International Journal of JOURNAL Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 AND 6359(Online) Volume 4, Issue 3, May June (2013) IAEME TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 3, May - June (2013), pp. 327-336 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

IJMET
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COMPUTATIONAL STUDY OF FILM COOLING IN HYPERSONIC FLOWS

Associate Professor & Head(ANE), Malla Reddy College of Engineering and Technology, Secunderabad 2 Assistant Professor, Malla Reddy College of Engineering and Technology, Secunderabad, 3 Director of Propulsion, DRDL, Hyderabad, Andhrapradesh, India

ABSTRACT A computational study of film cooling in hypersonic laminar flow has been performed using ANSYS-CFX, commercial software. The aim of this computational work is to investigate the mechanism and effectiveness of film cooling in hypersonic laminar flows. Hypersonic flow over a flat plate without film cooling was first studied to provide a reference datum to check the effectiveness of film cooling. For laminar film cooling three different primary flow conditions were first used for validation. Detailed information of the flow field including velocity profile, Mach contour, temperature contour and heat transfer rate was presented. The mechanism of film cooling has been revealed according to the plots of calculated velocity profiles, Mach contours and temperature contours downstream of the slot. Five coolant injection rates between 2.95 x10-4 and 7.33 x10-4kg/s and three slot heights, 0.8382; 1.2192; 1.6002mm, were examined in hypersonic laminar film cooling. Both the coolant and the primary flow were air. Film cooling was found to be an effective way to protect wall surfaces that are exposed under a high heat transfer environment especially in hypersonic laminar flow. Key words: Hypersonic, Heat transfer, transpiration cooling 1. INTRODUCTION

In general Mach number greater than 5 are known as Hypersonic flows. The kinetic energy of a high-speed, hypersonic flow is dissipated by the influence of friction within a boundary layer. The extreme viscous dissipation that occurs within hypersonic boundary
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

layers and shocks are very close and thin to the body in hypersonic flow, causes localization of heating can create very high temperatures and leads to the structural failure, due to thermal stresses induced. So, there is need of cooling technique for bodies traveling at Hypersonic Speeds. The employment of a secondary fluid injected through discrete slots to insulate thermally a solid surface from a gas stream owing over it is called film cooling. From this definition, it is clear that film cooling introduces a secondary fluid into the primary flow stream in order to decrease the heat transfer rate from the primary flow stream to the solid wall. Film cooling might be used on blades of gas turbines, scramjet intake surfaces and combustor walls of high-speed vehicles, rocket nozzles and the extension surfaces of rockets all of which usually work under high heating loads. The objective of the Paper is to evaluate application of film cooling in Hypersonic flows in conjunction with Scramjet of Hypersonic Air breathing propulsion. 2. LITERATURE SURVEY

Cary and Hefner [1] performed experiments to investigate the effects of slot height, coolant mass-flow rate, injection gas temperature, and heat conduction from the mainstream through the slot lip for a Mach 6 mainstream with sonic tangential slot injection. The efficiency was found to be significantly improved compared with cases at lower Mach numbers. Zakkay et al: [2] investigated tangential slot injection with a streamwise adverse pressure gradient in a Mach 6 axisymmetric wind tunnel. The results indicated that the better film cooling effectiveness could be obtained when an adverse pressure gradient was present and also considered the Reynolds number as a factor which also changes film cooling effectiveness. Majeski and Weatherford [3] found that film cooling was an effective means of reducing heat transfer to a sensor window at Mach number 8. Olsen et al: [4] performed experiments to study coolant delivery pressure, slot height and lip thickness, and incident shock effects in two-dimensional hypersonic film cooling. Some design guidelines were published as follows. Coolant pressure matched to the local boundary layer edge pressure was found to be most effective. Larger slot heights are more effective than smaller slot heights. And, lip thickness has no net effect on film cooling and can therefore be set by other design considerations. Incident shocks degrade film cooling effectiveness. The numerical study of film cooling in hypersonic laminar and turbulent flows has been performed by Yang et al[5], using an in-house Navier-Stokes solver. In his thesis, computational parametric investigation has carried out to assess the effect of primary flow condition, slot height and cooling injection rate on the mechanism and effectiveness of film cooling in hypersonic laminar and turbulent flows. In this present paper the parametric investigation has been carried out to evaluate the employability of film cooling application for Thermal management of Hypersonic Air breathing Vehicle by using ANSYS CFX, commercial CFD software. The results presented here are the preliminary analysis of Hypersonic Laminar film cooling using the boundary conditions mentioned by Yang et al[5].

