Stochastic aerodynamic analysis for compressor blades with manufacturing variability based on a mathematical dimensionality reduction method

It is essential for engineering manufacture and robust design to evaluate the impact of manufacturing variability on the aerodynamics of compressor blades efficiently and accurately. In the paper, a novel quadratic curve approximation method based on the scanning points of blade design profiles was introduced and combined with Karhunen–Loève expansion, a mathematical dimensionality reduction method for modeling manufacturing variability as truncated Normal process was proposed. Subsequently, Sparse Approximation of Moment-based Arbitrary Polynomial Chaos (SAMBA PC) and computational fluid dynamics (CFD) were applied to build a computational framework for stochastic aerodynamic analysis considering manufacturing variability. Finally, the framework was adopted to evaluate the aerodynamic variations of a high subsonic compressor cascade under the design incidence. The results illustrate that the SAMBA PC method is more efficient than the traditional methods such as Monte Carlo simulation (MCS) for stochastic aerodynamic analysis. Through uncertainty quantification, the impact of manufacturing variability on the global aerodynamic performance is primarily reflected in the fluctuation of aerodynamic losses, and the fluctuation of the total losses is mainly contributed by the fluctuation of the separation loss after the suction peak (a negative pressure spike near the leading edge (LE)) and the boundary-layer loss on the suction surface (SS). With sensitivity analysis, the most important geometric modes to aerodynamics can be revealed, which provides a useful reference for manufacturing inspection process and helps reduce computational cost in robust design.

The Computational Method of Estimating Vibration Stress Levels for GTE Compressor Blades

At present, the process of designing a GTE involves a large amount of computational modeling. With the help of computational modeling, it is possible to predict a behavior of an engine part during engine operations before conducting experimental studies. For example, the numerical dynamic behavior analysis of compressor blades and prediction of dynamic stress levels during fluctuations in free modes are urgent problems. A high level of dynamic stress in the compressor blades in resonant modes can break a blade and stop an engine. In this paper, we propose a simple vibration stress estimation method for the compressor blades based on the calculation of natural frequencies and vibration forms. The method is based on a comparative analysis and scaling of stresses by the value of the total potential or kinetic energy. This estimation method is valid for local changes in the blade geometry, which do not lead to changes in the natural frequencies and vibration forms of the blades, assuming that the geometry change does not change the level of the aerodynamic excitation of the blade or its damping. At the stage of development or revision of the blade, a large number of variants of the blade geometry needs to be analyzed in order to reduce dynamic stresses. The proposed vibration stress estimation method has shown its high efficiency in developing and refining the geometry of the compressor blade. The vibration stress estimation method was tested using the rotor blade of a high-pressure compressor. As a result of the experimental study of the rotor blade, a high level of vibration stresses exceeding the permissible level was found for natural frequencies and vibration forms. To reduce the vibration stresses, measures were proposed to modify the geometry of the blade. For the modified blade geometry, the vibration stress estimation was performed with a prediction of the vibration stress values based on the manifested vibration forms. In order to verify the estimated vibration stress change, an experimental study of the modified blade was conducted. The vibration stress estimation method for the compressor blades was successfully verified.

TECHNOLOGY FOR RESTORATION AND REPAIR OF AIRCRAFT ENGINE PARTS

Problems of increasing the service life of compressor blades of aircraft gas turbine engines using detonation spraying technology are considered. The simulation of the parameters of the velocity and temperature of the particles of the sprayed material in the barrel of the detonation unit and in the flooded space to the substrate was carried out, followed by the choice of the optimal technological parameters of the spraying process. The control system of the detonation unit has been modernized. An experiment was carried out on the deposition of the Al2O3 coatings on the samples of a substrate made of titanium alloy VT3-1. Based on the results of the experiment, technological recommendations were developed concerning both the parameters of the spraying process and the parameters of the preparation of the substrate surface before spraying. The equipment for brazing the blades of the guide vanes is described and a device for spraying coatings on the end surfaces of the compressor blades is proposed. Thus, a complex technology has been developed for restoring the end surfaces of titanium alloy compressor blades by deposition of Al2O3 coatings.

