Consideration of Unsteady Aerodynamics and Boundary-Layer Transition in Rotorcraft Airfoil Desig

Traditional rotorcraft airfoil design is based on steady-flow aerodynamic requirements. The approach assumes a strong correlation between steady and unsteady aerodynamic characteristics, which is often not observed in practice. This is particularly relevant at high speed and high thrust conditions, when the rotor is susceptible to dynamic stall and its many negative consequences. Given the abrupt nature of the phenomena, large margins are typically established to prevent fatigue loads on the blades and pitch links; thus, limiting operation under high altitudes, high payloads, high temperatures, as well as during maneuvers.;This work addresses the problem from the perspective of passive airfoil design. Typical design requirements are revisited to include metrics for improved dynamic stall and new ways to qualifying rotorcraft airfoils are proposed. A number of design studies are conducted to better understand the relation between airfoil shape and dynamic stall behavior. The design manipulations are handled by an inversedesign, conformal mapping method, and unsteady Reynolds-averaged Navier-Stokes equations are used to predict the aerodynamic performance under pitch motion.;In unsteady flow, the occurrence of aerodynamic lags in the development of pressures, boundary-layer separation, and viscous-inviscid interactions suggest more strict requirements than in steady flow. In order to postpone the onset of dynamic stall, the design needs to handle competing leading- and trailing-edge separation mechanisms, which are heavily influenced by local supersonic flow, strong shock waves, and laminar-turbulent transition effects. It is found that a particular tailoring of the trailing-edge separation development can provide adequate dynamic stall characteristics and minimize penalties in drag and nose-down pitching moment. At the same time, a proper design of the nose shape is required to avoid strong shock waves and prevent premature leading-edge stall.;A proof-of-concept airfoil is developed to improve dynamic stall behavior, while meeting stringent requirements on flight conditions away from stall. Trade-offs to the achievement of typical rotor design requirements are discussed. Performance calculations using information obtained from comprehensive analysis (RCAS) based on a UH-60A helicopter are conducted to estimate gains in the rotor stall boundaries. Results are compared to the baseline UH-60A rotor, as well as a blade that uses a VR-12 airfoil inboard. It is found that the new airfoil can provide expansion of the operational envelope compared to the other two configurations, while still reducing hover drag and maintaining very low pitching moments. Some compromises in the drag rise at high Mach numbers are found in comparison to the VR-12 airfoil. By placing the new airfoil up to r/R = 0.80 on the rotor, the baseline UH-60A maximum speed (mu = 0.37) can be achieved with considerable margins to drag rise.;Finally, pitching wing calculations are conducted to demonstrate the proposed concepts in three-dimensional flow. Differences in the development of stall between wings using a VR-12 airfoil and the new airfoil are discussed. Despite the complex evolution of 3-D flow structures, the stall onset mechanisms seem to follow the trends obtained with 2-D simulations. The new wing experiences a more favorable dynamic stall inception and considerable decreases in the integrated (3-D) peak pitching moments. The results are promising and give confidence in the design approach. The applied methodology can aid with the design of airfoils that are more suited for operation at high loading conditions.