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NASA NTRS1991

Blade Tip Rubbing Stress Prediction

An analytical model was constructed to predict the magnitude of stresses produced by rubbing a turbine blade against its tip seal. This model used a linearized approach to the problem, after a parametric study, found that the nonlinear effects were of insignificant magnitude. The important input parameters to the model were: the arc through which rubbing occurs, the turbine rotor speed, normal force exerted on the blade, and the rubbing coefficient of friction. Since it is not possible to exactly specify some of these parameters, values were entered into the model which bracket likely values. The form of the forcing function was another variable which was impossible to specify precisely, but the assumption of a half-sine wave with a period equal to the duration of the rub was taken as a realistic assumption. The analytical model predicted resonances between harmonics of the forcing function decomposition and known harmonics of the blade. Thus, it seemed probable that blade tip rubbing could be at least a contributor to the blade-cracking phenomenon. A full-scale, full-speed test conducted on the space shuttle main engine high pressure fuel turbopump Whirligig tester was conducted at speeds between 33,000 and 28,000 RPM to confirm analytical predictions.

Davis, Gary A.↗

NASA NTRS1991

Unified aeroacoustics analysis for high speed turboprop aerodynamics and noise. Volume 3: Application of theory for blade loading, wakes, noise, and wing shielding

Results of the program for the generation of a computer prediction code for noise of advanced single rotation, turboprops (prop-fans) such as the SR3 model are presented. The code is based on a linearized theory developed at Hamilton Standard in which aerodynamics and acoustics are treated as a unified process. Both steady and unsteady blade loading are treated. Capabilities include prediction of steady airload distributions and associated aerodynamic performance, unsteady blade pressure response to gust interaction or blade vibration, noise fields associated with thickness and steady and unsteady loading, and wake velocity fields associated with steady loading. The code was developed on the Hamilton Standard IBM computer and has now been installed on the Cray XMP at NASA-Lewis. The work had its genesis in the frequency domain acoustic theory developed at Hamilton Standard in the late 1970s. It was found that the method used for near field noise predictions could be adapted as a lifting surface theory for aerodynamic work via the pressure potential technique that was used for both wings and ducted turbomachinery. In the first realization of the theory for propellers, the blade loading was represented in a quasi-vortex lattice form. This was upgraded to true lifting surface loading. Originally, it was believed that a purely linear approach for both aerodynamics and noise would be adequate. However, two sources of nonlinearity in the steady aerodynamics became apparent and were found to be a significant factor at takeoff conditions. The first is related to the fact that the steady axial induced velocity may be of the same order of magnitude as the flight speed and the second is the formation of leading edge vortices which increases lift and redistribute loading. Discovery and properties of prop-fan leading edge vortices were reported in two papers. The Unified AeroAcoustic Program (UAAP) capabilites are demonstrated and the theory verified by comparison with the predictions with data from tests at NASA-Lewis. Steady aerodyanmic performance, unsteady blade loading, wakes, noise, and wing and boundary layer shielding are examined.

Hanson, D. B.↗

NASA NTRS1991

Aeroelastic modal characteristics of mistuned blade assemblies: Mode localization and loss of eigenstructure

An investigation of the effects of small mistuning on the aeroelastic modes of bladed disk assemblies with aerodynamic coupling between blades is presented. The cornerstone of the approach is the use and development of perturbation methods that exhibit the crucial role of the interblade coupling and yield general findings regarding mistuning effects. It is shown that blade assemblies with weak aerodynamic interblade coupling are highly sensitive to small blade mistuning, and that their dynamics is quantitatively altered in the following ways: the regular pattern that characterizes the root locus of the tuned aeroelastic eigenvalues in the complex plane is totally lost; the aeroelastic mode shapes becomes severely localized to only a few blades of the assembly and lose their constant interblade phase angle feature; and curve veering phenomena take place when the eigenvalues are plotted versus a mistuning parameter.

Pierre, Christophe↗

NASA NTRS1990

An enhanced integrated aerodynamic load/dynamic approach to optimum rotor blade design

An enhanced integrated aerodynamic load/dynamic optimization procedure is developed to minimize vibratory root shears and moments. The optimization is formulated with 4/rev vertical and 3/rev inplane shears at the blade root as objective functions and constraints, and 4/rev lagging moment. Constraints are also imposed on blade natural frequencies, weight, autorotational inertia, contrifugal stress, and rotor thrust. The Global Criteria Approach is used for formulating the multi-objective optimization. Design variables include spanwise distributions of bending stiffnesses, torsional stiffness, nonstructural mass, chord, radius of gyration, and blade taper ratio. The program CAMRAD is coupled with an optimizer, which consists of the program CONMIN and an approximate analysis, to obtain optimum designs. The optimization procedure is applied to an advanced rotor as a reference design. Optimum blade designs, obtained with and without a constraint on the rotor thrust, are presented and are compared to the reference blade. Substantial reductions are obtained in the vibratory root forces and moments. As a byproduct, improvements are also found in some performance parameters, such as total power required, which were not considered during optimization.

