Forced response prediction of turbine blades with flexible dampers: the impact of engineering modelling choices

This paper focuses on flexible friction dampers (or “strips”) mounted on the underside of adjacent turbine blade platforms for sealing and damping purposes. A key parameter to ensure a robust and trustworthy design is the correct prediction of the maximum frequency shift induced by the strip damper coupling adjacent blades. While this topic has been extensively addressed on rigid friction dampers, both experimentally and numerically, no such investigation is available as far as flexible dampers are concerned. This paper builds on the authors’ prior experience with rigid dampers to investigate the peculiarities and challenges of a robust dynamic model of blade-strips systems. The starting point is a numerical tool implementing state-of-the-art techniques for the efficient solution of the nonlinear equations, e.g., multi-harmonic balance method with coupled static solution and state-of-the-art contact elements. The full step-by-step modelling process is here retraced and upgraded to take into account the damper flexibility: for each step, key modelling choices (e.g., mesh size, master nodes selection, contact parameters) which may affect the predicted response are addressed. The outcome is a series of guidelines which will help the designer assign numerical predictions the proper level of trust and outline a much-needed experimental campaign

Comparison of contact parameters measured with two different friction rigs for nonlinear dynamic analysis

The accurate measurement of contact interface parameters is of great importance for nonlinear dynamic response computations since there is a lack of predictive capabilities for such input parameters. Several test rigs have been developed at different institutions, and a series of measurements published, but their reliability remains unknown due to a lack of direct comparisons. To somehow address this issue, a Round-Robin test campaign was performed including the high frequency friction rigs of Imperial College London and Politecnico di Torino. Comparable hysteresis loops were recorded on specimen pairs manufactured from the same batch of raw stainless steel, for a wide range of test conditions, including varying normal loads, sliding distances and nominal areas of contact. Measurements from the two rigs were compared to quantify the level of agreement between the two very different experimental setup, showing a reasonably good matching in the results, but also highlighting some differences. Results also demonstrated that loading conditions can strongly affect the contact parameters, and consequently their effect must be included in future nonlinear dynamic simulations for more reliable predictions

Nonlinear dynamics of turbine bladed disk with friction dampers: Experiment and simulation

Accurately predicting the nonlinear dynamic response of aero-engine components is critical, as excessive vibration amplitudes can considerably reduce the operational lifespan. This paper compares experimental and numerical nonlinear dynamic responses of an industrial aero-engine, specifically focusing on the first stage turbine bladed disk with under-platform dampers (UPDs). The friction forces between UPDs and blades result in a strongly nonlinear dynamic response, influenced by stick, slip and separation contact states at the interfaces. These contact states, and the resulting global dynamic responses, are predicted with an advanced industrial modelling approach for nonlinear dynamics. The predictions are compared, updated and validated against measurement data from an operational engine test. Results highlight the importance to validate models against industrial data and show that realistic contact pressure distributions are required for increased prediction reliability. The novelty of this work includes (1) the use of unique industrial experimental data from a fully operational aero-engine, (2) the observation, at the end of engine testing, of real contact conditions in blade/UPD interfaces, (3) detailed modelling of these contact conditions with high-fidelity finite element representations in nonlinear dynamic solvers. Based on this unique industrial validation work, guidelines are proposed to improve the state-of-the-art modelling of nonlinear dynamics in structures with friction contacts

Ultrasonic monitoring of friction contacts during shear vibration cycles

Complex high-value jointed structures such as aero-engines are carefully designed and optimized to prevent failure and maximise their life. In the design process, physically-based numerical models are employed to predict the nonlinear dynamic response of the structure. However, the reliability of these models is limited due to the lack of accurate validation data from metallic contact interfaces subjected to high-frequency vibration cycles. In this study, ultrasonic shear waves are used to characterise metallic contact interfaces during vibration cycles, hence providing new validation data for an understanding of the state of the friction contact. Supported by numerical simulations of wave propagation within the material, a novel experimental method is developed to simultaneously acquire ultrasonic measurements and friction hysteresis loops within the same test on a high-frequency friction rig. Large variability in the ultrasound reflection/transmission is observed within each hysteresis loop and is associated with stick/slip transitions. The measurement results reveal that the ultrasound technique can be used to detect stick and slip states in contact interfaces subjected to high-frequency shear vibration. This is the first observation of this type and paves the way towards real-time monitoring of vibrating contact interfaces in jointed structures, leading to a new physical understanding of the contact states and new validation data needed for improved nonlinear dynamic analyses

Modeling and Testing Friction Flexible Dampers: Challenges and Peculiarities

This paper deals with the dynamic of blades with strip dampers. The purpose is 1) to present the results of the dynamic numerical calculation, 2) to demonstrate the need for the experimental data on the blade-strip contact to be used as input to the calculation, 3) to propose a new test rig design to obtain them and 4) to test the key components of the new test rig. The forced responses of two blades coupled by a strip damper are calculated at different excitation and centrifugal force values. The dependence of the numerical results on the contact parameter values is confirmed in this significant reference case. The design of a new test rig is then proposed: both the blade frequency response function and the contact hysteresis cycles at the blade-strip contact are measured. It is shown how contact parameters can then be derived from experimental data. The main novelty of the test rig here proposed is the strip loading system, which simulates the uniform pressure distribution provided by the centrifugal force in real operating conditions. This loading system is non-contact and uses compressed air. Classical loading systems which see dead weights directly connected to the strip are assessed and their expected inadequacy is confirmed. The compressed air system is tested by measuring the pressure produced between strip and blades: pressure is uniform across the contact patch, constant in time and its mean value corresponds to realistic pressure values actually experienced by strip dampers during service

Effect of fretting-wear on dynamic analysis. Comparison between experimental results and numerical simulations for a vibratory friction rig.

