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Modeling of compressor blade behavior under tip rubbing conditions

Presentation · September 2018

DOI: 10.13140/RG.2.2.29211.90408

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Modeling of compressor blade behavior under tip rubbing conditions
23rd Blade Mechanics Seminar

Grzegorz Moneta
Winterthur, Switzerland
11th September 2018
Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 1
 Agenda

Ø Problem statement
Ø Introduction to the blade tip rubbing phenomenon
Ø Factors influencing tip clearance values
Ø Tip - casing rubbing mechanism
Ø Failure mechanisms of blades caused by rubbing and their
consequences
Ø Methods of increasing robustness against rubbing
Ø Modelling of compressor blade rubbing
Ø Literature research
Ø Modeling assumptions
Ø Results
Ø Haigh diagram
Ø Summary
Ø References
Ø Discussion
Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 2
 Problem statement

Fig. 1. Tip Clearance of a blade [1] Fig. 2. Tip Vortex Formation [1]

Fig. 3. End wall boundary layer interaction [1, 2] Fig. 4. Compressor Blade tip liberation
example caused by rubbing [3]
Tip clearance value is a compromise between performance and reliability of engine – how to choose optimum?

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 3
Introduction to the blade tip rubbing
phenomenon

ØFactors influencing tip clearance values

ØTip - casing rubbing mechanism
ØFailure mechanisms of blades caused by rubbing
and their consequences
ØMethods of increasing robustness against
rubbing

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 4
 Introduction
Factors influencing tip clearance values

Blade tip clearance value is not constant along time, it depends on:
- rotational velocity
- temperature
- plastic pre-deformation of parts, e.g. during rotor over-speed
- thermal inertia of blades, rotor and casing
- blade elongation caused by creep

Blade tip clearance value is not constant around the circumference of

the casing, it depends on:
- casing ovalisation
- bending due to the rotor gravity load and other accelerations
- Variable alignment of rotor axis with respect to casing axis

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 5
 Introduction
Tip - casing rubbing mechanism
Rubbing

Fig. 6. Casing ovalisation and rotor misalignment

effects on local blade tip clearance
Fig. 5. Schematic of rubbing between single blade and
elastic casing [4]

Fig. 7. Effects of blade tip rubbing: tip material rolling [5], local overheat Fig. 8. Example of casing wear map
[3], tip cracking [5] of casing by rotor misalignment
Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 6
 Introduction
Failure mechanisms of blades caused by rubbing and their consequences
Wear:
- crack initiation at the tip:
• can propagate during rubbing
• can propagate out of rubbing time, e.g. if resonance of mode with high dynamic stress
at the tip occurs
- overheat of the tip:
• blade material ignition
• changes of material structure

Forced vibrations (1 per revolution excitation):

- HCF without stress amplification in resonance
- HCF with stress amplification in resonance
à Focus of the study
Plastic deformation of the airfoil (bending, twist):
- locations with high values of residual stresses can be affected by cracking
- redistribution of the mass in the airfoil can redistribute stress, destroying balancing of the
blade and causing cyclic fatigue

Consequences:
- HCF cracking of blades à liberation of part of the airfoil
- consequential damages of next rows (DOD)
- unbalancing of the rotor à consequential damages of other parts

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 7
 Introduction
Methods of increasing robustness against rubbing

• More advanced FE modelling in design

phase: full engine cycle, reducing order of
simplifications and assumptions
• Reduction of casing ovalisation level:
optimum distribution of thickness and
supports
• Design features at blades: squealer tips,
abrasive layers on tips (cBN depositions)
• Design features at casing surfaces:
abradable coatings, honeycomb layers Fig. 9. Axial Flow Compressor rotor blade
with squealer tip [6]

Fig. 10. Blade and casing

with abrasive layers [7] Fig. 11. Compressor blade tip and liner diagram [8]
Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 8
Modelling of compressor blade rubbing

ØLiterature research
ØModeling assumptions
ØResults
ØHaigh diagram

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 9
 Modelling
Literature research
Type of model Paper Comments

Analytical model Hui M., Xingyu T., Qingkai H., Simplified analytical model
Accuracy and complexity of modelling increase

Zhiyuan W., Di W. (2015) [4]

FEM model with Williams R. (2011) [9] Simplified FEM model with blades
springs represented by spring system
FEM model with Salvat N., Batailly A., Legrand Bernoulli's beam formulation used for
beam elements M. (2014) [10] analysis
FEM model with Feifei W., et. al. (2014) [11] Transient analysis of engine
shell elements acceleration, shell model of airfoil
without pressure load applied,
experimental verification
FEM model with Turner K., Adams M., Dunn Transient explicit simulations of a
3D solid elements M. (2005) [12] simplified blade airfoil, comparison with
MATLAB code
FEM model with Berthoul B. et. al. (2018) [13] Transient simulation of wear of
3D solid elements abradable material under tip-casing
and wear mech. rubbing conditions

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 10
 Modeling
Modeling assumptions

Ø Casing has been defined using analytical surface

Ø Rotor misalignment and contact overlap taken into account (values chosen for
educational purposes, to demonstrate the phenomenon of rubbing at 20% of the
circumference)

