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At least 37 records · Page 2

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.↗

Data Collection and Analysis Software Development for Rotor Dynamics Testing in Spin Laboratory

Gas turbine engine components undergo high rotational loading another complex environmental conditions. Such operating environment leads these components to experience damages and cracks that can cause catastrophic failure during flights. There are traditional crack detections and health monitoring methodologies currently being used which rely on periodic routine maintenances, nondestructive inspections that often times involve engine and components dis-assemblies. These methods do not also offer adequate information about the faults, especially, if these faults at subsurface or not clearly evident. At NASA Glenn research center, the rotor dynamics laboratory is presently involved in developing newer techniques that are highly dependent on sensor technology to enable health monitoring and prediction of damage and cracks in rotor disks. These approaches are noninvasive and relatively economical. Spin tests are performed using a subscale test article mimicking turbine rotor disk undergoing rotational load. Non-contact instruments such as capacitive and microwave sensors are used to measure the blade tip gap displacement and blade vibrations characteristics in an attempt develop a physics based model to assess/predict the faults in the rotor disk. Data collection is a major component in this experimental-analytical procedure and as a result, an upgrade to an older version of the data acquisition software which is based on LabVIEW program has been implemented to support efficiently running tests and analyze the results. Outcomes obtained from the tests data and related experimental and analytical rotor dynamics modeling including key features of the updated software are presented and discussed.

Rotor Dynamics↗

How wind speed shear and directional veer affect the power production of a megawatt-scale operational wind turbine

Most megawatt-scale wind turbines align themselves into the wind as defined by the wind speed at or near the center of the rotor (hub height). However, both wind speed and wind direction can change with height across the area swept by the turbine blades. A turbine aligned to hub-height winds might experience suboptimal or superoptimal power production, depending on the changes in the vertical profile of wind, also known as shear. Using observed winds and power production over 6 months at a site in the high plains of North America, we quantify the sensitivity of a wind turbine's power production to wind speed shear and directional veer as well as atmospheric stability. We measure shear using metrics such as α (the log-law wind shear exponent), β bulk (a measure of bulk rotor-disk-layer veer), β total (a measure of total rotor-disk-layer veer), and rotor-equivalent wind speed (REWS; a measure of actual momentum encountered by the turbine by accounting for shear). We also consider the REWS with the inclusion of directional veer, REWS θ , although statistically significant differences in power production do not occur between REWS and REWS θ at our site. When REWS differs from the hub-height wind speed (as measured by either the lidar or a transfer function-corrected nacelle anemometer), the turbine power generation also differs from the mean power curve in a statistically significant way. This change in power can be more than 70 kW or up to 5 % of the rated power for a single 1.5 MW utility-scale turbine. Over a theoretical 100-turbine wind farm, these changes could lead to instantaneous power prediction gains or losses equivalent to the addition or loss of multiple utility-scale turbines. At this site, REWS is the most useful metric for segregating the turbine's power curve into high and low cases of power production when compared to the other shear or stability metrics. Therefore, REWS enables improved forecasts of power production.

17 WIND ENERGY↗

Rotor blade-vortex interaction impulsive noise source identification and correlation with rotor wake predictions

An acoustic source localization scheme applicable to noncompact moving sources is developed and applied to the blade-vortex interaction (BVI) noise data of a 40-percent scale BO-105 model rotor. A generalized rotor wake code is employed to predict possible VBI locations on the rotor disk and is found quite useful in interpreting the acoustic localization results. The highly varying directivity patterns of different BVI impulses generated at the same test condition are explained by both the localization results and predicted tip vortex trajectories. The effects of rotor tip-path-plane angle and advance ratio on the BVI source positions is studied. Decreasing tip-path-plane angle (at constant advance ratio) moves the general interaction region upwind on the rotor disk, significantly changing the interaction geometry. Increasing advance ratio (at constant tip-path-plane angle) shifts the general source region downwind on the rotor disk with the increased convection of the vortices until about 60 deg azimuth, where the BVI sources appear to become acoustically less effective. The region of strongest BVI sources lies between 60 and 70 deg azimuth and 80 and 90 percent radius for the moderate range of advance ratios studied.

