Radiation heat transfer model for complex superalloy turbine blade in directional solidification process based on finite element method

For the sake of a more accurate shell boundary and calculation of radiation heat transfer in the Directional Solidification(DS) process, a radiation heat transfer model based on the Finite Element Method(FEM)is developed in this study. Key technologies, such as distinguishing boundaries automatically, local matrix and lumped heat capacity matrix, are also stated. In order to analyze the effect of withdrawing rate on DS process,the solidification processes of a complex superalloy turbine blade in the High Rate Solidification(HRS) process with different withdrawing rates are simulated; and by comparing the simulation results, it is found that the most suitable withdrawing rate is determined to be 5.0 mm·min^(-1). Finally, the accuracy and reliability of the radiation heat transfer model are verified, because of the accordance of simulation results with practical process.

Finite Element Analysis of Diamond Saw Blades to Prevent Steel Base Wear

The FEM analysis of stress and deformation of steel base of the special diamond saw blades are carried out.The small carbide round segments are welded on the side of blades in order to increase the side wear re sistance of blade.Comparing with conventional saw blade,the maximum stress val ues of reasonable special saw blade are reduced respectively about 17%20% 33%,and the maximum deformation values are reduced respectively about 26%22 %44.7%in thetangential(X),radial(Y)and axial(Z)direction.The stress conce ntration zone is decreased for the special structure diamond saw blade.The stru ctures of diamond saw blade with different number of hard material pellet are an alyzed and optimized.

Finite element analysis of rolling process for variable cross-section blade

Due to the variation of the blade cross-section, the deformation stress and strain of the workpiece keep changing during the rolling process and the conventional rolling theory is no longer valid. The complexity and diversity of the blade cross-section determine it impossible to establish an universal theoretical model for the rolling process. Finite element analysis(FEA) provides a perspective solution to the prediction. The FEA software DEFORM was applied to discovering the deformation, stress, strain and velocity field of the variable cross-section workpiece, and the effects of friction coefficient and rolling speed during the rolling process. which indicates that the average rolling force at friction coefficient of 0.4 is 6.5% higher than that at 0.12, and the rolling velocity has less effect on the equivalent stress and strain distribution, which would confer instructive significance on the theoretical study as well as the engineering practice.

Finite Element Analysis of Elastic Deformation in Blade Machining

In the process of milling the half-open impeller, the milling force ACTS on the half-open impeller will cause the machining deformation error of the half-open impeller. The impeller material studied in this paper is 7050-t7451 aluminum alloy, whose elastic modulus is 70.3 GPa, with low stiffness. Therefore, during milling, it is easy to cause elastic deformation of the cutter, thus causing machining errors and reducing machining surface quality. In addition, due to the low stiffness of blade surface, the deformation of blade surface is much larger than that of hub surface. Therefore, this paper only studies the deformation law of blade surface in the process of milling.

Thermal Analysis of Turbine Blades with Thermal Barrier Coatings Using Virtual Wall Thickness Method

Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.

Analytical model and finite element computation of braking torque in electromagnetic retarder

An analytical model has been developed for analyzing the braking torque in electromagnetic retarder by flux tube and armature reaction method. The magnetic field distribution in air gap, the eddy current induced in the rotor and the braking torque are calculated by the developed model. Two-dimensional and three-dimensional finite element models for retarder have also been developed. Results from the analytical model are compared with those from finite element models. The validity of these three models is checked by the comparison of the theoretical predictions and the measurements from an experimental prototype. The influencing factors of braking torque have been studied.

Displacement Field Variable Modeling Method for Heterogeneous Materials in Wind Power Blade Core Plates

In order to study the mechanical properties of the heterogeneous core plate of the wind turbine blade,a modeling method of the core plate based on displacement field variables is proposed.Firstly,the wind turbine blade core plate was modeled according to the theory of modeling heterogeneous material characteristics.Secondly,the three-point bending finite element model of the wind turbine blade core plate was solved by the display dynamic equation to obtain the deformation pattern and force-deformation relationship of the core plate.Finally,the three-point bending static test was conducted to compare with the finite element analysis.The test results show that:the damage form of the wind turbine blade core plate includes elasticity,yield,and failure stages.The main failure modes are plastic deformation,core material collapse,and panel-core delamination.The failure load measured by the test is 1.59 kN,which is basically consistent with the load-displacement result obtained by the simulation,with a difference of only 1.9%,which verifies the validity and reliability of the model.It provides data references for wind turbine blade structure design.

