PSI - Issue 2_B

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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. 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Numerical analysis of a custom-mad pelvic prosthesis 1 G. La Rosa*, 1 C. Clienti, 2 S. Di Bella, 1 F. Rizza 1 Department of Industrial Engineering, University of Catania, Viale Andrea Doria, 6 - 95125 Catania, Italy 2 MT Ortho s.r.l., Via Fossa Lupo, 95025 Aci S.Antonio, Catania, Italy In recent years, 3D-printing technologies are able to fabricate complex shapes of a custom designed component by adding material layer-by-layer from the bottom up on top of each other. Electron Beam Melting (EBM) is a technique capable of manufacturing fully solid metallic parts, using a high-i tensity electr n b am to melt powder particles in layers in rder to form finished components. Aim of this paper is to perform a FEM analysis of custom-made implant in order to calculate the stress-strain state under daily activities loading. To this purpose, geometry, mechanical properties and boundary conditions have to be known. Geometry was reconstructed with a reverse-engineering process while loading conditions were obtained from literature. Ti6Al4V mechanical properties were determined experimentally with tensile testing. A deeper local analysis was carried out in order to simulate bone screw interface to define if daily activities can cause bone resorption. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. Keywords: Pelvis prostheses; Custom-made prostheses; 3D Electron Beam Melting; FE analysis 1. Introduction Metal orthopedic joint are fabricated from wrought or cast bar stock by CNC with very high waste of material and, often, significant cost. Moreover, these joints are mass-produced components, which are difficult to realize and sometime inaccurate with patients who need major resection. In these situations, custom – designed implant components are required. In recent years, 3D printing technologies have been developed and can be applied in orthopedics to facilitate the reconstruction of complex shapes bone parts. These rapid prototyping processes allow synthesize metal powder, in particular Ti alloy, and can be used to manufacture components with specific geometric 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Numerical analysis of a custom-made pelvic prosthesis 1 G. La Rosa*, 1 C. Clienti, 2 S. Di Bella, 1 F. Rizza 1 Department of Industrial Engineering, University of Catania, Viale Andrea Doria, 6 - 95125 Cata ia, Italy 2 MT Ortho s.r.l., Via Fossa Lupo, 95025 Aci S.Antonio, Catania, Italy Abstract In recent years, 3D-printing technologies are able to fabricate complex shapes of a custom designed component by adding material lay r-by-layer from the bottom up n top of each other. Electron Beam Melting (EBM) is a technique capable of manufacturing fully solid metallic parts, using a high-intensity electron beam to elt powder particles in layers in order to form finished components. Ai f thi paper is to perform a FEM analysis of custom-made imp ant in order to calculate the stress-strain state under daily activities loading. To this pu pose, geometry, mechanical properties and boundary conditions have o be known. G omet y was reconstructed with a reverse-engineering process while loading conditions were obtained from literature. Ti6Al4V echanic l proper ies were determin d xperim ntally with tensile testing. A deeper local analysis was carried out in order to simulate bone screw interfac to d fine if daily activi ies can cause bon resorption. © 2016 The Au hors. Published by Elsevier B.V. Peer-review under espons bility of the Scientific Committee of ECF21. Keywords: Pelvis prostheses; Custom-made prostheses; 3D Electron Beam Melting; FE analysis 1. Introduction Metal orthopedic joint are fabricated from wrought or cast bar stock by CNC with very high waste of material and, often, significant cost. Moreover, th se joints are mass-produced omponents, which are difficult to real ze a sometime inaccurate with patients who need major resection. In thes situations, custom – designed mpla t c ponents re required. In recent years, 3D printing t chnologies have been developed and can be applied in orthopedic to facilitat the reconstruction of complex shapes b ne parts. Th se rapid prototyping processes allow synthesize metal powd r, in particular Ti all y, and can be used to manufactur com onents with specific g ometric Copyright © 2016 The Authors. Published by Elsevier B.V. This is a open ac ess article under the CC BY-NC-ND license (http://creativec mmons.org/licens s/by-nc-nd/4.0/). Peer-review under responsibility of the Scientific Committee of ECF21. © 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. Abstract

* 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 ECF21. 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. * Corresponding author. Tel.: +390957382413; fax: +39095337994; E-mail address: glarosa@dii.unict.it * Corresponding author. Tel.: +390957382413; fax: +39095337994; E-mail address: glarosa@dii.unict.it

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Copyright © 2016 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/4.0/ ). Peer review under responsibility of the Scientific Committee of ECF21. 10.1016/j.prostr.2016.06.165