PSI - Issue 12

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedire t.com Sci ceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 12 (2018) 344–352 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000

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AIAS 2018 International Conference on Stress Analysis Design of a test rig for railway Axle-boxes AIAS 2018 International Conference on Stress Analysis Design of a test rig for railway Axle-boxes

XV Portuguese Conference on Fracture, PCF 2016, 10-12 February 2016, Paço de Arcos, Portugal Thermo-mechanical modeling of a high pressure turbine blade of an airplane gas turbine engine P. Brandão a , V. Infante b , A.M. Deus c * a Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal b IDMEC, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal c CeFEMA, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal Abstract During their operation, modern aircraft engine components are subjected to increasingly demanding operating conditions, especially the high pressure turbine (HPT) blades. Such conditions cause these parts to undergo different types of time-dependent degradation, one of which is creep. A model using the finite element method (FEM) was developed, in order to be able to predict the creep behaviour of HPT blades. Flight data records (FDR) for a specific aircraft, provided by a commercial aviation company, were used to obtain thermal and mechanical data for three different flight cycles. In order to create the 3D model needed for the FEM analysis, a HPT blade scrap was scanned, and its chemical composition and material properties were obtained. The data that was gathered was fed into the FEM model and different simulations were run, first with a simplified 3D rectangular block shape, in order to better establish the model, and then with the real 3D mesh obtained from the blade scrap. The overall expected behaviour in terms of displacement was observed, in particular at the trailing edge of the blade. Therefore such a model can be useful in the goal of predicting turbine blade life, given a set of FDR data. N. Bosso a, *, A. Gugliotta a , N. Zampieri a a Politecnico di Torino, C.so duca degli Abruzzi 24, 10129 Torino, Italy Abstract Railway axle-boxes are one of the more critical components of the railway vehicle. The axle-box is the housing of the bearings, which support the axle-load of the vehicle, a d the confinement of the lubricant required to maintain the performances of the bearings. Therefore, the axle-box is involved both in problems related to vehicle safety, and in problems related to maintenance, becoming an important part of the life cycle cost of the vehicle. To improve safety and reliability of the axle-box, in recent years, diagnostic systems are adopted to detect malfunctions, damage or degradation of the performances of the bearings. This is made both using onboard or wayside monitoring systems, which can be based on vibration or thermal analysis. The effectiveness of these systems rely in the accuracy of the algorithms, that are used to predict the condition status of the bearings. Therefore, it is necessary to be able to validate and tune the algorithms, by means of experimental tests. The tests can be performed on the track, but this implies high variability, costs and the impossibility to experience critical conditions (due to the related risks). The aim of this work is to design an experimental test rig, able to perform tests on railway axle-boxes and to reproduce the real conditions (axle-load, velocity). Several design layout are considered, each one evidencing some benefits and some limitations. The use of the test rig allows to reproduce different failures of the bearings in a safe environment. The repeatability of the tests and the controlled environmental conditions, allow a better setup of the onitoring system being developed. © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creative ommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of the Scientific C mmittee of AIAS 2018 Inter ational C ferenc on Stre s Analysis. Keywo ds: Railway Axle-box, bearing test rig, railw y oni oring. © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of the Scientific Committee of AIAS 2018 International Conference on Stress Analysis. N. Bosso a, *, A. Gugliotta a , N. Zampieri a a Politecnico di Torino, C.so duca degli Abruzzi 24, 10129 Torino, Italy Abstract Railway axle-boxes are one of the more critical components of the railway vehicle. The axle-box is the housing of the bearings, which support the axl -load of the vehicle, and the c finement of the lubricant required to maintain the performances of the bearings. Therefore, the axle-box is involved both in problems related to vehicle safety, and in problems related to maintenance, coming an important part of the life cycle cost of the vehicle. To improve safety and reliability of the axle-box, in recent years, diagnostic systems are adopted to detect malfunctions, damage or degradation of the performances of the bearings. This is m de both using onboard or wayside monitoring systems, which can be base on vibration or thermal analysis. The effectiveness of these systems rely in the accuracy of the algorith s, that are used to predict the condition status of the bearings. Therefore, it is necessary to be able to validate and tune the algorithms, by means of experimental tests. The tests can be performed on the track, but this implies high variability, costs and the impossibilit to experience critical conditions (due to the r lated risks). The aim of this work is to design an experimental test rig, able to p rform tests on railway axle-box s and to reproduce the real conditions (axle-load, velocity). Several design layout are considered, each one evidencing some benefits and some limitations. The use of the test rig all ws to reproduce different failures of the bearings i a safe environment. The repeatability of the tests and the c ntrolled environmental conditions, allow a better setup f the monitoring sy tem bein developed. © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://cr ativecommons.org/licenses/by-nc-nd/3.0/) Peer-review und r responsibility of the Scientific ommittee of AIAS 2018 Internat onal Conference o Stress Analysis. Keywords: R ilway Axle-box, bearing test rig, railway monitoring.

1. Introduction

© 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 1. Introduction

Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. One of the most critical mechanical components of the railway vehicle is the axle-box. In fact, this component contains the bearings that must support the axle-load while the vehicle runs on the track and allow the wheelset to rotate. It is therefore an extremely loaded component, with radial and axial loads (which are generated during One of the most critical mechanical components of the railway vehicle is the axle-box. In fact, this component contains the bearings that must support the axle-load while the vehicle runs on the track and allow the wheelset to rotate. It is therefore an extremely loaded component, with radial and axial loads (which are generated during

* Corresponding author. Tel.: +390110906952; fax: +390110906999. E-mail address: nicola.bosso@polito.it * Corresponding author. Tel.: +390110906952; fax: +390110906999. E-mail address: nic la.bosso@polito.it

2452-3216 © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-revi w u er responsibility of the Scientific Committee of AIAS 2018 International Conference on Stress Analysis. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review u der responsibility of t Scientific ommittee of AIAS 2018 Internati al Conference on Stress Analysis.

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216  2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of the Scientific Committee of AIAS 2018 International Conference on Stress Analysis. 10.1016/j.prostr.2018.11.082