, Tip Vortices Important for stage matching, throat setting, and thrust balance Future efforts will include: Create mini-maps for component simulations Using NPSS cycle code to balance engine and drive full engine simulation