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Documente Profesional
Documente Cultură
Filsinger
J. Szwedowicz
O. Schafer
R & D Turbochargers,
ABB Turbo Systems Ltd.,
5401 Baden, Switzerland
Approach to Unidirectional
Coupled CFDFEM Analysis
of Axial Turbocharger Turbine
Blades
This paper describes an approach to unidirectional coupled CFDFEM analysis developed at ABB Turbo Systems Ltd. Results of numerical investigations concerning the vibration behavior of an axial turbocharger turbine are presented. To predict the excitation
forces acting on the rotating blades, the time-resolved two-dimensional coupled stator
rotor flow field of the turbine stage was calculated. The unsteady pressure, imposed on the
airfoil contour, leads to circumferentially nonuniform and pulsating excitation forces acting on the rotating bladed disk. A harmonic transformation of the excitation forces into
the rotating coordinate system of a single blade was elaborated and the complex Fourier
amplitudes were determined. The bladed rotor was modeled by a single symmetric segment with complex circumferential boundary conditions. With respect to different nodal
diameter numbers, free vibration analyses of the disk assembly were then effectively
performed. For calculated resonance conditions, the steady-state responses of the turbocharger bladed disk were computed. By using this coupled CFDFEM analysis, the
dynamic loading of the turbine blades can be determined in the design process.
DOI: 10.1115/1.1415035
Introduction
Numerical Procedure
Contributed by the International Gas Turbine Institute and presented at the 46th
International Gas Turbine and Aeroengine Congress and Exhibition, New Orleans,
Louisiana, June 4 7, 2001. Manuscript received by the International Gas Turbine
Institute February 2001. Paper No. 2001-GT-288. Review Chair: R. Natole.
Journal of Turbomachinery
Computational Fluid Dynamics. The program system developed in-house was already adjusted to the prediction of unsteady
Fig. 3 Identical meshes to define complex bladed disk oscillations in the real domain
j 1
(1)
N/2
for N even
N1 /2
for N odd
(2)
q right q lefte jn
q right q lefte
jn
(3)
(4)
Rewriting the Euler function in trigonometric notation, eigenfrequencies of the cyclic finite element system can be computed in
the real domain. Consequently, the cyclic model has to be represented by two identical finite element meshes Fig. 3, whose
nodal boundaries on the circumferential sector sides are constrained as shown in Eqs. 3 and 4. For each mode i and nodal
diameter n besides n0 and nN/2, two identical eigenfrequencies are computed, which refer to two possible orthogonal
mode shapes of the disk assembly.
Static Calculation. By substituting n equal to 0 into Eq. 1
and Eqs. 3 and 4 as well as omitting the inertial term of Eq.
1, the static equation of the disk assembly rotating with the
angular speed is obtained in the following form:
K q P o T F
(5)
where P o , T , and F() are stationary gas pressure obtained from CFD, thermal loads obtained from thermal FE simulation, and centrifugal forces, respectively. In turbocharger blisks
the blades can be circumferentially coupled by a lacing wire, as
shown in Fig. 3. In this case, an effective contact area between the
airfoil and lacing wire is obtained from a nonlinear static computation by using contact elements 17. In the free vibration analyses, the nodes located on the computed contact area are fixed
rigidly to each other as demonstrated by Szwedowicz 18. Finally, for the considered rotational speed , the eigenfrequencies
of the bladed disk can be computed.
Damping Properties of Turbocharger Disks. Gust-response
and motion-dependent unsteady aerodynamics assure improveTransactions of the ASME
* T P k e j k l k e jkt
m i,n u i,n 2 i,n i u i,n k i,n u i,n i,n
(7)
CFDFEM Coupling
Even for simplified models of disk assemblies, a time-marching
structural finite element simulation of the bladed disk response is
ineffective because of the need of the excessive computational
time. Hence, the finite element calculations were performed in the
frequency domain as mentioned before.
