Flow Unsteadiness Analysis in the High-Altitude Aircraft Dual-Fan System and Geometric Optimization Control Strategies

When high-altitude aircraft operate in a low-density environment, the flow instability within their internal ducts poses a severe challenge to aerodynamic design and operational safety. Especially in the intake system of the tandem dual-fan configuration, the asymmetric flow caused by rotating machinery coupled with the low-density effect exacerbates flow distortion, momentum dissipation, and efficiency loss and may even trigger system instability risks such as rotational stall or surge. To address these challenges, this paper establishes a high-fidelity dynamic model of the internal flow field of the aircraft, based on the Reynolds-averaged Navier–Stokes equations and the SST k-ω turbulence model, combined with dynamic mesh technology. It reveals the unstable mechanism caused by angular momentum accumulation under co-rotation conditions and its intrinsic correlation with the degradation of aerodynamic performance. Inspired by the concept of micro-flow regulation, an active flow control strategy integrating discrete auxiliary injection and local geometric shape optimization is proposed. Numerical results show that by reasonably arranging auxiliary injection holes in the intake duct and optimizing local geometric fillets, the uniformity of intake flow can be effectively improved, and the formation of large-scale vortex structures can be suppressed. This method increases the system’s flow capacity by approximately 47.4%, significantly improves the total pressure recovery coefficient and fan aerodynamic efficiency, and reduces the amplitude of low-frequency pressure fluctuations by approximately 23.1%. Research shows that in high-altitude low-Reynolds-number conditions, micro-flow regulation combined with geometric reconstruction can effectively suppress flow instability induced by rotating machinery. This achievement provides a theoretical basis and feasible engineering path for aerodynamic stability design and optimization of key components, such as the aircraft intake and exhaust systems and thermal management systems, and is of significant value for improving the overall performance and reliability of high-altitude long-endurance aircraft.