The aim of this paper is to demonstrate how the harmonic balance method can be used to predict rotor–rotor and stator–stator interactions in turbomachinery. These interactions occur in the form of clocking and indexing. Whereas clocking refers to the dependency of the performance on the relative circumferential positioning of the rotors or stators, the term indexing is used when different blade (or vane) counts lead to an aperiodic time-averaged flow. The approach developed here is closely related to the one presented by He, Chen, Wells, Li, and Ning, who generalised the Nonlinear Harmonic method to zero-frequency disturbances. In particular, configurations with only one passage per blade row are used for the simulations. We validate the methods by means of the simulation of a fan stage configuration with rotationally asymmetric inlet conditions. It is demonstrated that the harmonic balance solver is able to accurately predict the inhomogeneity of the time-averaged flow field in the stator row. Moreover, the results show that the approach offers a considerable gain in computational efficiency.

Civil aviation is aiming at fuel efficient aircraft concepts. Propulsion systems using boundary layer ingestion (BLI) are promising to reach this goal. The focus of this study is on the DLR UHBR fan stage of a tube and wing aircraft with rear-integrated engines. In this integration scenario the propulsion system and especially the fan stage receives distorted inflow in steady-state flight conditions. The distortion pattern and distortion intensity are dependent on the operating conditions. Consequently, the interaction of the fan and the distortion changes over the flight envelope. The first part of the paper aims at gaining knowledge of the BLI fan performance in the operating points end of field, approach, cruise (CR) and top of climb (TOC) using high-fidelity, unsteady RANS approaches. The analysis includes fan map performance metrics and a deeper insight into the flow field at CR and TOC. The preliminary design of a fan stage requires fast turn-around times, which are not fulfilled by high-fidelity approaches. Therefore, a fast, throughflow-based methodology is developed, which enables aerodynamicists to design distortion-tolerant fans. The main characteristics of the methodology is outlined in the second part. Consequently, the methodology is taken advantage of to investigate parameter sensitivities in terms of tip speed, blade thickness, solidity, the annulus geometry and a non-axisymmetric stator. This study suggests that distortion-tolerant fans should be designed at higher tip speeds than conventional design experience recommends to limit the local operating point excursion.

Electrically driven ducted fans (e-fans), either underwing-mounted or located at the aft-fuselage, can potentially improve the system overall efficiency in hybrid-electric propulsion architectures by increasing their thrust share over the thrust generated by the main engines. However, the low design pressure ratio of such e-fans make them prone to operability issues at off-design conditions, i.e., takeoff, where nozzle pressure ratio is close or below the critical value. This paper investigates the operational limitations of such e-fans, proving the necessity of variable geometry. A component zooming approach is deployed by integrating a streamline curvature method within an aero-engine performance tool to investigate the e-fan installed performance and operability. The concepts of variable pitch fan (VPF) and variable area nozzle (VAN) are systematically explored to quantify any performance benefits, while the unavoidable added-weight challenges due to variable geometry are taken into account. Although e-fans with low design pressure ratio (PR) are more susceptible to operability issues compared to higher PR e-fans, the former show improved overall efficiency levels, mainly dominated by propulsive efficiency. It is found that variable geometry not only tackles operability but it can improve the off-design overall efficiency of e-fans even more. VPF mostly affects the component efficiency by reshaping the e-fan performance maps, while VAN has a greater impact on propulsive efficiency by moving the operating points.

This paper reconciles the assessment of fan and propeller performance by deriving common metrics that describe their design and operational characteristics and applies them to real-world design examples. Historically, various applications with large differences in flight Mach number and thrust requirements have led to different design methodologies and performance descriptors for ducted and unducted propulsors, making direct comparisons between these propulsion concepts challenging until today. One of the limitations of conventional propeller design methods is the difficulty in isolating the aerodynamic performance of blade sections from the overall design concept. The overall efficiency is largely impacted by top-level design parameters, while the aerodynamic quality is determined by the shaping and spanwise stacking of blade profiles. In contrast, turbomachinery design focuses primarily on the efficiency of the compression process and their respective efficiency metrics. This paper addresses these issues by systematically breaking down propeller efficiency into contributions commonly used in turbomachinery design. By applying consistent methodologies, we thereby enable a fair and quantitative comparison of the potential performance benefit of each concept. Furthermore, using common performance metrics simplifies the design process, making it more accessible to less experienced designers and facilitating the exploration of alternative design approaches for unducted propulsors.