Influence Factors for Impact Actions and Transient Trajectories of Fan Blades after Fan Blade Out in Typical 2-Shaft High Bypass Ratio Turbofan Engine

To enhance the understanding of design characters, which have prominent influences during the fan blade out event, a simplified geometrical and dynamic analysis method was derived, and a typical 2-shaft high bypass ratio turbofan engine was selected and modeled. Based on analytical deriving and engineering experience learned from the real engine failure case, three determinative impact actions were recognized from the fan blade out process. The transient trajectories of these impact actions were researched in analytical method, and then thickness of acoustic lining, quantity of fan blades and threshold load of structural fuse were analyzed as key design characters. 36 serialized fan blade out transient dynamic simulations were conducted by using the 2-shaft high bypass ratio turbofan engine model within different combinations of the three key design factors. The results from geometrical and dynamic analysis matched mainly well with the results from simulations. Characteristic phenomenon in simulation can be explained theoretically. Five conclusions can be summarized from these results. (1) If thickness fan acoustic lining was thinner, the deviation between simplified analytical calculation and simulation were not outstanding to predict Blade-Casing the first impact time and angular position. (2) An appropriate thickness of acoustic lining could make a lower impact stress of fan casing at the first impact. (3) Different thickness of acoustic linings leaded to two impact modes for blade 2, which were tip impact and root impact. (4) Different impact conditions between blade 1 and blade 2 caused remarkable speed components distinction of blade 1, and leaded to a wide range of transient trajectory of blade 1 during FBO event. (5) Thicker acoustic lining in this research can usually find the porper threshold loads setting, which can give a satisfactory outbound vibration. Two details were raised for further research, which were impact behavior of composite material fan blade and honeycomb and influences of wider FBO threshold load ranges in design cases with thinner acoustic lining.

Foreign Object Damage to Fan Rotor Blades of Aeroengine Part II: Numerical Simulation of Bird Impact

Bird impact is one of the most dangerous threats to flight safety. The consequences of bird impact can be severe and, therefore, the aircraft components have to be certified for a proven level of bird impact resistance before being put into service. The fan rotor blades of aeroengine are the components being easily impacted by birds. It is necessary to ensure that the fan rotor blades should have adequate resistance against the bird impact, to reduce the flying accidents caused by bird impacts. Using the contacting-impacting algorithm, the numerical simulation is carded out to simulate bird impact. A three-blade computational model is set up for the fan rotor blade having shrouds. The transient response curves of the points corresponding to measured points in experiments, displacements and equivalent stresses on the blades are obtained during the simulation. From the comparison of the transient response curves obtained from numerical simulation with that obtained from experiments, it can be found that the variations in measured points and the corresponding points of simulation are basically the same. The deforming process, the maximum displacements and the maximum equivalent stresses on blades are analyzed. The numerical simulation verifies and complements the experiment results.

Foreign Object Damage to Fan Rotor Blades of Aeroengine Part I:Experimental Study of Bird Impact

The conditions of experiment for bird impact to blades have been improved. The experiment of bird impact to the fan rotor blades of an aeroengine is carried out. Through analyzing the transient state response of blades impacted by bird and the change of blade profile before and after the impact, the anti-bird impact performance of blades in the first fan rotor is verified. The basis of anti-foreign object damage design for the fan rotor blades of an aeroengine is provided.

Numerical Simulation of Axial Inflow Characteristics and Aerodynamic Noise in a Large-Scale Adjustable-Blade Fan

Numerical simulation are conducted to explore the characteristics of the axial inflow and related aerodynamic noise for a large-scale adjustable fan with the installation angle changing from−12°to 12°.In such a range the maximum static(gauge)pressure at the inlet changes from−2280 Pa to 382 Pa,and the minimum static pressure decreases from−3389 Pa to−8000 Pa.As for the axial intermediate flow surface,one low pressure zone is located at the junction of the suction surface and the hub,another is located at the suction surface close to the casing position.At the outlet boundary,the low pressure is negative and decreases from−1716 Pa to−4589 Pa.The sound pressure level of the inlet and outlet noise tends to increase monotonously by 11.6 dB and 7.3 dB,respectively.The acoustic energy of discrete noise is always higher than that of broadband noise regardless of whether the inlet or outlet flow surfaces are considered.The acoustic energy ratio of discrete noise at the inlet tends to increase from 0.78 to 0.93,while at the outlet it first decreases from 0.79 to 0.73 and then increases to 0.84.