Aero-engine Blade Fatigue Analysis Based on Nonlinear Continuum Damage Model Using Neural Networks

Fatigue life and reliability of aero-engine blade are always of important significance to flight safety.The establishment of damage model is one of the key factors in blade fatigue research.Conventional linear Miner＇s sum method is not suitable for aero-engine because of its low accuracy.A back propagation neutral network（BPNN） based on the combination of Levenberg-Marquardt（LM） and finite element method（FEM） is used to describe process of nonlinear damage accumulation behavior in material and predict fatigue life of the blade.Fatigue tests of standard specimen made from TC4 are carried out to obtain material fatigue parameters and S-N curve.A nonlinear continuum damage model（CDM）,based on the BPNN with one hidden layer and ten neurons,is built to investigate the nonlinear damage accumulation behavior,in which the results from the tests are used as training set.Comparing with linear models and previous nonlinear models,BPNN has the lowest calculation error in full load range.It has significant accuracy when the load is below 500 MPa.Especially,when the load is 350 MPa,the calculation error of the BPNN is only 0.4%.The accurate model of the blade is built by using 3D coordinate measurement technology.The loading cycle in fatigue analysis is defined from takeoff to cruise in 10 min,and the load history is obtained from finite element analysis（FEA）.Then the fatigue life of the compressor blade is predicted by using the BPNN model.The final fatigue life of the aero-engine blade is 6.55 104 cycles（10 916 h） based on the BPNN model,which is effective for the virtual design of aero-engine blade.

Effects of Process Parameters on the Temperature Field in Ti-6Al-4V Alloy Blade Precision Forging Process

Blade precision forging is a high temperature and large plastic deformation process. Process parameters have a great effect on temperature distribution in billet, so in this paper, by taking a Ti-6Al-4V alloy blade with a tenon as an object, the influence of process parameters on the temperature distribution in precision forging process was investigated using 3D coupled thermo-mechanical FEM （finite element method） code developed by the authors. The results obtained illustrate that： （1） the gradient of temperature distribution increases with increasing the deformation degree; （2） with increasing the initial temperature of the billet, the zones of high temperature become larger, and the gradient of temperature distribution hardly has any increase; （3） friction factors have little effect on the distribution of temperature field; （4） with increasing upper die velocity, temperature of the billet increases while the temperature gradient in billet decreases. The results are helpful to the design and optimization of the process parameters in precision forging process of Ti-alloy blade.

Fatigue Assessment Method for Composite Wind Turbine Blade

Fatigue strength assessment of a horizontal axis wind turbine(HAWT)composite blade is considered.Fatigue load cases are identified,and loads are calculated by the GH Bladed software which is specified at the IEC61400 international specification and GL(Germanisher Lloyd)regulations for the wind energy conversion system.Stress analysis is performed with a 3-D finite element method(FEM).Considering Saint-Venant′s principle,a uniform cross section FEM model is built at each critical zone.Stress transformation matrixes(STM)are set up by applied six unit load components on the FEM model separately.STM can be used to convert the external load into stresses in the linear elastic range.The main material of composite wind turbine blade is fiber reinforced plastics(FRP).In order to evaluate the degree of fatigue damage of FRP,the stresses of fiber direction are extracted and the well-known strength criterion-Puck theory is used.The total fatigue damage of each laminate on the critical point is counted by the rain-flow counting method and Miner′s damage law based on general S-N curves.Several sections of a 45.3mblade of a 2 MW wind turbine are studied using the fatigue evaluation method.The performance of this method is compared with far more costly business software FOCUS.The results show that the fatigue damage of multi-axis FRP can be assessed conveniently by the FEM-STM method.And the proposed method gives a reliable and efficient method to analyze the fatigue damage of slender composite structure with variable cross-sections.

