Dynamics of piezoceramics-based mass and force actuators for rotating machines

In the past decade, it has become more and more common to install active vibration control devices on rotating systems like grinding machines, tooling centers, industrial fans and drive shafts. In the present research, two innovative actuation concepts for such devices are evaluated. The first device is a force actuator based on piezoceramic fibers, which has a low power consumption and high dynamic range. The second device is a mass redistribution actuator based on two piezoelectric ultrasonic motors, which is smaller and faster than conventional electromagnetic devices. At the basis of the analysis are rotor dynamic finite element models including actuators, sensors and feedback controllers. In simulations and experiments with device one, feedback control and scheduled feedforward control are considered. It is shown experimentally that the unbalance response at a critical speed can be reduced by some 97%. In experiments with device two, the positioning speed is determined

Sensitivity of combustion driven damage mechanisms to instability

A multi-disciplinary framework is developed to evaluate the damage on gas turbine engine liners including interrelated sub-domains such as combustion dynamics, stress, modal, fracture mechanics analyses and life assessment. Comparative operation conditions for the combustion dynamics have been investigated. Excessive vibrations induced by the limit cycle operation resulted in mechanical stresses and strains on the structure. The structural integrity of both the intact and damaged test specimens have been monitored by vibration-based and thermal-based techniques during the combustion operation. The progressive damage on the damaged specimen configuration has been analyzed and linked to the combustion driven mechanisms. Damage evaluation, life assessment and physical experimental approaches have been integrated and utilized to evaluate the fatigue dominant damage in combustion liner material. This study addresses a reference in ensuring the safety and reliability of gas turbine engine combustors. The outcome provides a better understanding and a quantification of the material damage progress and the component behavior in terms of life consumption and combustion dynamics

Damage evolution by using the near-tip fields of a crack in gas turbine liners

A residual lifetime prediction study has been performed on a combustion liner metallic material exposed to elevated temperatures by simulating the evolution of plastic work fields at a crack tip under monotonically loading. The strain and stress distribution has been computed by finite element analysis. The method gives a measure of the metal degradation and enables to evaluate the failure limit of a progressive damage under the operating conditions of gas turbine components. The study allows making a correlation between the progress of damage of a combustion liner and the loading conditions, the material type and the geometry of a specimen by the parametric design construction

Experimental validation of the interaction between combustion and structural vibration

To decrease NOx emissions from combustion systems, lean premixed combustion is used. A disadvantage is the increase in sound pressure levels in the combustor, resulting in an increased excitation of the surrounding structure: the liner. This causes fatigue, which limits the life time of the combustor. To study this problem experimentally, a test setup has been built consisting of a single burner, 500kW, 5 bar combustion system. The thin structure (liner) is contained in a thick pressure vessel with optical access for a traversing laser vibrometer system to measure the vibration levels and mode shapes of the liner. The acoustic excitation of the liner is measured using pressure sensors measuring the acoustic pressures inside the combustion chamber and in the cooling passage between the liner and the pressure vessel. To validate models, measurements were performed in steps of increasing complexity. Firstly, the structural properties, obtained by modal analysis of the liner outside the pressure vessel, have been compared with a finite element model. Subsequently, results of an acoustic finite element model of the setup have been compared to acoustic measurements on the test rig to validate the acoustic properties of the model, which are made by mounting a well defined acoustic source to the rig. Finally, measured pressures and vibration levels in the presence of combustion are shown

Design optimization applied in structural dynamics

This paper introduces the design optimization strategies, especially for structures which have dynamic constraints. Design optimization involves first the modeling and then the optimization of the problem. Utilizing the Finite Element (FE) model of a structure directly in an optimization process requires a long computation time. Therefore the Backpropagation Neural Networks (NNs) are introduced as a so called surrogate model for the FE model. Optimization techniques mentioned in this study cover the Genetic Algorithm (GA) and the Sequential Quadratic Programming (SQP) methods. For the applications of the introduced techniques, a multisegment cantilever beam problem under the constraints of its first and second natural frequency has been selected and solved using four different approaches

A flexible rotor on flexible supports: modeling & experiments

In this study, a flexible rotor with variable support stiffness has been analyzed. Simple support models consisting of mass, spring systems are extracted from modal analysis of the isolated support and by applying static loads to the finite element model of the supports. The derived equivalent models of the supports are then implemented in the finite element based structural model which predicts the dynamic behavior of the rotor. Finally experimental modal analysis of the rotor is performed with different support stiffnesses. The experimental and theoretical results have been compared and different support modeling approaches have been examined

Thermal modeling of a mini rotor-stator system

In this study the temperature increase and heat dissipation in the air gap of a cylindrical mini rotor stator system has been analyzed. A simple thermal model based on lumped parameter thermal networks has been developed. With this model the temperature dependent air properties for the fluid-rotor interaction models have been calculated. Next the complete system has also been modeled by using computational fluid dynamics (CFD) with Ansys-CFX and Ansys. The results have been compared and the capability of the thermal networks method to calculate the temperature of the air between the rotor and stator of a high speed micro rotor has been discussed

Sensitivity of combustion driven structural dynamics and damage to thermo-acoustic instability: Combustion-acoustics-vibration

The dynamic combustion process generates high amplitude pressure oscillations due to the thermo-acoustic instabilities, which are excited within the gas turbine. The combustion instabilities have a significant destructive impact on the life of the liner material due to the high cyclic vibration amplitudes at elevated temperatures. This paper presents a methodology developed for mechanical integrity analysis relevant to gas turbine combustors and the results of an investigation of combustion-acoustics-vibration interaction by means of structural dynamics. In this investigation, the combustion dynamics was found to be very sensitive to the thermal power of the system and the air-fuel ratio of the mixture that feed into the combustor. The unstable combustion caused a dominant pressure peak at a characteristic frequency, which is the first acoustic eigenfrequency of the system. Besides, the higher-harmonics of this peak were generated over a wide frequency-band. The frequencies of the higher-harmonics were observed to be close to the structural eigenfrequencies of the system. The structural integrity of both the intact and damaged test specimens mounted to the combustor were monitored by vibration-based and thermal-based techniques during the combustion operation. The flexibility method was found to be accurate to detect, localize and identify the damage. Furthermore, a temperature increase was observed around the damage due to the hot gas leakage from the combustor that can induce detrimental thermal stresses to consume the lifetime