Paul Storm

Thermomechanical Design of a Heat Exchanger for a Recuperative Aero Engine

Within the framework programs of the EU for Efficient and Environmentally Friendly Aero-Engines (EEFEA) MTU has developed a highly efficient cross-counter flow heat exchanger for the application in intercooled recuperated aero-engines. This very compact recuperator is based on the profile tube matrix arrangement invented by MTU and one of its outstanding features is the high resistance to thermal gradients. In this paper the combined thermomechanical design of the recuperator is presented. State-of-the-art calculation procedures for heat transfer and stress analysis are combined in order to perform a reliable life prediction of the recuperator. The thermal analysis is based upon a 3D parametric finite element model generation. A program has been generated, which allows the automatic generation of both the material mesh and the boundary conditions. Assumptions concerning the boundary conditions are presented as well as steady state and transient temperature results. The stress analysis is performed with a FEM code using essentially the same computational grid as the thermal analysis. With the static temperature fields the static loading of the profile tubes is determined. From transient thermal calculations successive 3D temperature fields are obtained which enable the determination of creep life and LCF life of the part. Finally, vibration analysis is performed in order to estimate the vibration stress of the profile tubes during engine operation. Together with the static stress a Goodman diagram can be constructed. The combined analysis shows the high life potential of the recuperator, which is important for economic operation of a recuperative aero-engine.Copyright

Thermomechanical Design of a Heat Exchanger for a Recuperative Aeroengine

Within the framework programs of the EU for Efficient and Environmentally Friendly Aero-Engines (EEFEA) MTU has developed a highly efficient cross-counter flow heat exchanger for the application in intercooled recuperated aeroengines. This very compact recuperator is based on the profile tube matrix arrangement invented by MTU and one of its outstanding features is the high resistance to thermal gradients. In this paper the combined thermomechanical design of the recuperator is presented. State-of-the-art calculation procedures for heat transfer and stress analysis are combined in order to perform a reliable life prediction of the recuperator. The thermal analysis is based upon a 3D parametric finite element model generation. A program has been generated, which allows the automatic generation of both the material mesh and the boundary conditions. Assumptions concerning the boundary conditions are presented as well as steady state and transient temperature results. The stress analysis is performed with a FEM code using essentially the same computational grid as the thermal analysis. With the static temperature fields the static loading of the profile tubes is determined. From transient thermal calculations successive 3D temperature fields are obtained which enable the determination of creep life and LCF life of the part. Finally, vibration analysis is performed in order to estimate the vibration stress of the profile tubes during engine operation. Together with the static stress a Goodman diagram can be constructed. The combined analysis shows the high life potential of the recuperator, which is important for economic operation of a recuperative aero-engine.

Derivation of an Anisotropic Model for the Pressure-Loss Through a Heat Exchanger for Aero Engine Applications

We present an effort to model the pressure loss together with the heat transfer mechanism, in a heat exchanger designed for an integrated recuperative aero engine. The operation of the heat exchanger is focusing on the exploitation of the thermal energy of the turbine exhaust gas to pre-heat the compressor outlet air before combustion and to decrease fuel consumption and pollutant emissions. Two basic parameters characterize the operation of the heat exchanger, the pressure loss and the heat transfer. The derivation of the pressure loss model is based on experimental measurements that have been carried-out on a heat exchanger model. The presence of the heat exchanger is modeled using the concept of a porous medium, in order to facilitate the computational modeling by means of CFD. As a result, inside the integrated aero engine, the operation of the heat exchanger can be sufficiently modeled as long as a generalized and accurate pressure drop and heat transfer model is developed. Hence, the porosity model formulation should be capable of properly describing the overall macroscopic hydraulic and thermal behavior of the heat exchanger. The effect of the presence of the heat exchanger on the flow field is estimated from experimental measurements. For the derivation of the porous medium pressure loss model, an anisotropic formulation of a modified Darcy-Forchheimer pressure drop law is proposed in order to take into account the effects of the three-dimensional flow development through the heat exchanger. The heat transfer effects are taken also into account with the use of a heat transfer coefficient correlation. The porosity model is adopted by the CFD solver as an additional source term. The validation of the proposed model is performed through CFD computations, by comparing the predicted pressure drop and heat transfer with available experimental measurements carried-out on the heat exchanger model.© 2009 ASME