Effects of Wind-Wave Misalignment on a Wind Turbine Blade Mating Process:Impact Velocities,Blade Root Damages and Structural Safety Assessment

Most wind turbine blades are assembled piece-by-piece onto the hub of a monopile-type offshore wind turbine using jack-up crane vessels.Despite the stable foundation of the lifting cranes,the mating process exhibits substantial relative responses amidst blade root and hub.These relative motions are combined effects of wave-induced monopile motions and wind-induced blade root motions,which can cause impact loads at the blade root’s guide pin in the course of alignment procedure.Environmental parameters including the wind-wave misalignments play an important role for the safety of the installation tasks and govern the impact scenarios.The present study investigates the effects of wind-wave misalignments on the blade root mating process on a monopile-type offshore wind turbine.The dynamic responses including the impact velocities between root and hub in selected wind-wave misalignment conditions are investigated using multibody simulations.Furthermore,based on a finite element study,different impact-induced failure modes at the blade root for sideways and head-on impact scenarios,developed due to wind-wave misalignment conditions,are investigated.Finally,based on extreme value analyses of critical responses,safe domain for the mating task under different wind-wave misalignments is compared.The results show that although misaligned wind-wave conditions develop substantial relative motions between root and hub,aligned wind-wave conditions induce largest impact velocities and develop critical failure modes at a relatively low threshold velocity of impact.

Numerical Simulation of the Demagnetization of a Permanent Magnet Retarder in High Temperature

As a auxiliary brake, Permanent Magnet Retarder （PMR） generates lots of energy and has greater temperature-rise when PMR works, so that it has a direct impact on PMR work performance and even causes demagnetization seriously. In order to analyze permanent magnet （PM） demagnetization in high-temperature in PMR, PMR mathematical model is established firstly, and the boundary conditions of finite element analysis are determined. Then the eddy current field distribution in the rotor is determined by solving eddy current demagnetization field, and PM dynamic permeance coefficient is obtained. Combined with PM demagnetization curve analysis, PMR permanent magnet demagnetization properties are analyzed. The analysis result is validated by the bench test. It shows that part of PM is demagnetized when PRM continues working for about 15 minutes, and the braking performance is declined. Finally, three PMR optimization design methods are proposed.

Application of Active Damping Control Using Piezoelectric Material in Modeling of a Wind Turbine Blade

On the basic of passive damping control, we do modeling and simulating in another approach to improve the vibration alleviating effect, the piezoelectric layer damping （PLD）, which is called active control. The piezoelectric damping patches are under control of PID controller （matlab simulating） in voltage defference. Here, we use the software PRO/ENGINEER to design and model a wind turbine blade before using COMSOL to simulate the dynamic motion of the wind turbine blade and its interaction with aerodynamic force of wind in finite element method. Some different models are built-- the original turbine blade and the turbine blade with damping patches on different location and quantity. Then, according to the simulation results, we compare the effects of passive and active damping control, also the effect of patches locations and quantities under different wind speed. This research can provide a direction for future study about ways to decrease vibration of turbine blades.

Dynamic probabilistic analysis of stress and deformation for bladed disk assemblies of aeroengine

In order to describe and control the stress distribution and total deformation of bladed disk assemblies used in the aeroengine, a highly efficient and precise method of probabilistic analysis which is called extremum response surface method(ERSM) is produced based on the previous deterministic analysis results with the finite element model(FEM). In this work, many key nonlinear factors, such as the dynamic feature of the temperature load, the centrifugal force and the boundary conditions, are taken into consideration for the model. The changing patterns with time of bladed disk assemblies about stress distribution and total deformation are obtained during the deterministic analysis, and at the same time, the largest deformation and stress nodes of bladed disk assemblies are found and taken as input target of probabilistic analysis in a scientific and reasonable way. Not only their reliability, historical sample, extreme response surface(ERS) and the cumulative probability distribution function but also their sensitivity and effect probability are obtained. Main factors affecting stress distribution and total deformation of bladed disk assemblies are investigated through the sensitivity analysis of the model. Finally, compared with the response surface method(RSM) and the Monte Carlo simulation(MCS), the results show that this new approach is effective.

