PSI - Issue 14

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedire t.com cienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 14 (2019) 345–353 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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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. © 2019 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selectio and peer-review under responsibility of Peer-review under responsibility of the SICE 2018 organizers. 2nd International Conference on Structural Integrity and Exhibition 2018 Weight Optimization of Housing Bracket for Electrical Starter Motor using FEA Varatharaj Neelakandan a* , Thulasirajan Ganesan b & Praveen Chakrapani Rao c a,b,c Department of Research and Development, Comstar Automotive T chnologies Pvt. Ltd, Ch nnai-603204, India. Abstract Starter motor is an electric motor which provides electro-mechanical motion to start the internal combustion engine. The electric starter ensures that anyone could easily start and run an internal combustion engine for any passenger vehicles. Starter motor housing bracket strength and weight has b n continuously a c ncern which may lead to operational cost high and durability life. The important causes of higher weight gain are overdesign, customer demand, casting feasibility and the operating conditions. This paper presents the design optimization methods for robust design to meet the product weight and fatigue life cycle requirements considering the manufacturing feasibilities of casting wall thickness and draft allowances with metal flow radius for the starter operating conditions. In the optimization of housing bracket, finite element analysis software was used for calculating the st ess and fatigu life and then the weight was optimized. The optimized n w housing b acket was proposed for new starter projects to ca ture new business and th desig was implemented to reduce cost in productionized starters. © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the SICE 2018 organizers. Keywords: Electrical starter motor Housing, Optimisation, Durability, Fatigue life, FEA 1. Introduction Starter motor is an electromechanical product which is used to crank the engine through pinion connected to the ring gear mounted on the engine flywheel as shown in Figure 1. The starter motor energized by the battery of voltage about 12V connected to the terminal and brushed commutator. The armature rotates and the internal planetary gear 2nd International Conference on Structural Integrity and Exhibition 2018 Weight Optimization of Housing Bracket for Electrical Starter Motor using FEA Varatharaj Neelakandan a* , Thulasirajan Ganesan b & Praveen Chakrapani Rao c a,b,c Departm nt f Res arch an Dev lopment, Comstar Automotive Technologies Pvt. Ltd, Chennai-603204, India. Abstract St rt motor is an electric m tor which provides electro-mechanical otion to start the internal combustion engine. Th electric starter ensures th t anyone could e sily start and run an int rnal combustion engin f r any passenger ve icles. Starter motor housing b acket str ngth and weight as been continuously a concern which may lead to operational cost high and durability life. e important causes of higher weight g in are over esign, customer demand, casting feasibility and the oper ting conditions. This pap r presents the design optimization method for robust design to meet the product w ight and f tigue life cycle requirements consideri g the manufacturing fe sibilities f casting wall thickn ss and draft allowances with metal fl w radius for t tarter ope ating conditions. In the optimization of housing bracket, finite element an lysis software was us d for calculating th stress and fatigu life and then the eight was optimized. Th optimized new housing bracket was proposed for new start r projects to capture new business and the design was implemented to reduce cost in productionized starters. © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the SICE 2018 organizers. Keywords: Electrical starter motor Housing, Optimisation, Durability, Fatigue life, FEA 1. Introduction Starter motor is an electrom chanical product which is used t crank the engine through pinion connected to th ring gear mount d on the engine flywheel as s own in Figure 1. The star e m tor energized by the battery of voltage about 12V connected to the terminal and brushed commutator. The armature rotates and the internal planetary gear © 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.: +91-7338823264 E-mail address: nvaratha@comstarauto.com * Corresponding author. Tel.: +91-7338823264 E-mail address: nvaratha@comstarauto.com

2452-3216 © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under of the SICE 2018 organizers. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. This is a open access article under C BY-NC-ND lic nse (https://creativecommons.org/licenses/by-nc-nd/4.0/)

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt Selection and peer-review under of the SICE 2018 organizers.

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216  2019 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of Peer-review under responsibility of the SICE 2018 organizers. 10.1016/j.prostr.2019.05.043