Chattopadhyay, Aditi↗

NASA NTRS1991

Aeroelastic modal characteristics of mistuned blade assemblies - Mode localization and loss of eigenstructure

An investigation of the effects of small mistuning on the aeroelastic modes of bladed-disk assemblies with aerodynamic coupling between blades is presented. The cornerstone of the approach is the use and development of perturbation methods that exhibit the crucial role of the interblade coupling and yield general findings regarding mistuning effects. It is shown that blade assemblies with weak aerodynamic interblade coupling are highly sensitive to small blade mistuning, and that their dynamics is qualitatively altered in the following ways: the regular pattern that characterizes the root locus of the tuned aeroelastic eigenvalues in the complex plane is totally lost; the aeroelastic mode shapes become severely localized to only a few blades of the assembly and lose their constant interblade phase angle feature; curve veering phenomena take place when the eigenvalues are plotted versus a mistuning parameter.

Pierre, Christophe↗

NASA NTRS1991

Blade design and analysis using a modified Euler solver

An iterative method for blade design based on Euler solver and described in an earlier paper is used to design compressor and turbine blades providing shock free transonic flows. The method shows a rapid convergence, and indicates how much the flow is sensitive to small modifications of the blade geometry, that the classical iterative use of analysis methods might not be able to define. The relationship between the required Mach number distribution and the resulting geometry is discussed. Examples show how geometrical constraints imposed upon the blade shape can be respected by using free geometrical parameters or by relaxing the required Mach number distribution. The same code is used both for the design of the required geometry and for the off-design calculations. Examples illustrate the difficulty of designing blade shapes with optimal performance also outside of the design point.

Leonard, O.↗

NASA NTRS1992

Impeller tandem blade study with grid embedding for local grid refinement

Flow non-uniformity at the discharge of high power density impellers can result in significant unsteady interactions between impeller blades and downstream diffuser vanes. These interactions result in degradation of both performance and pump reliability. The MSFC Pump Technology Team has recognized the importance of resolving this problem and has thus initiated the development and testing of a high head coefficient impeller. One of the primary goals of this program is to improve impeller performance and discharge flow uniformity. The objective of the present work is complimentary. Flow uniformity and performance gains were sought through the application of a tandem blade arrangement. The approach adopted was to numerically establish flow characteristics at the impeller discharge for the baseline MSFC impeller and then parametrically evaluate tandem blade configurations. A tandem design was sought that improves both impeller performance and discharge uniformity. The Navier-Stokes solver AEROVISC was used to conduct the study. Grid embedding is used to resolve local gradients while attempting to minimize model size. Initial results indicate that significant gains in flow uniformity can be achieved through the tandem blade concept and that blade clocking rather than slot location is the primary driver for flow uniformity.

Bache, George↗

NASA NTRS1992

A new aeroelastic model for composite rotor blades with straight and swept tips

An analytical model for predicting the aeroelastic behavior of composite rotor blades with straight and swept tips is presented. The blade is modeled by beam type finite elements along the elastic axis. A single finite element is used to model the swept tip. The nonlinear equations of motion for the finite element model are derived using Hamilton's principle and based on a moderate deflection theory and accounts for: arbitrary cross-sectional shape, pretwist, generally anisotropic material behavior, transverse shears and out-of-plane warping. Numerical results illustrating the effects of tip sweep, anhedral and composite ply orientation on blade aeroelastic behavior are presented. Tip sweep can induce aeroelastic instability by flap-twist coupling. Tip anhedral causes lag-torsion and flap-axial couplings, however, its effects on blade stability is less pronounced than the effect due to sweep. Composite ply orientation has a substantial effect on blade stability.

