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Research Papers

Study of Sand Particle Trajectories and Erosion Into the First Compression Stage of a Turbofan

[+] Author and Article Information
Adel Ghenaiet

Laboratory of Thermal Power Systems, Applied Mechanics, EMP, BP17, Bordj el Bahri, 16111 Algiers, Algeriaag1964@yahoo.com

J. Turbomach 134(5), 051025 (May 24, 2012) (17 pages) doi:10.1115/1.4004750 History: Received April 15, 2011; Accepted July 12, 2011; Published May 24, 2012; Online May 24, 2012

Aero-engines operating in dusty environments are subject to ingestion of erodent particles leading to erosion damage of blades and a permanent drop in performance. This work concerns the study of particle dynamics and erosion of the front compression stage of a commercial turbofan. Particle trajectories simulations used a stochastic Lagrangian tracking code that solves the equations of motion separately from the airflow in a stepwise manner, while the tracking of particles in different cells is based on the finite element method. As the locations of impacts and rates of erosion were predicted, the subsequent geometry deteriorations were assessed. The number of particles, sizes, and initial positions were specified conformed to sand particle distribution (MIL-E5007E, 0-1000 micrometers) and concentrations 50–700 mg/m3 . The results show that the IGV blade is mainly eroded over the leading edge and near hub and shroud; also the rotor blade has a noticeable erosion of the leading and trailing edges and a rounding of the blade tip corners, whereas in the diffuser, erosion is shown to spread over the blade surfaces in addition to the leading edge and trailing edge.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

IGV, rotor, and diffuser blades

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Figure 2

CAD of the front compression fan stage

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Figure 3

Computational domains and boundary conditions

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Figure 4

IGV, rotor, and diffuser mid-span grids

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Figure 5

Vectors of flow velocities: (a) mid-span, (b) blade tip, (c) in tip clearance

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Figure 6

Mach number: (a) at mid-span, (b) at tip

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Figure 7

Static pressure at mid-span

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Figure 8

Sample of particle (10 micrometer) trajectories: (a) seeding globally, (b) seeding near shroud

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Figure 9

Sample of particle (250 micrometer) trajectories: (a) seeding globally, (b) seeding near shroud

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Figure 10

Sample of particle impacts on spinner and IGV blade: (a) Impacting particle size (micrometers), (b) impact velocities (m/s), (c) impingement angles (degree), (d) local erosion rates (mg/g)

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Figure 11

Sample of impacts on the rotor blade: (a) Impacting particle size (micrometers), (b) impact velocities (m/s), (c) impingement angles (degree), (d) local erosion rates (mg/g)

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Figure 12

Sample of particle impacts on the diffuser blade: (a) impacting particle size (micrometers), (b) impact velocities (m/s), (c) impingement angles (degree), (d) local erosion rates (mg/g)

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Figure 13

Equivalent erosion rates (mm3 /g/mm2 ) in the spinner and IGV at a concentration (700 mg/m3 ), at takeoff conditions: (a) 1/19 of spinner, (b) pressure side, (c) suction side, (d) shroud, (e) hub

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Figure 14

Equivalent erosion rates (mm3 /g/mm2 ) in the rotor at a concentration (700 mg/m3 ), at takeoff conditions: (a) pressure side, (b) suction side, (c) shroud

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Figure 15

Equivalent erosion rates (mm3 /g/mm2 ) in the diffuser due to sand ingestion (700 mg/m3 ), at takeoff conditions: (a) pressure side, (b) suction side, (c) shroud

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Figure 16

Eroded rotor blade profile after 1 hour of sand ingestion (700 mg/m3 ), at takeoff conditions: (a) tip profile, (b) mid span profile

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Figure 17

Eroded diffuser blade profile after 1 h of sand ingestion (700 mg/m3 ), at takeoff conditions: (a) tip profile, (b) mid span profile

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Figure 18

Erosion in IGV after 1 h of sand ingestion

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Figure 19

Erosion in rotor after 1 h of sand ingestion

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Figure 20

Deterioration in rotor geometry after 1 h of sand ingestion

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Figure 21

Erosion in diffuser after 1 h of sand ingestion

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Figure 22

Deterioration in diffuser geometry after 1 h of sand ingestion

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Figure 23

Photographs of eroded IGV and rotor blades of the tested high speed fan stage [(7),10]: (a) IGV pressure side, (b) rotor pressure side, (c) rotor suction side

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