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NASA NTRS1979

Materials and structural aspects of advanced gas-turbine helicopter engines

Advances in materials, coatings, turbine cooling technology, structural and design concepts, and component-life prediction of helicopter gas-turbine-engine components are presented. Stationary parts including the inlet particle separator, the front frame, rotor tip seals, vanes and combustors and rotating components - compressor blades, disks, and turbine blades - are discussed. Advanced composite materials are considered for the front frame and compressor blades, prealloyed powder superalloys will increase strength and reduce costs of disks, the oxide dispersion strengthened alloys will have 100C higher use temperature in combustors and vanes than conventional superalloys, ceramics will provide the highest use temperature of 1400C for stator vanes and 1370C for turbine blades, and directionally solidified eutectics will afford up to 50C temperature advantage at turbine blade operating conditions. Coatings for surface protection at higher surface temperatures and design trends in turbine cooling technology are discussed. New analytical methods of life prediction such as strain gage partitioning for high temperature prediction, fatigue life, computerized prediction of oxidation resistance, and advanced techniques for estimating coating life are described.

Freche, J. C.↗

NASA NTRS1985

Vibrations of blades and bladed disk assemblies; Proceedings of the Tenth Biennial Conference on Mechanical Vibration and Noise, Cincinnati, OH, September 10-13, 1985

The papers presented in this volume provide an overview of recent theoretical and analytical research in bladed disk assemblies, with particular attention given to forced response, mistuning, and damping. Specific topics discussed include the response of mistuned bladed disk assemblies; forced response analysis of an aerodynamically detuned supersonic turbomachine rotor; dynamic analysis of blade groups using component mode synthesis; and pendulum dynamic vibration absorbers for reducing blade vibration in industrial fans.

Kielb, R. E.↗

NASA NTRS1991

Calculating Flow Through A Helicopter Rotor

New method for calculating flow of air through and around helicopter rotor incorporated into General Rotorcraft Aeromechanical Stability Program (GRASP) (computer program for aeroelastic analysis). Flow about helicopter rotor represented by axisymmetric flow field in cylindrical region with actuator disk as source of flow.

Kunz, Donald L.↗

NASA NTRS2004

Composite Fan Blade Design for Advanced Engine Concepts

The aerodynamic and structural viability of composite fan blades of the revolutionary Exo-Skeletal engine are assessed for an advanced subsonic mission using the NASA EST/BEST computational simulation system. The Exo-Skeletal Engine (ESE) calls for the elimination of the shafts and disks completely from the engine center and the attachment of the rotor blades in spanwise compression to a rotating casing. The fan rotor overall adiabatic efficiency obtained from aerodynamic analysis is estimated at 91.6 percent. The flow is supersonic near the blade leading edge but quickly transitions into a subsonic flow without any turbulent boundary layer separation on the blade. The structural evaluation of the composite fan blade indicates that the blade would buckle at a rotor speed that is 3.5 times the design speed of 2000 rpm. The progressive damage analysis of the composite fan blade shows that ply damage is initiated at a speed of 4870 rpm while blade fracture takes place at 7640 rpm. This paper describes and discusses the results for the composite blade that are obtained from aerodynamic, displacement, stress, buckling, modal, and progressive damage analyses. It will be demonstrated that a computational simulation capability is readily available to evaluate new and revolutionary technology such as the ESE.

Abumeri, Galib H.↗

NASA NTRS1971

Actuator disk theory for incompressible highly rotating flows.

A solution has been obtained for a stator-rotor pair operating in an annulus with constant hub and tip radii. The stator and rotor are represented as actuator discs, and perfect fluid flow is assumed. The solutions are exact within these limitations, no linearization being required. The forms of blade loadings considered allow the introduction of large vorticity by either the rotor or stator. As a result, the rotor may be a ?nonconstant-work' row. The solutions obtained are of summational form, but many of the summations are obtained in closed form, the resultant formulas allowing rapid calculation of desired examples. An example numerical result is included.

Oates, G. C.↗

NASA NTRSDate not supplied

Validation of Actuator Disk, Actuator Line and Sliding Mesh Methods within the LAVA Solver

In this study the implementation of actuator-disk, actuator-line and sliding-mesh methodologies in the Launch Ascent and Vehicle Aerodynamics (LAVA) solver is described and validated against several test-cases. The different models are validated against available numerical as well as experimental data. Both steady and unsteady Reynolds-Averaged Navier-Stokes (RANS) simulations using the Spallart Allmaras (SA) turbulence model are performed for several different configurations representative of aeroscience applications. The first part of the paper is focused on the verification and validation of the implemented propulsor models. The first validation case is a theoretical rotor in hover, compared with the 1D analytical solution derived from momentum theory. The second validation is the Rotor-Airframe Interaction Model of Georgia Institute of Technology (GIT), representing the application of actuator disks to top-mounted rotorcraft vehicles or unmanned aerial vehicles (UAVs). The third case is a representative configuration for tip-mounted rotor-craft vehicles such as NASA’s X57 airplane. The second part of the paper shows the implemented models applied to realistic engineering configurations such as NASA’s X57 airplane and the R4 Advanced Ducted Propellor (ADT). A modification to the actuator line method in order to represent the blade geometry more closely is proposed and comparisons with simulations modeling the blade utilizing a sliding-mesh approach are made.