Yuan, Kuo-An↗

NASA NTRS1991

Three-dimensional blade vortex interactions

A three-dimensional time dependent Navier-Stokes analysis was applied to the rotor blade vortex interaction problem. The numerical procedure is an iterative implicit procedure using three point central differences to represent spatial derivatives. A series of calculations were made to determine the time steps, pseudo-time steps, iterations, artificial dissipation level, etc. required to maintain a nondissipative vortex. Results show the chosen method to have excellent non-dissipative properties provided the correct parameters are chosen. This study was used to set parameters for both two- and three-dimensional blade vortex interaction studies. The case considered was the interaction between a vortex and a NACA0012 airfoil. The results showed the detailed physics during the interaction including the pressure pulse propagating from the blade. The simulated flow physics was qualitatively similar to that experimentally observed. The BVI phenomena is the result of the buildup and violent collapse of the shock waves and local supersonic pockets on the blade surfaces. The resulting pressure pulse build-up appears to be centered at the blade leading edge.

Davoudzadeh, Farhad↗

NASA NTRS1992

Unsteady blade pressures on a propfan - Predicted and measured compressibility effects

The effect of compressibility on unsteady blade pressures is studied by solving the 3D Euler equations. The operation of the eight-bladed SR7L propfan at 4.75 deg angle of attack was considered. Euler solutions were obtained for three Mach numbers, 0.6, 0.7, and 0.8 and the predicted blade pressure waveforms were compared with flight data. In general, the effect of Mach number on pressure waveforms are correctly predicted. The change in pressure waveforms are minimal when the Mach number is increased from 0.6 to 0.7. Increasing the Mach number from 0.7 to 0.8 produces significant changes in predicted pressure levels. The predicted amplitudes, however, differ from measurements at some transducer locations. Also the predicted appearance of a shock in the highly loaded portion of the blade revolution is not indicated by the measurements. At all the three Mach numbers, the measured (installed propfan) pressure waveforms show a relative phase lag compared to the computed (propfan alone) waveforms due to installation effects. Measured waveforms in the blade tip region show nonlinear variations which are not captured by the present numerical procedure.

Nallasamy, M.↗

NASA NTRS1991

Research on measurement and control of helicopter rotor response using blade-mounted accelerometers 1990-91

Wind tunnel testing of the full-size Model 412/IBC rotor performed at the NASA Ames Research Center is described. The use of blade-mounted accelerometers is found to be feasible for estimating or measuring blade flapping, lagging, and bending accelerations, rates, and displacements. Application of the imaginary swash plate concept to IBC systems leads to useful filtering of the blade accelerometer signals while permitting the control of a four-bladed rotor using measurements from any three blades. Rotor state measurements in the rotating system can be transformed to the corresponding nonrotating rotor states using the IBC algorithm with its associated filtering properties.

Ham, Norman D.↗

NASA NTRS1993

An improved CAMRAD model for aeroelastic stability analysis of the XV-15 with advanced technology blades

In pursuit of higher performance, the XV-15 Tiltrotor Research Aircraft was modified by the installation of new composite rotor blades. Initial flights with the Advanced Technology Blades (ATB's) revealed excessive rotor control loads that were traced to a dynamic mismatch between the blades and the aircraft control system. The analytical models of both the blades and the mechanical controls were extensively revised for use by the CAMRAD computer program to better predict aeroelastic stability and loads. This report documents the most important revisions and discusses their effects on aeroelastic stability predictions for airplane-mode flight. The ATB's may be flown in several different configurations for research, including changes in blade sweep and tip twist. The effects on stability of 1 deg and 0 deg sweep are illustrated, as are those of twisted and zero-twist tips. This report also discusses the effects of stiffening the rotor control system, which was done by locking out lateral cyclic swashplate motion with shims.

Acree, C. W., Jr.↗

NASA NTRS1993

Blasim: A computational tool to assess ice impact damage on engine blades

A portable computer called BLASIM was developed at NASA LeRC to assess ice impact damage on aircraft engine blades. In addition to ice impact analyses, the code also contains static, dynamic, resonance margin, and supersonic flutter analysis capabilities. Solid, hollow, superhybrid, and composite blades are supported. An optional preprocessor (input generator) was also developed to interactively generate input for BLASIM. The blade geometry can be defined using a series of airfoils at discrete input stations or by a finite element grid. The code employs a coarse, fixed finite element mesh containing triangular plate finite elements to minimize program execution time. Ice piece is modeled using an equivalent spherical objective that has a high velocity opposite that of the aircraft and parallel to the engine axis. For local impact damage assessment, the impact load is considered as a distributed force acting over a region around the impact point. The average radial strain of the finite elements along the leading edge is used as a measure of the local damage. To estimate damage at the blade root, the impact is treated as an impulse and a combined stress failure criteria is employed. Parametric studies of local and root ice impact damage, and post-impact dynamics are discussed for solid and composite blades.