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

3. MODELLING OF FLOW PROBLEM 3.1 Geometry of flat plate The Geometrical modeling and meshing of the problem has been done using ICEM CFD. The computational domain of the flat plate is illustrated in Fig.1. Two blocks are included in the topology. In the laminar film cooling study, the first block was defined by the distance from the sharp leading edge to the slot of 33.02mm, corresponding to the experimental configuration. The second block was defined by the distance 254.00mm downstream of the slot. In the normal direction, the computational domains were chosen to be 76.20mm, which is sufficiently far from the plate such that the oblique shock wave passed out of the flow field at the downstream boundary.

Fig 1: Geometry of Flate Plate. 3.2 Boundary Conditions Freestream conditions were set at the leading edge and top of the computational domain and supersonic out condition is employed at the trailing edge. All physical surfaces are modeled as no-slip (viscous flow) isothermal wall surfaces. Zero pressure gradients is used on these wall surfaces. Similar boundary conditions were applied in all film cooling calculations and tabulated in Table 1. LFP Case 1 2 3 M 9.90 9.90 9.90 Re/m 6.46x10
6

P(Pa) 476.00 341.00

T0(K) 1290.00 1170.00

T(K) 62.62 56.79 50.00

Tw(K) 290.00 290.00 290.00

5.45 x106
6

4.24 x10 214.00 1030.00 Table 1: Boundary Conditions

3.3Geometry of flat plate for Film Cooling

Fig 2: Geometry of flat plate with Injectant slot

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

Film cooling analysis is carried out for first case of flat plate. Coolant is injected tangentially through a slot at a height of 1.2192mm from plate. Coolant is air with varying mass flow rates as shown in table 2 is analyzed. LFC Case 1 2 3 4 5 M 9.9 Re/m 6.46x106 T0(K) 1290.0 S(mm) 1.2192 Wc(kg/s) 2.95x10-4

9.9 6.46x106 1290.0 1.2192 4.08 x10-4 9.9 6.46x106 1290.0 1.2192 5.07 x10-4 9.9 6.46x106 1290.0 1.2192 6.12 x10-4 9.9 6.46x106 1290.0 1.2192 7.33 x10-4 Table 2: Film cooling cases with varying coolant mass flow rates

The slot width is 0.1143m giving a slot area of 1.39x10-4 m2. With the film reservoir temperature of room temperature, 290.0K, and the conditions of the film at the slot exit, which is assumed to be a nozzle throat, and the coolant flow sonic, then the pressure in the reservoir to give this mass flow rate is 1532.0 Pa and the flow conditions at the throat are: c = 0.01167 kg/m3; pc = 809.34 Pa; Tc = 241.67K. Coolant flow conditions at the slot exit for all cases are listed in Table 3. c(kg/m3) 6.79x10
-3 -3

LFC Case 1 2 3 4 5

Mc 1.0

Pc(Pa) 471.11

Tc(K) 241.67 241.67 241.67 241.67 241.67

1.0 6.46x10 652.30 -2 1.0 6.46x10 809.34 -2 1.0 6.46x10 978.46 -2 1.0 6.46x10 1171.73 Table 3: Coolant Boundary conditions

4. RESULTS Analysis of the above mentioned cases is carried out in CFX software. Various contours of Pressure, Mach number, Temperature has taken to discuss the results. 4.1 Laminar flow over flat plate Temperature profiles Static temperature profiles of various LFP Cases I, II & III over the flat plate are depicted in Fig 3. The thickness of the thermal boundary layer is clearly growing. At x/L = 0.5, the temperature boundary layer is about 5mm, that is, in such a thin layer, large temperature gradient exists at the wall leading to strong heat transfer from the fluid to the wall. The static temperature contours illustrated in Fig 3 again clearly shows the development of the temperature profile through the boundary layer including a high temperature layer in the vicinity of the wall.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

