Modern methods for axial compressor design are capable of shaping the blade surfaces in a three-dimensional way. Linking these methods with automated optimization techniques provides a major benefit to the design process. The application of nonaxisymmetric contoured endwalls is considered to be very successful in turbine rotors and vanes. Concerning axial compressors, nonaxisymmetric endwalls are still a field of research. This two-part paper presents the recent development of a novel endwall design. An aerodynamic separator, generated by a nonaxisymmetric endwall groove, interacts with the passage vortex. This major impact on the secondary flow results in a significant loss reduction because of load redistribution, reduction in recirculation areas, and suppressed corner separation. The first paper deals with the development of the initial endwall design using a linear compressor cascade application. A brief introduction of the design methods is provided, including the automated optimization and the 3D process chain with a focus on the endwall contouring tool. Hereafter, the resulting flow phenomena and physics due to the modified endwall surface are described and analyzed in detail. Additionally, the endwall design principal is transferred to an axial compressor stage. The endwall groove is applied to the hub and casing endwalls of the stator, and the initial numerical investigation is presented. For highly loaded operating points, the flow behavior at the hub region can be improved in accord with the cascade results. Obviously, the casing region is dominated by the incoming tip vortex generated by the rotor and still remains an area for further investigations concerning nonaxisymmetric endwall contouring.

Modern methods for axial compressor design are capable of shaping the blade surfaces in a three-dimensional way. Linking these methods with automated optimization techniques provides a major benefit to the design process. The application of nonaxisymmetric contoured endwalls is considered to be very successful in turbine rotors and vanes. Concerning axial compressors, nonaxisymmetric endwalls are still a field of research. This two-part paper presents the recent development of a novel endwall design. A vortex created by a nonaxisymmetric endwall groove acts as an aerodynamic separator, preventing the passage vortex from interacting with the suction side boundary layer. This major impact on the secondary flow results in a significant loss reduction by means of load redistribution, reduction in recirculation areas, and suppressed corner separation. Part I of this paper deals with the endwall design and its compressor application. The resulting flow phenomena and physics are described and analyzed in detail. The second paper presents the detailed experimental and numerical investigation of the developed endwall groove. The measurements carried out at the transonic cascade wind tunnel of DLR in Cologne, demonstrated a considerable influence on the cascade performance. A loss reduction and redistribution of the cascade loading were achieved at the aerodynamic design point, as well as near the stall condition of the cascade. This behavior is well predicted by the numerical simulation. The combined analysis of experimental and numerical flow patterns allows a detailed interpretation and description of the resulting flow phenomena. In this context, high fidelity 3D-Reynolds-averaged Navier–Stokes flow simulations are required to analyze the complex blade and endwall boundary layer interaction.

Modern methods for axial compressor design are capable of shaping the blade surfaces in a three dimensional way. Linking these methods with automated optimization techniques provides a major benefit to the design process. The application of non-axisymmetric contoured endwalls is considered to be very successful in turbine rotors and vanes. Concerning axial compressors non-axisymmetric endwalls are still a field of research. This two-part paper presents the recent development of a novel endwall design. An aerodynamic separator, generated by a non-axisymmetric endwall groove, interacts with the passage vortex. This major impact on the secondary flow results in a significant loss reduction because of load redistribution, reduction of recirculation areas and suppressed corner separation. The first paper deals with the development of the initial endwall design using a linear compressor cascade application. A brief introduction of the design methods is provided, including the automated optimization, the 3D process chain with a focus on the endwall contouring tool. Hereafter the resulting flow phenomena and physics due to the modified endwall surface are described and analyzed in detail. Additionally, the endwall design principal is transferred to an axial compressor stage. The endwall groove is applied to the hub and casing endwalls of the stator and the initial numerical investigation is presented. For highly loaded operating points the flow behaviour at the hub region can be improved in accord with the cascade results. Obviously, the casing region is dominated by the incoming tip vortex generated by the rotor and still remains an area for further investigations concerning non-axisymmetric endwall contouring.

Secondary flow loss in modern axial compressors is considered to be the prime reason for the reduction of overall isentropic efficiency in these engine components. This paper presents a new methodology to diminish blade secondary loss and endwall loss by an axis-asymmetric modification of endwalls using an automated multiobjective optimizer in conjunction with 3D-RANS-flow-simulations. In order to obtain a favorable design for a wide operating range, the most important operating-points are considered in the optimization process. The existing multiobjective optimization package is enhanced by implementation of DLR’s in-house 3D-flow-solver TRACE. A straightforward stator optimization was performed for a 3D-process-chain test run. Finally, the novel endwall design technique is introduced and the first optimization results and further studies are discussed.

Modern methods for axial compressor design are capable of shaping the blade surfaces in a three dimensional way. Linking these methods with automated optimization techniques provides a major benefit to the design process. The application of non-axisymmetric contoured endwalls is considered to be very successful in turbine rotors and vanes. Concerning axial compressors non-axisymmetric endwalls are still a field of research. This two-part paper presents the recent development of a novel endwall design. A vortex created by a nonaxisymmetric endwall groove acts as an aerodynamic separator, preventing the passage vortex from interacting with the suction side boundary layer. This major impact on the secondary flow results in a significant loss reduction by means of load redistribution, reduction of recirculation areas and suppressed corner separation. Part I of this paper deals with the endwall design and its compressor application. The resulting flow phenomena and physics are described and analysed in detail. The second paper presents the detailed experimental and numerical investigation of the developed endwall groove. The measurements carried out at the transonic cascade wind tunnel of DLR in Cologne, demonstrated a considerable influence on the cascade performance. A loss reduction and redistribution of the cascade loading were achieved at the aerodynamic design point as well as near the stall condition of the cascade. This behaviour is well predicted by the numerical simulation. The combined analysis of experimental and numerical flow patterns allows a detailed interpretation and description of the resulting flow phenomena. In this context high fidelity 3D-RANS flow simulations are required to analyse the complex blade and endwall boundary layer interaction.