PSI - Issue 5

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedire t.com ienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 5 (2017) 369–376 Available online at www.sciencedirect.com ScienceDirect Structural I tegr ty Procedia 00 (2017) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2017) 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. 2nd International Conference on Structural Integrity, ICSI 2017, 4-7 September 2017, Funchal, Madeira, Portugal Failure investigation of the crankshaft of diesel engine Lucjan Witek a *, Feliks Stachowicz a , Arkadiusz Załęski b a Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, 8 Powstancow Warszawy Ave., 35-959 Rzeszow, Poland. b MTU Aero Engines Polska, Tajecina 108, 36-002 Jasionka, Poland Abstract In this wo k the ailure, stress and modal analysis of the crankshaft of diesel engine was performed. Visual examination of damaged part showed that the fatigue beach marks were observed on the fracture. Results of additional investigation using the scanning electron microscope revealed the presence of micro-cracks in crack origin area. In next part of experimental investigations the specimens were cut from damaged shaft. Results of tension test showed that mechanical properties of the steel used for the crankshaft manufacturing is in the range defined by the standard. In order to explain the reason of premature crankshaft damage, the finite element method was utilized. In first step the numerical model of crankshaft with the connecting rods was prepared. The boundary conditions were next defined on bearing journal su faces. The complex load cases were also defined in order to model the real engine loadings. Results of nonlinear stress analysis performed for the crankshaft m del showed that during work of engine with a maximum power the high stress area was located in another zone than the crack origin. This result was a reason for extension of investigation on the dynamic problems. In last part of the study the numerical modal analysis was performed for the crankshaft. In this analysis both the frequencies and modes of free vibration were obtained. Results of modal analysis showed that during second mode of free vibration the high stress area was located in the crack origin zone. Based on results of performed investigations it was concluded that the main reasons of premature failure are resonant vibrations of the crankshaft. © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ICSI 2017. 2nd International Conference on Structural Integrity, ICSI 2017, 4-7 September 2017, Funchal, Madeira, Portugal Failure investigation of the crankshaft of diesel engine Lucjan Witek a *, Feliks Stachowicz a , Arkadiusz Załęski b a Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, 8 Powstancow Warszawy Ave., 35-959 Rzeszow, Poland. b MTU Aero Engines Polska, Tajecina 108, 36-002 Jasionka, Poland Abstract In this work the failure, stress and modal analysis of the crankshaft of diesel engine was performed. Visual examination of damaged part showed that the fa gue beach marks were observed on the fracture. Results of additional investigation using the scanning electron microscope revealed the presence of micro-cracks in crack origin area. In next part of experimental investigations the specimens were cut from damaged shaft. Results of tension test showed that mechanical properties of the steel used for the crankshaft manufacturing is in the range defined by the standard. In order to explain the reason of premature crankshaft damage, the finite element method was utilized. In first step the numerical model of crankshaft with the connecting rods was prepared. The boundary conditions were next defined on bearing journal surfaces. The complex load cases were also defined in order to model the real engine loadings. Results of nonlinear stress analysis performed for the crankshaft model showed that during work of engine with a maximum power the high stress area was located in another zone than the crack origin. This result was a reason for extension of investigation on th ynamic problems. In last part of the study the num rical modal analysis was performed for the crankshaft. In this analysis both the frequencies and modes of free vibration were obtained. Results of modal analysis showed that during second mode of free vibration the high stress area was located in the crack origin zone. Based on results of performed investigations it was concluded that the main reasons of premature failure are resonant vibrations of the crankshaft. © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsib lity of the Scientific Committee of ICSI 2017. 20 7 The Authors. Published by Elsevier B.V. er-review under responsibility of the Scientific Committee of ICSI 2017 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: Crankshaft, failure analysis, finite element method, modal analysis, diesel engine. Keywords: Crankshaft, failure analysis, finite element method, modal analysis, diesel engine.

Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

* Corresponding author. Tel.: +48-178651324 E-mail address: e-mail: lwitek@prz.edu.pl * Corresponding author. Tel.: +48-178651324 E-mail address: e-mail: lwitek@prz.edu.pl

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216  2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ICSI 2017 10.1016/j.prostr.2017.07.184 * Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452-3216 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ICSI 2017. 2452-3216 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ICSI 2017.