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Blade-to-hub mounting concept assures excellent alignment integrity and results in elimination of some welding problems associated with designs. With this design, if rework is required, blade removal and replacement may be readily accomplished without damage to blade positioning media on the wheel hub.
The sensitivity of vibratory hub loads of a four-bladed hingeless rotor with respect to blade design parameters is investigated using a finite element formulation in space and time. Design parameters include nonstructural mass distribution (spanwise and chordwise), chordwise offset of center of gravity from aerodynamic center, blade bending stiffnesses (flap, lag and torsion). Hub loads selected are 4/rev vertical hub shear and 3/rev hub moment in the rotating reference frame. The sensitivity derivatives of vertical hub loads with respect to blade design parameters are compared using two approaches, finite difference scheme and analytical approach using chain rule differentiation. The analytical derivative approach developed as an integral part of response solution (finite element in time) is a powerful method for an aeroelastic optimization of a helicopter rotor.
Several recent helicopter vibration reduction research programs are described. Results of studies of blade design parameters in rotor vibratory response and of an advanced blade design for reduced vibration are examined. An optimization approach to develop a general automated procedure for rotor blade design is described, and analytical results for an articulated rotor operating at a steady 160 kt flight condition are reported. The use of a self-adaptive controller to implement higher harmonic control in closed-loop fashion is addressed, and a computer simulation used to evaluate and compare the performance of alternative algorithms included in the generic active controller is discussed. Results are presented for steady level flight conditions, short-duration maneuvers, blade stresses and rotor performance, blade-appended aeroelastic devices, vibratory airloads, wake-induced blade airloads, and airloads from blade motions, the interaction of rotor and fuselage, and the interaction of rotor and empennage.
The constant-inside-diameter flowpath was scaled for testing in an existing turbine test facility. Blading detailed design is discussed, and design data are summarized. Predicted performance maps are presented. Steady-state stresses and vibratory behavior are discussed and the results of the mechanical design analysis are presented.
A gas turbine engine blade design is optimized using STAEBL. To validate the STAEBL analysis, the optimized blade design is analyzed using MARC, MHOST and BEST3D. The results show good agreement between STAEBL, MARC, and MHOST. The conclusion is that STAEBL can be used to optimize an engine blade design.
Design and evaluation of stator blades for use in boundary layer bleed techniques in axial flow compressor
Results of tests conducted on preliminary design polymeric-composite fan blade for the under the wing (UTW) OCSEE engine are presented. During this phase of the program a total of 17preliminary OCSEE UTW composite fan blades were manufactured for various component tests including frequency characteristics, strain distribution, bench fatigue, dovetail pull, whirligig overspeed and whirligig impact. All tests were successfully completed with the exception of whirligig impact tests. Improvements in local impact capability are being evaluated for the OCSEE blade under other NASA and related programs.
A low cost wind turbine blade based on a stainless steel fiberglass foam Budd blade design concept, was evaluated for its principle characteristics, low cost features, and its advantages and disadvantages. A blade structure was designed and construction methods and materials were selected. A complete blade tooling concepts, various technical and economic analysis, and evaluations of the blade design were performed. A comprehensive fatigue test program is conducted to provide data to verify the design stress allowables.
The engine blade design optimization program STAEBL (Structural Tailoring of Engine Blades) is available at the NASA Lewis computer facility. The analysis capabilities of this program were extended to typical loading conditions for SSME turbopump blades including thermal and pressure loading. Input files for representative SSME blade designs were developed and sample optimization studies for these blades completed. The structural tailoring program combines a general optimization package and a finite element blade analysis package. The analysis package's capabilities include natural frequency, maximum stress, and forced response computation, and fatigue life and flutter analysis. Optimization is performed using the feasible directions method. The current design is modified by perturbing the design variables so that the design constraints are satisfied while the objective function, such as blade weight, is reduced at the maximum rate. The program's geometric design variables include blade thickness distribution, thickness to chord ratios, and root chord.
Blade design aspects most affecting producibility and means of measurement and control of length, scallop, fullness and straightness requirements and tolerances were extensively considered. Alternate designs of the panel seams and edge reinforcing members are believed to offer advantages of seam integrity, producibility, reliability, cost and weight. Approaches to and requirements for highly specialized metalizing methods, processes and equipment were studied and identified. Alternate methods of sail blade fabrication and related special machinery, tooling, fixtures and trade offs were examined. A preferred and recommended approach is also described. Quality control plans, inspection procedures, flow charts and special test equipment associated with the preferred manufacturing method were analyzed and are discussed.
The rotor dynamic design considerations are essentially limitations on the vibratory response of the blades which in turn limit the dynamic excitation of the fuselage by forces and moments transmitted to the hub. Quantities which are associated with the blade response and which are subject to design constraints are discussed. These include blade frequencies, vertical and inplane hub shear, rolling and pitching moments, and aeroelastic stability margin.
