journal article·2021-03

Containment of blade shedding in gas turbine engines: part I—design and development of a scaled down test rig

P. A. Roy, S. A. Meguid

Publisher page

Abstract

Part I of this complementary article is concerned with the design, development and commissioning of a novel instrumented scaled down test rig to examine the dynamics and containment of a released blade during blade shedding (blade out) incidents in aviation gas turbine engines. The scaled down fully bladed disk is designed using non-dimensional parameters derived using Buckingham’s dimensional analysis technique. These parameters are enforced to ensure dynamic equivalency of the scaled down model and a realistic full size gas turbine engine. The rotor with drive system is encapsulated in a thick protective casing to contain all fragments within the confines of test rig and ensure safety of operation. The test rig is equipped with a high speed camera and numerous sensors interconnected via data acquisition system to two processors for data collection and data management. The purpose is to measure the released blade trajectory, its multiple interactions with the trailing blades, containment within the ring, the stresses resulting from dynamic unbalance and blade impingement, and their effect on engine mount. The successful operation of the newly commissioned test rig is tested under steady state conditions and we were able to demonstrate the applicability of the rig to blade shedding and containment tests in an efficient and cost effective manner.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Bladed Disk Vibration Dynamics · High Temperature Alloys and Creep · High-Velocity Impact and Material Behavior

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (28)

