Analytical Estimation of Microslip Damping in Bladed Disks

Analytical Estimation of Microslip
Damping in Bladed-Disks
J.S. Rao
Chief Science Officer, Altair Engineering
Mercury 2B Block, 5th Floor, Prestige Tech Park, Sarjapur Marathahalli
Outer Ring Road, Bangalore, Karnataka, 560103, India
js.rao@altair.com

Rejin Ratnakar
Altair Engineering
rejjnratnakar@altair.com

R. Narayan
Altair Engineering
narayanrangarajan@altair.com

www.altairproductdesign.com
copyright Altair Engineering, Inc. 2011

Copyright Altair Engineering, Inc., 2011 2
Abstract

Most usually damping in a blade is attributed to material and friction damping. Friction
damping can be either due to Macroslip obeying Coulomb laws of friction or Microslip (also
called Fretting Fatigue) which occurs at high critical speeds with tight blade-disk junctions due
to heavy centrifugal loads. This paper is concerned with microslip damping which is
conventionally determined through tests.

Oloffson and Hagman developed a theoretical model for micro-slip between flat surfaces
based on deformation of ellipsoidal elastic asperities and this model is verified experimentally
in Hitachi laboratory. In this paper Oloffson-Hagman microslip damping model is adopted to
determine analytically an effective friction coefficient which is a function of the tangential and
normal forces at the slipping surface junction, tangential contact stiffness and slip amplitude at
a resonance. Here an iterative method is developed to determine the microslip damping
coefficient.

Introduction

Turbine blades have very little damping and therefore when they go through a resonance at
critical speed, the stresses can easily get magnified by 100 times or even higher of steady
stress. These very high resonant stresses are responsible for fatigue damage. Therefore,
Damping has been identified long ago as a key parameter in blade design. Rowett (1914)
conducted tests on elastic hysteresis in steel. Effects of friction and loose mounting were
studied by Hansen et al. (1953).

Lazan (1968), also see Nashif, Jones and Henderson (1986), measured hysteresis in tension
tests and defined the loss of energy per cycle by a simple relation.

A nonlinear damping model was quantified through experiments by Rao, Gupta and Vyas
(1986); the equivalent viscous damping is expressed as a function of strain amplitude at a
reference point in a given mode of vibration at a given speed of rotation.

Centrifugal load is simulated by means of thermal expansion to avoid rotation and simplify the
test rigs. Rieger and Beck (1980) performed such tests for EPRI. Rao, Usmani and
Ramakrishnan (1990) presented a finite element method to study the friction damping
between blade root and disk by using contact elements. They have also designed and built a
test rig simulating the centrifugal load by means of cryogenic liquid cooling on a blade pair
mounted in the frame contracted by thermal cooling.

Rao and Saldanha (2003) developed an analytical procedure using Lazans hysteresis law
(1968) to obtain a nonlinear relationship as observed in experiments of Rao, Gupta and Vyas
(1986). Friction damping characteristic is obtained by determining the transient response due
to an impulse excitation at a suitable point on the blade to simulate the desired mode of
vibration and assessing the decay curve. Coulombs friction law is used assuming that
macroslip occurs between the blade and disk interfaces.

Rao, Narayan and Ranjith (2008) developed process driven approach to incorporate material
damping in determining an equivalent viscous damping ratio as a function of reference strain

amplitude in the chosen mode of vibration to perform life estimation. Rao, Narayan, Ranjith,
and Rejin (2008), determined the material damping and combined material friction damping of
a bladed disk in estimating blade life. A code TurboManager is developed to run on
HyperWorks platform.

The response strain amplitudes decrease considerably as the speeds go up when the blade
and disk get locked in the root. Because of the tightness at high speeds, slip amplitudes get
reduced and the friction is governed by contacts at asperity level rather than global Coulombs
laws. This microslip is important from the point of fretting fatigue that is commonly observed in
turbomachine blades, see Fig. 1.

Fig. 1 Fretting Fatigue due to Micro-Slip

Burdekin, Cowley and Back (1978) proposed a theoretical model for micro-slip based on
reasonable physical properties, assuming that the contacting asperities are substituted by
prismatic rods of equal stiffness. Hagman (1993) proposed a theoretical model with contacting
asperities replaced by spherical bodies of constant radius. Olofsson (1995) and Olofsson and
Hagman (1997) expanded this model to include oscillating displacements and elliptical shaped
asperities.