Application of high speed, advanced turboprops, or propfans, to subsonic transport aircraft received significant attention and research in the 1970s and 1980s when fuel efficiency was the driving focus of aeronautical research. Recent volatility in fuel prices and concern for aviation s environmental impact have renewed interest in unducted, open rotor propulsion, and revived research by NASA and a number of engine manufacturers. Unfortunately, in the two decades that have passed since open rotor concepts were thoroughly investigated, NASA has lost experience and expertise in this technology area. This paper describes initial efforts to re-establish NASA s capability to assess aircraft designs with open rotor propulsion. Specifically, methodologies for aircraft-level sizing, performance analysis, and system-level noise analysis are described. Propulsion modeling techniques have been described in a previous paper. Initial results from application of these methods to an advanced single-aisle aircraft using open rotor engines based on historical blade designs are presented. These results indicate open rotor engines have the potential to provide large reductions in fuel consumption and emissions. Initial noise analysis indicates that current noise regulations can be met with old blade designs and modern, noiseoptimized blade designs are expected to result in even lower noise levels. Although an initial capability has been established and initial results obtained, additional development work is necessary to make NASA s open rotor system analysis capability on par with existing turbofan analysis capabilities.
The use of superhybrid materials in the manufacture and testing of large fan blades is analyzed. The FOD resistance of large metal spar/superhybrid fan blades is investigated. The technical effort reported was comprised of: (1) preliminary blade design; (2) detailed analysis of two selected superhybrid blade designs; (3) manufacture of two process evaluation blades and destructive evaluation; and (4) manufacture and whirligig testing of six prototype superhybrid blades.
An experimental and analytical investigation of two fan blade designs was conducted. The fan blades tested were 15 percent scale models of the blades used in the National Full Scale Aerodynamic Complex fan drive at NASA Ames Research Center. The fan blades were composed of NACA-65 and modified NACA-65-series airfoil design sections. The blades with modified 65-series sections incorporated increased thickness on the upper surface, between the leading edge and the one-half chord position. Twist and taper were the same for both blade designs. The fan blades with modified 65-series sections were found to have an increase in stall margin when they were compared with the unmodified blades. The experimental performance data agreed favorably with theoretical calculations.
Blade-vortex interaction (BVI) noise is one of the most objectionable types of helicopter noise. This impulsive blade-slap noise can be particularly intense during low-speed landing approach and maneuvers. Over the years, a number of flight and model rotor tests have examined blade tip modification and other blade design changes to reduce this noise. Many times these tests have produced conflicting results. In the present paper, a number of these studies are reviewed in light of the current understanding of the BVI noise problem. Results from one study in particular are used to help establish the noise reduction potential and to shed light on the role of blade design. Current blade studies and some new concepts under development are also described.
The vibration and performance optimization procedure using regression analysis was successfully applied to an advanced aeroelastic blade design study. The major advantage of this regression technique is that multiple optimizations can be performed to evaluate the effects of various objective functions and constraint functions. The data bases obtained from the rotorcraft flight simulation program C81 and Myklestad mode shape program are analytically determined as a function of each design variable. This approach has been verified for various blade radial ballast weight locations and blade planforms. This method can also be utilized to ascertain the effect of a particular cost function which is composed of several objective functions with different weighting factors for various mission requirements without any additional effort.
Resonant vibrations of aircraft engine blades cause blade fatigue problems in engines, which can lead to thicker and aerodynamically lower performing blade designs, increasing engine weight, fuel burn, and maintenance costs. In order to mitigate undesirable blade vibration levels, active piezoelectric vibration control has been investigated, potentially enabling thinner blade designs for higher performing blades and minimizing blade fatigue problems. While the piezoelectric damping idea has been investigated by other researchers over the years, very little study has been done including rotational effects. The present study attempts to fill this void. The particular objectives of this study were: (a) to develop and analyze a multiphysics piezoelectric finite element composite blade model for harmonic forced vibration response analysis coupled with a tuned RLC circuit for rotating engine blade conditions, (b) to validate a numerical model with experimental test data, and (c) to achieve a cost-effective numerical modeling capability which enables simulation of rotating blades within the NASA Glenn Research Center (GRC) Dynamic Spin Rig Facility. A numerical and experimental study for rotating piezoelectric composite subscale fan blades was performed. It was also proved that the proposed numerical method is feasible and effective when applied to the rotating blade base excitation model. The experimental test and multiphysics finite element modeling technique described in this paper show that piezoelectric vibration damping can significantly reduce vibrations of aircraft engine composite fan blades.
This report describes the Aero/Structural Tailoring of Engine Blades (AERO/STAEBL) program, which is a computer code used to perform engine fan and compressor blade aero/structural numerical optimizations. These optimizations seek a blade design of minimum operating cost that satisfies realistic blade design constraints. This report documents the overall program (i.e., input, optimization procedures, approximate analyses) and also provides a detailed description of the validation test cases.