Numerical simulation for sheet metal forming process of 16Mn blade of large concrete-mixer truck

A finite element analysis method was used to simulate the stamping process of the blade of a large concrete-mixer truck. The updated Lagrange method and the elasto-plastic constitutive equation were adopted to solve the large strain and displacement deformation of the blade. A modified Coulomb friction model was used to solve the sliding contact between the blade and the dies. The von Mises stress distribution in the blade, the spatial displacement variation and the spring-back of the typical node were investigated in the simulation. The von Mises stress in the blade where the spring-back occurs is lowered from 463.0MPa to 150.0MPa before and after the spring-back. A typical node in the blade has a 3.33mm spring-back in Z direction. The results of the (experiments) agree well with the simulation. The analysis results are valuable for designing optimal tool dies.

Research on Static and Dynamic Characteristics of the Damping Blade of the Blast Furnace Top Gas Recovery Turbine

A blast furnace top gas recovery turbine （TRT） device is af/ected by the Jbrce of steady-state flow and nonsteady-state interaction so that the working-station is poor. A damper which is made of metal rubber is designed to improve stabilization of the blade of the TRT, and to reduce vibration of the TRT.The damping blade of the TRT is analyzed about its static stress and displacement, modal and transient in ANSYS. The results are contrasted. The result indicates that the damper can reduce inherent failure of the blade, and dynanffc-stress. The structure of the damper is simple, and easy to be made.

Finite Element Simulation on Thermal Fatigue of a Turbine Blade with Thermal Barrier Coatings

In this paper, a finite element model was developed for a turbine blade with thermal barrier coatings to investigate its failure behavior under cyclic thermal loading. Based on temperature and stress fields obtained from finite element simulations, dangerous regions in ceramic coating were determined in terms of the maximum principal stress criterion. The results show that damage preferentially occurs in the chamfer and rabbet of a turbine blade with thermal barrier coatings and its thermal fatigue life decreases with the increase of thermal stress induced by high service temperature.

FINITE ELEMENT ANALYSIS OF THE FLOW INDUCED BY ROTATING BLADES IN AN INCOMPRESSIBLE VISCOUS FLUID

Aerodynamic loads on a multi-bladed helicopter rotor in hovering flight were calculated by solving the three-dimensional incompressible Navier-Stokes equations. The rotor wake effects were accounted by the correction of local geometric angle of attack according to a free-wake modeling in addition to an empirical modification for the tip flow effect. The validity and efficiency of the present method were verified by the comparisons between numerical results and experimental data.

Finite Element Method Analysis of Effect of Blade Clearance on Plate Shearing Process

Blade clearance is an important technical parameter of the shear, which determines the shear quality of plate. The finite element method was used to simulate shearing process which is in the different specifications and blade clearances, and the impact on blade section and shearing force of blade clearance was analyzed. Comparing with traditional experience formulas and measured values, the limitations of the experience formulas were proved. And by contrasting with the shearing force data collected from Linfen Iron and Steel Company, the reliability of the finite element method was further proved. The simulated results show that the simulated values controlled by ductile fracture criterion and measured values are very close, and the deviation value is in the range of 4.8%-20.8%. For the same steel, if the plate is thicker, the blade clearance will be greater, and thickness and blade clearance are approximately linear. The difference between numerical simulation of the maximum shearing force and the measured results is 7.7% to 12.0%, and the simulation results are close to facts. With the increase of blade clearance and the thickness, the shearing force was increased to some degree.

Finite Element Simulation Study on Blade Coating of Wind Turbine

Due to the surface protection structure of wind turbine blades,coating plays a key role in ensuring the surface quality of blades and improving the working performance of wind turbine.In this paper,a simplified method of finite element simulation on blade coating of wind turbine is carried out by means of theoretical analysis and computer software simulation.The influence of particle erosion velocity,mass flow rate and particle diameter was made clear on the coating erosion.This will provide a theoretical reference for improving the cover technique of wind turbine blade coating and improving the coating reliability.