Reddy, E. S.↗

NASA NTRS1992

Investigation of rotor blade roughness effects on turbine performance

The cold air test program was completed on the SSME (Space Shuttle Main Engine) HPFTP (High Pressure Fuel Turbopump) turbine with production nozzle vane rings and polished coated rotor blades with a smooth surface finish of 30 microinch (0.76 micrometer) RMS (Root Mean Square). The smooth blades were polished by an abrasive flow machining process. The test results were compared with the air test results from production rough coated rotor blades with a surface finish of up to 400 microinch (10.16 micrometer) RMS. Turbine efficiency was higher for the smooth blades over the entire range tested. Efficiency increased 2.1 percentage points at the SSME 104 percent RPL (Rated Power Level) condition. This efficiency improvement could reduce the SSME HPFTP turbine inlet temperature by 57 degrees Rankine (32 degrees Kelvin) increasing turbine durability. The turbine flow parameter increased and the mid-span outlet swirl angle became more axial with the smooth rotor blades.

Boynton, J. L.↗

NASA NTRS1993

BLASIM - A computational tool to assess ice impact damage on engine blades

A portable computer code called BLASIM is developed at NASA LeRC to assess the ice impact damage on aircraft engine blades. In addition to the ice impact analyses, the code is also capable of carrying out static, dynamic, resonance margin and flutter analyses. The blade can be solid, hollow, superhybrid or composite material. An optional preprocessor (input generator) is also developed to generate input to the code through interactive process. The blade geometry can be defined either by a series of airfoils at discrete input stations or by a finite element grid. The code employs a coarse fixed finite element mesh with triangular plate finite elements and has quick turnaround time. The ice piece is modeled as an equivalent spherical object and has the velocity opposite to that of the aircraft with direction parallel to the engine axis. For the local impact damage assessment, the impact force is considered as a distributed load acting over a region around the impact point and the average radial strain of the finite elements along the leading edge is taken as a measure of the local damage. To estimate the damage at the blade root, the impact is considered to be an impulse and a combined stress failure criteria is employed. Parametric studies for local and root ice impact damage, and post-impact dynamics are discussed for solid and composite blades.

Reddy, E. S.↗

NASA NTRS1993

Vibration localization in mono- and bi-coupled bladed disks - A transfer matrix approach

A transfer matrix approach to the analysis of the dynamics of mistuned bladed disks is presented. The study focuses on mono-coupled systems, in which each blade is coupled to its two neighboring blades, and bi-coupled systems, where each blade is coupled to its four nearest neighbors. Transfer matrices yield the free dynamics, both the characteristic free wave and the normal modes - in closed form for the tuned assemblies. Mistuned assemblies are represented by random transfer matrices and an examination of the effect of mistuning on harmonic wave propagation yields the localization factor - the average rate of spatial wave amplitude decay per blade - in the mono-coupled assembly. Based on a comparison of the wave propagation characteristics of the mono- and bi-coupled assemblies, important conclusions are drawn about the effect of the additional coupling coordinate on the sensitivity to mistuning and the strength of mode localization predicted by a mono-coupled analysis.

Ottarsson, Gisli↗

NASA NTRS1992

Aeroelastic behavior of composite rotor blades with swept tips

This paper presents an analytical study of the aeroelastic behavior of composite rotor blades with straight and swept tips. The blade is modeled by beam type finite elements. A single finite element is used to model the swept tip. The nonlinear equations of motion for the finite element model are derived using Hamilton's principle and based on a moderate deflection theory and accounts for: arbitrary cross-sectional shape, pretwist, generally anisotropic material behavior, transverse shears and out-of-plane warping. Numerical results illustrating the effects of tip sweep, anhedral and composite ply orientation on blade aeroelastic behavior are presented. It is shown that composite ply orientation has a substantial effect on blade stability. At low thrust conditions, certain ply orientations can cause instability in the lag mode. The flap-torsion coupling associated with tip sweep can also induce aeroelastic instability in the blade. This instability can be removed by appropriate ply orientation in the composite construction.

Yuan, Kuo-An↗

NASA NTRS1993

An iterative multidisciplinary analysis for rotor blade shape determination

A CFD solver called ADPAC-APES is coupled with a NASTRAN structural analysis and a MARC thermal/heat transfer analysis to determine rotor blade shape. Nonlinear blade displacements due to centrifugal loads, aerodynamic pressures, and nonuniform temperature distribution are determined simultaneously. The effect of blade displacements on aerodynamic pressures and temperatures is then analyzed. These calculations are iterated till a steady state is reached across all the disciplines. This iterative procedure is applied to a ducted fan rotor blade and the manufactured shape is determined from a given operating shape. Effect of a part-span shroud on blade deflections is also analyzed.

Mahajan, Aparajit J.↗