In the context of an engine design calculation, isentropic or polytropic efficiencies of turbomachinery components are assumed at the outset of the cycle analysis and their values are updated or validated following the aerodynamic design of the components. In the present paper, aerodynamic design calculations of axial-flow compressors and turbines are directly integrated into the corresponding performance component models. This creates a consistent, single-step preliminary design and performance modelling process using a relatively small number of physical and geometric inputs. The aerodynamic design for establishing a component’s overall efficiency is accomplished through a mean-line, stage-by-stage approach where the stagewise isentropic efficiency is calculated employing either loss or semi-empirical correlations. From this process, the stagewise flow annulus radii are also obtained and are used to axially size the component stages assuming the blade aspect ratio and axial gapping distributions. The component flowpath geometry is then produced by simply “stacking” axially the component stages. The developed method is validated against publicly available data for a high-pressure compressor and a low-pressure turbine. Finally, the effectiveness of the method is demonstrated by considering the multi-point design of a High Bypass Ratio Geared Turbofan Engine with bypass Variable Area Nozzle.

This paper presents a modular, flexible, extendable and fast-computational framework that implements a multidisciplinary, varying fidelity, multi-system approach for the conceptual and preliminary design of novel aero-engines. In its current status, the framework includes modules for multi-point steady-state engine design, aerodynamic design, engine geometry and weight, aircraft mission analysis, Nitrogen Oxide (NOx) emissions, control system design and integrated controller-engine transient-performance analysis. All the modules have been developed in the same software environment, ensuring consistent and transparent modeling while facilitating code maintainability, extendibility and integration at modeling and simulation levels. Any simulation workflow can be defined by appropriately combining the relevant modules. Different types of analysis can be specified such as sensitivity, design of experiment and optimization. Any combination of engine parameters can be selected as design variables, and multi-disciplinary requirements and constraints at different operating points in the flight envelope can be specified. The framework implementation is exemplified through the optimization of an ultra-high bypass ratio geared turbofan engine with a variable area fan nozzle, for which specific aircraft requirements and technology limits apply. Although the optimum design resulted in double-digit fuel-burn benefits compared to current technology engines, it did not meet engine-response requirements, highlighting the need to include transient-performance assessments as early as possible in the preliminary engine design phase.

Disks in gas turbines are optimized for minimum weight, while satisfying both geometry and stress constraints, in order to minimize the engine production, operation, and maintenance costs. In the present paper, a tool is described for the preliminary mechanical design of gas turbine disks. A novel formulation is presented, where the disk weight minimization is achieved by maximizing the stresses developed in the disk. The latter are expressed in the form of appropriately defined design and burst margins. The computational capabilities of the tool developed are demonstrated through comparisons to calculations with a higher fidelity tool. The importance of accurately calculating thermal stresses is demonstrated and the ability of the tool for such calculations is discussed. The potential and efficiency of the tool are illustrated through a proposed re-design of the disks of a well-documented ten-stage compressor. Finally, the integration of the tool into an overall engine design framework is discussed.

A mean-line compressor performance calculation method is presented that covers the entire operating range, including the choked region of the map. It can be directly integrated into overall engine performance models, as it is developed in the same simulation environment. The code materializing the model can inherit the same interfaces, fluid models, and solvers, as the engine cycle model, allowing consistent, transparent, and robust simulations. In order to deal with convergence problems when the compressor operates close to or within the choked operation region, an approach to model choking conditions at blade row and overall compressor level is proposed. The choked portion of the compressor characteristics map is thus numerically established, allowing full knowledge and handling of inter-stage flow conditions. Such choking modelling capabilities are illustrated, for the first time in the open literature, for the case of multi-stage compressors. Integration capabilities of the 1D code within an overall engine model are demonstrated through steady state and transient simulations of a contemporary turbofan layout. Advantages offered by this approach are discussed, while comparison of using alternative approaches for representing compressor performance in overall engine models is discussed.