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ARPN Journal of Engineering and Applied Sciences

2006-2015 Asian Research Publishing Network (ARPN). All rights reserved.

www.arpnjournals.com

Ali S. Bahr Ennil1 and Abdulhafid M. Elfaghi2

1Department of Aeronautical Engineering, Engineering Academey Tajoura, Libya

2Department of Aeronautical Engineering, University of Zawia, Libya

E-Mail: hafied@zu.edu.ly

ABSTRACT

The effect of film cooling over flat plate is investigated using the commercial CD code; Fluent 6.3. The

computational domain includes the coolant supply tube as well as the main mixing region. A tube L/D of 4 and injection

angles of (30o, 60o, and 90o) were employed for blowing ratio of (0.33, 0.5, and 1.67), and a density ratio of 1.14. Adiabatic

film cooling effectiveness distributions were also determined for inline and staggered arrangements. The main observation

from this study that the 30o hole gave larger effectiveness values than 60o and 90o at the blowing ratio of 0.33 with the

same length-to-diameter ratio. The maximum effectiveness was achieved with a blowing ratio of 0.5. The results show that

the increase of blowing ratio negatively affects film cooling, such that for the blowing ratio of 1.67 the injected coolant

tends to lift off from the wall due to the increase of the wall normal momentum. The comparisons for numerical results

with experimental data are presented.

The advance of turbine engine technology has led results of this study are compared with experimental data.

to higher turbine inlet temperatures. This requires active

cooling in order to maintain the blades of the turbine Numerical model

engine at a safe temperature, since the excessive high The flat plate to be film is illustrated in Figure-1.

temperature levels will reduce the life of blades and can Table-1 shows test cases data.

even cause the failure of those blades. Film cooling is a The geometry of numerical model is as follows:

widely used technique to achieve this goal. Due to the

large number of influencing parameters, design The plate is 360mm wide 1000mm long 163mm

optimization through experiments can be quite expensive thick.

and time consuming. Hole diameter (D) is 10mm.

Consequently a reliable computationally efficient Pitch to diameter is 3.

predictive procedure would be extremely beneficial. Even Injection angles 300, 600, and 900.

for a row of holes, the flow field is quite complex with a

wide variety of influences parameters such as hole

injection angle, hole diameter and shape, blowing ratio,

lateral spacing, and the effect of the length of the coolant

supply tube.

The present study used FLUENT 6.3 to solve the

flow field and properties through the different

configurations with standard k- model. Temperature

contours, average effectiveness values and effectiveness

Figure-1. Flat plate configuration.

One hole 12.5

30 , 60, and 90 Two inline rows 3 12.5 0.33, 0.5, 1.0, 1.67

Two staggered row 3 12.5

The following assumptions are made: The flow field is symmetrical about the vertical plane

passing through the stream wise centerline of a

Both the hot mainstream gas and the cooling fluid are cooling hole (hole-center plane).

approximated as air. The flow field is symmetrical about the vertical plane

passing in the mid-distance between cooling holes

(mid-pitch plane).

2518

VOL. 10, NO. 6, APRIL 2015 ISSN 1819-6608

ARPN Journal of Engineering and Applied Sciences

2006-2015 Asian Research Publishing Network (ARPN). All rights reserved.

www.arpnjournals.com

The mesh is generated using GAMBIT2.3.16. It employed with unstructured meshes. The size function

is crucial that the grid size be as small as possible at applied has a minimum grid dimension of 0.5 mm at the

boundaries (near flat plate and cooling hole internal walls). tested flat plate and cooling hole. It uses a growth rate of

It is also important that the grid volumes be as large as 1.05 and maximum grid dimension of 1mm. A zoomed

possible to reduce the computational time and allocated snapshot of the mesh control volume is shown in Figure-2

memory. The grid was non-orthogonal in the tube and near in more detail.

the injection hole. Conservation was maintained by

The flow field and temperatures in numerical Continuity equation, linear momentum equations

models studied are solved using FLUENT6.3, for the and turbulence model (k-) equations are solved for the

following boundary conditions: mesh volumes to a residual of 10-5, while the energy

equation is solved to a residual of 10-6. The different

a) Hot main stream inlet ` equations are solved implicitly, for seven run cases, for

The mainstream gases are approximated as air, steady state solution using FLUENT6.3.

with a temperature 333 K. The inlet mainstream flow is

considered to have a uniform velocity of 10 m/s. As Grid sensitivity study

measured by [14], the turbulence level is 11% and Three models are built, for cooling holes (30, 60,

turbulent length scale of 5 mm. and 90 degree) with the same dimensions illustrated in [5],

with three different mesh resolutions. These three models

b) Coolant inlet contain different numbers of mesh elements, namely

The coolant inlet is taken to be air, with a 217998, 598830 and 1253317 elements. Studying the

temperature 293 K. The inlet coolant flow is considered to effect on centerline effectiveness of film cooling, the

have a uniform velocity. Due to the temperature ratio of model sensitivity to resolution begins to vanish at the third

333/293, density ratio is maintained at 1.14. resolution (1253517 cells) with a maximum error of 5%.

The flat plate surfaces upstream and downstream To minimize the processing time and allocated memory,

of the hole injection are considered adiabatic (zero heat this resolution is taken in all configurations of the present

flux). studies.

