Numerical studies on small rotor configurations with validation using acoustic wind tunnel data

This paper addresses the acoustic and aerodynamic characteristics of small rotor configurations, including the influence of the rotor–rotor interactions. For this purpose, a Rotor/Rotor/Pylon configuration is chosen for both the test and numerical simulations. The wind tunnel experiments on various rotor configuration were performed in DLR’s Acoustic Wind Tunnel Braunschweig (AWB). The experiments involve isolated rotors, and rotors in tandem and coaxial configuration in hover and forward flight. For numerical simulations, an unsteady free wake 3D panel method (UPM) is used to account for aerodynamic non-linear effects associated with the mutual interference among the Rotor/Rotor/Pylon configurations. The effect of the pylon is simulated using potential theory in form of a panelized body. Finally, the sound propagation into the far field is calculated with DLR’s FW–H code APSIM, using UPM blade surface pressure as input. The validation effort is supported by CFD TAU steady simulations on selected hover test cases. The experiments and numerical results indicate that the noise at the blade passing frequency (BPF) and its higher harmonics is the dominant source of the noise for the present rotor selection. The extra subharmonics between two BPFs appearing in the results are caused by the small geometric discrepancy between the blades as well as the motor noise. Broadband noise is also observed in the experiment, but its contribution to the overall sound pressure is very small and can be neglected. The simulation of the acoustic scattering from the rotor support system for the isolated rotor cases indicated an influence about 1–3 dB on the overall sound pressure of the polar microphones. In both the coaxial and the tandem configuration, the acoustic interferences are particularly well visible in the numerical simulations and cause a more complex noise directivity. There is almost no change in time-averaged inflow by applying phase angles. In the coaxial condition, in hover, the phase delay between rotors does not change the maximum noise level. In forward flight, the phase delay can influence the maximum level of the noise radiation. In both coaxial and tandem configuration, the position of the downstream rotor is key for the noise radiation, and therefore, avoiding the interaction with upstream wake can reduce the noise radiation. © 2023, The Author(s).