Nonsynchronous Vibration (NSV) due to a Flow-Induced Aerodynamic Instability in a Composite Fan Stator

This paper describes the identification and prediction of a new class of nonsynchronous vibration (NSV) problem encountered during the development of an advanced design composite fan stator for an aircraft engine application. Variable exhaust nozzle testing on an instrumented engine is used to map out the NSV boundary, with both choke- and stall-side instability zones present that converge toward the nominal fan operating line and place a limit on the high-speed operating range. Time-accurate three-dimensional viscous CFD analyses are used to demonstrate that the NSV instability is being driven by dynamic stalling of the fan stator due to unsteady shock-boundary layer interaction. The effects of downstream struts in the front frame of the engine are found to exasperate the problem, with the two fat service struts in the bypass duct generating significant spatial variations in the stator flow field. Strain gage measurements indicate that the stator vanes experiencing the highest vibratory strains correspond to the low static pressure regions of the fan stator assembly located approximately 90 degrees away from the two fat struts. The CFD analyses confirm the low static pressure sectors of the stator assembly are the passages in which the flow-induced NSV instability is initiated due to localized choking phenomena. The CFD predictions of the instability frequency are in reasonable agreement with the strain gage data, with the strain gage data indicating that the NSV response occurs at a frequency approximately 25% below the frequency of the fundamental bending mode. The flow patterns predicted by the CFD analyses are also correlated with the results of an engine flow visualization test to demonstrate the complex nature of the flow field.