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

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

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

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