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Research Papers: Gas Turbines: Manufacturing, Materials, and Metallurgy

Numerical-Experimental Confrontation in the Simulation of Tool/Abradable Material Interaction

[+] Author and Article Information
Alain Batailly, Mathias Legrand

Structural Dynamics and Vibration Laboratory,
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montréal, PQ, H3A 0C3, Canada

Marion Cuny, Sylvain Philippon

Laboratory of Mechanics, Biomechanics,
Polymers, Structures (LaBPS),
National Engineering School of Metz (E.N.I.M.),
1 Route d'Ars Laquenexy,
Metz 57078, France

50,000 abradable elements are used in front of each contact nodes so that the total number of abradable elements is 250,000.

Full 3D simulations involve 3D finite element models of the structures combined with the one-dimensional plastic constitutive law.

A symmetric domain with respect to the abscissa axis shall also be assumed depending on the type of solicitation on the plastic element.

For a given contact node i, Fi,a is the mean contact force of Fi defined in Eq. (2).

Depending on the Young's modulus, the model may predict a restoration of the liner depth after deformation instead of removal.

The value of the strain-rate given in this paper comes from industrial observations.

Contributed by the International Gas Turbine Institute (IGTI) of ASME for publication in the Journal of Engineering for Gas Turbines and Power. Manuscript received November 8, 2012; final manuscript received November 15, 2012; published online May 20, 2013. Editor: Dilip R. Ballal.

J. Eng. Gas Turbines Power 135(6), 062102 (May 20, 2013) (10 pages) Paper No: GTP-12-1432; doi: 10.1115/1.4023262 History: Received November 08, 2012; Revised November 15, 2012

In turbomachinery, depositing abradable coatings along the circonference of casings is recognized as a robust solution which combines the adjustment of operating clearances with the reduction of nonrepairable damages potentially affecting the rotating blades. Accordingly, the modeling of the removal process experienced by these materials is of growing industrial importance. Based on a numerical strategy detailed in a previous publication by the authors, the present study aims at describing the mechanical behavior of abradable coatings used within turbomachines in the context of translational high-speed interactions with a rigid tool. The developed plastic constitutive law macroscopically capturing the abradable material removal is first enriched to account for its strain rate dependence. Then, a sensitivity analysis with respect to a few parameters of interest is conducted and calibration of the numerical investigation with existing experimental data validates the proposed approach. Finally, the strain-rate dependence of the viscoplastic law implemented within a full numerical three-dimensional rotor/stator interaction is addressed. Results reveal that viscoplastic terms have minor effects in turbomachinery interactions.

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Figures

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Fig. 1

Experimental test bench

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Fig. 2

Tool mesh and prescribed boundary conditions

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Fig. 3

Schematics of the numerical simulation

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Fig. 4

Tool blade zoom: cut view in the (ci, z, x) plane

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Fig. 5

Numerical profile/abradable material interface

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Fig. 6

Displacement of node c3 in the X direction for h = 10-8 s (green line), h = 5×10-9 s (red line) and h = 10-9 s (black line); ‖V‖ = 200 m/s and p = 0.5 mm (to view this figure in color, please go to the online version)

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Fig. 7

Investigated constitutive laws

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Fig. 8

Contact force acting on node c3; ‖V‖ = 200 m/s and p = 0.2 mm

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Fig. 9

Displacements ux,3 and uz,3 of node c3; ‖V‖ = 200m/s and p = 0.2 mm

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Fig. 10

Wear profile after interaction; ‖V‖ = 200 m/s and p = 0.2 mm

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Fig. 11

Sensitivity of the numerically predicted contact force

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Fig. 12

Experimental data [12] and numerical results. Uncertainty on experimental data is highlighted in gray.

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Fig. 13

Blade response spectrum for η = 50,000 Pa s

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Fig. 14

Final abradable profile maps after fifty blade revolutions, η = 50,000 Pa s

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