Methodology Development and Investigation of Turbofan Engine Response to Simultaneous Inlet Total Pressure and Swirl Distortion

As a contribution to advancing turbofan engine ground test technology in support of propulsion system integration in modern conceptual aircraft, a novel inlet distortion generator (ScreenVaneTM) was invented. The device simultaneously reproduces combined inlet total pressure and swirl distortion elements in a tailored profile intended to match a defined turbofan engine inlet distortion profile. The device design methodology was intended to be sufficiently generic to be utilized in support of any arbitrary inlet distortion profile yet adequately specific to generate high-fidelity inlet distortion profile simulation.

For the current investigation, a specific inlet distortion profile was defined using computational analysis of a conceptual boundary layer ingesting S-duct turbofan engine inlet. The resulting inlet distortion profile, consisting of both total pressure and swirl distortion elements, was used as the objective profile to be matched by the ScreenVane in a turbofan engine ground test facility.

A ScreenVane combined inlet total pressure and swirl distortion generator was designed, computationally analyzed, and experimentally validated. The design process involved specifying a total pressure loss screen pattern and organizing a unique arrangement of swirl inducing turning vanes. Computational results indicated that the ScreenVane manufactured distortion profile matched the predicted S-duct turbofan engine inlet manufactured distortion profile with excellent agreement in pattern shape, extent, and intensity. Computational full-field total pressure recovery and swirl angle profiles matched within approximately 1% and 2.5° (RMSD), respectively. Experimental turbofan engine ground test results indicated that the ScreenVane manufactured distortion profile matched the predicted S-duct turbofan engine inlet manufactured distortion profile with excellent agreement in pattern shape, extent, and intensity. Experimental full-field total pressure recovery and swirl angle profiles matched within approximately 1.25% and 3.0° (RMSD), respectively.

Following the successful reproduction of the S-duct turbofan engine inlet manufactured distortion profile, a turbofan engine response evaluation was conducted using the validated ScreenVane inlet distortion generator. Flow measurements collected at discrete planes immediately upstream and downstream of the fan rotor isolated the component for performance analysis. Based on the results of this particular engine and distortion investigation, the adiabatic fan efficiency was negligibly altered while operating with distorted inflow conditions when compared to nominal inflow conditions. Fuel flow measurements indicated that turbofan engine inlet air mass flow specific fuel consumption increased by approximately 5% in the presence of distortion.

While a single, specific turbofan engine inlet distortion profile was studied in this investigation, the ScreenVane methodology, design practices, analysis approaches, manufacturing techniques, and experimental procedures are applicable to any arbitrary, realistic combined inlet total pressure and swirl distortion.