1. 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.

2. 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

3. 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

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

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

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

7. 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.

8. 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

9. 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

10. 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

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

12. 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

13. 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

14. Computer Timings

15. 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

16. 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..

17. Aerodynamic Blockage linear function of g with T Mass Average Area

18. Blockage Results
booster stator 2
Fan
Booster

19. Booster Stator 2

20. HPC Blockage
HPC rotor 6

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

22. 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