Fatigue Life Estimation for an Aircraft Engine Fan Blade

In this paper,stress states under corresponding condition of an aero-engine fan blade using finite element stress-strain analysis for three work cycles in the 900 h load spectrum are obtained.Through the nominal stress method,we calculated the fatigue notch factor and combined the material characteristics of TC6 to correct the material curve to the fan blades curve. Finally,the fatigue life of a fan blade was estimated using the linear cumulative damage rule and nonlinear cumulative damage theory.

NON-DIMENSIONAL DESIGN PARAMETERS FOR FOD TOLERANT FAN BLADES

Non-dimensional design concept for FOD tolerant fan blades is introduced based on the analyses of simplified impact models. The fan blades arc idealized as either beams or plates of elastic or rigid-plastic materials. The case of constant force impact as well as that of mass impact is analyzed. The centrifugal force effects are also considered in the beam models. The critical fracture conditions arc shown in simple npn-dimensional formulae or diagrams for each case.

Effects of circumferential configuration concerning splitter blade on the aerodynamic performance in a transonic axial fan

For a certain type of transonic axial fan, the flow field of a fan rotor with splitter blade was computed by numerical simulation, and the shape of the rotor was modified. The effects of different circumferential distributions concerning the splitter cascades upon the aerodynamic performance were investigated. The studies show that the optimum splitter cascade is not very close to the suction side of main blade. The load between the main blade and the splitter blade can be soundly distributed in terms of the adjustment of circumferential position of the splitter blade. The best aerodynamic performance can be successfully obtained according to the optimum shape of the expanding fluid channel reasonably formed by the splitter blade and the main blade.

民用运输机吊挂设计强度要求研究

论述了民用运输机吊挂设计强度要求,并重点阐述了以下几个方面:吊挂初步设计载荷、FBO载荷计算要求、发动机非包容性转子损坏下的适航符合性思路及离散源损伤容限剩余强度评估要求。在这几部分的阐述中,有具体的设计数据及案例,对设计工作有很好的指导作用。

Numerical Experiment of the Solid Particle Erosion of Bionic Configuration Blade of Centrifugal Fan

In this paper, a bionic method was presented to improve the erosion resistance of blade of the centrifugal fan. A numerical investigation of the solid particle erosion on the standard and bionic configuration blade of 4-72N_o10C centrifugal fan was presented. The numerical study employs computational fluid dynamics （CFD） software, based on a finite volume method, in which the discrete phase model was used to modele the solid particles flow, and the Eulerian conservation equation was adopt to simulate the continuous phase. Moreover, user-defined function was used to define wear equation. The various diameters of the particles were taken into account. The positions of collision of standard and bionic fan blades were discussed, and two kinds of centrifugal fan blade wear were compared. The results show that the particles from the incident source with different positions have different processes of turning and movement when enter into the impeller. The trajectories of flow in the fan channel are significantly different for the particles with different diameters. Bionic fan blade have lower erosion rate than the standard fan blade when the particle size is 20 μm. The anti-erosion mechanism of the bionic fan blade was discussed.

Three-dimensional modeling and reconstructive change of residual stress during machining process of milling, polishing, heat treatment, vibratory finishing, and shot peening of fan blade

Residual stress during the machining process has always been a research hotspot,especially for aero-engine blades.The three-dimensional modeling and reconstructive laws of residual stress among various processes in the machining process of the fan blade is studied in this paper.The fan blades of Ti-6Al-4V are targeted for milling,polishing,heat treatment,vibratory finishing,and shot peening.The surface and subsurface residual stress after each process is measured by the X-ray diffraction method.The distribution of the surface and subsurface residual stress is analyzed.The Rational Taylor surface function and cosine decay function are used to fit the characteristic function of the residual stress distribution,and the empirical formula with high fitting accuracy is obtained.The value and distribution of surface and subsurface residual stress vary greatly due to different processing techniques.The reconstructive change of the surface and subsurface residual stress of the blade in each process intuitively shows the change of the residual stress between the processes,which has a high reference significance for the research on the residual stress of the blade processing and the optimization of the entire blade process.

Internal structural optimization of hollow fan blade based on sequential quadratic programming algorithm

Several structural design parameters for the description of the geometric features of a hollow fan blade were determined.A structural design optimization model of a hollow fan blade which based on the strength constraint and minimum mass was established based on the finite element method through these parameters.Then,the sequential quadratic programming algorithm was employed to search the optimal solutions.Several groups of value for initial design variables were chosen,for the purpose of not only finding much more local optimal results but also analyzing which discipline that the variables according to could be benefit for the convergence and robustness.Response surface method and Monte Carlo simulations were used to analyze whether the objective function and constraint function are sensitive to the variation of variables or not.Then the robust results could be found among a group of different local optimal solutions.