In this paper, Olofsson and Hagman model is used in developing an analytical procedure for
determining the effective friction between blade and disk interfaces under microslip conditions.

Nomenclature

A apparent area of contact
a, b semi-axes in x and y directions
C surface parameter
c major semi-axis
d
slip
slip displacement
d
stick
stick displacement
d
total
total slip and stick displacement
E composite modulus of elasticity given by
2
2
2
1
2
1
1 1
'
1
E E E
v v
+
=
F friction load

F
t
tangential (friction) load
F
n
normal load
F
*
initially applied load
G composite shear modulus given by
2
2
1
1
2 2
'
1
G G G
v v
+
=
k ovality ratio a/b, a<b and b/a, b<a.
K
t
shear (tangential) stiffness
K
tc
tangential contact stiffness
K
tc,im
imaginary tangential contact stiffness
N number of asperities in contact
n exponent in friction equation
P normal load
P
i
normal load for an asperity at depth z
i

R curvature sum of elliptical contact
y x
r r R
2 2
1 1 1
+ =
r radius of curvature
z
i
depth of an asperity
o displacement
k,c complete elliptic integrals of the first and second
kind with argument
2
1 k e =
| see equation (6)
normal approach or penetration
friction coefficient
v Poissons ratio

OLOFSSON AND HAGMAN MODEL

Olofsson and Hagman (1997) considered a flat smooth surface in contact with a rough flat
surface shown in Fig. 2. The frictional load is parallel to x axis.

Fig. 2 Flat Surface in Contact with Rough Surface



Fig. 3 Schematic of Contact

The following assumptions are made:
1. Shape of asperities is ellipsoidal
2. Height distribution of asperities is uniform
3. Surface contact is elastic and the behavior of an individual asperity follows Hertz
theory for elliptical contacts.
4. All asperities have their semi-axes a and b in the same global x- and y- directions,
respectively
5. Contacting asperities have the same constant ovality ratio k = a/b, a<b and k = b/a, b<a.

The surface is brought into contact with a normal approach , see Fig. 2. The normal load, P
i
,
for an asperity at depth z
i
and the major semi-axis c for that asperity is expressed as:

2
3
2
1
2
9
' 2
|
.
|
\
|
|
.
|
\
|
=
k
c
t
i
i
z
R
k
E
P
(1)

3
1
2
'
3
|
.
|
\
|
=
E k
R P
c
i
t
c

(2)

The number of asperities in contact, N, is assumed to increase linearly with the approach of
the two surfaces. Thus

Cz N =
(3)

where C is a surface parameter which relates the number of contacts per unit area and z the
approach of the surfaces. The normal load for the approach can be expressed as


2
5
2
1
0
2
9
5
' 4
|
.
|
\
|
|
.
|
\
|
= =
}
k
c
kt
R
k
E CA
dz P CA P
i

(4)

Deresiewicz (1957) expressed the force-displacement relationship for an individual asperity, i,
as

(5)

(6)

F
i
will deflect upto F
i
= P
i
. Equation (5) gives the limit deflection o
Li

| t
o
'
' 8
E
G
z
Li
=
(8)

The total frictional load becomes

} }
+ = + =

Li
Li
z
i
z
i
CAdz P CAdz F F F F
0
slip spring

(9)

where F
spring
is the frictional load from the active asperities which have not reached their
limiting tangential deflection and F
slip
is the contribution from asperities which have reached
their limiting tangential deflection.

The total frictional load is obtained from using equations (1), (5) and (8) in equation (9)

|
|
|
|
.
|
\
|
|
|
.
|
\
|
=
2
5
'
3
16
1 1
|
o
d
i
i i
P
cG
P F
( )
( )
a b
e e
b a
e e
<
(
|
.
|
\
|
+
(
=
<
(
+ |
.
|
\
|

(
=
, 1
2
4
, 1
2
4
2
2
2
2
2
2
2
2
2
2
2
c v
k
v
v
v t
|
c v
k
v
v t
|

(
(
(
|
|
.
|
\
|
=
(
(
(
|
|
.
|
\
|

|
.
|
\
|
|
.
|
\
|
=
2
5
2
5
2
5
2
1
'
' 8
1 1
'
' 8
2
9
'
5
4
| t
ok
| t
o
k
c
t
k
E
G
P
E
G
R
k
E
CA F

(10)

The above is valid until

(11)

Suppose that after reaching a value F*, the frictional load F is reduced; the force displacement
relationship under unloading for an individual asperity i can be expressed as, see Fig. 4.

