Forced response prediction for industrial gas turbine blades

A highly efficient aeromechanical forced response system is developed for predicting resonant forced vibration of turbomachinery blades with the capabilities of fully 3-D non-linear unsteady aerodynamics, 3-D finite element modal analysis and blade root friction modelling. The complete analysis is performed in the frequency domain using the non linear harmonic method, giving reliable predictions in a fast turnaround time. A robust CFD-FE mesh interface has been produced to cope with differences in mesh geometries, and high mode shape gradients. A new energy method is presented, offering an alternative to the modal equation, providing forced response solutions using arbitrary mode shape scales. The system is demonstrated with detailed a study of the NASA Rotor 67 aero engine fan rotor. Validation of the forced response system is carried out by comparing predicted resonant responses with test data for a 3-stage transonic Siemens industrial compressor. Two fully-coupled forced response methods were developed to simultaneously solve the flow and structural equations within the fluid solver. A novel closed-loop resonance tracking scheme was implemented to overcome the resonant frequency shift in the coupled solutions caused by an added mass effect. An investigation into flow-structure coupling effects shows that the decoupled method can accurately predict resonant vibration with a single solution at the blade natural frequency. Blade root-slot friction damping is predicted using a modal frequency-domain approach by applying linearised contact properties to a finite element model, deriving contact Droperties from an advanced semi-analytical microslip model. An assessment of Coulomb and microslip approaches shows that only the microslip model is suitable for predicting root friction damping.