Effects on fan design by introducing Boundary Layer Ingestion (BLI) to a pusher fan in an axi-symmetric flow are studied. Boundary layer ingestion provides a potential way forward for improved aircraft fuel consumption. The fundamental principles have been established in studies, showing considerable benefits over traditional configurations with podded engines. One natural consequence of ingesting boundary layers into the propulsor is that distortion to the inlet flow will impose important design considerations for the fan. A wide range of possible system configurations are considered in literature. Unconventional fuselages as well as concepts with a fan mounted on the aft body. The precise nature of the ingested flow field will eventually be determined by the choice of aircraft and installation configuration. One possibility that appears attractive is to add a propulsor on the rear of the fuselage that ingests part of the boundary layer flow surrounding the aircraft body. Ideally the efficiency gain in the BLI propulsor compared to a conventional fan is larger the lower the incoming momentum is. This would favour ingesting the flow very close to the surface. Since the boundary layer only represents a finite mass flow determined by the body, the amount of thrust that can be generated at this higher efficiency is diminished if only the flow closest to the boundary is used. The focus here is to establish a qualitative understanding on how the fan design is affected. It is found that effects of a lower average total pressure tend to make the matching easier in that the operating line at sea level static operation is closer to the operating point at cruise where the fan needs to be optimized for efficiency. Other findings lie in the more detailed response of the aerodynamics to the incoming low pressure at the hub end changing which part of the fan separates first.

A Boundary Layer Ingesting fan is designed to function in a tail cone thruster configuration on an existing aircraft. This means that the fan ingests part of the boundary layer developing over the fuselage all around the circumference. While the fuselage drag induced on the ingested flow makes it possible to obtain a higher propulsive efficiency, it also means that the fan will operate in a severely distorted flow. In the configuration studied here the incoming flow will generally have a lower impulse near the hub, but also substantial non-axisymmetric components. The incoming flow profile is evaluated from a CFD model of a complete Fokker 100 aircraft modified with a tail cone thruster installed. Having the aircraft modeled in detail allows the extraction of the flow entering the fan inlet, which makes up the inlet boundary condition to design for. In order to make a rational design of the fan, the incoming flow is circumferentially averaged at each radial location to form the radial profile used in the design. A fan map is created to evaluate critical points in the operating envelope in order to demonstrate that the given design is stable in operation. Operation of the fan in static ground conditions is within the operating envelope of the fan without variable nozzle area.

Integrating a fan with a boundary layer ingestion (BLI) configuration into an aircraft fuselage can improve propulsion efficiency by utilizing the lower momentum airflow in the boundary layer developed due to the surface drag of the fuselage. As a consequence, velocity and total pressure variations distort the flow field entering the fan in both the circumferential and radial directions. Such variations can negatively affect fan aerodynamics and give rise to vibration issues. A fan configuration to benefit from BLI needs to allow for distortion without large penalties. Full annulus unsteady computational fluid dynamics (CFD) with all blades and vanes is used to evaluate the effects on aerodynamic loading and forcing on a fan designed to be mounted on an adapted rear fuselage of a Fokker 100 aircraft, i.e., a tail cone thruster. The distortion pattern used as a boundary condition on the fan is taken from a CFD analysis of the whole aircraft with a simplified model of the installed fan. Detailed simulations of the fan are conducted to better understand the relation between ingested distortion and the harmonic forcing. The results suggest that the normalized harmonic forcing spectrum is primarily correlated to the circumferential variation of inlet total pressure. In this study, the evaluated harmonic forces correlate with the total pressure variation at the inlet for the first 12 engine orders, with some exceptions where the response is very low. At higher harmonics, the distortion content as well as the response become very low, with amplitudes in the order of magnitude lower than the principal disturbances. The change in harmonic forcing resulting from raising the working line, thus, increasing the incidence on the fan rotor, increases the forcing moderately. The distortion transfers through the fan resulting in a non-axisymmetric aerodynamic loading of the outlet guide vane (OGV) that has a clear effect on the aerodynamics. The time average aerodynamic load and also the harmonic forcing of the OGV vary strongly around the circumference. In particular, this is the case for some of the vanes at higher back pressure, most likely due to an interaction with separations starting to occur on vanes operating in unfavorable conditions.