LFP Case I at X/L =0

LFP Case I at X/L =0.2

LFP Case I at X/L =0.5

LFP Case I at X/L =0.8

LFP Case II at X/L =0.2

LFP Case II at X/L =0.5

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

LFP Case II at X/L =0.8

LFP Case III at X/L =0.2

LFP Case III at X/L =0.5

LFP Case III at X/L =0.8

LFP Case - I

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

LFP case II

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

LFP Case-III

Laminar Film Cooling Study It is obvious that film cooling for this laminar flow case is very effective. Here the length from the slot to the point where heat transfer rate becomes greater than zero is defined as the "cooling length". Under the flow conditions in LFC Case 5, the cooling length is about 20 s. The wall surface is thus fully protected from heating from the primary flow within the cooling length.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

Effect of Injection rate Five different coolant injection rates from 2.95x10-4 to 7.33 x10-4 kg/s were computed under the same primary flow conditions and the same slot height. These are LFC Cases in Table 2. The heat transfer rate decreases and film cooling effectiveness increases with increased coolant injection rate. This is because as the coolant flow injection rate is increased, more energy and momentum are contained in the coolant flow stream. The unmixed coolant flow penetrates the primary flow further from the slot. Thus the convective heat transfer rate between the primary flow and the wall surface is reduced. Film cooling effectiveness therefore increases. The coolant fluid is seen to affect the primary boundary layer in two ways: 1) a separate layer created by the coolant fluid itself, and 2) a mixing layer between the primary and coolant flow streams. These are two fundamental characters of film cooling. The main contribution to heat protection by film cooling is that the separate coolant layer penetrates into the primary boundary layer and isolates it from the wall. At the same time, the coolant fluid mixes with the primary fluid, from which finally develops a new boundary layer. Therefore, we can conclude that the development of the primary boundary layer is delayed by the injection. Under all five coolant flow injection rates, the coolant flow is found to be choked at the slot. The coolant flow will accelerate as it expands from the slot and become supersonic downstream of the slot. It is clear that increasing the coolant injection rate will provide improved cooling effectiveness. Also the film remains fully effective some distance downstream of the slot. Then mixing between the coolant flow and the primary flow becomes stronger, which reduces the effect of film cooling. But the effectiveness remains high even far from the slot CONCLUSIONS Film cooling in hypersonic laminar flow has been numerically investigated for three primary flow conditions, five coolant injection rates. By modeling the flow in the coolant inlet, heat transfer rate is better predicted compared with using a uniform boundary at the slot exit. The following conclusions are drawn: Film cooling in hypersonic flow can be very effective in laminar flow. At some distance downstream of the slot the effectiveness is fully effective. The effectiveness drops further downstream due to mixing between the coolant and the primary flow streams. In laminar flow, the effectiveness was found to be still quite high even far downstream of the slot. Increasing the coolant injection rate can obviously increase the film cooling effectiveness for laminar cases. Primary flow conditions are important as expected. Under a single coolant injection rate, lower heat transfer rate can be obtained when total temperature and static pressure of the primary flow decrease. Isothermal wall conditions are shown to be helpful to reduce the computational cost of determining approximation film cooling effectiveness.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

REFERENCES 1. A.M. Cary Jr. and J.N. Hefner. Film-cooling effectiveness and skin friction in hypersonic turbulent flow. AIAA Journal, 10(9):1188{1193, 1972. 2. V. Zakkay, C.R. Wang, and M. Miyazawa. Effect of adverse pressure gradient on film cooling effectiveness. AIAA Journal, 12(5):708{709, 1974. 3. J.A. Majeski and R.H. Weatherford. Development of an empirical correlation for film-cooling effectiveness. AIAA Paper 88-2624, 1988. 4. G.C. Olsen, R.J. Nowak, M.S. Holden, and N.R. Baker. Experimental results for film cooling in 2-d supersonic flow including coolant delivery pressure, geometry, and incident shock effects. AIAA Paper 90-0605, 1990. 5. Xiaobo Yang, B.Eng. Numerical Study of Film Cooling in Hypersonic Flows Ph d Thesis to Department of Aerospace Engineering at the University of Glasgow November 2002. 6. Kapil Chopra, Dinesh Jain, Tushar Chandana and Anil Sharma, Evaluation of Existing Cooling Systems for Reducing Cooling Power Consumption, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 210 - 216, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 7. B. Bounegta, R. Dizene and M. Abdelkarim, Numerical Simulation for Film Cooling Technique with Inlet Boundary Conditions Perturbation, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 559 - 572, ISSN Print: 0976 6340, ISSN Online: 0976 6359.

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