(
(
(
|
|
.
|
\
|
=
2
3
3 2
' 16
1 1 2
|
o
i
di
i di
P
cG
P F
(12)

Fig. 4 Frictional Load vs. Displacement for an Individual Ellipsoidal Body

Corresponding limit deflection for unloading is twice that for loading. The maximum height of
the asperities z
dli
for which they will slip is

' 8
'
max
G
E
k
| t
o =

| t
o
'
' 4
E
G
z
dLi
=
(13)

The sense of slip must be reversed, see Mindlin and Deresiewicz (1953) but its absolute
magnitude is not altered during unloading. Then the slip part of the tangential load during
unloading is twice that for loading. The equation for the frictional load during unloading is

(
(
(
|
|
.
|
\
|
=
+ =
} }
2
5
0
'
' 4
1 1 2
2
| t
k o
E
G
P
CAdz P CAdz F F
d
z
i
z
di d
dLi
dLi

(14)

where o
d
is the reduction in the initially loaded displacement, o
*
, and F
d
is the reduction in the
initially applied load, F
*
.

The equation for frictional load transformed to the original co-ordinate system is

( )
(
(
(
|
|
.
|
\
|
=
2
5
*
*
'
' 4
1 1 2
| t
o o k
E
G
P F F
r

(15)

Suppose now that the frictional load is oscillating between F
*
and F
*.
The situation at F = F
*

is identical with that at F = F
*
, except for the reversal of sign. Hence the frictional load then
becomes
( )
( )
(
(
(
|
|
.
|
\
| +
+ = =
2
5
*
*
'
' 4
1 1 2
| t
o o k
o
E
G
P F F F
r s

(16)

The area enclosed by the curves F
s
and F
r
gives the energy dissipation during micro-slip per
cycle. Integration gives the energy dissipation, W as


( )
(
(
(
(
(
(
(
(

|
|
|
|
.
|
\
|

|
.
|
\
|
|
.
|
\
|
+
= =
}
* *
2
2
7
*
2
5
2
*
*
*
7
' 2
'
'
' 8 '
' 2
'
14
7
4
o
k
| t
| t
o |
k
t
k
| t
o
o
o
o
F
G
E P
E
G E
G
E P
P
d F F W
r s

Now consider when | = 1, a = b (asperities modeled as spheres, then k = c = t, equations
(10), (14) and (17) become

(10a)

(
(
(
|
|
.
|
\
|
=
2
5
'
' 2
1 1 2

o
E
G
P F
d
d

(14a)
( )
(
(
(
(
(

+
=
* *
2
2
7
*
2
5
2
5
2
3
*
7
'
'
' 4 '
' '
14
7
4
o

o

o
F
G
E
G E
G E
P
P
W
(17a)

These are same as Hagman (1993) and Olofsson (1995) for the case where the asperities are
replaced with spheres.

MARQUINA MODEL

For blade-disk junction case, Marquina et al (2008) adopted the above Olofsson and
Hagmans micro-slip model into their approach. First the Shear (tangential) stiffness is
obtained from equation (10a) written as

(
(
|
|
.
|
\
|
=
n
N t
E
G
F F

o
'
' 4
1 1
(
(
(
|
|
.
|
\
|
=
2
5
'
' 4
1 1

o
E
G
P F

(18)

1
'
' 4
1
'
' 4

|
|
.
|
\
|
= =
n
N t
t
E
G
E
nG F
d
dF
K

o
o

(19)

Limiting o to
' 4
'
max
G
E
o = the above equation (18) is simplified to give
(
(
(
|
|
.
|
\
|
=
2
5
1 1
N
t
N t
nF
K
F F
(20)

Multiharmonic balance-based prediction is used to obtain displacement results in the
frequency domain for non-linear analysis involving friction.