ARMD↗

NASA NTRS1993

Experimental investigation of turbine disk cavity aerodynamics and heat transfer

An experimental investigation of turbine disk cavity aerodynamics and heat transfer was conducted to provide an experimental data base that can guide the aerodynamic and thermal design of turbine disks and blade attachments for flow conditions and geometries simulating those of the space shuttle main engine (SSME) turbopump drive turbines. Experiments were conducted to define the nature of the aerodynamics and heat transfer of the flow within the disk cavities and blade attachments of a large scale model simulating the SSME turbopump drive turbines. These experiments include flow between the main gas path and the disk cavities, flow within the disk cavities, and leakage flows through the blade attachments and labyrinth seals. Air was used to simulate the combustion products in the gas path. Air and carbon dioxide were used to simulate the coolants injected at three locations in the disk cavities. Trace amounts of carbon dioxide were used to determine the source of the gas at selected locations on the rotors, the cavity walls, and the interstage seal. The measurements on the rotor and stationary walls in the forward and aft cavities showed that the coolant effectiveness was 90 percent or greater when the coolant flow rate was greater than the local free disk entrainment flow rate and when room temperature air was used as both coolant and gas path fluid. When a coolant-to-gas-path density ratio of 1.51 was used in the aft cavity, the coolant effectiveness on the rotor was also 90 percent or greater at the aforementioned condition. However, the coolant concentration on the stationary wall was 60 to 80 percent at the aforementioned condition indicating a more rapid mixing of the coolant and flow through the rotor shank passages. This increased mixing rate was attributed to the destabilizing effects of the adverse density gradients.

Daniels, W. A.↗

NASA NTRS1980

Application of superalloy powder metallurgy for aircraft engines

In the last decade, Government/Industry programs have advanced powder metallurgy-near-net-shape technology to permit the use of hot isostatic pressed (HIP) turbine disks in the commercial aircraft fleet. These disks offer a 30% savings of input weight and an 8% savings in cost compared in cast-and-wrought disks. Similar savings were demonstrated for other rotating engine components. A compressor rotor fabricated from hot-die-forged-HIP superalloy billets revealed input weight savings of 54% and cost savings of 35% compared to cast-and-wrought parts. Engine components can be produced from compositions such as Rene 95 and Astroloy by conventional casting and forging, by forging of HIP powder billets, or by direct consolidation of powder by HIP. However, each process produces differences in microstructure or introduces different defects in the parts. As a result, their mechanical properties are not necessarily identical. Acceptance methods should be developed which recognize and account for the differences.

Dreshfield, R. L.↗

NASA NTRS1984

Stagger angle dependence of inertial and elastic coupling in bladed disks

Conditions which necessitate the inclusion of disk and shaft flexibility in the analysis of blade response in rotating blade-disk-shaft systems are derived in terms of nondimensional parameters. A simple semianalytical Rayleigh-Ritz model is derived in which the disk possesses all six rigid body degrees of freedom, which are elastically constrained by the shaft. Inertial coupling by the rigid body motion of the disk on a flexible shaft and out-of-plane elastic coupling due to disk flexure are included. Frequency ratios and mass ratios, which depend on the stagger angle, are determined for three typical rotors: a first stage high-pressure core compressor, a high bypass ratio fan, and an advanced turboprop. The stagger angle controls the degree of coupling in the blade-disk system. In the blade-disk-shaft system, the stagger angle determines whether blade-disk motion couples principally to the out-of-plane or in-plane motion of the disk on the shaft. The Ritz analysis shows excellent agreement with experimental results.

Crawley, E. F.↗

NASA NTRS1961

An Investigation of the Effect of Downwash from a VTOL Aircraft and a Helicopter in the Ground Environment

Dynamic-pressure measurement, in ground effect, have been obtained about a single-rotor helicopter and a dual-propeller VTOL (Vertical Take-Off and Landing) aircraft. The results indicate that the slipstream dynamic pressure along the ground, some distance from the center of rotation, is not a function of disk loading but merely a function of the gross weight or thrust of the aircraft. Furthermore, for a given gross weight the thickness of this outward flowing sheet of air is less for a small-diameter propeller (higher disk loading propeller). The variation of the dynamic-pressure flow field for single and dual propellers or rotors is significantly different in the plane of symmetry between the two rotors than in a direction normal to this plane. The interaction of the two flows produces a region of upflow in this plane where the fuselage is located, and the decay of the maximum dynamic pressure with distance ahead of the fuselage is slower.