Splettstoesser, W. R.↗

Inflow velocity perturbations due to fuselage effects in the presence of a fully interactive wake

The velocity field at locations above the plane of the rotor disk of a generic helicopter configuration has been measured experimentally and modeled using two computational models. The first computational model represents only the portion of the velocity field due to the fuselage, using only the potential due to freestream onset flow. The second model represents all elements of the problem in an incompressible field: the rotor, the rotor wake, and the non-lifting fuselage. The first model is used to assess the fidelity requirement for fuselage paneling. Comparisons are made between a much simplified body shape, an accurate body shape, a body shape with a crude hub/shaft model and wind-tunnel measurements. The second model is used to assess the relative magnitude of the velocity perturbations at the rotor disk due to the effects of the fuselage. A fully interactive time-stepping wake method is used to predict the velocities at the rotor disk. These velocities are computed with and without the fuselage in the model and compared with measured wind-tunnel inflow velocities. The difference between the velocities computed with and without the fuselage is then compared with the perturbation velocity field computed by the first method.

Berry, John D.↗

Structural response of a rotating bladed disk to rotor whirl

A set of high speed rotating whirl experiments were performed in the vacuum of the MIT Blowdown Compressor Facility on the MIT Aeroelastic Rotor, which is structurally typical of a modern high bypass ratio turbofan stage. These tests identified the natural frequencies of whirl of the rotor system by forcing its response using an electromagnetic shaker whirl excitation system. The excitation was slowly swept in frequency at constant amplitude for several constant rotor speeds in both a forward and backward whirl direction. The natural frequencies of whirl determined by these experiments were compared to those predicted by an analytical 6 DOF model of a flexible blade-rigid disk-flexible shaft rotor. The model is also presented in terms of nondimensional parameters in order to assess the importance of the interation between the bladed disk dynamics and the shaft-disk dynamics. The correlation between the experimental and predicted natural frequencies is reasonable, given the uncertainty involved in determining the stiffness parameters of the system.

Crawley, E. F.↗

Air cooling of disk of a solid integrally cast turbine rotor for an automotive gas turbine

A thermal analysis is made of surface cooling of a solid, integrally cast turbine rotor disk for an automotive gas turbine engine. Air purge and impingement cooling schemes are considered and compared with an uncooled reference case. Substantial reductions in blade temperature are predicted with each of the cooling schemes studied. It is shown that air cooling can result in a substantial gain in the stress-rupture life of the blade. Alternatively, increases in the turbine inlet temperature are possible.

Gladden, H. J.↗

Analysis of axisymmetric body effects on rotor aerodynamics using modified slender body theory

A modified slender body theory was used in modelling the flowfield around an axisymmetric body at zero angle of attack. The model was defined in an attempt to characterize body-induced effects on helicopter rotor performance and loading using efficient computation methods. The streamfunction for an axial source distribution was applied in the body model, which was then adapted to the helicopter analysis code (CAMRAD). The body-induced velocities were calculated for separate locations on the rotor disk. Three different rotor models in nonuniform inflow with a free wake geometry were considered. Comparison of predictions with data on ellipsoidal and axisymmetric bodies showed good agreement for moderately thick ellipsoidal bodies. Oscillatory blade bending moments were increased by the presence of the body, but overall performance impact was negligible. Computational efficiency was 10-20 percent better than with a potential flow panel code.

Yamauchi, G. K.↗

Multi-Fidelity CFD Simulation of the Multirotor Test Bed

The high-fidelity and reduced order CFD method's validation and analysis are presented for the Multirotor Test Bed. The reduced-order method uses a rotor-disk model in the OVERFLOW CFD code and is an important aspect of this study. A rotor-trim option loosely coupling the Comprehensive code CAMRAD II with the OVERFLOW CFD code is included in the simulation that captures rotor blade aerodynamics, blade and rotor performance, rotor-rotor, and rotor-body interactions. Detailed comparison and validation were performed for both higher-fidelity full rotor unsteady flows and reduced-order rotor-disk methods. The tunnel geometry is included in the detailed computational effort. Computations of the low-Reynolds number flows were performed for a different number of in-plane rotors as well as for a single rotor modeled inside the tunnel.

