Analysis and Optimization of Robotized Grinding of Titanium High Pressure Compressor Blades

2016 ◽  
Author(s):  
M. Meshreki ◽  
Z. Shi ◽  
F. Arrien ◽  
M. H. Attia
Keyword(s):  
High Pressure ◽  
Natural Frequency ◽  
Dynamic Characteristics ◽  
Robotic Arm ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Compressor Blades ◽  
Part Quality ◽  
High Pressure Compressor ◽  
Pressure Compressor

An analysis for a robotized grinding process of aerospace Titanium high pressure compressor blades was performed. In this process, the blade was grabbed on the robotic arm. A Scotch-Brite grinding wheel, on a pneumatic actuator, was used to grind the edges of the blades. The objective of this research work was to identify the major factors that influence the accuracy of the process and the final part quality. This objective was achieved by analyzing the dynamic characteristics of the wheel grabbed on the motor as well as analyzing the dynamic characteristics of the blade grabbed on the robotic arm. The frequency response functions (FRF) were identified at different robot configurations and positions. In addition, the vibrations of the various system components during the grinding process were monitored and analyzed to determine the effect of the speed on the relative vibrations between the workpiece and the wheel. Considering the dynamics of the wheel and the motor, rotational speed ranges were recommended. It was found that the vibrations of the grinding process were higher at two ranges: The first corresponds to the first natural frequency of the robot and the second corresponds to the first natural frequency of the wheel and the second natural frequency of the robot. By avoiding these ranges, part quality within the specified tolerances was obtained.

Corrosion Studies of High and Low Pressure Compressor Blades of a Gas Turbine

2005 ◽  
Author(s):  
A. Boschetti ◽  
E. Y. Kawachi ◽  
M. A. S. Oliveira
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Low Pressure ◽  
Compressor Blade ◽  
Compressor Blades ◽  
X Ray ◽  
Corrosion Studies ◽  
High Pressure Compressor ◽  
Pressure Compressor ◽  
Base Superalloy

This work presents preliminary results of corrosion studies for three blades, one of the low pressure compressor and two of two different stages of the high pressure compressor of a gas turbine, which has been operating for 5,000 hours. Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS), X-ray diffraction (XRD), Electrochemical Impedance Spectroscopy (EIS) in aqueous solution containing chloride, and Atomic Absorption Spectrometry (AAS) were used to characterize the blades surfaces. The SEM and EDS results showed that the homogeneity and amount of contaminants, such as sodium, potassium, calcium, magnesium, chloride and sulphur are bigger in the high pressure compressor blade surfaces than in the low pressure compressor blade surface. The EIS results showed that the degradation process in turbine compressor blades increases with the temperature and pressure increase inside the compressors and depends of the blade composition. The low pressure compressor blade, which was made of a Ti base superalloy exhibited smaller corrosion resistance (smallest charge transfer resistance value (Rct)) than the two high pressure compressor blades, which were made of a Fe base superalloy. However, despite of its lower resistance to corrosion, after 5,000 hours of service, the low pressure compressor blade did not present pitting corrosion while the high pressure compressor blades did.

Form Factor for the Top-Level Comparison of the Condition of Supply of High-Pressure Compressor Blades

2012 ◽  
Author(s):  
Marcus Schrade ◽  
Stephan Staudacher ◽  
Matthias Weißschuh ◽  
Matthias Voigt
Keyword(s):  
High Pressure ◽  
Form Factor ◽  
Gas Turbines ◽  
Principal Component ◽  
Complex Geometries ◽  
Compressor Blades ◽  
High Pressure Compressor ◽  
Geometric Deviations ◽  
Pressure Compressor ◽  
Component Feature

High-pressure compressor (HPC) performance and maintenance of gas turbines is influenced by blade production scatter and in-service deterioration. Complex geometries in HPC, especially at blades, yield to a large amount of component features, which individually influence performance and maintenance characteristics. This results in a highly complex and poorly observable system. Hence, the correlation of a single component feature to performance or maintenance characteristics is not purposeful and a reduction of the parameter space is advantageous. A form factor is introduced that reduces geometric deviations of component features to a scalar. Principal component analysis (PCA) of measured HPC blades is used to support the form factor concept. The meaningfulness of this approach is shown in identifying process capabilities of different forges based on the form factor.