Stand for dynamic tests of methods vibration diagnostics of compressor blades

В статье рассматривается стендовая реализация предложенного авторами способа проведения экспериментов с рабочими лопатками аксиальных компрессоров, целью которых является отработка методов мониторинга вибраций лопаток и алгоритмов выявления характерных дефектов (усталостных трещин) непосредственно во время работы компрессора. Для обеспечения безопасности экспериментов с повреждёнными компрессорными лопатками в конструкции стенда применён один из эвристических принципов решения изобретательских задач, сформулированный Г.С. Альтшуллером, который состоит в том, что движущиеся на натурном объекте детали (лопатки) делают неподвижными, а неподвижные детали (датчики) приводят в движение таким образом, чтобы сохранить скорости их относительных перемещений. Рассмотрена конструкция стенда и состав измерительных приборов. Приведены результатов экспериментов с исправными компрессорными лопатками и с лопатками, имеющими различные стадии развития дефектов (усталостных трещин). Показано, что графическое представление ранжированных массивов измеренных временных интервалов позволяет судить о наличии дефекта и о стадии его развития. The article discusses the bench implementation of the method proposed by the authors for conducting experiments with rotor blades of axial compressors, the purpose of which is to develop methods for monitoring blade vibrations and algorithms for detecting characteristic defects (fatigue cracks) directly during compressor operation. To ensure the safety of experiments with damaged compressor blades, one of the heuristic principles for solving inventive problems, formulated by G.S. Altshuller, which consists in the fact that parts (blades) moving on a full-scale object are made stationary, and stationary parts (sensors) are set in motion in such a way as to maintain the speed of their relative movements. The design of the stand and the composition of the measuring instruments are considered. The results of experiments with serviceable compressor blades and blades with different stages of development of defects (fatigue cracks) are presented. It is shown that the graphical presentation of ranked arrays of measured time intervals allows one to judge the presence of a defect and the stage of its development.

Method for Dynamic Stress Design in a Variable Section Blade of a Turbo Machine

The problem of assessing the dynamic stresses arising from vibrations of the blades of turbo machines is an urgent and significant problem affecting the overall reliability of the turbo machine. Its solution requires a mathematical study and a physical experiment to determine the intensity of the gas flow impact and the blade reaction.However, there is relatively little information in the scientific publications on this issue. The article considers a semi-empirical method for calculating dynamic stresses at the base of a variable cross-section blade at the first tone resonant vibrations. These vibrations can be considered as the most dangerous because of the maximum amplitude. To perform the calculation a real blade was replaced with a calculated one, composed of separate portions with a constant profile, and the contribution of each part to the stress in the base section was determined. An example of calculating the dynamic stress by the proposed method with a resonant vibration of the first tone of a constant-section blade is given. The calculation showed that the solution to a complex problem can be represented as a sum of solutions to simpler problems. The calculation method can be used in the design of turbine and compressor blades.

Dependence of thermogasodynamic parameters of operation of a helicopter gas turbine engine on its operation and dust in the atmosphere

By scanning the blades of the impeller and the guide devices of the full-scale compressor of the helicopter gas turbine engine, a solid-state design model of the compressor with a tunable geometry in the height of the blades was developed. The empirical dependencies of the values of nonlinear wear of the blade of the 1st stage of the compressor on the operating time and the concentration of dust in the air are presented. A block diagram of the procedure for calculating the characteristics and parameters of a helicopter gas turbine compressor is presented. When calculating the flow in the gas–air path of the compressor, the numerical solution of the Navier–Stokes equations averaged by Reynolds, the finite element method in combination with the establishment of patterns of erosive wear of the blades depending on the operating conditions of the engine is used. Mathematical dependencies of the thermogasodynamic parameters of the helicopter gas turbine compressor operation on its operating time and the dustiness of the atmosphere are obtained using modeling. The obtained results can be used in the development of a methodology for automated monitoring of the wear condition of the compressor blades of a helicopter gas turbine engine according to its thermogasodynamic parameters, applied to various climatic operating conditions.