ARMD↗

Lead-Lag Control for Helicopter Vibration and Noise Reduction

As a helicopter transitions from hover to forward flight, the main rotor blades experience an asymmetry in flow field around the azimuth, with the blade section tangential velocities increasing on the advancing side and decreasing on the retreating side. To compensate for the reduced dynamic pressure on the retreating side, the blade pitch angles over this part of the rotor disk are increased. Eventually, a high enough forward speed is attained to produce compressibility effects on the advancing side of the rotor disk and stall on the retreating side. The onset of these two phenomena drastically increases the rotor vibratory loads and power requirements, thereby effectively establishing a limit on the maximum achievable forward speed. The alleviation of compressibility and stall (and the associated decrease in vibratory loads and power) would potentially result in an increased maximum forward speed. In the past, several methods have been examined and implemented to reduce the vibratory hub loads. Some of these methods are aimed specifically at alleviating vibration at very high flight speeds and increasing the maximum flight speed, while others focus on vibration reduction within the conventional flight envelope. Among the later are several types passive as well as active schemes. Passive schemes include a variety of vibration absorbers such as mechanical springs, pendulums, and bifilar absorbers. These mechanism are easy to design and maintain, but incur significant weight and drag penalties. Among the popular active control schemes in consideration are Higher Harmonic Control (HHC) and Individual Blade Control (IBC). HHC uses a conventional swash plate to generate a multi-cyclic pitch input to the blade. This requires actuators capable of sufficiently high power and bandwidth, increasing the cost and weight of the aircraft. IBC places actuators in the rotating reference frame, requiring the use of slip rings capable of transferring enough power to the actuators. Both schemes cause an increase in pitch link loads. Trailing Edge Flap (TEF) deployment can also used to generate unsteady aerodynamic forces and moments that counter the original vibratory loads, and thereby reduce rotor vibrations. While the vibrations absorbers, HHC, IBC, and TEF concepts discussed above attempt to reduce the vibratory loads, they do not specifically address the phenomena causing the vibrations at high advance ratios. One passive method that attempts to directly alleviate compressibility and stall, instead of reducing the ensuing vibrations, is the use of advanced tip designs. Taper, sweep, anhedral, and the manipulation of other geometric properties of the blade tips can reduce the severity of stall and compressibility effects , as well as reduce rotor power. A completely different approach to solve these problems is the tiltrotor configuration. As the forward velocity of the aircraft increases, the rotors, in this case, are tilted forward until they are perpendicular to the flow and act as propellers. This eliminates the edgewise flow encountered by conventional rotors and circumvents all the problems associated with flow asymmetry. However, the success involves a tremendous increase in cost and complexity of the aircraft. Another possible approach that has been proposed for the alleviation of vibratory loads at high forward flight speeds involves the use of controlled lead-lag motions to reduce the asymmetry in flow. A correctly phased 1/rev controlled lag motion could be introduced such that it produces a backward velocity on the advancing side and a forward velocity on the retreating side, to delay compressibility effects and stall to a higher advance ratio. Using a large enough lead-lag amplitude, the tip velocities could be reduced to levels encountered in hover. This concept was examined by two groups in the 1950's and early 1960's. In the United States, the Research Labs Division of United Aircraft developed a large lead-lag motion rotor, meant to achieve lag motion amplitudes up to 45 degrees. In order to reduce the required actuation force, the blade hinges were moved to 40% of the blade radius to increase the rotating lag frequency to approximately 1/rev. The blade hinges were redesigned to produce a flap-lag coupling so the large flapwise aerodynamic loads could be exploited to actuate the blades in the lag direction. A wind tunnel test of this rotor concept revealed actuation and blade motion scheduling problems. The project was eventually discontinued due to these problems and high blade stresses. Around the same time, at Boelkow in Germany, a similar lead-lag rotor program was conducted under the leadership of Hans Derschmidt. Here, too, the blade hinges were moved outboard to 34% radius to reduce the actuation loads. The main difference between this and the United Aircraft program was the use of a mechanical actuation scheme with maximum lead-lag motions of 400. This program was also discontinued for unclear reasons. The present study is directed toward conducting a comprehensive analytical examination to evaluate the effectiveness of controlled lead-lag motions in reducing vibratory hub loads and increasing maximum flight speed. Since both previous studies on this subject were purely experimental, only a limited data set and physical understanding of the problem was obtained. With the currently available analytical models and computational resources, the present effort is geared toward developing an in-depth physical understanding of the precise underlying mechanisms by which vibration reduction may be achieved. Additionally, in recognition of the fact that large amplitude lead-lag motions would - (i) be difficult to implement, and (ii) produce very large blade stresses; the present study examines the potential of only moderate-to-small lead-lag motions for reduction of vibratory hub loads. Using such an approach, the emphasis is not on eliminating the periodic variations in tangential velocity at the blade tip, but at best reducing these variations slightly so that compressibility and stall are delayed to slightly higher advance ratios. This study was conducted in two steps. In the first step, a hingeless helicopter rotor was modeled using rigid blades undergoing flap-lag-torsion rotations about spring restrained hinges and bearings. This model was then modified by separating the lead-lag degree of freedom into two components, a free and a prescribed motion. Using this model, a parametric study of the effect of phase and amplitude of a prescribed lead-lag motion on hub vibration was conducted. The data gathered was analyzed to obtain an understanding of the basic physics of the problem and show the capability of this method to reduce vibration and expand the flight envelope. In the second half of the study, the similar analysis was conducted using an elastic blade model to confirm the effects predicted by the simpler model.

