TURBO POWER Program Conference

April 13-14, 2011, Göteborg

Overview of Aeromechanical Research

at KTH Energy Technology

Damian Vogt, KTH

2011-04-13

1
 Aeromechanics

Concerned with interactions between fluid and structure,

both from a static and a dynamic point-of-view

These interactions can be harmful to machine integrity

 overload, HCF

2
Aeromechanics in Turbomachines
• Excitation of structural components by flow
External sources: forced response
Self-excited: flutter

 Unless properly damped, these vibrations might lead to

material fatigue

3
Which are the turbomachines that are
typically affected?

4
 Wind turbines

Aircraft engines

Industrial gas turbines

5
How green is aeromechanics?

6
Aeromechanics and Sustainability
• Aeromechanics by itself is not driving up the efficiency of
your machine, but …
… a machine that is not aeromechanically safe will disintegrate

• In the perspective of developing the next generation of

more sustainable turbomachines
New processes drive machines into new (and aeromechanically
unexplored) operating regimes
Current trends are in direction of reduced component count,
longer time between overhauls, at unchanged power output
The design of the next generation of turbomachines is
increasingly relying on numerical predictions

 Aeromechanics is one of the primary (if not THE) key

enabling technology to ensure sustainable, reliable and
affordable energy supply of the future

7
Effects on TURBO POWER Goals
Better control of vibration
allows earlier and a more
rapid introduction of new
technologies
HCF toolbox improvements
 Valid both for turbines and
compressors

 New designs
 Retrofits

Increased confidence in
using numerical
Improvements of prediction tools
availability of machines

8
Presentation of FUTURE Project

Flutter-Free Turbomachinery Blades

www.future-project.eu

9
FUTURE Project Partners
Industry Research Academia
Institutes Lead

Duration 2008-2012, budget: 10.6M€

10
Expected Benefits
• The FUTURE project shall contribute to making
turbomachinery aeroelastic predictions more reliable

Numerical tools validated on new, relevant and unique

aeroelastic test cases that shall lead to best practice
guidelines

• Achieving this will …

… help making turbomachinery blades flutter-free
… make new aircraft engines more efficient
… cut development costs and time frames

 The FUTURE project will provide key enabling technologies

towards a green, safe, reliable and affordable air transport
of the future

11
Presentation of OFFWINDTECH
Project

Offshore Wind Enabling Technology

www.innoenergy-initiative.com

12
OFFWINDTECH Project Partners
Industry Research Academia
Institutes
Lead

Duration 2011-2013, budget: 8M€

13
Expected Benefits
• The OFFWINDTECH project shall contribute to making the next
generation of off-shore wind parks feasible
Very large wind turbines
Deep water

 From an aeromechanical point of view this is extremely interesting

and it pushes our design and analysis methods into new areas

• Achieving this will …

… open up for increasing the share of wind power in the global energy
mix
… make an advanced analysis tool accessible to the wind turbine
industry  dual use

 The OFFWINDTECH project will provide key enabling

technologies towards the next generation of off-shore wind
turbines, both aero/aeromech and system-wise

14
How do we ensure that new findings
are disseminated to today’s and
tomorrow’s engineers?

15
Presentation of THRUST Programme

TurbomacHinery AeRomechanical UniverSity Training

www.explorethrust.eu

16
THRUST Partners
Academia Industry/Research Institutes

 The world’s first Master’s Programme in Turbomachinery

Aeromechanics

17
Programme Overview

18
enabling sustainability

19
 TURBO POWER Program Conference
April 13-14, 2011, Göteborg

WP1, WP2 & Synthesis

Compressor Technology

María Mayorca, KTH

Nenad Glodic, KTH
Florian Fruth, KTH
Damian Vogt, KTH

2011-04-13

20
 CFD solver
FE solver

AROMA – WP1
Aeroelastic
Pre-stress

Reduced Order
Harmonic Forces Aeroforcing

M, K, φ
Modeling Analyses Mapping forces
CFD to FEM
mesh
Static
Stresses

Structural
CFD aerodamping
Damping
calculation
Coupled Model

Aerodamping

WP2
Reduction, ROM Full 360 Model

AROMA solver Mistuning

Back
Expansion

Amplitudes

Dynamic
Stresses

HCF material Haigh Stability

data Diagram

21
Beyond State-of-the-Art
• What is new

Integration of the Aeromechanical Design Change in a

Numerical Tool
New methods for the prediction of aero-coupled mistuned
analyses
Estimation of the contribution of different parts of the
aeromechanical design chain to the final fatigue risk

• Challenges

Standardization of aeromechanical practices

Adaptability to different FE and CFD solvers
Keep up with new emerging methods and techniques
Consideration of mistuning

22
Hulda, Validation Case
5 Frame
15 VIGV
23 Rotors
51 Stators
8 OGV

Tip Timing Data from VAC

Resonance Crossing
Mode 4, 3300Hz
Rpm: 13201
15EO
ND8 Forward
Nominal Case VIGV 0 deg
Amplitude: 0.136 +/- 0.005mm
23
How can we predict the response?

