Engineering topics

Sawicki, Jerzy T.

Publications and source records attributed to Sawicki, Jerzy T..

15 records

NASA NTRS2019

Swept Volume Approach for the Characterization of Pumping Loss of Shrouded Meshed Cylindrical Gears

High speed rotorcraft transmissions are subject to load-independent power losses consisting of drag and pumping loss. Tightly conforming shrouds enclosing the transmission gears are often incorporated to reduce the drag component of the total load-independent losses. However, tightly conforming axial shrouding can result in an increase in the pumping loss component. Quantifying the pumping loss of shrouded gear transmissions has been the subject of many studies. This study presents a new approach for estimating pumping loss based on the concept of swept volume borrowed from the positive displacement pump and compressor industry. In this study, pumping loss of shrouded gear transmissions is considered to be related to the swept volume of the gear sets and the downstream flow resistance created by the shroud clearances. The drag loss and pumping loss of a spur gear pair have been determined through testing using the NASA Glenn Research Center Gear Windage Test Facility. The results from this testing have been compared to theoretical results using the formulations presented in this study. Good correlation exist between the test pumping power loss and the predicted pumping power loss for tightly conforming axial shroud configurations.

Hurrell, Michael J.↗

NASA NTRS2006

Transient Response of Rotor on Rolling-Element Bearings with Clearance

Internal clearance in rolling element bearings is usually present to allow for radial and axial growth of the rotor-bearing system and to accommodate bearing fit-up. The presence of this clearance also introduces a "dead band" into the load-deflection behavior of the bearing. Previous studies demonstrated that the presence of dead band clearance might have a significant effect on synchronous rotor response. In this work, the authors investigate transient response of a rotor supported on rolling element bearings with internal clearance. In addition, the stiffness of the bearings varies nonlinearly with bearing deflection and with speed. Bearing properties were accurately calculated with a state of the art rolling bearing analysis code. The subsequent rotordynamics analysis shows that for rapid acceleration rates the maximum response amplitude may be less than predicted by steady-state analysis. The presence of clearance may shift the critical speed location to lower speed values. The rotor vibration response exhibits subharmonic components which are more prominent with bearing clearance.

Fleming, David P.↗

NASA NTRS2005

Vibration Based Crack Detection in a Rotating Disk: Experimental Results - Part 2

This paper describes the experimental results concerning the detection of a crack in a rotating disk. The goal was to utilize blade tip clearance and shaft vibration measurements to monitor changes in the system's center of mass and/or blade deformation behaviors. The concept of the approach is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Here, a notch was used to simulate an actual crack. The vibration based experimental results failed to identify the existence of a notch when utilizing the approach described above, even with a rather large, circumferential notch (l.2 in.) located approximately mid-span on the disk (disk radius = 4.63 in. with notch at r = 2.12 in.). This was somewhat expected, since the finite element based results in Part 1 of this study predicted changes in blade tip clearance as well as center of mass shifts due to a notch to be less than 0.001 in. Therefore, the small changes incurred by the notch could not be differentiated from the mechanical and electrical noise of the rotor system. Although the crack detection technique of interest failed to identify the existence ofthe notch, the vibration data produced and captured here will be utilized in upcoming studies that will focus on different data mining techniques concerning damage detection in a disk.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Ability of Impedance-Based Health Monitoring To Detect Structural Damage of Propulsion System Components Assessed

Impedance-based structural-health-monitoring uses piezoelectric (PZT) patches that are bonded onto or embedded in a structure. Each individual patch behaves as both an actuator of the surrounding structural area as well as a sensor of the structural response. The size of the excited area varies with the geometry and material composition of the structure, and an active patch is driven by a sinusoidal voltage sweep. When a PZT patch is subjected to an electric field, it produces a mechanical strain; and when it is stressed, it produces an electric charge. Since the patch is bonded to the structure, driving a patch deforms and vibrates the structure. The structure then produces a localized dynamic response. This structural system response is transferred back to the PZT patch, which in turn produces an electrical response. The electromechanical impedance method is based on the principle of electromechanical coupling between the active sensor and the structure, which allows researchers to assess local structural dynamics directly by interrogating a distributed sensor array. Because of mechanical coupling between the sensor and the host structure, this mechanical effect is picked up by the sensor and, through electromechanical coupling inside the active element, is reflected in electrical impedance measured at the sensor s terminals.