Dry friction in contact interfaces can have an important impact on the dynamic response of jointed structures subjected to vibration. It may cause frettingwear leading to a modification of the contact surface geometry by producing wear debris through material removal and dissipating energy. Consequently, the contact behaviour is modified and the worn geometry induces a change in vibrations level. Therefore, it is important to be able to simulate these complex phenomena occurring at the interfaces to predict the forced response of assembled structures and also their life-expectancy to design high confidence components. A multi-scale approach is implemented considering a slow-scale for wear phenomena and a fast-scale for the non-linear dynamic response and applied to validate an experimental test

The impact of fretting wear on structural dynamics: Experiment and simulation

This paper investigates the effects of fretting wear on frictional contacts. A high frequency friction rig is used to measure the evolution of hysteresis loops, friction coefficient and tangential contact stiffness over time. This evolution of the contact parameters is linked to significant changes in natural frequencies and damping of the rig. Hysteresis loops are replicated by using a Bouc-Wen modified formulation, which includes wear to simulate the evolution of contact parameters and to model the evolving dynamic behaviour of the rig. A comparison of the measured and predicted dynamic behaviour demonstrates the feasibility of the proposed approach and highlights the need to consider wear to accurately capture the dynamic response of a system with frictional joints over its lifetime

The impact of fretting wear on structural dynamics: Experiment and simulation

This paper investigates the effects of fretting wear on frictional contacts. A high frequency friction rig is used to measure the evolution of hysteresis loops, friction coefficient and tangential contact stiffness over time. This evolution of the contact parameters is linked to significant changes in natural frequencies and damping of the rig. Hysteresis loops are replicated by using a Bouc-Wen modified formulation, which includes wear to simulate the evolution of contact parameters and to model the evolving dynamic behaviour of the rig. A comparison of the measured and predicted dynamic behaviour demonstrates the feasibility of the proposed approach and highlights the need to consider wear to accurately capture the dynamic response of a system with frictional joints over its lifetime

The Pre-Modern Manuscript Trade and its Consequences, ca. 1890-1945

This collection brings together current research into the development of the market for pre-modern manuscripts. Between 1890 and 1945 thousands of manuscripts made in Europe before 1600 appeared on the market. Many entered the collections in which they have remained, shaping where and how we encounter the books today. These collections included libraries that bear their founders’ names, as well as national and regional public libraries. The choices of the super-rich shaped their collections and determined what was available to those with fewer resources. In addition, wealthy collectors sponsored scholarship on their manuscripts and participated in exhibitions, raising the profile of some books. The volume examines the collectors, dealers, and scholars who engaged with pre-modern books, and the cultural context of the manuscript trade in this era

Dataset of contact parameters and hysteresis loops from a round robin test for nonlinear dynamic analysis

This dataset is described in the data article [1] and presents friction hysteresis loops and contact parameters measured during the round robin test of the original research article [2]. Friction forces and tangential relative displacements for each specimen pair are stored as hysteresis raw data. Each hysteresis loop was post-processed to extract friction coefficient, tangential contact stiffness and energy dissipated, whose evolution with wear was thus obtained and stored as well. Matlab codes for post-processing and plotting data are included too.The dataset can be used by researchers as a benchmark to validate theoretical models or numerical simulations of friction hysteresis models and wear mechanisms, and also to study the physics of friction hysteresis and its contact parameters. This high-frequency friction data can also be used as input in models for nonlinear dynamics applications as well as to provide information on the contact measurement uncertainty under high-frequency reciprocating motion. This data can also be used as a training set for machine learning applications or data-driven models, as well as supporting grant applications.References[1] Fantetti A., Botto D., Schwingshackl C., Zucca S., Experimental dataset from a round robin test of contact parameters and hysteresis loops for nonlinear dynamic analysis, Data in Brief, 2024, submitted.[2] Fantetti A., Botto D., Zucca S., Schwingshackl C., Guidelines to use input contact parameters for nonlinear dynamic analysis of jointed structures: Results of a round robin test, Tribology International, 2023. https://doi.org/10.1016/j.triboint.2023.109158THIS DATASET IS ARCHIVED AT DANS/EASY, BUT NOT ACCESSIBLE HERE. TO VIEW A LIST OF FILES AND ACCESS THE FILES IN THIS DATASET CLICK ON THE DOI-LINK ABOV