Bowed Stators: An Example of CFD Applied to Improve Multistage Compressor Efficiency

Analysis of multistage compressor stator surface static pressure data reveals that the radial growth of suction surface corner separation prematurely separates core flow stator sections, limiting their pressure rise capability and generating endwall loss. Modeling of the stator flowfield, using a three-dimensional Euler analysis, has led to the development of “bowed” stator shapes, which generate radial forces that reduce diffusion rates in the suction surface corners, in order to delay the onset of corner separation. Experimental testing of the bowed stator concept in a three-stage research compressor has confirmed the elimination of suction surface corner separation, the resulting reduction of the endwall loss, and the increase in pressure rise capability of the stator core sections. This results in more robust pressure rise characteristics and substantially improved efficiency over the entire flow range of the compressor. The strong interaction effects of the bowed stator with the viscous endwall flowfield are shown to be predictable using a three-dimensional multistage Navier–Stokes analysis. This permits matching of the rotors to the altered stator exit profiles, in order to avoid potential stability limiting interactions. Application of bowed stators to a high bypass ratio engine eleven-stage high-pressure compressor has resulted in substantial improvement in efficiency, with no stability penalty.