Probabilistic CFD Simulation of a High-Pressure Compressor Stage Taking Manufacturing Variability Into Account

2010 ◽  
Author(s):  
Alexander Lange ◽  
Matthias Voigt ◽  
Konrad Vogeler ◽  
Henner Schrapp ◽  
Erik Johann ◽  
...  
Keyword(s):  
High Pressure ◽  
Point Cloud ◽  
Cfd Simulation ◽  
Three Dimensional ◽  
Parameter Vector ◽  
Compressor Blades ◽  
The Monte Carlo Method ◽  
High Pressure Compressor ◽  
Pressure Compressor

The present paper addresses a non-deterministic CFD simulation of a high-pressure compressor (HPC) stage. The investigation focuses on the determination of the influence of the manufacturing scatter of compressor blades on the aerodynamic performance of the analyzed HPC stage. A set of 150 blades was scanned using an optical 3D digitizer to obtain a three-dimensional point cloud representing the surface of the blades. Classical profile parameters were identified at several sections of constant spanwise coordinate. The radial stacking of these parameters forms a parameter vector that constructs the airfoil model of each scanned blade. Consequently these parameters were used to define the geometric variability of the entire measured blade set. A statistical analysis of the distribution of these parameters defines the input data of the probabilistic 3D CFD simulation. The Monte-Carlo method is used to identify the scatter of the performance values of the HPC stage and their sensitivity to the geometric variability of profile parameters.

Impact of Nonuniform Stagger Angle Distribution on High-Pressure Compressor Rotor Performance

2018 ◽  
Author(s):  
Siyu Zheng ◽  
Jinfang Teng ◽  
Yu Wu ◽  
Fushui Guo ◽  
Shaopeng Lu ◽  
...  
Keyword(s):  
High Pressure ◽  
Nonuniform Distribution ◽  
Angle Distribution ◽  
Compressor Blades ◽  
High Pressure Compressor ◽  
Manufacturing Tolerances ◽  
Total Performance ◽  
Stagger Angle ◽  
Pressure Compressor ◽  
Sinusoidal Function

The focus of the present study is to find a solution to the manufacturing tolerances of rotor stagger angle in the high pressure compressor. The manufacturing processes of compressor blades may lead the stagger angle to be out of tolerance, which would reduce the performance of the high-pressure compressor. Meanwhile, the assembly may cause the nonuniform distribution of the variable blades. To investigate the influence of stagger angle variability and its nonuniform distribution in multiple passages, amount of 3D numerical simulations of a high pressure compressor rear-stage rotor were conducted in the present paper. The Gaussian Probabilistic Density Function was used to obtain the sampled blades with variable stagger angles, and then the blades were randomly allocated in a single passage to a half period, respectively. Numerical results show that with the increase of passage number, the total performance varies more stably. In order to get an appropriate tolerance range of the stagger angle to control the deterioration of the total performance, different ranges were tried, and [−1.5°, +1.5°] was determined as the final range to do further analyses. The different stagger angle distribution along the circumferential direction of a specific group of several sampled blades led to the different performance variations. When the stagger angle distribution approximately satisfied the sinusoidal function during assembly, the rotor performance was better than other distributions. Hence, the sinusoidal function during assembly is an effective solution to the manufacturing tolerances of rotor stagger angle.

Review on the aerodynamics of intermediate compressor duct

2020 ◽  
Vol 14 (4) ◽  
pp. 7446-7468
Author(s):  
Manish Sharma ◽  
Beena D. Baloni
Keyword(s):  
High Pressure ◽  
Pressure Loss ◽  
Flow Analysis ◽  
Outer Wall ◽  
Optimization Techniques ◽  
Optimum Pressure ◽  
Research Areas ◽  
Static Pressure Distribution ◽  
High Pressure Compressor ◽  
Pressure Compressor

In a turbofan engine, the air is brought from the low to the high-pressure compressor through an intermediate compressor duct. Weight and design space limitations impel to its design as an S-shaped. Despite it, the intermediate duct has to guide the flow carefully to the high-pressure compressor without disturbances and flow separations hence, flow analysis within the duct has been attractive to the researchers ever since its inception. Consequently, a number of researchers and experimentalists from the aerospace industry could not keep themselves away from this research. Further demand for increasing by-pass ratio will change the shape and weight of the duct that uplift encourages them to continue research in this field. Innumerable studies related to S-shaped duct have proven that its performance depends on many factors like curvature, upstream compressor’s vortices, swirl, insertion of struts, geometrical aspects, Mach number and many more. The application of flow control devices, wall shape optimization techniques, and integrated concepts lead a better system performance and shorten the duct length.  This review paper is an endeavor to encapsulate all the above aspects and finally, it can be concluded that the intermediate duct is a key component to keep the overall weight and specific fuel consumption low. The shape and curvature of the duct significantly affect the pressure distortion. The wall static pressure distribution along the inner wall significantly higher than that of the outer wall. Duct pressure loss enhances with the aggressive design of duct, incursion of struts, thick inlet boundary layer and higher swirl at the inlet. Thus, one should focus on research areas for better aerodynamic effects of the above parameters which give duct design with optimum pressure loss and non-uniformity within the duct.