风扇叶片脱落机匣包容性仿真并行计算一致性研究

风扇叶片脱落并行计算结果的一致性非常重要。在共享内存并行(SMP)模式下,由于计算随机误差和误差累积现象的存在,计算结果可能不一致。针对该问题,对某型大涵道比涡扇发动机简化的三叶片模型进行并行仿真计算,分析造成计算结果不一致的误差来源,提出四种控制策略,研究表明,通过计算方法的改进和计算平台的选择可以有效避免误差累积现象,提高并行计算精度。

Numerical simulation of a UAV impacting engine fan blades

A 3D digital model of a small Unmanned Aerial Vehicle(UAV)is obtained by using the method of scanning reverse modeling and joint mapping.A numerical simulation of a small UAV strikes on rotary engine blades,presented in this paper,was performed with a Transient Nonlinear Finite Element code PAM-CRASH software.A test of motor strike on plate was developed and the dynamic response of the plate were obtained to validate the numerical simulation method of a UAV strike on blades.Based on this,dynamic damage response caused by UAV on the engine blades were studied.It is indicated that the impact process between the UAV and a single blade can be divided into two typical stages:cutting and impact.Cutting mainly leads to the failure of the leading edge material,and impact mainly leads to the plastic deformation of the blade.At the same time,it is compared with the damage impacted by bird with the same mass.For the same mass of bird and UAV,the damage caused by UAV striking fan blade is more serious,and 1.345 kg UAV striking fan blade of typical civil aviation engine is enough to cause damage to flight safety.

Parametric study on the flutter sensitivity of a wide-chord hollow fan blade

In recent years, the hollow fan blades have been widely used to meet the demand for light weight and good performance of the aero-engine. However, the relationship between the hollow structure and the aeroelastic stability has not been studied yet in the open literature. In this paper,it has been investigated for an H-shaped hollow fan blade. Before studying the flutter behavior, the methods of parametric modeling and auto-generation of Finite Element Model(FEM) are presented. The influence of the feature parameters on the vibration frequency and mode shape(as the input of flutter calculation) of the first three modes are analyzed by the Orthogonal Experimental Design(OED) method. The results show that the parameters have a more remarkable impact on the first torsional mode and thus it is concerned in the flutter sensitivity analysis. Compared with the solid blade, the minimum aerodynamic damping of the hollow blade decreases, indicating that the hollow structure makes the aeroelastic stability worse. For the parameters describing the hollow section, the rib number N has the greatest influence on the minimum aerodynamic damping, followed by the wall thickness W5. For the parameters in the height of hollow segment, the aerodynamic damping increases with the increase of parameters M1 and M2. This means that reducing the height of the hollow segment is helpful to improve the aeroelastic stability. Compared with the impact of parameters in hollow section, the variation of aerodynamic damping caused by the height of the hollow segment is small.

风扇叶片飞失显式动力学仿真网格与时间步长研究

为了研究大涵道比涡扇发动机风扇叶片飞失仿真中网格尺度与时间步长对于瞬态显式动力学分析结果的影响,采用有限元法中单元计算理论分析的方法分析了网格尺度和时间步长在计算稳定性方面的理论联系。采用多因素试验设计方法组织了针对叶片应力分布、转子轴心轨迹和支点外传振动应力3个风扇叶片飞失的典型输出参数的网格尺度和时间步长的影响研究方案,开展了典型物理过程、模型简化和数值计算无关性研究。针对时间步长为7×10^(-7)、5×10^(-7)、3×10^(-7)和2×10^(-7)s,网格尺度为40、30、20和15 mm的计算结果进行分析,结果表明:对于给定物理过程和目标时长,存在着网格尺度和时间步长的门槛值,如:2×10^(-7)s时间步长和30 mm网格尺度,超过该值进一步细化网格和减小时间步长对于精度提升不明显;显式动力学的计算原理决定了目标时间越长偏差累计越大,所需的网格精度就越高;碰摩过程对于风扇叶片飞失仿真的应力和外传振动偏差影响较大。

Numerical Investigation on Super-cooled Large Droplet Icing of Fan Rotor Blade in Jet Engine

