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GT2010
June 14-18, 2010, Glasgow, UK
GT2010-23302
EVALUATION OF THE ENERGY DISSIPATED AS FRICTION/HEAT BETWEEN
TURBINES FOLLOWING SHAFT FAILURE
I.Rojo, A.Psarra, V.Pachidis, P.Pilidis
Cranfield University
School of Engineering
Dept. of Power and Propulsion
Gas Turbine Engineering Group
Cranfield, Bedfordshire
ABSTRACT
The prevention of primary failure that may lead to a
potentially hazardous event has always been a predominant aim
in engine design and development. In the event of a shaft
failure event, the turbine operates under high power conditions
which may lead to blade release or disc burst. A potential
mechanism to eliminate quickly the power of the free running
turbine involves the dissipation of the kinetic energy as
friction/heat due to structural interaction between turbines.
In the scope of this paper, a finite element model is
developed to study the energy dissipated due to structural
interaction. A coupled thermo-mechanical analysis is carried
out taking into account the temperature increase in the turbines
structure following the severe impact.
The coupled thermo-mechanical analysis addresses the
effects of temperature rise and material softening on the
evolution of the shaft failure event. The part of the kinetic
energy converted into thermal and the wear rate of the seal
segment structure are investigated in order to assess the
potential of the contact mechanisms to act towards reducing the
power of the free running turbine as quickly as possible due to
blade tangling. Finally, the dependency of frictional energy and
wear rate on the structural damping and the definition of the
thermal material model have been studied highlighting their
importance in the impact simulations.
ACRONYMS
EOS
Equation of state
HBR
High bypass ratio
IP
Intermediate pressure
JC
Johnson-Cook material model
LP
Low pressure
NGVs Nozzle guide vanes
SF
Scaling factor
NOMENCLATURE
Italic
Cp
Specific heat capacity
Fn
Load
k
Thermal conductivity
Heat generation rate
Q
q f
q p
p
R
Greek
p
p
p
Pressure
Radius of the disc
Temperature
flow
eff
INTRODUCTION
Nowadays, the development of more advanced gas turbine
engines requires the evaluation of extreme loading conditions
and assessment of possible failure scenarios. A possible failure
scenario that needs to be assessed is the shaft break. The
behavior of a gas turbine following a shaft break is complicated
SIMULATION STRATEGY
In the case of an IP shaft failure of a HBR turbofan
engine, the free running turbine can move rearwards if there is
no restriction from the arrangement of the shaft support
bearings. This downstream movement of the IP turbine is
mainly caused by a gas load on the surface of the blades
derived from the gas pressure differences in the main gas path.
During the evolution of the event, an additional but opposite
gas load is applied on the disc due to the pressure in the LPT
cavity forcing the turbine rotor towards the opposite direction.
Both of these time dependent axial loads are responsible for the
downstream dislocation of the IPT rotor.
As it is indicated in figure 1a, the first material
interaction will take place between the lock-plate of the rotor
disc and the seal segment and NGVs platform after the axial
dislocation of the turbine rotor. Due to the high axial loads
applied on the IPT, the material interaction of the disc and the
seal segment and platform is so severe, that after a few
milliseconds the surfaces of all involved structures are expected
to melt away leading to a further dislocation of the IPT and the
occurrence of blade tangling. Blade tangling may be used as a
potential mechanism to limit the terminal speed attained by the
rotor to an acceptable value. This is an outcome of an
increasing frictional energy between rotors and stators.
However, the blade tangling will take place after the melting of
parts of the platform and seal segment. Therefore, to investigate
the structural interaction event using FE, it is significant to
simulate initially the contact between the lower parts of rotors
and stators focusing on the interaction between lock-plate and
seal segment and, in a further step, study the blade tangling.
A structural model of the disc/lock-plate seal
segment/ platform based on the geometry of a typical turbofan
engine is depicted in figure 1b. This analytical model has been
used in [11] [12] in order to explore the finite element codes
ability to capture the frictional wear. The extensive parametric
analysis study presented in [11] [12] assisted in finalizing the
modelling approach of the impact based on a FE model without
including thermal effects.
Although, the high fidelity model and the parametric
studies gave a better understanding of the impact phenomenon,
they also underlined the importance of a coupled thermalmechanical analysis. When structures manufactured out of
nickel alloys come in contact under high load and speed
conditions, they are expected to generate heat and dissipate it
between the contact interfaces by increasing material
temperature. In addition to mechanical analysis, coupled
thermal mechanical analysis has the potential to simulate
conditions with heat generation from interface friction and
plastic work and provide the temperature distribution on every
element based on geometry. The main restriction of this
analysis is indentified in the demand of high computation
power and time. Therefore, a simplified structure shown in
Figure 1c has been used to carry out a thermal-mechanical
coupled analysis. This model is based on the geometric
characteristics of a notional 3D structure; however the seal
segment is modified to exclude from calculations any sharp
edges while the structure of the platform is not included either
since it impacts on the lock-plate only when a considerable
amount of material has melted away from the seal segment.
This paper provides an analytical description of the
finite element model used to investigate the first contact
interaction between the IP turbine and the first row of the LP
NGVs, and presents results of the impact and the response of
the model under certain boundary conditions. Its contribution
enfolds the effect of modeling parameters on the behavior of
JC material model
NGV platform
rigid structure
IPT lock-plate
Seal segment
Figure 1 a. Schematic of the IPT and the surrounding static structure, b. High fidelity structure of disc/lock-plate seal
segment/ platform c. Simplified model of coupled thermal mechanical analysis
the model, the physics behind the element erosion and the
frictional heat generation.