Gandhi, Farhan↗

High speed helicopter noise sources

The state-of-the art of helicopter rotor impulsive noise is reviewed. A triangulation technique for locating impulsive noise sources is developed using once-per-rev index signals as time references. A computer program (INSL) was written implementing this technique. Applying triangulation to the full-scale UH-1 noise data of NASA/Ames Research Center 40- by 80-Foot Wind Tunnel, three different noise sources are found on the rotor disk. The primary sources of thickness noise are in the second quadrant and on the advancing side of rotor disk. Two aerodynamic sources due to blade/vortex interaction are found in the first quadrant.

Lee, A.↗

An advanced stochastic model for threshold crossing studies of rotor blade vibrations.

A stochastic model to analyze turbulence-excited rotor blade vibrations, previously described by Gaonkar et al. (1971), is generalized to include nonuniformity of the atmospheric turbulence velocity across the rotor disk in the longitudinal direction. The results of the presented analysis suggest that the nonuniformity of the vertical turbulence over the rotor disk is of little influence on the random blade flapping response, at least as far as longitudinal nonuniformity is concerned.

Gaonkar, G. H.↗

Blade vortex interaction noise reduction techniques for a rotorcraft

An active control device for reducing blade-vortex interactions (BVI) noise generated by a rotorcraft, such as a helicopter, comprises a trailing edge flap located near the tip of each of the rotorcraft's rotor blades. The flap may be actuated in any conventional way, and is scheduled to be actuated to a deflected position during rotation of the rotor blade through predetermined regions of the rotor azimuth, and is further scheduled to be actuated to a retracted position through the remaining regions of the rotor azimuth. Through the careful azimuth-dependent deployment and retraction of the flap over the rotor disk, blade tip vortices which are the primary source for BVI noise are (a) made weaker and (b) pushed farther away from the rotor disk (that is, larger blade-vortex separation distances are achieved).

Charles, Bruce D.↗

Blade vortex interaction noise reduction techniques for a rotorcraft

An active control device for reducing blade-vortex interactions (BVI) noise generated by a rotorcraft, such as a helicopter, comprises a trailing edge flap located near the tip of each of the rotorcraft's rotor blades. The flap may be actuated in any conventional way, and is scheduled to be actuated to a deflected position during rotation of the rotor blade through predetermined regions of the rotor azimuth, and is further scheduled to be actuated to a retracted position through the remaining regions of the rotor azimuth. Through the careful azimuth-dependent deployment and retraction of the flap over the rotor disk, blade tip vortices which are the primary source for BVI noise are (a) made weaker and (b) pushed farther away from the rotor disk (that is, larger blade-vortex separation distances are achieved).