Icing(or ice accretion) is a phenomenon in which super-cooled water droplets impinge and accrete on a body.It is well known that ice accretion on blades and vanes leads to performance degradation and has caused severe accidents.Although various anti-icing and deicing systems have been developed,such accidents still occur.Therefore,it is important to clarify the phenomenon of ice accretion on an aircraft and in a jet engine.However,flight tests for ice accretion are very expensive,and in the wind tunnel it is difficult to reproduce all climate conditions where ice accretion can occur.Therefore,it is expected that computational fluid dynamics(CFD),which can estimate ice accretion in various climate conditions,will be a useful way to predict and understand the ice accretion phenomenon.On the other hand,although the icing caused by super-cooled large droplets(SLD) is very dangerous,the numerical method has not been established yet.This is why SLD icing is characterized by splash and bounce phenomena of droplets and they are very complex in nature.In the present study,we develop an ice accretion code considering the splash and bounce phenomena to predict SLD icing,and the code is applied to a fan rotor blade.The numerical results with and without the SLD icing model are compared.Through this study,the influence of the SLD icing model is numerically clarified.

Motion Characteristic Analysis of a Parallel Mechanism with 2-DOF for Industrial Fan Blades' Scribing

Abstract：With the application background of 16 inch industrial fan blades＇ scribing process, a simple and prac tical 2DOF parallel plane scribing device is proposed to replace the traditional manual scribing. The direct and inverse kinematics solutions, workspace and singular configuration of the mechanism are analyzed and solved. Some contour curve equations are fitted based on the data points which are measured by a three coordinate meas uring machine. According to the blade＇s contour curve, each input link＇s motion characteristic is obtained by u sing MATLAB, which provides a new way to realize blades＇ automatic scribing process technology.

模型转子突加不平衡响应分析及试验验证

为准确获取风扇叶片飞失引起的瞬态载荷,利用显式动力学有限元仿真方法进行了接触建模和瞬态分析,开展了多层次的试验标定和校核工作,利用这些试验结果与分析进行了对比验证。结果表明:采用的显式动力学有限元仿真方法为准确模拟突加不平衡过程中的动态特征提供一种可行的仿真手段,形成了一套构件-组件-整机、从静力学到动力学的模型修正方法。按照测试优先级定义的主要传力路径载荷、突加不平衡载荷等物理量,确定了模型修正的测试参数选取方法。利用支承锥壁动应变测量数据,结合模型标定结果,可以准确地获得支点峰值径向动载荷,预测的峰值动态载荷与试验获取的结果误差小于10%,此方法可以运用到支点冲击载荷间接测量中,提高测量的精度及简便性。

Erosion-Resistant Surfaces Inspired by Tamarisk

Tamarisk, a plant that thrives in arid and semi-arid regions, has adapted to blustery conditions by evolving extremely ef- fective and robust anti-erosion surface patterns. However, the details of these unique properties and their structural basis are still unexplored. In this paper, we demonstrate that the tamarisk surface only suffers minor scratches under wind-sand mixture erosion. The results show that the anti-erosion property of bionic sample, inspired by tamarisk surface with different surface morphologies, can be attributed to the flow rotating in the grooves that reduces the particle impact speed. Furthermore, the simulation and experiment on the erosion wear behavior of the bionic samples and bionic centrifugal fan blades show that the bionic surface with V-type groove exhibits the best erosion resistance. The bionic surface on centrifugal fan blades with opti- mum parameters can effectively improve anti-erosion property by 28.97%. This paper show more opportunities for bionic application in improving the anti-erosion performance of moving parts that work under dirt and sand particle environment, such as helicopter rotor blades, airplane propellers, rocket motor nozzles, and pipes that regularly wear out from erosion.

冲击载荷作用下的锥壁失效仿真及试验验证

根据航空发动机支承锥壁结构受力特点,对风扇叶片飞失冲击载荷作用下的锥壁失效破坏机理进行了研究。利用显式动力学有限元仿真方法,对冲击载荷作用下的锥壁结构动态失效过程进行了瞬态分析。开展了对锥壁的落锤冲击试验,并与分析结果进行了对比验证。试验和分析结果表明:冲击载荷作用下锥壁减薄处破坏为剪切失效破坏。采用的显式动力学有限元仿真方法为准确模拟冲击载荷作用下的锥壁结构失效提供了一种可行的仿真手段,分析获得的峰值加速度与试验结果误差小于5%;利用GISSMO(generalized incremental stress state dependent damage model)可以准确预测锥壁减薄处断裂时间、断裂位置。经过试验验证的分析方法及失效模型可运用到风扇叶片飞失冲击载荷下的锥壁失效设计参数的确定,提高锥壁降载结构设计的精度。