Sea level static calibration of a compact multimission aircraft propulsion simulator with inlet flow distortion

Wind tunnel tests of propulsion-integrated aircraft models have identified inlet flow distortion as a major source of compressor airflow measurement error in turbine-powered propulsion simulators. Consequently, two Compact Multimission Aircraft Propulsion Simulator (CMAPS) units were statically tested at sea level ambient conditions to establish simulator operating performance characteristics and to calibrate the compressor airflow against an accurate bellmouth flowmeter in the presence of inlet flow distortions. The distortions were generated using various-shaped wire mesh screens placed upstream of the compressor. CMAPS operating maps and performance envelopes were obtained for inlet total pressure distortions (ratio of the difference between the maximum and minimum total pressures to the average total pressure) up to 35 percent, and were compared to baseline simulator operating characteristics for a uniform inlet. Deviations from CMAPS baseline performance were attributed to the coupled variation of both compressor inlet-flow distortion and Reynolds number index throughout the simulator operating envelope for each screen configuration. Four independent methods were used to determine CMAPS compressor airflow; direct compressor inlet and discharge measurements, an entering/exiting flow-balance relationships, and a correlation between the mixer pressure and the corrected compressor airflow. Of the four methods, the last yielded the least scatter in the compressor flow coefficient, approximately + or - 3 percent over the range of flow distortions.