Martin, Richard E.↗

NASA NTRS2005

Damage Assessment of Aerospace Structural Components by Impedance Based Health Monitoring

This paper addresses recent efforts at the NASA Glenn Research Center at Lewis Field relating to the set-up and assessment of electro-mechanical (E/M) impedance based structural health monitoring. The overall aim is the application of the impedance based technique to aeronautic and space based structural components. As initial steps, a laboratory was created, software written, and experiments conducted on aluminum plates in undamaged and damaged states. A simulated crack, in the form of a narrow notch at various locations, was analyzed using piezoelectric-ceramic (PZT: lead, zirconate, titarate) patches as impedance measuring transducers. Descriptions of the impedance quantifying hardware and software are provided as well as experimental results. In summary, an impedance based health monitoring system was assembled and tested. The preliminary data showed that the impedance based technique was successful in recognizing the damage state of notched aluminum plates.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗

NASA NTRS2004

Vibration-Based Data Used to Detect Cracks in Rotating Disks

Rotor health monitoring and online damage detection are increasingly gaining the interest of aircraft engine manufacturers. This is primarily due to the fact that there is a necessity for improved safety during operation as well as a need for lower maintenance costs. Applied techniques for the damage detection and health monitoring of rotors are essential for engine safety, reliability, and life prediction. Recently, the United States set the ambitious goal of reducing the fatal accident rate for commercial aviation by 80 percent within 10 years. In turn, NASA, in collaboration with the Federal Aviation Administration, other Federal agencies, universities, and the airline and aircraft industries, responded by developing the Aviation Safety Program. This program provides research and technology products needed to help the aerospace industry achieve their aviation safety goal. The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center is currently developing propulsion-system-specific technologies to detect damage prior to catastrophe under the propulsion health management task. Currently, the NDE group is assessing the feasibility of utilizing real-time vibration data to detect cracks in turbine disks. The data are obtained from radial blade-tip clearance and shaft-clearance measurements made using capacitive or eddy-current probes. The concept is based on the fact that disk cracks distort the strain field within the component. This, in turn, causes a small deformation in the disk's geometry as well as a possible change in the system's center of mass. The geometric change and the center of mass shift can be indirectly characterized by monitoring the amplitude and phase of the first harmonic (i.e., the 1 component) of the vibration data. Spin pit experiments and full-scale engine tests have been conducted while monitoring for crack growth with this detection methodology. Even so, published data are extremely limited, and the basic foundation of the methodology has not been fully studied. The NDE group is working on developing this foundation on the basis of theoretical modeling as well as experimental data by using the newly constructed subscale spin system shown in the preceding photograph. This, in turn, involved designing an optimal sub-scale disk that was meant to represent a full-scale turbine disk; conducting finite element analyses of undamaged and damaged disks to define the disk's deformation and the resulting shift in center of mass; and creating a rotordynamic model of the complete disk and shaft assembly to confirm operation beyond the first critical concerning the subscale experimental setup. The finite element analysis data, defining the center of mass shift due to disk damage, are shown. As an example, the change in the center of mass for a disk spinning at 8000 rpm with a 0.963-in. notch was 1.3 x 10(exp -4) in. The actual vibration response of an undamaged disk as well as the theoretical response of a cracked disk is shown. Experiments with cracked disks are continuing, and new approaches for analyzing the captured vibration data are being developed to better detect damage in a rotor. In addition, the subscale spin system is being used to test the durability and sensitivity of new NDE sensors that focus on detecting localized damage. This is designed to supplement the global response of the crack-detection methodology described here.

