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Research Papers

Mistuning Evaluation Comparison Via As-Manufactured Models, Traveling Wave Excitation, and Compressor Rigs

[+] Author and Article Information
Daniel L. Gillaugh, Jeffrey M. Brown

Turbine Engine Division,
U.S. Air Force Research Laboratory,
Wright-Patterson AFB, OH 45431

Alexander A. Kaszynski

Advanced Structural Analysis,
Dayton, OH 45434

Joseph A. Beck

Perceptive Engineering Analytics LLC,
Minneapolis, MN 55418

Joseph C. Slater

Wright State University,
Dayton, OH 45435

Manuscript received September 19, 2018; final manuscript received November 13, 2018; published online January 9, 2019. Editor: Jerzy T. Sawicki.This work is in part a work of the U.S. Government. ASME disclaims all interest in the U.S. Government's contributions.

J. Eng. Gas Turbines Power 141(6), 061006 (Jan 09, 2019) (13 pages) Paper No: GTP-18-1617; doi: 10.1115/1.4042079 History: Received September 19, 2018; Revised November 13, 2018

As-manufactured rotors behave quite differently than nominal as-designed rotors due to small geometric and material property deviations in the rotor, referred to as mistuning. The mistuning of a 20 bladed, integrally bladed rotor (IBR) will be evaluated via analytical methods, benchtop testing, and using a rotating compressor research facility. Analytical methods consist of the development of an as-manufactured model based on geometry measurements from a high fidelity optical scanning system. Benchtop testing of the IBR is done using a traveling wave excitation (TWE) system that simulates engine order excitation in stationary bladed disks for the purpose of determining potentially high responding blades due to mistuning. The compressor research facility utilizes blade tip timing to measure the blade vibration of the IBR. The resonant response of the IBR at various modes and harmonic excitations is investigated. A comprehensive mistuning and force amplification comparison between the as-manufactured model, TWE, and the compressor rig is performed. Mistuning of each method is evaluated using three different methods. First, the tuned absorber factor (TAF), which is a metric to determine potential high responding blades, is determined for each system. Next, mistuning is analyzed by isolating individual blades both experimentally on the bench and analytically to determine the mistuning patterns. Lastly, the mistuning determined by each system will be evaluated using a reduced-order model, namely the fundamental mistuning model identification (FMM ID). It will be shown that TAF shows variability between each method providing indications TAF may not be the best approach of force amplification predictions. Basic mistuning agreements exist when isolating blades both experimentally and analytically exhibiting as-manufactured models are capable of representing full experiments. System ID methods provide a basic agreement between both the mistuning pattern and the mistuning amplification for all three methods analyzed. This ultimately shows the importance and the ability to use as-manufactured models to help increase detailed understanding of IBR's.

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Figures

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Fig. 6

First bend EO4 RIG NSMS response

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Fig. 5

PBS R4 compressor rig

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Fig. 2

PBS R4 Campbell diagram

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Fig. 1

PBS R4 stage schematic

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Fig. 4

First bend EO4 TWE response

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Fig. 7

Mesh morphing process: (a) premesh morphing and (b) postmesh morphing

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Fig. 8

PBS R4 mode shapes (tuned: left, mistuned: right)

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Fig. 9

First bend EO4 as-manufactured FEM response: (a) stationary TWE FEM with TWE damping ratio and (b) rotating compressor RIG FEM with RIG damping ratio

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Fig. 11

PBS R4 isolated blade ping testing

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Fig. 12

Individual blade response isolated blade

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Fig. 13

Nodal diameter map

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Fig. 10

Example tuned absorber factor

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Fig. 14

Maximum TAF comparison

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Fig. 15

Isolated blades sector mistuning: (a) first bend (EO3), (b) first bend (EO4), (c) second bend (EO7), and (d) first torsion (EO7)

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Fig. 17

Second bend actual versus predicted sector mistuning (%): (a) TWE versus GMM TWE, (b) TWE versus RIG, (c) RIG versus GMM TWE, and (d) RIG versus GMM RIG

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Fig. 16

FMM ID nonisolated blades sector mistuning: (a) first bend (EO3), (b) first bend (EO4), (c) second bend (EO7), and (d) first torsion (EO7)

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Fig. 18

First bend EO4 predicted mistuning amplification: (a) TWE, (b) RIG, (c) GMM TWE, and (d) GMM RIG

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Fig. 19

Maximum mistuning amplification comparison

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