Analysis and Optimization of a Hybrid Fan Blade

28.04.2006

Analysis and Optimization of a Hybrid Fan BladePermas Users´ Conference

27.04.06 – 28.04.06 Strassbourg

DLR German Aerospace Center, StuttgartInstitute of Structures and Design

J. Ehrmanntraut, F. Kocian, V. Plevnik, T. Schmidt, D. Schwinn

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 228.04.2006

Topics

• Single spool LPC (Low Pressure Compressor) based on EJ200 turbo jet engine

• Mass reduction in first stage by implementation of CFRP (Carbon Fibre Reinforced Plastics)

• FEM modelling and structural analysis of a hybrid blade

• Modification of dynamic response of a titanium blade by topologyoptimization

• Introduction of a new monolithic stacked rotor

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 328.04.2006

LPC Low Pressure Compressor (EJ200 Turbo Jet Engine)

Titanium BLISK

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 428.04.2006

Hybrid Blade

• Titanium in the front region due to erosion and foreign object damage

• CFRP (Carbon Fibre Reinforced Plastics) in the rear region for mass reduction (CF-PEEK Prepreg)

• ± 45° and 0° lay-up optimized for torsion and bending stiffness

• Consolidation of CFRP and joining to the titanium in one process step

Target: mass reduction

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 528.04.2006

Hybrid BladeAsymmetric Double Lap Shear Joint

suction side view

CFRP part

titanium part

joining area

pressure side view

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 628.04.2006

FEM Model:• Blade:

- 2746 HEXE8, 287 QUAD4, 782 SHELL4 elements- 25 properties

• Disc: - 6334 HEXE8 elements

• Material : - Ti64, CF-PEEK (based on unidirectional thermoplastic

prepreg)• Loading:

- inertial rotation, aerodynamic pressure, temperature load• Cyclic symmetry by MPC JOIN• Blade/disc joint by MPC ISURFACE

Hybrid Blisk: Pressure Side ViewAA

Suppressed DOF 2,3 (cyl. coor. system)

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 728.04.2006

Approach for QUAD4 (Ti) - SHELL4 (CFRP) Coupling in Double Lap Shear Joint Region

• Different deformation mechanisms of isotropic and orthotropic materials by transverse loading

• Dominance of bending deformation in titanium and shear deformation in CFRP leads to different rotation at element nodes

• Incorrect increase of stiffness by coupling of all DOFs=> MPC RIGID only DOFs 1,2,3

• Separation of element reference and laminate middle surface in SHELL4 elementsby

• Using forces on dependent nodesfor further evaluation of joining area

Titanium

CFRP

Titanium

CFRP

1=ξ

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 828.04.2006

Hybrid Blade: Meshing of Double Lap Shear Joint Region

1ξ =

HEXE8

QUAD4

SHELL4

outer ply (first ply in stacking sequence)

MPC RIGID (1,2,3)

MPC ILIN2 (1,2,3) MPC VST (1,2,3,4,5,6)

MPC RIGID (1,2,3)

Section AA (scaled)

pressure side

suction side

1ξ =

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 928.04.2006

Stress Distribution in Double Lap Shear Joint Region

A1

A3A2

A4

force on dependent node

F

normal vector n1

F1j out of planeF1j

F1j in plane

1

4

11

1

1

4

11

1

11

4

1

)()(;

)()(

;

A

planeinFshear

A

planeofoutFpeel

AAFFAA

jj

jj

ji

i

∑∑

∑

==

≤

=

==

⋅==

τσ

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1028.04.2006

1. HEXE8 elements in the front titanium region2. QUAD4 elements for titanium in joining area3. SHELL4 elements for CFRP4. HEXE8 - QUAD4 transition by MPC VST and MPC ILIN25. QUAD4 - SHELL4 coupling in joining area by MPC RIGID (1,2,3)6. Evaluation of forces on dependent nodes for stress calculation in the joining area 7. Conversion of forces on dependent nodes to element forces8. Splitting of element forces in “in plane” and “out of plane”9. Calculation of peeling and shear stresses

Summary for FEM Modelling of Hybrid Joints

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1128.04.2006

• nonlinear analysis• inertial rotation, • aerodynamic pressure• temperature load

“continuous” v. Mises stress distribution in the volume/shell region

Hybrid Blisk: V. Mises Stress Distribution in Titanium Part [MPa]

suction side pressure side

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1228.04.2006

nonlinear analysis, inertial rotation, aerodynamic pressure and temperature load

pressure side suction side

Peeling Stress Distribution in Double Lap Shear Joint Region

4.18 [MPa] 2.63 [MPa]