Show source-provided references
1. ATSB: In-flight uncontained engine failure Airbus A380-842, VH-OQA (2013)
2. Bansal, S., Mobasher, B., Rajan, S.D., Vintilescu, I.: Development of fabric constitutive behavior for use in modeling engine fan blade-out events. J. Aerosp. Eng. 22, 249–259 (2009). https://doi.org/10.1061/(ASCE)0893-1321(2009)22:3(249)10.1061/(ASCE)0893-1321(2009)22:3(249) ↗
3. Bresciani, L.M., Manes, A., Ruggiero, A., Iannitti, G., Giglio, M.: Experimental tests and numerical modelling of ballistic impacts against Kevlar 29 plain-woven fabrics with an epoxy matrix: macro-homogeneous and meso-heterogeneous approaches. Compos. Part B 88, 114–130 (2016). https://doi.org/10.1016/j.compositesb.2015.10.03910.1016/j.compositesb.2015.10.039 ↗
4. Carney, K.S., Pereira, J.M., Revilock, D.M., Matheny, P.: Jet engine fan blade containment using an alternate geometry. Int. J. Impact Eng. 36, 720–728 (2009). https://doi.org/10.1016/j.ijimpeng.2008.10.00210.1016/j.ijimpeng.2008.10.002 ↗
5. Carter, T.J.: Common failures in gas turbine blades. Eng. Fail. Anal. 12, 237–247 (2005). https://doi.org/10.1016/j.engfailanal.2004.07.00410.1016/j.engfailanal.2004.07.004 ↗
6. Gogolewski, R.P., Cunningham, B.J.: Terminal Ballistic Experiments for the Development of Turbine Engine Blade Containment Technology. Lawrence Livermore National Laboratory, Livermore (1995)10.2172/87317 ↗
7. Gogolewski, R.P., Morgan, B.R.: Ballistic Experiments with Titanium and Aluminum Targets. Lawrence Livermore National Laboratory, Livermore (2001)
8. He, Q., Xie, Z., Xuan, H., Hong, W.: Ballistic testing and theoretical analysis for perforation mechanism of the fan casing and fragmentation of the released blade. Int. J. Impact Eng. 91, 80–93 (2016a). https://doi.org/10.1016/j.ijimpeng.2016.01.00110.1016/j.ijimpeng.2016.01.001 ↗
9. He, Q., Xie, Z., Xuan, H., Liu, L., Hong, W.: Multi-blade effects on aero-engine blade containment. Aerosp. Sci. Technol. 49, 101–111 (2016b). https://doi.org/10.1016/j.ast.2015.11.03710.1016/j.ast.2015.11.037 ↗
10. He, Q., Xuan, H., Liu, L., Hong, W., Wu, R.: Perforation of aero-engine fan casing by a single rotating blade. Aerosp. Sci. Technol. 25, 234–241 (2013). https://doi.org/10.1016/j.ast.2012.01.01010.1016/j.ast.2012.01.010 ↗
11. He, Z., Xuan, H., Bai, C.: A blade release method for FBO test. Exp. Tech. 42, 311–318 (2018). https://doi.org/10.1007/s40799-018-0233-610.1007/s40799-018-0233-6 ↗
12. Hradecky, S.: Incident: France A388 over Greenland on Sep 30th 2017, uncontained engine failure, fan and engine inlet separated. https://avherald.com/h?article=4af15205 (2018)
13. Lepeshkin, A., Bychkov, N., Vaganov, P., Nozhnitsky, Y., Baluev, B.: The blade releasing method for test of engine casing containment. In: Proceedings of the ASME 2013 International Mechanical Engineering Congress and Exposition, pp. 1–5 (2013)10.1115/IMECE2013-63749 ↗
14. Liu, L., Chen, W., Zhao, Z., Luo, G.: Investigation on the dynamic response of aero-engine structures due to fan blade out event through subscale testing. In: 52nd AIAA/SAE/ASEE Joint Propulsion Conference, 2016, pp. 1–9 (2016)10.2514/6.2016-4861 ↗
15. Lundin, S.J., Mueller, R.B.: Advanced aircraft materials, engine debris penetration testing. U.S. Department of Transportation, Washington, DC (2005)
16. Naik, D., Sankaran, S., Mobasher, B., Rajan, S.D., Pereira, J.M.: Development of reliable modeling methodologies for engine fan blade out containment analysis. Part I: experimental studies. Int. J. Impact Eng. 36, 1–11 (2009). https://doi.org/10.1016/j.ijimpeng.2008.03.00710.1016/j.ijimpeng.2008.03.007 ↗
17. Nilakantan, G., Merrill, R.L., Keefe, M., Gillespie, J.W., Wetzel, E.D.: Experimental investigation of the role of frictional yarn pull-out and windowing on the probabilistic impact response of kevlar fabrics. Compos. Part B 68, 215–229 (2015). https://doi.org/10.1016/j.compositesb.2014.08.03310.1016/j.compositesb.2014.08.033 ↗
18. NTSB: Uncontained Engine Failure and Subsequent Fire, American Airlines Flight 383, Boeing 767-323, N345AN, Chicago, Illinois, October 28, 2016 (2016)
19. NTSB: Left Engine Failure and Subsequent Depressurization, Southwest Airlines Flight 1380, Boeing 737-7H4, N772SW (2018)
20. Pandya, K.S., Kumar, C.V.S., Nair, N.S., Patil, P.S., Naik, N.K.: Analytical and experimental studies on ballistic impact behavior of 2D woven fabric composites. Int. J. Damage Mech. 24, 471–511 (2015). https://doi.org/10.1177/105678951453144010.1177/1056789514531440 ↗
21. Pereira, J.M., Lerch, B.A.: Effects of heat treatment on the ballistic impact properties of Inconel 718 for jet engine fan containment applications. Int. J. Impact Eng. 25, 715–733 (2001). https://doi.org/10.1016/S0734-743X(01)00018-510.1016/S0734-743X(01)00018-5 ↗
22. Pereira, J.M., Revilock, Jr. D.M.: Ballistic impact response of Kevlar 49 and zylon under conditions representing jet engine fan containment. J. Aerosp. Eng. 22(3), 240–248 (2009). https://doi.org/10.1061/(ASCE)0893-1321(2009)22:3(240)10.1061/(ASCE)0893-1321(2009)22:3(240) ↗
23. Sengoz, K., Kan, S., Eskandarian, A.: Development of a Generic Gas Turbine Engine Fan Blade-Out Full-Fan Rig Model. U.S. Department of Transportation, Washington, DC (2015)
24. VanderKlok, A., Stamm, A., Xiao, X.: Fan-blade-out experiment at small scale. Exp. Tech. (2016). https://doi.org/10.1007/s40799-016-0135-410.1007/s40799-016-0135-4 ↗
25. Wang, Y., Chen, X., Young, R., Kinloch, I., Garry, W.: An experimental study of the effect of ply orientation on ballistic impact performance of multi-ply fabric panels. Text. Res. J. 86, 34–43 (2016). https://doi.org/10.1177/004051751456611010.1177/0040517514566110 ↗
26. Wei, G., Zhang, W.: Perforation of thin aluminum alloy plates by blunt projectiles: an experimental and numerical investigation. J. Phys. Conf. Ser. 500, 112065 (2014). https://doi.org/10.1088/1742-6596/500/11/11206510.1088/1742-6596/500/11/112065 ↗
27. Xuan, H., Wu, R.: Aeroengine turbine blade containment tests using high-speed rotor spin testing facility. Aerosp. Sci. Technol. 10, 501–508 (2006). https://doi.org/10.1016/j.ast.2006.04.00610.1016/j.ast.2006.04.006 ↗
28. Zhang, T., Chen, W., Guan, Y., Gao, D.: Study on titanium alloy TC4 ballistic penetration resistance part I: ballistic impact tests. Chin. J. Aeronaut. 25, 388–395 (2012). https://doi.org/10.1016/S1000-9361(11)60402-010.1016/S1000-9361(11)60402-0 ↗