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A Zero-D cycle simulation of the GE90-94B high bypass turbofan engine has been achieved utilizing mini-maps generated from a high-fidelity simulation. The simulation utilizes the Numerical Propulsion System Simulation (NPSS) thermodynamic cycle modeling system coupled to a high-fidelity full-engine model represented by a set of coupled 3D computational fluid dynamic (CFD) component models. Boundary conditions from the balanced, steady-state cycle model are used to define component boundary conditions in the full-engine model. Operating characteristics of the 3D component models are integrated into the cycle model via partial performance maps generated from the CFD flow solutions using one-dimensional meanline turbomachinery programs. This paper high-lights the generation of the highpressure compressor, booster, and fan partial performance maps, as well as turbine maps for the high pressure and low pressure turbine. These are actually “mini-maps” in the sense that they are developed only for a narrow operating range of the component. Results are compared between actual cycle data at a take-off condition and the comparable condition utilizing these mini-maps. The mini-maps are also presented with comparison to actual component data where possible.

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The occurrence of ice accretion within commercial high bypass aircraft turbine engines has been reported under certain atmospheric conditions. Engine anomalies have taken place at high altitudes that were attributed to ice crystal ingestion, partially melting, and ice accretion on the compression system components. The result was degraded engine performance, engine roll back, compressor surge and stall, and flameout of the combustor. As ice crystals are ingested into the fan and low pressure compression system, the air temperature increases and a portion of the ice crystals melt. This allows the ice-water mixture to stick to the metal surfaces of the compressor components. The resulting accretion causes a blockage on stationary components such as the stator vanes, and subsequently results in the deterioration in performance of the compressor and engine. The main focus of this research is the development of a computational tool that can estimate whether there is a risk of ice accretion by tracking key parameters through the compression system blade rows at all engine operating points within the flight trajectory. The tool has an engine system thermodynamic cycle code, coupled with a compressor flow analysis code, and an ice particle melt code that has the capability of determining the rate of sublimation, melting, and evaporation through the compressor blade rows. Assumptions are made to predict the complex physics involved in engine icing. Specifically, the code does not directly estimate ice accretion and does not have models for particle breakup, or erosion. Two key parameters have been suggested as conditions that must be met at the same location for ice accretion to occur: the local wet-bulb temperature to be near freezing and below, and the minimum local melt ratio must be above 10%. These parameters were deduced from analyzing normalized laboratory icing test data. These two parameters are the criteria that are used to determine whether ice accretion due to ice crystals is possible in an engine, and are used to identify the specific blade row where it could occur. Once the possibility of accretion is determined from these parameters, the degree of blockage due to ice accretion on the local stator vane can be estimated from an empirical model of ice growth rate and time spent at that operating point in the flight trajectory. The computational tool can be used to assess specific turbine engines to their susceptibility to ice accretion in an ice crystal environment. NomenclatureA = Area, ft 2 w p c , a p c = Specific heat of water vapor, air, BTU/(lb m -R) wet p c = Specific heat air-water vapor mix, BTU/(lb m -R) i p c = Specific heat of ice, BTU/(lb m -R)C U = Tangential velocity of air, ft/s D v = Diffusion coeff. of water vapor into air d = Ice particle size, diameter, microns F w , F a = Molar flow rates of water vapor, air G = Ice growth rate, in/s g c = Unit conversion, 32.2 lb m -ft/(lbf-sec 2 ) h m = Mass transfer coefficient, ft/hr h = Convective heat transfer coefficient, BTU/(hr-ft 2 -R) ∆H melt = ...

The Propulsion Systems Laboratory (PSL), an altitude test facility at NASA Glenn Research Center, has been used to test a highly instrumented turbine engine at simulated altitude operating conditions. This is a continuation of the PSL testing that successfully duplicated the icing events that were experienced in a previous engine (serial LF01) during flight through ice crystal clouds, which was the first turbofan engine tested in PSL. This second model of the ALF502R-5A serial number LF11 is a highly instrumented version of the previous engine. The PSL facility provides a continuous cloud of ice crystals with controlled characteristics of size and concentration, which are ingested by the engine during operation at simulated altitudes. Several of the previous operating points tested in the LF01 engine were duplicated to confirm repeatability in LF11. The instrumentation included video cameras to visually illustrate the accretion of ice in the low pressure compressor (LPC) exit guide vane region in order to confirm the ice accretion, which was suspected during the testing of the LF01. Traditional instrumentation included static pressure taps in the low pressure compressor inner and outer flow path walls, as well as total pressure and temperature rakes in the low pressure compressor region. The test data was utilized to determine the losses and blockages due to accretion in the exit guide vane region of the LPC. Multiple data points were analyzed with the Honeywell Customer Deck. A full engine roll back point was modeled with the Numerical Propulsion System Simulation (NPSS) code. The mean line compressor flow analysis code with ice crystal modeling was utilized to estimate the parameters that indicate the risk of accretion, as well as to estimate the degree of blockage and losses caused by accretion during a full engine roll back point. The analysis provided additional validation of the icing risk parameters within the LPC, as well as the creation of models for estimating the rates of blockage growth and losses.