O'Bryan, Thomas C.↗

NASA NTRS1994

Effects of Mistuning on the Forced Response of Turbomachinery Rotors

The basic purpose of this research has been to develop a fundamental understanding of the effects of blade-to-blade dissimilarities, or mistuning, on the dynamics of nearly cyclic bladed-disk assemblies. This topic is of importance as mistuning has been shown to increase the forced response amplitudes of some blades significantly, and even to lead to blade failure. Furthermore, the current trend toward high performance propulsion turbomachinery designed for finite service life demands an accurate prediction of system performance and dynamics at the design stage. This objective has been achieved by carrying out the following tasks. First, the investigation of the free and forced responses of representative, yet sufficiently simple blade assembly models that capture all the important characteristics of typical turbomachinery rotors. Second, the development of computational methods that predict the effects of mistuning in a systematic and reliable way, along with the development of a systematic reduced-order modeling procedure for mistuned bladed disks. Third, the application of these findings and the tools developed to an industrial rotor, namely the first stage of turbine blades of the oxidizer turbopump in the space shuttle main rocket engine (SSME). The research supported by NASA has led to the development of a coherent theory for mistuned blade assemblies. The further implementation of these computational tools into the forced response prediction system currently under development in the Structural Dynamics Branch-FREPS-would enable the designer and the analyst to: (1) identify types of blade assemblies highly sensitive to mistuning in various frequency and other parameter ranges and (2) characterize mistuning effects on their forced response by predicting true response amplitudes and fatigue life estimates.

Pierre, Christophe↗

NASA NTRS1994

Effects of Mistuning on the Forced Response of Turbomachinery Rotors

The basic purpose of this research has been to develop a fundamental understanding of the effects of blade-to-blade dissimilarities, or mistuning, on the dynamics of nearly cyclic bladed-disk assemblies. This topic is of importance as mistuning has been shown to increase the forced response amplitudes of some blades significantly, and even to lead to blade failure. Furthermore, the current trend toward high performance propulsion turbomachinery designed for finite service life demands an accurate prediction of system performance and dynamics at the design stage. This objective has been achieved by carrying out the following tasks. First, the investigation of the free and forced responses of representative, yet sufficiently simple blade assembly models that capture all the important characteristics of typical turbomachinery rotors. Second, the development of computational methods that predict the effects of mistuning in a systematic and reliable way, along with the development, of a systematic reduced-order modeling procedure for mistuned bladed disks. Third, the application of these findings and the tools developed to an industrial rotor, namely the first stage of turbine blades of the oxidizer turbopump in the space shuttle main rocket engine (SSME). The research supported by NASA has led to the development of a coherent theory for mistuned blade assemblies. The further implementation of these computational tools into the forced response prediction system currently under development in the Structural Dynamics Branch Forced Response Prediction System (FREPS) would enable the designer and the analyst (1) to identify types of blade assemblies highly sensitive to mistuning in various frequency and other parameter ranges and (2), to characterize mistuning effects on their forced response by predicting true response amplitudes and fatigue life estimates.

Stefko, George L.↗

NASA NTRS1973

Transient response of rotor-bearing systems.

The equations of motion necessary to calculate the transient response of a multimass flexible rotor supported by nonlinear, damped bearings are derived from energy principles. Rotor excitation may be the result of imbalance, internal friction, rotor acceleration, nonlinear forces due to any number of bearing or seal stations, and gyroscopic couples developed from skewed disk effects. The method of solution for transient response simulation is discussed in detail and is based on extensive evaluation of numerical methods available for transient analysis. Examples of the application of transient response for the analysis of rotor bearing systems are presented and compared to actual machine performance. Recommendations for the use and extension of the present system simulation model are discussed.

Kirk, R. G.↗

NASA NTRS1986

Analytical and experimental investigation of the coupled bladed disk/shaft whirl of a cantilevered turbofan

A simple analytical model for the structural dynamics of a rotating flexible blade/rigid disk/flexible cantilevered shaft system yields the equations of motion expressed in the rotating frame, showing that the blade's one-nodal diameter modes dynamically couple to the rigid body whirling motion of the shaft-disk system. This analytical model is correlated with the results of a structural dynamic experiment performed on an aeroelastic rotor fan that is similar to a high bypass ratio shroudless turbofan. The agreement between the predicted and experimental natural frequencies is good, and suggests significant interaction of the one-nodal diameter blade modes with the shaft-disk modes.