Charles, Bruce D.↗

A directional array approach for the measurement of rotor noise source distributions with controlled spatial resolution

A special array system has been designed to examine noise source distributions over a helicopter rotor model. The particular measurement environment is for a rotor operating in the open jet of an anechoic wind tunnel. An out-of-flow directional microphone element array is used with a directivity pattern whose major directional lobe projects on the rotor disk. If significant contributions from extraneous tunnel noise sources in the direction of the side lobes are excluded, the dominant output from the array would be that noise emitted from the projected area on the rotor disk. The design incorporates an array element signal blending features which serves to control the spatial resolution of the size of the directional lobes. (Without blending, the resolution and side lobe size are very strong functions of frequency, which severely limits the array's usefulness).

Brooks, T. F.↗

The influence of quadrupole sources in the boundary layer and wake of a blade on helicopter rotor noise

It is presently noted that, for an observer in or near the plane containing a helicopter rotor disk, and in the far field, part of the volume quadrupole sources, and the blade and wake surface quadrupole sources, completely cancel out. This suggests a novel quadrupole source description for the Ffowcs Williams-Hawkings equation which retain quadrupoles with axes parallel to the rotor disk; in this case, the volume and shock surface sourse terms are dominant.

Farassat, F.↗

Solving Recent Challenges for Wrought Ni-Base Superalloys

This paper reviews the status of technology in design and manufacture of new wrought 21 polycrystalline Ni-base superalloys for critical engineering applications. There is a strong 22 motivation to develop new alloys that are capable of operating at higher temperatures to 23 realise improvements in thermal efficiency, which are necessary to achieve environmental 24 targets for reduced emissions of harmful green-house gases. From the aerospace sector, 25 the development of new powder metallurgy and ingot metallurgy alloys are discussed for 26 disk rotor and static applications. New compositions for powder metallurgy contain about 27 50-55% of gamma prime (γ') strengthening precipitates to ensure components operate 28 successfully at temperatures up to 788°C (1450°F). In contrast, new compositions for ingot 29 metallurgy aim to occupy a design space in temperature capability between Alloy 718 and 30 current powder alloys that are in-service, and show levels of γ' of about 30-44%. The focus 31 in developing these alloys was design for manufacturability. To complement the aerospace 32 developments, a review of work to understand the suitability of candidate alloys for multiple 33 applications in Advanced-Ultra Supercritical (AUSC) power plants has been undertaken by 34 Detrois, Jablonski and Hawk from the National Energy Technology Laboratory. In these 35 power plants, steam temperatures are required to reach 700-760°C. The common thread is 36 to develop alloys that demonstrate a combination of high temperature properties, which are 37 reliant on both the alloy composition and microstructure and can be produced readily at the 38 right price. For the AUSC applications, the emphasis is on high temperature strength, long 39 term creep life, phase stability, oxidation resistance and robust welding for fabrications. 40 Whereas for powder disk rotors in aircraft engines, the priority is enhanced resistance to 41 time dependent crack growth, phase stability and resistance to environmental damage, while 42 extending the current strength levels, which are shown by existing alloys, to higher 43 temperatures.

36 MATERIALS SCIENCE↗

Steady-state unbalance response of a three-disk flexible rotor on flexible, damped supports

Experimental data are presented for the unbalance response of a flexible, ball bearing supported rotor to speeds above the third lateral bending critical. Values of squeeze film damping coefficients obtained from measured data are compared to theoretical values obtained from short bearing approximation over a frequency range from 5000 to 31 000 cycles/min. Experimental response for an undamped rotor is compared to that of one having oil squeeze film dampers at the bearings. Unbalance applied varied from 0.62 to 15.1 gm-cm.

Cunningham, R. E.↗