Gyekenyesi, Andrew L.↗

NASA NTRS2004

Vibration-Based Method Developed to Detect Cracks in Rotors During Acceleration Through Resonance

In recent years, there has been an increasing interest in developing rotating machinery shaft crack-detection methodologies and online techniques. Shaft crack problems present a significant safety and loss hazard in nearly every application of modern turbomachinery. In many cases, the rotors of modern machines are rapidly accelerated from rest to operating speed, to reduce the excessive vibrations at the critical speeds. The vibration monitoring during startup or shutdown has been receiving growing attention (ref. 1), especially for machines such as aircraft engines, which are subjected to frequent starts and stops, as well as high speeds and acceleration rates. It has been recognized that the presence of angular acceleration strongly affects the rotor's maximum response to unbalance and the speed at which it occurs. Unfortunately, conventional nondestructive evaluation (NDE) methods have unacceptable limits in terms of their application for online crack detection. Some of these techniques are time consuming and inconvenient for turbomachinery service testing. Almost all of these techniques require that the vicinity of the damage be known in advance, and they can provide only local information, with no indication of the structural strength at a component or system level. In addition, the effectiveness of these experimental techniques is affected by the high measurement noise levels existing in complex turbomachine structures. Therefore, the use of vibration monitoring along with vibration analysis has been receiving increasing attention.

Sawicki, Jerzy T.↗

NASA NTRS2003

High Temperature Fusion Reactor Cooling Using Brayton Cycle Based Partial Energy Conversion

For some future space power systems using high temperature nuclear heat sources most of the output energy will be used in other than electrical form, and only a fraction of the total thermal energy generated will need to be converted to electrical work. The paper describes the conceptual design of such a partial energy conversion system, consisting of a high temperature fusion reactor operating in series with a high temperature radiator and in parallel with dual closed cycle gas turbine (CCGT) power systems, also referred to as closed Brayton cycle (CBC) systems, which are supplied with a fraction of the reactor thermal energy for conversion to electric power. Most of the fusion reactor's output is in the form of charged plasma which is expanded through a magnetic nozzle of the interplanetary propulsion system. Reactor heat energy is ducted to the high temperature series radiator utilizing the electric power generated to drive a helium gas circulation fan. In addition to discussing the thermodynamic aspects of the system design the authors include a brief overview of the gas turbine and fan rotor-dynamics and proposed bearing support technology along with performance characteristics of the three phase AC electric power generator and fan drive motor.

Juhasz, Albert J.↗

NASA NTRS2003

Vibration Based Crack Detection in a Rotating Disk: An Analytical Study - Part 1

This paper describes the analytical results concerning the detection of a crack in a rotating disk. The concept of the approach is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system s center of mass occurs. Finite element analyses were conducted concerning a notched disk in order to define the sensitivity of the method. The notch was used to simulate an actual crack and will be the method utilized for upcoming experiments. Various notch sizes were studied. The geometric deformations and shifts of center of mass were documented as a function of rotational speed. In addition, a rotordynamic analysis of a 2-bearing, disk and shaft system was conducted. The overall response of the system was required in order to design the experimental system for operation beyond the first critical. The results of the FE analyses of the disk indicated that the overall changes in the disk s geometry and center of mass were rather small. The difference between the maximum centrifugal radial displacements between the undamaged and damaged disks at 8000 RPM was 0.00014 in. for a 0.963 in. notch length. The shift in center of mass was also of this magnitude. The next step involves running experiments to verify the analysis.

Gyekenyesi, Andrew L.↗

NASA NTRS2003

Methods Developed by the Tools for Engine Diagnostics Task to Monitor and Predict Rotor Damage in Real Time