Crawley, E. F.↗

NASA NTRS2004

Fully Suspended, Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig With Forced Excitation

The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig, a significant advancement in the Dynamic Spin Rig (DSR), is used to perform vibration tests of turbomachinery blades and components under rotating and nonrotating conditions in a vacuum. The rig has as its critical components three magnetic bearings: two heteropolar radial active magnetic bearings and a magnetic thrust bearing. The bearing configuration allows full vertical rotor magnetic suspension along with a feed-forward control feature, which will enable the excitation of various natural blade modes in bladed disk test articles. The theoretical, mechanical, electrical, and electronic aspects of the rig are discussed. Also presented are the forced-excitation results of a fully levitated, rotating and nonrotating, unbladed rotor and a fully levitated, rotating and nonrotating, bladed rotor in which a pair of blades was arranged 180 degrees apart from each other. These tests include the bounce mode excitation of the rotor in which the rotor was excited at the blade natural frequency of 144 Hz. The rotor natural mode frequency of 355 Hz was discerned from the plot of acceleration versus frequency. For nonrotating blades, a blade-tip excitation amplitude of approximately 100 g/A was achieved at the first-bending critical (approximately 144 Hz) and at the first-torsional and second-bending blade modes. A blade-tip displacement of 70 mils was achieved at the first-bending critical by exciting the blades at a forced-excitation phase angle of 908 relative to the vertical plane containing the blades while simultaneously rotating the shaft at 3000 rpm.

Morrison, Carlos R.↗

NASA NTRS2008

Effects of a Rotating Aerodynamic Probe on the Flow Field of a Compressor Rotor

An investigation of distortions of the rotor exit flow field caused by an aerodynamic probe mounted in the rotor is described in this paper. A rotor total pressure Kiel probe, mounted on the rotor hub and extending up to the mid-span radius of a rotor blade channel, generates a wake that forms additional flow blockage. Three types of high-response aerodynamic probes were used to investigate the distorted flow field behind the rotor. These probes were: a split-fiber thermo-anemometric probe to measure velocity and flow direction, a total pressure probe, and a disk probe for in-flow static pressure measurement. The signals acquired from these high-response probes were reduced using an ensemble averaging method based on a once per rotor revolution signal. The rotor ensemble averages were combined to construct contour plots for each rotor channel of the rotor tested. In order to quantify the rotor probe effects, the contour plots for each individual rotor blade passage were averaged into a single value. The distribution of these average values along the rotor circumference is a measure of changes in the rotor exit flow field due to the presence of a probe in the rotor. These distributions were generated for axial flow velocity and for static pressure.

Lepicovsky, Jan↗

NASA NTRS2007

Stability Analysis of a High-Speed Seal Test Rotor With Marginal and Extended Squeeze-Film Dampers: Theoretical and Experimental Results

A case study of a high-speed seal test rotor shows how rotor dynamic analysis can be used to diagnose the source of high vibrations and evaluate a proposed remedy. Experimental results are compared with the synchronous and non-synchronous whirl response analysis of a double overhung, high-speed seal test rotor with ball bearings supported in 5.84- and 12.7-mm-long, un-centered squeeze-film oil dampers. Test performance with the original damper of length 5.84 mm was marginal. Non-synchronous whirling occurred at the overhung seal test disk and there was a high amplitude synchronous response near the drive spline above 32,000 rpm. Nonlinear synchronous unbalance and time transient whirl studies were conducted on the seal test rotor with the original and extended damper lengths. With the original damper design, the nonlinear synchronous response showed that unbalance could cause damper lockup at 33,000 rpm. Alford cross-coupling forces were also included at the overhung seal test disk for the whirl analysis. Sub-synchronous whirling at the seal test disk was observed in the nonlinear time transient analysis. With the extended damper length of 12.7 mm, the sub-synchronous motion was eliminated and the rotor unbalance response was acceptable to 45,000 rpm with moderate rotor unbalance. Seal test rotor orbits and vibration levels with the extended squeeze film dampers showed smooth operation to 40,444 rpm.

Proctor, Margaret P.↗

NASA NTRS1981

Supersonic stall flutter of high-speed fans

An analytical model is proposed for predicting the onset of supersonic stall bending flutter in high-speed rotors. The analysis is based on a modified two-dimensional, compressible, unsteady actuator disk theory. The stability boundary predicted by the analysis is shown to be in good agreement with the measured boundary of a high speed fan. The prediction that the flutter mode would be a forward traveling wave sensitive to wheel speed and aerodynamic loading is confirmed by experimental measurements. In addition, the analysis shows that reduced frequency and dynamic head also play a significant role in establishing the supersonic stall bending flutter boundary of an unshrouded fan.

Adamczyk, J. J.↗