A design of a sub-scale Boundary Layer Ingestion (BLI) fan for a transonic test rig is presented. The fan is intended to be used in flow conditions with varying distortion patterns representative of a BLI application on an aircraft. The sub-scale fan design is based on a design study of a full-scale fan for a BLI demonstration project for a Fokker 100 aircraft. CFD results from the full-scale fan design and the ingested distortion pattern from CFD analyses of the whole aircraft are used as inputs for this study. The sub-scale fan is designed to have similar performance characteristics to the full-scale fan within the capabilities of the test facility. The available geometric rig envelope in the test facility necessitates a reduction in geometric scale and consideration of the operating conditions. Fan blades and vanes are re-designed for these conditions in order to mitigate the effects of the scaling. The effects of reduced size, increased relative tip clearance and thicknesses of the blades and vanes are evaluated as part of the step-by-step adaption of the design to the sub-scale conditions. Finally, the installation effects in the rig are simulated including important effects of the by-pass flow on the running characteristics and the need to control the effective fan nozzle area in order to cover the available fan operating range. The predicted operating behaviour of the fan as installed in the coming transonic test rig gives strong indication that the sub-scale fan tests will be successful.

The BLI (boundary layer ingestion) concept for propulsion seeks to improve the energy efficiency of aircraft propulsion. This is achieved by accelerating low momentum flow ingested from boundary layers and wakes developed over the fuselage through the fan. A major challenge that needs to be overcome to realise the benefits is that the fan needs to work efficiently in distorted flow. Understanding the effects of distortion on the aerodynamic performance and the distortion transfer through the fan is therefore essential to future designs. A BLI fan, designed at reduced scale, is used for analytic modelling and experiments in a rig designed for this purpose. The test rig replicates BLI conditions for a fan installed at the aircraft tail cone. An unsteady model that includes all blades and vanes of the fan, as well as the nacelle and the by-pass duct of the test rig is used for CFD (computational fluid dynamics) simulations. Test results are used to confirm that the CFD model is representative of the aerodynamics of the fan. The tests are conducted using varying fan operating conditions but also tests with an added distortion screen. Analysis results are then used to investigate the effects of distortion on the fan efficiency, as well as on the overall efficiency. The fan efficiency is found to be moderately decreased depending on the level of and extent of inlet circumferential distortion. In terms of overall energy efficiency, a net improvement over a similar fan in clean inlet flow is found.

Boundary Layer Ingestion (BLI) is a concept with the potential to reduce energy consumption needed for aircraft propulsion. For the fan this results in a need to work well in an environment of increased continuous distortion. The objective of this study is to increase the understanding of unsteady aerodynamic forces due to total pressure distortion in a BLI fan. This is done by using computational fluid dynamics to analyze a fan design intended for a BLI installation. Results include low subsonic to transonic operating speeds and distortion in a wide range of wave numbers. The forcing exhibits a significant dependency on the aeroacoustic cut-on/cut-off condition. This is in particular true at part speed where the normalized unsteady force rises sharply before dropping suddenly as the corrected speed or engine order increases. Unsteady pressure in the blade passage is observed to exhibit the same increase in level followed by a sudden drop once the cut-on limit is passed and undamped pressure waves propagating out from the blade row appear. The unsteady forces on the first three modes exhibit different sensitivities to the distortion wavelength but all are affected by the acoustic condition. By comparing results for the reference fan to a similar fan design with a higher blade count the cascade properties of the blade row are found to dominate the interaction. A result of this is that a higher blade count fan may be less affected by the distortion, and be less prone to propagate noise due to low engine order distortion.

A distorted air stream entering an aeroengine fan or compressor leads to harmonic forces on the rotating blades. These aerodynamically induced forces are well-known causes of blade vibration and associated fatigue problems. Significant levels of distortion arise from different sources like side wind and high angles of attack that occur at specific operating conditions. For aircraft with the engine closely integrated with the fuselage, the engine will be exposed to distortion during the entire flight cycle. With a focus on understanding the aeroacoustic interaction the computational fluid dynamics (CFD) analyses used here consider harmonics of the distortion. Harmonic responses are calculated from low to transonic speeds for a range of cases. Major phenomena and driving parameters affecting the forcing strength and pressure amplitudes in the blade passage are identified from the analyses. It is demonstrated that the forcing strength is strongly affected by the cut-on/cutoff conditions upstream and downstream of the blades. Also, depending on design parameters of the blade, the aeroacoustics of the blade passage is important for the resulting forcing. All analyses are made in two-dimensional over a wide range of flow conditions as well as geometric variations. The results of the study provide an increased understanding of the harmonic forcing of blades. A simple model is proposed that can identify conditions where increased pressure amplitudes in the blade passage may be expected. The sensitivities to parameters may also give some guidance in how design and operation can be adapted to reduce the aerodynamic forcing.