ASAI FORMULATION

Here the formulation is slightly different made in such a way to verify Olofssons formulation for blades.
Their microslip damping model of two surfaces under contact with F
t
and F
n
as tangential and normal
forces is given in Fig. 5, see Asai et al (2009); the tangential contact stiffness is

stick
t
tc
d
F
K =
(21)

For the linear model without hysteresis, the material property is Imaginary Tangential Contact
Stiffness K
tc,im
given by
total
t
im tc
d
F
K =
,

(22)

In Fig. 5, the total displacement is stick and slip as shown and given by

slip
tc
t
slip stick total
d
K
F
d d d
+ =
+ =

(23)

If o
slip
is the displacement due to the normal force F
n
(slip per unit normal force) and tangential
stiffness k
tc
, we define a parameter
slip
slip
n
tc slip
d
F
K d
o
=
(24)


Fig. 5 Micro-Slip Damping Model

Under constant normal load, as the displacements are increasing in Oloffsons oscillating
displacements model, the asperities are replaced by spheres with the same radius. It is
assumed that the height distribution of the asperities is uniform and the behavior of an
individual asperity follows Hertz theory. The resulting contact model is
(
(
|
|
.
|
\
|
=
n
n
total tc
n
t
nmF
d K
m
F
F
1 1
(25)

where n and m are constants. Using (23) the above becomes

(
(
|
|
.
|
\
|
=
n
n
tc slip
n
t
n
t
F
K d
F
F
nm
m
F
F 1
1 1
(26)

Asai et al (2009) verified the above experimentally for the parameter
n
tc slip
F
K d
as shown in Fig.
6 for three different test specimens. Microslip occurs for large values of F
n
(F
t
< F
n
) as shown
and d
slip
values are in the range of 0.1 to 5 microns. m and n are obtained from the mean curve
of experimental results.


Fig. 6 Asai et al (2009) Experimental Result for Microslip

Asais experiments have shown that Hagman and Olofsson elasto-plastic theory of contact
provides a workable model for blades given by (10a). The problem however is not simple and
highly nonlinear.

MODEL IN THE PRESENT STUDY

A simple rectangular blade (Sandvik O&T steel) 5 cm by 1 cm with a T root shown in Fig. 7 is
considered for the study. The blade length is 30 cm. The contact surfaces on either side are 5 cm by 1
cm. The disk is taken to be 14 cm long and 25 cm wide with 1 cm thickness for the purpose of modeling
and the contact surfaces are 4 cm from the top of the disk. The blade root is taken as 15 cm by 5 cm.
The blade and its root are modeled using 606 SOLID 45 elements. The interfacial surfaces between the
blade root and disk are modeled as, 20 CONTACT 173 and 20 TARGET 170 contact elements with
numbers as shown in Fig. 8.
The material density is 7800 kg/m
3
. The elastic modulus is taken as 210 GPa. The blade rotates at
20000 RPM.
m = 0.9, n = 2.5


Fig. 7 Blade-Disk Model

Macro-friction study was made for this model using Coulombs friction coefficient = 0.4 by Rao
and Saldanha (2003). This analysis was done by giving an impact load to determine the decay
curve at a given natural frequency for a given critical speed. From this decay curve the
nonlinear model for equivalent viscous damping as a function of reference strain amplitude in
a given mode of vibration at a given speed of operation is obtained.

Blade
Disc
Contact elements


(a) Contact Elements

(b) Left Side Contact Elements

(c) Right Side Contact Elements
Fig. 8 Contact Elements with Numbers

ANALYSIS AND ITERATIVE SOLUTION

Here Olofssons relation is written as
(
(
(
(
|
|
.
|
\
|
=
2
5
'
' 4
1 1

o
E
i
G
i
n
F
t
F

(27)

The friction coefficient is denoted instantaneous value with a subscript i which will vary during
iteration process proposed here. The first thing we notice that the following condition should
be satisfied
0
'
' 4
1 >

o
E
G
i

(28)

for microslip conditions to exist. If equation (28) is not satisfied, the friction follows global
conditions. First a check is made whether micro-slip according to Olofssons relation occurs by
checking 1
'
' 4
<

o
E
G
i

From the above we see that microslip occurs for lower values of
o
. The three quantities,
o, and are dependent on each other.


