Anti-Phase Vortex Reduction Control for Rotor Noise Suppression

An investigation is conducted in 2019 under the NASA Ames Center Innovation Funds (CIF) project entitled “Anti-Phase Vortex Reduction Control for Rotor Noise Suppression“ to experimentally validate an anti- phase rotor noise suppression concept. The first objective of the investigation is to conduct computational fluid dynamics (CFD) simulations to investigate the noise characteristics of several anti-phase rotor designs. The second objective is to conduct a series of acoustic tests of anti-phase rotors in an anechoic chamber at Pennsylvania State University (PSU) to evaluate the merit of the anti-phase rotor concept. The CFD investigation seeks to optimize the anti-phase alternating trailing edge patterns for rotor noise suppression. The design objective is to maximize the noise reduction while maintaining the aerodynamic thrust. The investigation is performed using a three-dimensional (3D) Unsteady Reynolds-Averaged Navier-Stokes (URANS) commercial solver STAR-CCM+ together with the Ffowcs-Williams and Hawkings (FW-H) formula to obtain the aerodynamic thrust and far-field noise level. An acoustic study is conducted for 13 anti-phase design candidates based on a proprietary rotor design. The CAD geometry of the rotor is furnished by PSU. These design candidates include different alternating trailing edge (TE) waveforms, TE segment lengths, TE deflection amplitudes, and transition characteristics. The best design candidate among those explored is an anti-phase rotor that has a four-period TE waveform which results in a reduction in far-field noise level of 2.1 dB in the hover condition and a reduction of 1.1 dB in the forward flight condition at 9.7 m/s. A further acoustic study is conducted for a different rotor manufactured by APC. Five APC rotor design candidates are simulated. The best anti-phase design candidate for the APC rotor results in a reduction in far- field noise level of 4.0 dB in the hover condition. An in-phase design candidate is also studied. This in-phase design provides a noise reduction of 2.5 dB. A series of acoustic experiments in the PSU anechoic chamber have been conducted in July 2019 and October 2019. Both anti-phase and in-phase rotors fabricated for the left-hand and right-hand rotations are tested. In the hover condition, all the rotors do not provide sufficient evidence of improved acoustic performance. However, the experimental data in the hover condition are deemed to be inconclusive due to the flow recirculation in the anechoic chamber caused by the rotor downwash. In the forward flight condition at 9.7 m/s, the anti-phase right-hand rotor produces a noise reduction by as much as 6.5 dB in the frequency range of 2000-4000 Hz, while the in-phase right-hand rotor produces a noise reduction by as much as 5 dB in the same frequency range. Both the anti-phase and in-phase left hand rotors offer no evidence of noise reduction. The difference in the acoustic performance of the left-hand and right-hand rotors could be explained by the location of the microphone array which is placed to the left side of the rotors. This microphone array location could create a bias in the sound pressure level in favor of the right-hand rotor. Using the average noise reduction values, the anti-phase 4H rotor could offer a noise reduction by as much as 3.25 dB while the in-phase 4I rotor could produce up to a 2.5 dB noise reduction. Both the computational and experimental results have provided sufficient evidence to support the noise suppression capability of the proposed anti-phase rotor concepts.