The internal walls of the coolant pipe are The computational methodology implemented in

considered adiabatic. the present research was developed and validated for

studying jet- cross flow interactions as described by Yuen

Periodic boundary conditions et al. [5]. CFD analysis was performed using fluent solver

Symmetry boundary condition is applied to the and turbulence closure was attained using standard k

upper boundary of the control volume. turbulence model in conjunction with the standard wall

functions. The computational results of centerline

effectiveness are presented and compared with

2519

VOL. 10, NO. 6, APRIL 2015 ISSN 1819-6608

ARPN Journal of Engineering and Applied Sciences

2006-2015 Asian Research Publishing Network (ARPN). All rights reserved.

www.arpnjournals.com

experimental results. The results are classified into the should be noted that values on effectiveness contours can

following: be drawn in the reverse manner to those on temperature

contours. That is; a temperature of 333 K corresponds to

Effects of hole angles zero effectiveness and a temperature of 293 K corresponds

In this section, the effect of hole injection angle to an effectiveness of 100%. When plotting contours of

was studied for three angles (30o, 60o, and 90o) and temperatures and effectiveness on RGB color scales, a red

blowing ratio of 0.33. Figure-3 shows the contours of color on a temperature map will correspond to a blue color

effectiveness of single hole of 30o holes and a length -to- on an effectiveness map. The results show the temperature

diameter ratio of 4 with blowing ratio of 0.33. Also the distribution on the plate, a slight asymmetry is observed

temperature distribution contours is shown in Figure-4. It around and near the hole.

Figures 5, shows the comparison of centerline temperature. The high free stream turbulence here has

effectiveness for different injection angles. It is obvious significantly shortened the distance that the cooling air

that the injection angle affects the cooling effectiveness travels downstream. This is attributed to the increased

and there is an optimum injection angle to achieve high mixing of coolant with main flow due to the high

cooling efficiency. However, this angle is correlated with turbulence. The high effectiveness regions are narrow as

blowing ratio and cooling holes arrangement. As can be the injection angle increases; however, the effectiveness

from simulation results, the injection angle of 30o provides distribution in the span wise direction becomes extremely

highest effectiveness for different holes arrangement. At uniform. The main observation from this study that the 30o

X/D 30 the simulation and experimental results are hole gave larger effectiveness values than angles at the

closely approach, because the wall temperature in this blowing ratio of 0.33 with the same length-to-diameter

region becomes higher and closer to hot stream ratio.

2520

VOL. 10, NO. 6, APRIL 2015 ISSN 1819-6608

ARPN Journal of Engineering and Applied Sciences

2006-2015 Asian Research Publishing Network (ARPN). All rights reserved.

www.arpnjournals.com

Effects of blowing ratio blowing ratio of 0.5 in the immediate and near field

Effect of blowing ratio on effectiveness is regions. This is larger than that of blowing ratios 0.33, 1.0,

studied, by varying the blowing ratio (0.33, 0.5, 1.0, and and 1.67. This provides support for rapid mixing of jet

1.67) in simulation for single hole with injection angle of fluid with the flow between the jets. This effect raises the

30o. The results are shown in Figure-6. This result shows question of turbulence intensity. Also at M=1 a smaller

an effectiveness of around 0.57 at mid-span with a amount of film is spread along the simulated surface.

0.7 0.33

0.4

0.5

0.6

0.8

1

0.5 1.5

1.67

Effectivness

0.4 2

0.3

0.2

0.1

0

0 10 20 30 40 50 60

X/D

The maximum effectiveness was achieved with a with the lift-off effect, shown in Figure-7, which comes as

blowing ratio of 0.5, and the results shows that the a result of the increased mixing between coolant jet and

increase of blowing ratio negatively affects film cooling, mainstream. Coolant coverage on the surface is reduced as

where increasing blowing ratio dramatically reduces both the blowing ratio increases. So the optimum blowing ratio

the area of coverage of the film cooling air and the depends on hole injection angle. At (X/D=30) the blowing

magnitude of the effectiveness. This is attributed to the jet ratio has much less effect on effectiveness. The high

lifting off the surface due to higher y-momentum in the jet effectiveness level results from the attachment of the

and stronger kidney vortices. This phenomenon is known injectant to the wall.

2521

VOL. 10, NO. 6, APRIL 2015 ISSN 1819-6608

ARPN Journal of Engineering and Applied Sciences

2006-2015 Asian Research Publishing Network (ARPN). All rights reserved.

www.arpnjournals.com

In this section the numerical study focused on the angle and a pitch-to-diameter ratio of 3 with blowing ratio

holes arrangement by comparing two different of 0.33.

arrangements in line and staggered. Figure-8 shows the

CONCLUSIONS [3] Kohli A., Bogard D.G. 1998. Effects of very high

free-stream turbulence on the jet-mainstream

The value of effectiveness and sensitivity is affected interaction in a film cooling flow. ASME J. Turbo

by many factors as injection angle, blowing ratio, mach. 120, 785-790.

holes arrangement, etc. that makes film cooling

performance study not easy. [4] Guo T, Li S. 2006. Numerical simulation of turbulent

This study indicates that the best hole angle is 300 at jets with lateral injection into a cross flow. J

blowing ratio of 0.33, where 30o 60o 900 . HydrodynSer B. 18(3): 319-23.

The optimum blowing ratio for injection angle 300 is [5] C.H.N. Yuen and R.F. Martinez-Botas. Film cooling

0.5. characteristics of rows of round holes at various

Staggered holes were similar to those inline rows of stream wise angles in a cross flow: Part1.

the same injection angle, and the effectiveness was

decreased.

REFERENCES

thermal fields, and velocity fields for film cooling

with large angle injection, ASME J. Turbo mach. 119:

352-358.

of Film Cooling Physics Part I: Stream wise Injection

with Cylindrical Holes. ASME Paper 97-GT-269.

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