1. Larger value of is conducive for microslip and the penetration is higher with high
speeds (or high normal loads). This is why we have macroslip at low speeds when the
two interfacial surfaces are well separated beyond asperity level. At high speeds,
microslip can only occur with the two surfaces closer at asperity level.
2. The ratio
o
should be lower that can be conducive for microslip conditions to occur.

Nonlinear Steady Centrifugal Analysis: To get a feel of macroslip and microslip regimes, a
nonlinear steady state analysis for different rotational speeds (i.e., penetration ) and friction
coefficients is performed. The material data is

v
xy
= 0.3
E = 210 GPa
E = 115GPa
G = 80.7 GPa
G = 23.7 GPa

Using the resulting tangential displacement o the parameter

o
'
' 4
1
E
i
G
in equation (27) is
plotted in Fig. 9 as a function of rotational speed and friction coefficient.

Fig. 9 Macro and Micro Slip Regions

Microslip regime is denoted by green and macroslip regime in red color.

For an oscillating case, the o
slip
values depend on excitation on the blade.

Blade under Excitation: For the present problem, the blade is excited by a 1 sinusoidal force
with a pressure distributed on the blade surface as shown in Fig. 10. The model was
constrained at hub.

Material data is given individually to each element as micro-slip conditions are checked for all
slipping surfaces.


Because it is a nonlinear problem a transient analysis is performed to determine the slip
displacement o and penetration after reaching steady state conditions.

Fig. 10 Pressure Loads in Pa

To determine penetration augmented Lagrangian algorithm approach developed by
Zavarise, Wriggers and Schrefler (1995) in Ansys is used. This method combines a
micromechanical approach that takes the real stiffness of the asperities into account, with a
mean surface concept. The advantage in this method is in avoiding any numerical ill-
conditioning as in Penalty Method.

To begin with a global friction value can be used; in this case 0.8 was used as initial value.

Macros were developed in Ansys to perform the iterations automatically. This iteration gets
activated only when Olofssons condition is satisfied at each step. The time step used in
transient solution is 0.0002 sec.

The iterations are stopped once there is a convergency on the slip displacement.

RESULTS

All the elements are found to have microslip conditions. Two outer elements on the right side
contact surface are considered here to observe the friction coefficient values. The initial run
with = 0.8 for the outermost element number 600 is given in Fig. 11. The converged value of
friction coefficient under microslip is 0.046.

For element 611, the converged value for friction coefficient under microslip is 0.043 as given
in Fig. 12.

The converged friction coefficient is 0.0643 for element 699 as given in Fig. 13.


Similarly Fig. 14 gives for element 688, = 0.0643. The right side contact surface has slightly
higher friction coefficient compared to the left side.

Blade at 5000 RPM: In order to study the effect of speed on the occurrence of microslip in the
blade under consideration, the speed was reduced to 5000 RPM and the analysis repeated.
Here the iterations are started with a coefficient of friction = 0.2.

In this case two outer elements 688 and 699 given above on the right contact surface are
found to be completely sticking with no change in the initial friction value 0.2. This can be
observed in Figs 15 and 16. We notice that there is no slip in these elements.

The remaining all elements are found to have microslip. The friction coefficient is found to be
in the range 0.08 to 0.017.

CONCLUSIONS

A procedure for assessing micro-slip conditions in blades is presented. This along with
material friction and macro-slip with global Coulomb friction can define complete damping
mechanism in a turbomachinery bladed-disk.

ACKNOWLEDGEMENTS

The authors are thankful to Altair Engineering India in carrying out this work.

REFERENCES

1. Asai K, Sakurai S, Kudo T and Ozawa N, (2009) Evaluation of Friction Damping in
Dovetail Root Joints based on Dissipation Energy on Contact Surfaces, ASME Turbo
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2. Burdekin N, Cowley A and Back N, (1978) An Elastic Mechanism for the Micro-Sliding
Characteristics between Contacting Machined Surfaces, J Mech Engng Sci., vol. 20, p.
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Analytical Estimation of Microslip Damping in Bladed Disks

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Analytical Estimation of Microslip Damping in Bladed Disks

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Analytical Estimation of Microslip

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