Coupled Design of Multi-Component Distortion-Generating Devices for Aircraft Engine Ground Tests – Part I: Design Methodology and Numerical Validation

Abstract Engine performance, operability and vibration can be drastically affected by inlet flow non-uniformity. Devices that can accurately and flexibly recreate total pressure and swirl distortion cartographies in test environments are required to assess engine-airframe incompatibilities as soon as possible during the design process. This paper presents a numerical design methodology for a two-component distortion device that a) is manufacturable with additive manufacturing for maximum flexibility, and b) is able to reproduce complex and realistic patterns featuring high levels of total pressure distortion and flow angles magnitudes. The device consists in the combination of a honeycomb total pressure screen with airfoil-shaped edges, and a turning vanes assembly. This first part paper describes the design methodology, from the preliminary design of each isolated component to their joint optimization by means of a global surrogate-assisted optimization strategy making use of a multi-fidelity model for the coupled device. The preliminary design tools are applied and validated on two canonical configurations for each type of distortion. Then the coupled design strategy is applied on two realistic configuration patterns featuring combined total pressure and swirl distortions. The experimental testing of the screens and a cross-comparison between design and experimental tests is discussed in the second part of this paper.