FINITE ELEMENT MODEL
Since the first contact interaction occurs between the lockplate of the disc and the seal segment, it is significant firstly to
define this interaction before including the structure of the
blades and vanes. The analytical geometry of the impact
between lower parts of IP turbine and the downstream
stationary structure, geometry of which is showed in Figure 1b,
has been used to study the impact without thermal effects.
However, as it is aforementioned, in order to simplify the
analysis and reduce the computational power in the coupled
thermo-mechanical analysis and the cost of the impact
simulations, the detailed model is substituted by the simplified
version of the Figure 1c.
The structures of the lock-plate and seal segment are both
considered to be made of INCONEL 718. Details of the finite
element modeling of the disc and lock-plate and the seal
segment structure of the stationary arrangement are described
below.
Finite element mesh
The mesh size is important for every FEA simulation. If
the mesh is too coarse, too many elements experience severe
distortion due to high hourglass energy. On the contrary, if the
mesh is too fine the computational time increases significantly
without improving the results. However, it is a requirement to
define a fine mesh able to capture the dynamics of the impact
phenomenon.
In order to achieve a considerable reduction in
computational time without affecting the results, areas coming
in contact are modelled as deformable bodies, while the rest of
the structure is considered to be rigid (Figure 1c). The high
quality meshing of the structures is achieved employing eightnode hexahedron elements. The numbers of elements involved
in the simulation are shown in the following table:
flow ( A B
pn
) 1 C n * 1 T *m
(1)
T Troom
Tmelt Troom
(2)
p
f
(3)
Table 2 JC and polynomial equation of state model constants for INCONEL 718[3][13][14]
Mechanical
Density
Youngs Modulus
Yield strength
Hardening Modulus
Properties
Poissons ratio
3]
[kg/m
[Pa]
[Pa]
[Pa]
at 650 OC
8220
1.689e+11
0.28
9.80e+8
8.774e+9
Strength
A [Pa]
B [Pa]
n
C
m
Constants
1.150e+9
1.305e+9
0.6
0.0075
1.3
Fracture
D1
D2
D3
D4
D5
Constants
-0.0134
0.0255
0.3
0.07
2.5
Polynomial
C0
C1
EOS constants
0
1.68e+11
in which the strain at fracture is calculated according to the
following equation:
f D1 D2 exp D3 * 1 D4 n * 1 D5 T * (4)
and the
* p / eff is the
is applied to simulate the effect of both the gas flow and the air
stored in the secondary air system. Due to the absence of the
structure of the disc bore for decreasing computational time, it
is essential to scale down both applied loads taking into account
the inertia and mass of the disc in the model.
Finally, a ring-like structure around the simplified seal
segment avoids any translation and rotation of the structure. A
part of this structure is considered as deformable in order not to
have an excessively stiff structure, while the lower is rigid to
avoid any translation or rotation of the stationary structure.
Contact Algorithm
The contact between the lock-plate and the seal
segment is modeled using a 3D automatic contact algorithm
with thermal option. The lock-plate counterfaces are designed
as the master entity while the seal segment counterfaces are
defined as the slave entities for the numerical contact.
Temperature
(K)
Thermal Conductivity
(W/m K)
Heat Capacity
(J/kg K)
373
573
773
973
1173
1373
1503
2500
15.4
19.1
21
24.8
28.5
32
33.78
38.8
471
525
578
631
684
738
773
840
Thermo-mechanical Calculations
The friction and the plastic deformation generate heat
and elevate the temperature of both structures coming into
contact. The thermo-mechanical
mechanical coupling involves the
interactionn between wear, friction, temperature and plasticity.
The heat generated by friction and plastic work for the current
geometry acts as a source for the thermal analysis. The
corresponding thermal softening and the mass loss due to wear
has an influence in the mechanical analysis.. Therefore, for a
given sliding geometry, the wear is dependent on the force
acting on the sliding surfaces, their relative velocity, their initial
temperature and the thermo-mechanical
mechanical properties of the
material. [19]
During the mass loss process, an essential amount of
heat may be generatedd as a result of plastic deformation
deformation. The
heat generation due to plastic deformation is:
q p
(5)
q f 2 R Fn
Q q f q p
3.00E-03
2.50E-03
2.00E-03
1.50E-03
1.00E-03
5.00E-04
0.00E+00
0
(6)
IMPACT RESULTS
After the analytical description of the model, tthis
section is devoted to the results of the FE simulations
simulations. In the
couple thermo-mechanical analysis,, a great number of
parameters
rameters are involved in the definition of the FE model.
Thus, it is essential to find a balance between the complexity of
the FEA model and the requirements of the impact problem.
The simplified model is an appropriate example to carry out the
3.50E-03
displacement
[m]
diplacement (m)
20
40
60
80
100
% of simulation time
constant k,Cp
45000
Eroded mass %
98
96
94
92
90
40000
35000
30000
25000
20000
15000
10000
5000
0
88
0
20
40
60
80
100
20
40
60
80
100
% of simulation time
% of simulation time
50000
100
45000
98
40000
96
Eroded mass %
50000
100
35000
30000
25000
20000
15000
10000
94
92
90
88
86
84
82
5000
80
0
0
20
40
60
80
100
20
40
60
80
100
% of simulation time
% of simulation time
Temperature [K]
constant k and Cp
1100
1050
1000
950
900
850
800
750
700
650
600
1st row of
elements
2nd row of
elements
3rd row of
elements
4th row of
elements