Contra-rotating fans (CRFs) have garnered significant attention due to their higher power-to-weight ratio compared to traditional fans; however, limited focus has been given to the localization and development of local aerodynamic losses. Furthermore, there is a need for further research on the impact of load distribution along the radius on local entropy production. Therefore, this study aims to investigate a contra-rotating fan as the research subject. An optimal design for load distribution along the radius is achieved by constructing a surrogate model in combination with a genetic algorithm. The effectiveness of this design has been verified through experimentation using a specific test device. In this study, a local entropy production rate (EPR) model adapted to the shear stress transport-detached eddy simulation (SST-DES) technique is constructed to evaluate the loss distribution of the contra-rotating fan. This paper primarily focuses on comparing and analyzing the blade profile and overall performance of the CRFs before and after optimization. The EPR contribution of each interval along the radius is compared to the corresponding blade channel to identify the approximate range of high-EPR regions. Furthermore, an investigation is conducted to examine the distribution of EPR along the streamwise direction in these high-EPR regions. After that, by comparing the development of the flow structure near a stall before and after optimization, combined with the analysis of the EPR contours, the EPR mechanism of this CRF is revealed.

In recent years, few studies focused on adjusting the load distribution of contra-rotating fan (CRF) blades. To improve the overall performance of CRFs, we used a design code to build 32 sets of CRFs to determine the effects of three factors—the front and rear rotor load matching, the load distribution of each rotor and the axial distance between the rotors—on the total pressure rise and efficiency of CRFs using numerical calculations. The relationship between the CRF blades load and velocity components was theoretically analyzed using blade element analysis and the forward problem method. According to the performance curve, it can be concluded that the rear rotor (RR) is the key factor that determines the performance of CRFs. Through analyzing Mach number contours from different perspectives, the relationship between velocity and adjustment load was verified. Furthermore, the flow field characteristics for three specific CRFs were explored at the stall points, design points and choke points to reveal their flow mechanisms. This study provides a reference for the CRF blade design method.

Quantification of the loss generation of ducted contra-rotating fan (CRF) blades is difficult to achieve, since there are no guide vanes between rotors. A blade design program was established to investigate the relationship between radial velocity distribution and incurred loss. Numerical and experimental techniques were used to confirm the optimal configuration’s overall performance. The relationship between loss and velocity distribution under the impact of spanwise load distribution was confirmed by the entropy contour from various perspectives. The appropriate radial velocity distribution can improve the operating efficiency of a CRF by reducing the entropy around the annulus under design and near-stall conditions. This regularity could provide some strategies in the design of contra-rotating blades.

The primary purpose of this study is the reduction of local entropy production in a contra-rotating stage. As such, the unsteady flow phenomena and the impact of radial load distribution on these phenomena and local entropy production need to be clarified. In this study, the SBES turbulence model is utilized to capture the vortices in the flow separation zone, and the γ-Re_θ transition model is employed to predict the transition phenomenon within the boundary layer. Entropy production rate models suitable for different turbulence models are constructed separately to calculate local entropy production. Vortex visualization is achieved according to the Lambda_ci criterion, and the relative vorticity change rate is used to analyze the components of the tip clearance vortices. The transition phenomenon is analyzed from the perspectives of both the Euler and the Lagrange descriptions. The primary findings can be summarized as follows: The transition begins earlier and progresses more rapidly in the rear rotor. Wake propagation, occurring at double the frequency, entropy production rate within the boundary layer changes in synchrony with the wall shear stress at the same frequency. Additionally, an investigation of the tip clearance vortices concludes that the main structure of the tip clearance vortices coincides with the flow pattern of the high entropy production rate region, and the flow structure related to the high divergence area is essential for considering subsequent optimization with the aim of reducing the entropy production rate.