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Research Papers: Gas Turbines: Structures and Dynamics

Uncertainties of an Automated Optical 3D Geometry Measurement, Modeling, and Analysis Process for Mistuned Integrally Bladed Rotor Reverse Engineering

[+] Author and Article Information
Alex A. Kaszynski

e-mail: Alex.Kasynski@wpafb.af.mil

Joseph A. Beck

e-mail: Joseph.Beck@wpafb.af.mil

Jeffrey M. Brown

e-mail: Jeffrey.Brown@wpafb.af.mil
Turbine Engine Division,
Air Force Research Laboratory,
Wright-Patterson AFB, OH 45433

1Corresponding author.

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received June 19, 2013; final manuscript received July 9, 2013; published online September 6, 2013. Editor: David Wisler.

J. Eng. Gas Turbines Power 135(10), 102504 (Sep 06, 2013) (8 pages) Paper No: GTP-13-1172; doi: 10.1115/1.4025000 History: Received June 19, 2013; Revised July 09, 2013

An automated reverse engineering process is developed that uses a structured light optical measurement system to collect dense point cloud geometry representations. The modeling process is automated through integration of software for point cloud processing, reverse engineering, solid model creation, grid generation, and structural solution. Process uncertainties are quantified on a calibration block and demonstrated on an academic transonic integrally bladed rotor. These uncertainties are propagated through physics-based models to assess impacts on predicted modal and mistuned forced response. Process details are discussed and recommendations made on reducing uncertainty. Reverse engineered parts averaged a deviation of 0.0002 in. (5 μm) which did not significantly impact low and midrange frequency responses. High frequency modes were found to be sensitive to these uncertainties demonstrating the need for future refinement of reverse engineering processes.

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Figures

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Fig. 1

Optical 3D scanning system

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Fig. 2

Transonic rotor point cloud (low resolution)

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Fig. 3

Automated reverse engineering process

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Fig. 4

Extracted airfoil cross sections

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Fig. 5

Airfoil cross section modal convergence

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Fig. 6

Airfoil cross section & nominal disk

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Fig. 7

1-2-3 calibration block scan

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Fig. 8

Measured deviations from average

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Fig. 9

Average scan-to-scan deviations

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Fig. 10

Absolute scan-to-scan frequency difference

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Fig. 11

First bend forced response

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Fig. 12

First torsion forced response

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Fig. 13

1B-1T forced response

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Fig. 14

2CWB forced response

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