Forward design and aerothermal performance improvement of low-radius pre-swirl system in an aero-engine

To address performance limitations of conventional reverse-engineering approaches of imitation in advanced aero-engine pre-swirl systems, this study develops an innovative forward-design methodology. Through efficient work-heat conversion mechanisms, the framework initiates from critical design-point parameters to establish a systematic design protocol, incorporating vane-shaped hole-type nozzles and oblique receiver holes. Through primary phase one-dimensional design analysis, the proposed approach determines (a) the aerodynamic characteristics across critical cross sections, (b) the dimensional specifications of key components, and (c) a preliminary temperature drop performance prediction at operational conditions. Subsequent three-dimensional computational validation demonstrates remarkable consistency with initial predictions, showing merely a 0.8% mean deviation in flow parameters and a 5.12% discrepancy in temperature drop efficiency. Comprehensive performance evaluation reveals crucial relationships between receiver hole airflow angles of attack (−7° to 3° operational stability range) and system performances, as quantified through entropy increase, temperature drop efficiency, and power consumption characteristics. Comparative assessments demonstrate that the vane-shaped hole-type nozzle configuration achieves 10.63% and 4.58% improvements in discharge coefficients over conventional hole-type and cascade vane-type designs, respectively. The oblique receiver hole implementation further reduces rotational flow losses while lowering the area resistance. Ultimately, the forward-designed low-radius pre-swirl configuration attains 0.66 temperature drop efficiency, representing 45.2% enhancement over pervasive systems while maintaining structural integrity under extreme operational loads. The application of forward design methodology to high-performance pre-swirl configurations holds considerable theoretical and practical implications for pioneering the innovative development of next-generation aero-engine secondary air systems.