PSI - Issue 13

ScienceDirect Available online at www.sciencedirect.com Available online at ww.sciencedire t.com cienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 13 (2018) 953–958 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural I t gri y Procedia 00 (2018) 000–000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

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. ECF22 - Loading and Environmental effects on Structural Integrity A numerical analysis of the effects of manufacturing processes on material pre-strain in offshore wind monopiles Satya Anandavijayan*, Ali Mehmanparast, Feargal Brennan a Offshore energy engineering centre, Cranfield University, MK43 0AL, UK b Naval architecture and marine engineering, University of Strathclyde, G4 0LZ, UK Abstract The majority of offshore wind turbines in Europe are supported by monopile type foundation structures. Monopiles are made of large thickness steel plates which are longitudinally welded to fabricate “cans” and these cans are subsequently welded around the circumference to manufacture a monopile. Monopile structures can have diameters of 4-10m, with wall thicknesses of 40-150mm. To achieve the cylindrical shape in individual cans, large thickness steel plates are typically cold formed via the three-roll bending proce s. During forming of these plates, the material is subjected to plastic pre-strain, which subsequently influences the fracture and fatigue properties of monopile structures. In this study, a finite element model has been developed to predict the pre-straining levels i monopiles of different dimensions. To det rmine the i fluence of numerous manufacturing practices, a sensi vity a alysis of different factors as been conduct d. These include fabrication dependen variable such as the in luence of friction coefficient an ben ing force, and geometry dependent factors suc as plate thickness, length, and dist nce b tween rollers. Fr m the numerical results, a range of expected material pre-strain levels have been identified and presented in this paper. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: material pre-strain; monopile; fatigue; fracture; S355; finite element analysis; three roll bending 1. Introduction Renewable en rgy is predicted to be one of the fast st growing maritime sectors. Currently, wind energy already meets 11% of the EU’s power demand and is predicted that by the year 2030, its installed capacity will reach up to 23% of Europe’s total electricity demand (European Wind Energy Association, 2017). For this to be technically feasible, it is crucial for new offshore concepts and designs to be developed in order to utilize the deeper, larger expanses and wind potential of areas such as the Mediterranean, Atlantic and North Sea waters (European Wind Energy Association, 2013). © 2018 The Aut ors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. ECF22 - Loading and Environmental effects on Structural Integrity A numerical analysis of the effects of manufacturing processes on material pre-strain in offshore wind monopiles Satya Anandavijayan*, Ali Mehmanparast, Feargal Brennan a Offshore energy engineering centre, Cranfield University, MK43 0AL, UK b Naval architecture and marine engineering, University of Strathclyde, G4 0LZ, UK Abstract The majority of offshore wind turbines in Europe are supported by monopile type foundation structures. Monopiles are made of large thickness steel plates which are longitudinally welded to fabricate “cans” and these cans are subsequently welded aroun the circumfere ce to manufacture a monopile. Mo opile structures can h ve diameters of 4-10m, with wall thicknesses of 40-150mm. To achi v the cylindrical shape in individual cans, large thickness steel plates are typically cold formed via the three-roll bending process. During forming of these plates, the material is subjected to plastic pre-strain, which subsequ ntly influenc s the fracture and fa igue properties of monopile structur s. In this study, a finite element model has been developed to predict th pre-str ining levels in monopiles of different dimensions. To determine the influenc of u erous manufacturing ractices, a sensitivity analysis of different factors h s been conducted. Thes include fabrication dependent variables such as the influence of frictio coefficient and bending force, and geometry dependent factors such s plate thickn ss, length, and distance between rollers. From the numerical results, a range of expected material pre-strain levels have been identified and presented in this pap r. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: material pre-strain; monopile; fatigue; fracture; S355; finite element analysis; three roll bending 1. Introduction Renewable energy is predicted to be one of the fastest growing maritime sectors. Currently, wind energy already meets 11% of the EU’s power demand and is predicted that by the year 2030, its installed capacity will reach up to 23% of Europe’s total electricity demand (European Wind Energy Association, 2017). For this to be technically feasible, it is crucial for new offshore concepts and designs to be developed in order to utilize the deeper, larger expanses and wind potential of areas such as the Mediterranean, Atlantic and North Sea waters (European Wind Energy Association, 2013). © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer review under r sponsibility of the ECF22 organizers.

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. Peer-review under responsibility of the ECF22 organizers. 10.1016/j.prostr.2018.12.178