24
 Numerical Structural Domain

Crossing OK
at 3302.5Hz

Blisk Structural Model (Finite

Element)
Pre-stressed Conditions (OP)
OP
25
Nominal Case, 0deg VIGV
Steady State at OP (CFD)
2.2
21000
2.1 13201gas DP
13201 no gas
2 Test
gas

1.9

Validation OP Steady State Calculation - HULDA Compressor

pressure ratio, -

1.8
1.37

1.7 1.36
13201rpm
1.35
1.6

pressure ratio, -
1.34
1.5
1.33
10
1.4 1.32 9
8
6
1.3 1.31 5
4
1.3
11 12 13 14 15 16 17 18 19 20 21 1
1.29
mass flow, kg/s 11 11.5 12 12.5
mass flow, kg/s

26
Unsteady CFD Analysis, Forced
Response
Scaled Sector

1 strut  5EO
3 VIGV  15EO
5 R1  25EO
10 S1  50EO

27
Harmonic Forces Rotor

Cylindrical
Integrated
Force

15EO indicated

Fgen=0.106N
(generalized force
M4)

28
Aerodynamic Damping
Mode 4
Very localized • Extract Mesh Rotor Domain
• Extract Initial Solution from SS Stage
• Extract inlet and outlet profile BC
• Extract M4 and frequency to import to
Linearized Navier Stokes solver
• Solve TWM, include ND8

8ND, 0.42%

29
Reduced Order Modeling
(ROM)
Blade nodes: 11+1 (same as in MLS)
Disk nodes: 7 (at the outer part)

M4 8ND
4000

3500

3000

2500
frequency, Hz

2000

1500

1000

500

0
1 2 3 4 5 6 7 8 9 10 11
nodal diameter,-

30
Forced Response 8ND (Tuned)
Freq: 3289Hz M4 Blisk ROM
Max amp: 0.042mm
Dr=0.42%
Test: 0.136+/- 0.005mm
3 times lower
-5
x 10
4.5
sec001

3.5

amplitude, m
2.5

1.5

0.5
3200 3220 3240 3260 3280 3300 3320
frequency, Hz

31
Where do the differences come
from?

32
Structural Perturbations
(Mistuning)
CASE +/- 1%, ABC
100

90

Maximum
probability for maximum amp mag, %

80
Amplitude
70
Magnification:
60 1.55
50

40

30

20

10

0
1.15 1.2 1.25 1.3 1.35 1.4 1.45 1.5 1.55 1.6
amplitude magnification -

33
 Forcing Predictions (WP1)

• Effect of Scaling of
Blade Row Sectors

“… a rule of
thumb is suggested
to not exceed 5%
total scaling ratio…”

34
Mesh sensitivity in prediction of
aerodynamic damping

Difference in predicted aerodynamic damping up to ~50 % !

35
 Aerodynamic Perturbations
Considerations (WP2)
TWM stability curve Cumulative probability

stable

unstable

Monte Carlo 1000 cases •Each 5th blade randomly mistuned

•In ~85% of cases stability has increased
(for this particular case)
Observed deviation of aerodynamic damping value
due to asymmetries was ~15% from the tuned case
36
How can we design for a
reduced fatigue risk?

37
Physical Understanding of
Unsteady Aerodynamics
• Effect of the Blade Count Ratio on the
Aerodynamic Forcing (WP1)

Lower
FORCING

38
Development of Integrated
Methods

39
 Including Mistuning ROM, MLS MLS tuned
MLS mistuned
mode: 2
0.8
Tuned
0.6 Mistuned
Interacting Modes

damping ratio, %
Aerodynamic
Damping 0.4
x 10
-4 mode: 2 and 3

1T
0.2
19

absolute amplitude, m
0 20
1930 1940 1950 1960 1970 1980 2 1T 21
frequency, Hz
22
mode: 2
23
2
1
1.8 1 2
2F Combined
amplitude magnification,-

2F & 1T 3
1.6
4
1.4
Forced Resposne
Amplitude 1.2 0
1800 1900 2000 2100 2200 2300
Magnification 1 frequency, Hz
0.8

0.6 SDOF
MLS
0.4
-15 -10 -5 0 5 10 15
nodal diameter,-
40
 Overall Target
Accuracy Prediction

Stress amplitude change, %

150
Scaling
hysical Contributions 100 Mapping
Mode Superposition
Forcing with BCR
50 Aerodamping Mesh
Aerodamping with mistunig Material Damp. Meass
Coating
0 damping with thickness
ROM
Mistuning
FE Mesh
-50
Physical Contributions Accuracy Prediction

Stress amplitude change, %

150
Stress amplitude change, %

100 -100
Positive Impact Negative Impact
Forcing with BCR
50 100
Aerodamping with mistunig
Coating damping with thickness
e Impact Negative Impact 0 50
Mistuning

