As the aircraft cruising at high altitude over 20,000 m with subsonic speed, the Reynolds number in terms of the compressor blade becomes very low and the compressor performance decreases dramatically due to separation of boundary layer and secondary-flow. The main objective in this paper is to understand the physical mechanism by which Reynolds number affects the compressor stable range. In this paper, a series of steady and unsteady numerical simulations were carried out for a transonic compressor rotor under several conditions, which corresponded to the operations at sea level, and at high altitude. Detailed analyses of the flow visualization have exposed the different flow topologies of the complicated secondary flow. It was found that the transonic axial-flow compressor rotor used in current investigation was prone to tip stall behavior, and the complex flow mechanisms which occur near the blade tip are found to be the key factors for the limited flow stability both under high Reynolds number and low Reynolds number. Under high Reynolds number, the tip flow field was dominated by the low momentum zones generated by the interaction between tip leakage flow and incoming flow, and with the decrease of Reynolds number, the tip leakage flow was weakened and the low-momentum fluid due to the surface boundary layer separation and radial transport of low-energy fluid was dominant in the tip flow.

The laminar-turbulent transition process on the compressor blade surface is often induced by the laminar separation flow at low Reynolds number ( Re). In the present study, numerical simulations were conducted to investigate the structure of the laminar separation bubble and its effects on the profile loss of a high subsonic compressor airfoil under different Re conditions, and the mechanism for the performance deterioration of compressor airfoil at low Re was clarified. Besides, the airfoil was redesigned to obtain a series of airfoils with different loading distributions, and the aerodynamic performance of these airfoils was compared and analyzed in detail. According to the simulation results, the laminar separation bubble mainly determined the loss generation process of a compressor airfoil. When Re decreased from 12 × 10⁵ to 1.5 × 10⁵, the laminar separation bubble on the suction surface grew thicker and the length was increased by 11.2% of the axial chord. As such, the reversed flow inside the laminar separation bubble became more obvious and the turbulence level downstream of the maximum thickness of laminar separation bubble was increased. Also, the growth in the turbulent boundary layer was enhanced, causing more serious flow blockage and wake mixing. According to the Denton's profile loss model, the larger trailing edge loss caused by the stronger displacement effect of laminar separation bubble was supposed to be the main reason for the performance deterioration of compressor airfoil under low Re conditions. The ultra-front loading distribution for airfoil has the possibility to suppress or even eliminate the negative effect of laminar separation bubble, and the profile loss was decreased by 26.7% at Re = 1.5 × 10⁵; however, the less significant performance improvement was observed at some higher Re. Moreover, the ultra-front loaded airfoil was less sensitive to the inlet turbulence level and the superiority still holds even at some supercritical conditions.

Due to the complexity of the internal flow field of compressors, the aerodynamic design and optimization of a highly loaded axial compressor with high performance still have three problems, which are rich engineering design experience, high dimensions, and time-consuming calculations. To overcome these three problems, this paper takes an engineering-designed 2.5-stage highly loaded axial flow compressor as an example to introduce the design process and the adopted design philosophies. Then, this paper verifies the numerical method of computational fluid dynamics. A new Bezier surface modeling method for the entire suction surface and pressure surface of blades is developed, and the multi-island genetic algorithm is directly used for further optimization. Only 32 optimization variables are used to optimize the rotors and stators of the compressor, which greatly overcome the problem of high dimensions, time-consuming calculations, and smooth blade surfaces. After optimization, compared with the original compressor, the peak efficiency is still improved by 0.12%, and the stall margin is increased by 2.69%. The increase in peak efficiency is mainly due to the rotors. Compared with the original compressor, for the second-stage rotor, the adiabatic efficiency is improved by about 0.4%, which is mainly due to the decreases of total pressure losses in the range of above 30% of the span height and 10%–30% of the chord length. Besides, for the original compressor, due to deterioration of the flow field near the tip region of the second-stage stator, the large low-speed region eventually evolves from corner separation into corner stall with three-dimensional space spiral backflow. For the optimized compressor, the main reason for the increased stall margin is that the flow field of the second-stage stator with a span height above 50% is improved, and the separation area and three-dimensional space spiral backflow are reduced.

Pipe diffusers with several different geometries were designed for a highly loaded centrifugal compressor originally using a wedge diffuser. Parametric studies on the effect of pipe diffuser performance of a highly loaded centrifugal compressor by varying pipe diffuser inlet-to-impeller exit radius ratio, throat length, divergence angle, and throat area on centrifugal compressor performance were performed using a state-of-the-art multiblock flow solver. An optimum design of pipe diffuser was obtained from the parametric study, and the numerical results indicate that this pipe diffuser has remarkable advantageous effects on the compressor performance. Furthermore, a detailed comparison of flow visualization between the pipe diffuser and the wedge diffuser was conducted to identify the physical mechanism that account for the beneficial effects of the pipe diffuser on the performance and stability of the compressor. It was found that the performance enhancement afforded by the pipe diffuser is a result of the unique diffuse inlet flow pattern. Alleviating flow distortion in the diffuser inlet and reducing the possibility of a flow separation in discrete passages are the physical mechanisms responsible for improving the highly loaded centrifugal compressor performance.