-1.79 -1.77

maximum 4.18 MPa

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1328.04.2006

Shear Stress Distribution in Double Lap Shear Joint Region

pressure side suction side

nonlinear analysis, inertial rotation, aerodynamic pressure and temperature load

0.48 0.44

23.0 [MPa] 14.2 [MPa]

maximum 23.0 MPa

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1428.04.2006

maximum approx. 80%

Utilisation Factor in CFRP Region Tsai-Wu Criterion

pressure side suction side

nonlinear analysis, inertial rotation, aerodynamic pressure and temperature load

1.0 1.0

0.0 0.0

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1528.04.2006

Hybrid Blade:Campbell-Diagram

• Vibration analysis• Consideration of nonlinear effects caused

by inertial rotation, aerodynamic pressure and temperature load

1C1T

1F 2F

deformation magnitude

Campbell Diagram BLISK17 hybrid

60% Nn 100% Nn43% Nn

EO 1

EO 2

EO 3

EO 4

EO 5

EO 53

1F

2F

1T

1C

2C

0

500

1000

1500

2000

0 50 100 150 200

Shaft speed rot/s

Freq

uenc

y H

z

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1628.04.2006

Topics

Single spool LPC (Low Pressure Compressor) based on EJ200 turbo jet engine

Mass reduction in first stage by implementation of CFRP (Carbon Fibre Reinforced Plastics)

FEM modelling and structural analysis of a hybrid blade

• Modification of dynamic response of a titanium blade by topologyoptimization

• Introduction of a new monolithic stacked rotor

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1728.04.2006

FEM Model:• Blade:

- 15008 elements (HEXE8)• Disk:

- 21528 elements (HEXE8)• Material : Ti64• Loading:

- inertial rotation, aerodynamic pressure, temperature load

• Cyclic symmetry by MPC JOIN• Blade/disc joint by MPC ISURFACE

Modification of Dynamic Eigenfrequencies of Titanium Blade using Topology Optimization

Suppressed DOF 2,3 (cyl. coor. system)

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1828.04.2006

Campbell Diagram C03i4_h23_ti_cold

EO 1

EO 2

EO 3

EO 4

EO 5

70% Nn ADP 110% NnEO 53

1F

2F

1T

0

500

1000

1500

2000

2500

0 50 100 150 200 250Shaft speed rot/s

Freq

uenc

y Hz

• Vibration analysis• Consideration of nonlinear effects

caused by inertial rotation, aerodynamic pressure and temperature load

• Interaction between second flexural and first torsion mode in the whole operating range (risk of twist bend coupling)

Titanium Blade:Campbell Diagram

2F 1T

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 1928.04.2006

Modification of Dynamic Eigenfrequenciesof Titanium Blade using Topology Optimization

• Design elements (DHEXE8) with variable filling ratio (density, stiffness) in the inner part of titanium blade

• Definition of design objective function by $DCFUNCTION: [ f(1T) – f(2F) ] => AbsMax

• Combination of vibration analysis with TOPO• Analysis of results and modification of the inner part of

the titanium blade by deleting FEM-elements with negligible filling ratio

• Verification of topology optimization results by a vibration analysis

design region

outer blade elements not

shown

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 2028.04.2006

filling ratio f after 30 iterations,convergence achieved

deleting of FEM elements with negligible filling ration in the top blade region

Modification of Dynamic Eigenfrequenciesof Titanium Blade using Topology Optimization

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 2128.04.2006

Separation of second flexural and first torsion mode in the whole operating range !

Campbell Diagram C03i4_h23_ti_topo_1

EO 1

EO 2

EO 3

EO 4

EO 5

70% Nn ADP 110% NnEO 53

1F

2F

1T

0

500

1000

1500

2000

2500

0 50 100 150 200 250Shaft speed rot/s

Freq

uenc

y Hz

Optimized Titanium Blade:Campbell Diagram

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 2228.04.2006

Realization Concept of Optimized Rotor:Monolithic Stacked Rotor

• Repair of the rotor by replacing any planar discs

• Joining of the planar discs by brazing or welding

• Combination of different materials to hybrid structures

• Implementation of damping mechanisms

• Several planar discs building the whole rotor• Each planar disc is sustainable of its own• Accessibility allows any cavities in blades and

discs

Computer Supported Component Design Permas Users´ Conference 2006 J. Ehrmanntraut foil 2328.04.2006

Conclusion:

• Simple approach for modelling of hybrid joints leads to good results• Approach for QUAD4 (Ti) - SHELL4 (CFRP) coupling applicable to

similar joining structures • Successful verification of approach for QUAD4 (Ti) - SHELL4 (CFRP)

coupling by simple test specimens• Dynamic eigenfrequencies separation of titanium blade achieved by

topology optimization

28.04.2006

Thank you for your attention