-50 0

-100 -50

-150 -100
Positive Impact Negative Impact Positive Impact Negative Impact

41
Research Efforts Planned
• Validation with Tip Timing Test Data
HULDA compressor, M4, 15EO

• Estimation of “accuracy” and “physical effects” throughout

the chain from the preliminary state currently shown

• As the research in the other WP:s continue their results

will be picked up in the synthesis

42
 Dissemination Activities WP1
Name (Main author) Title Type

Maria Mayorca Effect of Scaling of Blade Row Sectors on the ASME J. of

Prediction of Aerodynamic Forcing in a Highly- Turbomachinery
Loaded Transonic Compressor Stage (2010)
Florian Fruth Influence of the Blade Count Ratio on ASME Paper (2011)
Aerodynamic Forcing – Part II: Turbine

Maria Mayorca Effect of Scaling of Blade Row Sectors on the ASME Paper (2009)
Prediction of Aerodynamic Forcing in a Highly-
Loaded Transonic Compressor Stage
Florian Fruth Influence of the Blade Count Ratio on ASME Paper (2010)
Aerodynamic Forcing – Part I: Compressor
Seyed Mohammad Effect of Scaling of Blade Row Sectors on the ASME Paper (2011)
Hosseini Prediction of Aerodynamic Forcing in a High-
Pressure Transonic Turbine Stage
Jesus de Andrade Effect of the scaling technique of blade row MSc thesis (2008)
sectors on the prediction of aerodynamic forcing
Seyed Mohammad Aeromechanic Analysis of an Industrial HPT MSc thesis (2010)
Journal Hosseini Rotor
Adrián García Domingo Validation of a Harmonic Balance Method for MSc thesis (2010)
Journal Prediction of Aerodynamic Forcing
Recommend. Antonio Sanz Parametric Study … Part IIA: Forced Response MSc thesis (2010)
Paper Behavior of a Turbine
Alessio Contran Parametric Study of … Part IIB: Forced Response MSc thesis (2010)
Thesis Behavior of a Compressor

43
 Dissemination Activities, WP2
Name (Main author) Title Type

Nenad Glodic Experimental and Numerical Investigation of ISUAAAT Paper

Aeroelastic Properties of Combined Mode Shapes (2009)
in an Oscillating LPT Cascade
Damian Vogt The Effect of Unsteady Aerodynamic Asymmetric ISUAAAT Paper
Perturbations on the Mode Shape Sensitivity of (2009)
an Oscillating LPT Cascade
Nenad Glodic Experimental and Numerical Investigation of ASME Turbo Expo
Mistuned Aerodynamic Influence Coefficients in (2011)
an Oscillating LPT Cascade
Michael Bartelt Numerical and Experimental Investigation of MSc thesis (2008)
Aeroelastic Properties of Combined Modes in an
Oscillating LPT Cascade
Yaoguang Zhai Flutter Analysis of Transonic Compressor Rotors MSc thesis (2009)

Carlos Gomez Investigation of … - Part I: Direct Simulations of MSc thesis (2009)

Influence Coefficients
Muhammad Shaban Investigation of … - Part II: Travelling Wave MSc thesis (2010)
Mode Approach

Guillaume Gondre Parametric Study … - Part III B: Aerodynamic MSc thesis (2010)
Damping Behavior - Turbine Profiles
Journal
Lucio Monaco Parametric Study … - Part III A: Aerodynamic MSc thesis (2010)
Paper Damping Behavior - Compressor Profiles

Thesis Pedro Hernández Mesh Sensitivity Study…- Part I: Turbine cascade MSc thesis (2011)

Miguel Rodriguez Mesh Sensitivity Study…- Part II: Compressor MSc thesis (2011)
cascade

44
 Dissemination Activities,
Synthesis
Name (Main author) Title Type

Maria Mayorca A new reduced order modeling for stability and ASME Paper (2010)
forced response analysis of aero-coupled blades
considering various mode families
Hans Mårtensson Simplified Forced Response HCF Assessment of ASME Paper 2009
Turbomachinery Blades

Maria Mayorca Numerical Tool for Prediction of Aeromechanical ISABE Paper (2009)
Phenomena in Gas Turbines
Maria Mayorca Prediction of Turbomachinery Aeroelastic ASME Paper (2011)
Behavior from a Set of Representative Modes

Damian Vogt Effect of Reduced Order Modeling on the HCF IFToMM Paper
Assessment of a Transonic Compressor (2009)

Pierre-Emmanuel Effect of ROM Size on Prediction Accuracy of HCF Thesis (2009)

Journal Laurens Behavior of a Transonic Compressor Stage

Paper Maria Mayorca Development and Validation of a Numerical Tool Tek Lic Thesis
for Aeromechanical Analyses in Turbomachinery (2010)
MSc Thesis

Lic Thesis

45
enabling sustainability

46