Joints - Rolls-Royce Perspective
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1 Joints - Rolls-Royce Perspective Dr John Schofield / Dr Jeff Green Joints Workshop April Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.
2 Joints in Gas Turbine Fan - dovetail - snubbers Engine Structure - Flanges / spigots - Splines - V-blade 2 Turbine Blades - Dampers / seals - Firtree - Shroud - Lockplate / cover plates Compressor - Rotor dovetails - Stator shrouds Key Damping Stiffness / frequency Stress
3 Whole Engine Issues Whole engine uses a simplified model. Need simplified respresentation of joints. Static loads (thrust / external loads / manoeuvres) Are stiffness effects adequate for tip clearances and load distribution etc? Dynamic Loads Engine/Wing Dynamics (0-10 Hz) Frequency, damping, loads Engine Rotordynamics ( Hz) Frequency, damping, loads Extreme events (eg Fan Blade Off) Simplified Engine Model 3 Example Joint (and simplification)
4 Damping 4 Drive towards prediction of vibration amplitude for design and certification. Structure (known) Force (usually known) Response HCF capability Damping (aero & mechanical) (non-linear) (measured?) Wear / deterioration / contamination
5 Effect of Non-linear Contact on Frequency 5 Dampers can have a significant influence on resonant frequency. Affect on resonant speed Change in force amplitude Gas Turbine Campbell Diagram of HP Turbine M5 With Damper Without Damper Upstream vanes Frequency [Hz] Frequency [Hz] F 1T 1E Downstream vanes No. of Burners F Low engine order High Pressure Turbine Stage Shaft Speed [%]
![M5 With Damper Without Damper Upstream vanes Frequency [Hz] Frequency [Hz] 5000 4000 3000 2000 2F 1T 1E Downstream](/docs-images/46/21233900/images/page_5.jpg "vanes No.")
6 Effect of Joint on Modeshape => Stress 6 Contours of WP Stress At 2F resonance Typical position of strain gauges In engine tests Gauge Position Gauge Sensitivity [Mpa/mm] 1T Mode 2F Mode Undamped No damper With damper Damped
![3 1 2 Gauge Position Gauge Sensitivity [Mpa/mm] 1T Mode 2F Mode 1 579](/docs-images/46/21233900/images/page_6.jpg "779 Undamped 2 156 394 3 731 354 No damper With damper Damped 1 2 348 62")
7 Effect of Shroud Contact on Stator Response 7 Uncertainty about inner shroud restraint => variability in effective stiffness Change of stiffness leads to change in amplitude and frequency. Difficulty interpreting measured results
8 Effect of Shroud Contact on Stator Modes It gets more complicated... 8
9 Structural Integrity Assessment of Fan Dovetail Joints 9 Assessment capabilities enhanced significantly in recent years Steady and vibration stress predictions r 1 based on load extraction from coarse FE model and analytical half-space model. Converged stresses using detailed FE sub-sub modelling. Robustness determined using short crack modelling techniques. Integrity of root managed via use of surface coatings and treatments. More careful design possible. σ bulk M σ punch r P 1 r1 Q σ punch σ bulk
10 Outstanding Issues? Varying (patchy) friction, local wear, effect of local fillet, halfspace assumptions. Longer lasting surface coatings have clear cost benefits. EoB and near edge of bedding locations can be life limiting features. Prediction of stresses near edge of bedding in vibration is problematic. Use of locked contact can be misleading 10 Locked contact during vibration. Stress from fillet and EOB and fillet merge into one stress peak ABAQUS friction analysis shows separation of fillet and EoB stress. Region close to EoB is now showing a much reduced stress.
11 Summary of Needs 11 Damping Stability & Amplitude prediction (including non-linear effects) Friction Properties Validation of System Behaviour Interpretation of measured results (in engine) Rotor dynamics for stability Frequency Effect of blade dampers is already under control Snubbers / Interlocks (mainly for fleet support) Whole engine at high frequencies accessories Stress Edge of bedding stress including steady stress and vibration. Surface treatments, coatings Wear
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