Conceptual Design of a Counter-Rotating Fan System for Distributed Boundary Layer Ingesting Propulsion

The present paper details the design of the counter rotating fans for a Turboelectric Distributed Propulsion (TeDP) system. Sixteen propulsors installed in mail-slot-shape nacelles are embedded on an aerodynamically optimized hybrid wing-body configuration. The hybrid-wing/body (HWB) configuration which was previously designed to satisfy the conditions of trim, longitudinally static stability and specific cargo space is employed as the baseline configuration in pursuing an optimal distributed propulsion system. A set of distributed propulsors is conceptually designed and the collective performance is evaluated against the target thrust mandated by the mission requirements. The concept of the distributed propulsion allows the fan pressure ratio to be around 1.27~1.32 for the target thrust. In addition, further splitting of the fan pressure ratio by using the counter-rotating fans for each slot realizes the target pressure ratio with low tip speed. In the distributed propulsion system, the nature of the flow conditions and/or the thickness of the ingested boundary layer may differ and result in different propulsive reaction of each individual propulsor. The optimization is, thus, approached from both the propulsion system and individual propulsor perspectives. An optimal distribution of the thrust and power output is determined by how the system utilizes each passage's propulsive characteristics and its interaction with the airframe. These system level analysis and optimization are conducted using an actuator disk model to account for the propulsion-airframe integration numerically. With respect to the propulsor level, aerodynamic shape optimizations of the fan blades are performed in a sequential multi-objective optimization process for various design objectives, such as mass flow rate condition, fan pressure ratio, efficiency and the exit flow angle of the fan stage by using a genetic algorithm, NSGA-II. The radial chord distribution, and meanline distribution of the rotors are designed on the circumferentially averaged axi-symmetric inlet profiles and tested on the six inlet profiles from six divided sectors to reckon flow distortion. The performances of the counter rotating fans are, thus, evaluated accordingly for obtaining distortion tolerant fan. The performance of the distributed propulsion system is evaluated by two CFD tools, i.e., a multi-stage turbo-machinery CFD code and one propulsion-airframe integration flow solver coupled with a body-force model. The optimized boundary layer ingestion propulsion system of 16 distributed slots not only reaches the system target thrust, but also delivers a close to 20% fuel saving benefit against its counterpart 12 distributed clean inlet propulsion system.