scholarly journals Redesign of a High-Pressure Compressor Blade Accounting for Nonlinear Structural Interactions

2014 ◽  
Author(s):  
Alain Batailly ◽  
Mathias Legrand ◽  
Antoine Millecamps ◽  
Sèbastien Cochon ◽  
François Garcin
Keyword(s):  
High Pressure ◽  
Forced Response ◽  
Compressor Blade ◽  
Design Stage ◽  
Blade Design ◽  
Early Integration ◽  
Nonlinear Structural ◽  
High Pressure Compressor ◽  
Structural Interactions ◽  
Pressure Compressor

Recent numerical developments dedicated to the simulation of rotor/stator interaction involving direct structural contacts have been integrated within the Snecma industrial environment. This paper presents the first attempt to benefit from these developments and account for structural blade/casing contacts at the design stage of a high-pressure compressor blade. The blade of interest underwent structural divergence after blade/abradable coating contact occurrences on a rig test. The design improvements were carried out in several steps with significant modifications of the blade stacking law while maintaining aerodynamic performance of the original blade design. After a brief presentation of the proposed design strategy, basic concepts associated with the design variations are recalled. The iterated profiles are then numerically investigated and compared with respect to key structural criteria such as: (1) their mass, (2) the residual stresses stemming from centrifugal stiffening, (3) the vibratory level under aerodynamic forced response and (4) the vibratory levels when unilateral contact occurs. Significant improvements of the final blade design are found: the need for an early integration of nonlinear structural interactions criteria in the design stage of modern aircraft engines components is highlighted.

A Machine Learning Based Approach of Performance Estimation for High-Pressure Compressor Airfoils

2018 ◽  
Author(s):  
Jonas Marx ◽  
Stefan Gantner ◽  
Jörn Städing ◽  
Jens Friedrichs
Keyword(s):  
Machine Learning ◽  
High Pressure ◽  
Machine Learning Algorithms ◽  
Performance Estimation ◽  
Predictive Maintenance ◽  
Support Vector ◽  
K Nearest Neighbor ◽  
Operating Characteristics ◽  
High Pressure Compressor ◽  
Pressure Compressor

In recent years, the demands of Maintenance, Repair and Overhaul (MRO) customers to provide resource-efficient after market services have grown increasingly. One way to meet these requirements is by making use of predictive maintenance methods. These are ideas that involve the derivation of workscoping guidance by assessing and processing previously unused or undocumented service data. In this context a novel approach on predictive maintenance is presented in form of a performance-based classification method for high pressure compressor (HPC) airfoils. The procedure features machine learning algorithms that establish a relation between the airfoil geometry and the associated aerodynamic behavior and is hereby able to divide individual operating characteristics into a finite number of distinct aero-classes. By this means the introduced method not only provides a fast and simple way to assess piece part performance through geometrical data, but also facilitates the consideration of stage matching (axial as well as circumferential) in a simplified manner. It thus serves as prerequisite for an improved customary HPC performance workscope as well as for an automated optimization process for compressor buildup with used or repaired material that would be applicable in an MRO environment. The methods of machine learning that are used in the present work enable the formation of distinct groups of similar aero-performance by unsupervised (step 1) and supervised learning (step 2). The application of the overall classification procedure is shown exemplary on an artificially generated dataset based on real characteristics of a front and a rear rotor of a 10-stage axial compressor that contains both geometry as well as aerodynamic information. In step 1 of the investigation only the aerodynamic quantities in terms of multivariate functional data are used in order to benchmark different clustering algorithms and generate a foundation for a geometry-based aero-classification. Corresponding classifiers are created in step 2 by means of both, the k Nearest Neighbor and the linear Support Vector Machine algorithms. The methods’ fidelities are brought to the test with the attempt to recover the aero-based similarity classes solely by using normalized and reduced geometry data. This results in high classification probabilities of up to 96 % which is proven by using stratified k-fold cross-validation.

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