Tools for Engine Diagnostics is a major task in the Propulsion System Health Management area of the Single Aircraft Accident Prevention project under NASA s Aviation Safety Program. The major goal of the Aviation Safety Program is to reduce fatal aircraft accidents by 80 percent within 10 years and by 90 percent within 25 years. The goal of the Propulsion System Health Management area is to eliminate propulsion system malfunctions as a primary or contributing factor to the cause of aircraft accidents. The purpose of Tools for Engine Diagnostics, a 2-yr-old task, is to establish and improve tools for engine diagnostics and prognostics that measure the deformation and damage of rotating engine components at the ground level and that perform intermittent or continuous monitoring on the engine wing. In this work, nondestructive-evaluation- (NDE-) based technology is combined with model-dependent disk spin experimental simulation systems, like finite element modeling (FEM) and modal norms, to monitor and predict rotor damage in real time. Fracture mechanics time-dependent fatigue crack growth and damage-mechanics-based life estimation are being developed, and their potential use investigated. In addition, wireless eddy current and advanced acoustics are being developed for on-wing and just-in-time NDE engine inspection to provide deeper access and higher sensitivity to extend on-wing capabilities and improve inspection readiness. In the long run, these methods could establish a base for prognostic sensing while an engine is running, without any overt actions, like inspections. This damage-detection strategy includes experimentally acquired vibration-, eddy-current- and capacitance-based displacement measurements and analytically computed FEM-, modal norms-, and conventional rotordynamics-based models of well-defined damages and critical mass imbalances in rotating disks and rotors.

Baaklini, George Y.↗

NASA NTRS2003

Multi-Discipline Analytical Modeling of a Cracked Disk in a Turbine Engine: Applied to TF41 Experiment at China Lake

The investigated crack detection method is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Finite element analyses were conducted concerning a notched disk in order to define the sensitivity of the method. The notch was used to simulate an actual crack and will be the method utilized for upcoming experiments. Various notch sizes were studied and the geometric deformations and shifts of center of mass were documented as a function of rotational speed. In addition, a rotordynamic analysis of a two-bearing, disk and shaft system was conducted. The results of the FE analyses of the disk indicated that the overall changes in the disk's geometry and center of mass were rather small. Comparing the 9.25 in. disk's maximum radial displacements due centrifugal forces at 8000 RPM between an un-notched and a 0.962 in. notched disk, the difference was on the order of 0.00014 in. The shift in center of mass was also of this magnitude. The next step involves running experiments to verify the analysis.

Sawicki, Jerzy T.↗

NASA NTRS2002

Vibration Monitoring Techniques Applied to Detect Damage in Rotating Disks

Rotor health monitoring and online damage detection are increasingly gaining the interest of the manufacturers of aircraft engines. This is primarily due to the need for improved safety during operation as well as the need for lower maintenance costs. Applied techniques for detecting damage in and monitoring the health of rotors are essential for engine safety, reliability, and life prediction. The goals of engine safety are addressed within the NASA-sponsored Aviation Safety Program (AvSP). AvSP provides research and technology products needed to help the Federal Aviation Administration and the aerospace industry improve aviation safety. The Nondestructive Evaluation Group at the NASA Glenn Research Center is addressing propulsion health management and the development of propulsion-system-specific technologies intended to detect potential failures prior to catastrophe.

Gyekenyesi, Andrew L.↗

NASA NTRS2001

Gear Damage Detection Integrating Oil Debris and Vibration Measurement Technologies Developed

The development of highly reliable health-monitoring systems is one technology area recommended for reducing the number of helicopter accidents. Helicopter transmission diagnostics are an important part of a helicopter health-monitoring system because helicopters depend on the power train for propulsion, lift, and flight maneuvering. One technique currently being tested for increasing the reliability and decreasing the false alarm rate of current transmission diagnostic tools is the replacement of simple single-sensor limits with multisensor systems integrating different measurement technologies.

Gyekeyeski, Andrew L.↗

NASA NTRS1996

Attitude Control Subsystem for the Advanced Communications Technology Satellite

This paper provides an overview of the on-orbit operation of the Attitude Control Subsystem (ACS) for the Advanced Communications Technology Satellite (ACTS). The three ACTS control axes are defined, including the means for sensing attitude and determining the pointing errors. The desired pointing requirements for various modes of control as well as the disturbance torques that oppose the control are identified. Finally, the hardware actuators and control loops utilized to reduce the attitude error are described.

Hewston, Alan W.↗