Ø Static pre-step with full load (Temperature + Pressure + Centrifugal load) including
geometrical nonlinearities

Ø Dynamic calculation (time domain) in next step

LE TE TE LE

PS LE SG PS SS
SS SG

Fig. 12. Locations of virtual Strain Gauges (SG) Fig. 13. Model of blade and casing
surface – scheme of misalignment

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 11
 Modeling
Results
Stress
Compressive stress ß à Tensile stress

Both locations are affected by cyclic stress, but only for PS LE location, it has tensile character

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 12
 Modeling
Results

LE
TE TE LE

PS SS

HCF

Videos

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 13
 Modeling
Results

0.0 ms 9.8 ms 10.3 ms 12.3 ms

24.8 ms 29.8 ms 30.3 ms 32.3 ms

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 14
Modeling
Stress results

Highest stress amplitudes appear at moments of tip-casing contact

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 15
 Modeling
Haigh diagram

For applied assumptions (chosen for educational purpose), PS LE location shows limited HCF lifetime

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 16
 Summary

ü The new advanced compressor blades require higher loading per stage and
smaller clearances which increase risk of rubbing and failure.

ü There are many design features and methods to achieve optimum clearance for
engine design point and increase robustness of design.

ü Modern designs require more accurate modeling of phenomena happening in

engine: more advanced models, reduction of simplifications, etc.

ü Open literature shows many methods and strategies to simulate blade-casing

rubbing, but the choice which one should be used, every time depends on specific
problem.

ü Presented study has shown behavior of compressor blade under rubbing

conditions. Additionally, a HCF assessment has been performed to predict critical
location with risk of fatigue cracking.

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 17
 References (1 of 2)

[1] Brossman, J. R., 2012. An investigation of rotor tip leakage flows in the rear-block of a
multistage compressor. PhD thesis, Purdue University.
[2] Ostad M., Kamali R.: Evaluating the effects of blade tip clearance in various stages on
the performance of an axial compressor, Journal of Applied Fluid Mechanics 11(2): pp
475-481, January 2018
[3] Borescope inspections reveal 7EA users’ ongoing battle against clashing, IGV
rubs, shim migration, Combined Cycle Journal Online, 20.11.2011, access:
http://www.ccj-online.com/7ea-inspections/
[4] Hui Ma, Xingyu Tai, Qingkai Han, Zhiyuan Wu, Di Wang, et al.. A revised model for
rubbing between rotating blade and elastic casing. Journal of Sound and Vibration,
Elsevier, 2015, 337, pp.301 - 320.
[5] Borescope clinic: Condition-based maintenance demands good intel, 02.06.2013,
access: http://www.ccj-online.com/borescope-clinic-condition-based-maintenance-
demands-good-intel/
[6] U.S. Department of Energy-National Energy Technology Laboratory (NETL); Smith
L., Karim H., Etemad Sh., Pfefferle W.C., "The Gas Turbine Handbook“ (2006).
Engineering Faculty Book Gallery. 3.
[7] Patent EP 0 837 222 A1, Gas turbine compressor clearance control with abrasive blade
tip and abradable shroud sealing and method of manufacturing
[8] Beale S.: Precision engineering for future propulsion and power systems: a perspective
from Rolls-Royce, Philosophical Transactions of the Royal Society of London A:
Mathematical, Physical and Engineering Sciences, A (2012). Vol 370, pp 4130-53.
Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 18
 References (2 of 2)

[9] Williams R.: Simulation of Blade Casing Interaction Phenomena in Gas Turbines
Resulting From Heavy Tip Rubs Using an Implicit Time Marching Method. ASME 2011
Turbo Expo: Turbine Technical Conference and Exposition, Jun 2011, Vancouver,
Canada.
[10] Salvat, N., Batailly, A., Legrand, M.: Two-dimensional modeling of shaft precessional
motions induced by blade/casing unilateral contact in aircraft engines. In: ASME Turbo
Expo2014: Turbine Technical Conference and Exposition, American Society of
Mechanical Engineers (2014)
[11] Feifei W., Yunyong Ch., Zhiqing W., Lulu Ch., Jin M.: Failure Analysis of Rubbing of the
Fan Tip and Case of an Engine, “APISAT2014”, 2014 Asia-Pacific International
Symposium on Aerospace Technology
[12] Turner K., Adams M., Dunn M.: Simulation of Engine Blade Tip-Rub Induced Vibration,
Proceedings of GT2005; ASME Turbo Expo 2005: Power for Land, Sea and Air; June 6-
9, 2005, Reno-Tahoe, Nevada, USA
[13] Berthoul B., Batailly A., Stainier L., Legrand M., Cartraud P.: Phenomenological
modeling of abradable wear in turbomachines. Mechanical Systems and Signal
Processing, Elsevier, 2018, 98, pp.770-785.

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 19
 Thank you!

Questions?

Modeling of compressor blade behavior under tip rubbing conditions, Grzegorz Moneta, 11th September 2018 20

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