Experimental validation of a three-dimensional through-flow model for high-speed compressor surge

This paper describes the validation of surge simulations produced using the low-order code ACRoSS with experimental data from a 4. 5-stage high-speed rig, representative of the front stages of a modern high-pressure compressor (HPC). ACRoSS is an unsteady, 3D through-flow code developed at Cranfield University to predict compressor performance during stall events. The experimental data was derived during the Rig250 build 6B test campaign, carried out in 2016 by the DLR Institute of Propulsion Technology. To correctly represent the surge events, the ducting of the testbed upstream and downstream of the compressor is included in the simulation.

The results from the low-order model are compared with measurements from unsteady probes for two surge events at design speed with different downstream plenum sizes. The surge frequency and pressure profiles in time are closely reproduced by the low-order model. Analysis of the unsteady pressure measurement and the acoustic waves modelled by ACRoSS indicates that the surge period is likely to be influenced by the reflection of the initial surge wave in the inlet duct.

Using the ACRoSS model, surge can be accurately reproduced both in 3D and 2D. Two-dimensional, axisymmetric simulations are shown to be sufficient for the cases investigated, and surge can be simulated with a computational cost of less than one hour per event using just 40 CPUs. This represents over an order of magnitude improvement in computational power and time required to simulate surge, compared to traditional URANS 3D CFD.