From CFD simulations Fig. 1, the time-dependent twodimensional pressure distribution on the blade midsection is obtained. To realize a quite simple first approach, a single excitation
force, split into axial and circumferential direction, is calculated
from the pressure distribution assuming a uniform radial distribution along the blade height. This force, acting on the center of
gravity of the blade midsection, represents the blade stimulation in
the forced response analyses. This simplification is acceptable
since in the scope of this project, there is major interest in vibrations caused by the pressure pulses of the diesel engine exhaust
system, which mainly excite low, simple bending blade modes
21.
Forced Response Analysis. In general, forced vibrations of a
single coupled blade can be expressed in the Cartesian system by
b M e jm c q D q b K e jm , c q P
(6)
22 where k1,2, . . . , describes the engine order, i1,2,3 indicates the number of the considered mode shapes, l denotes the
circumferential position of the excited node of the cyclic finite
element model Figs. 3 and 11. In Eq. 7, m i,n
* T M (e jn ) i,n and k i,n i,n
* T K(e jn ) i,n are the
i,n
modal mass and modal stiffness of the cyclic FE model, respec* T is the conjugate transposed vector of
tively, Fig. 3, and i,n
the disk eigenform i,n . The nodal circumferential position l is
determined from Cartesian coordinates of the excited node l. For
each nodal diameter n, constant either minimum or maximum
values of the damping ratio i evaluated from the experimental
resonance curves see Fig. 4 are only taken into account in Eq.
7. Therefore, the global damping matrix D in the space-time
differential Eq. 6 can be simplified by 2 i,n i in the modal
dynamic Eq. 7 of the cyclic FE blade model shown in Fig. 3.
Amplitudes P k and phase delay k are obtained from the Fourier decomposition of the nonuniform pressure P. For the applied
twin FE models Fig. 3, excitation loads of each engine order k
have to be imposed simultaneously on node l of the real and
imaginary blade as shown by Szwedowicz 22
F l,real
P k, cos k l k, j sin k l k,
(8.1)
F l,imag
P k, sin k l k, j
(8.2)
cos k l k,
Results
With the help of these numerical tools, different turbine configurations under a variety of operating conditions were analyzed.
This paper gives a summary of two loading cases of the turbine
disk with the lacing wire. The first one was a turbine stage under
constant pressure loading. The second example demonstrates the
loading of a turbocharger turbine under pulse charging engine
conditions. The numerical results were compared to experimental
data as far as available.
Constant Pressure. For a first assessment of the CFDcalculations, three different turbine stages under full admission
were analyzed. The output power P T of the stages was calculated
by means of the tangential blade forces F 1 multiplied with the
rotational speed of the turbine n TC , the Euler radius r, and the
number of turbine blades N
P T 2 n TC rNF t
(9)
Fig. 5 Comparison of relative change in output power for different turbine configurations
Fig. 7 Pressure distribution in the midsection of the turbine stage for a single time step upper plot and qualitative loading of the turbine blades lower diagram
the lower part of Fig. 9. For this particular excitation order, the
unsteady excitation amplitude is about 3 percent of the steady
load. These data compose the excitation input for the forced finite
element response calculation.
Fig. 8 Resulting blade force versus time
Figure 9 displays the power spectrum of the Fourier decomposition for the forces acting on the blade. The high values at frequencies below the first turbocharger order result from the charging system. Their frequencies are characterized by multiples of the
speed of the Diesel engine n DE . Further peaks are detected for
multiples of the turbocharger rotation n TC . Even turbocharger orders k are directly identified see k2,4,6, . . . in Fig. 9, because
maximal peaks refer to the frequency kn TC as it is illustrated for
the sixth engine order in the lower part of Fig. 9. For uneven
turbocharger orders k see k1,3,5, . . . in Fig. 9, the highest
peaks correspond to two particular frequencies kn TC mn DE
and kn TC mn DE where m denotes the pulsation order (m
1,2, . . . ).
For each turbocharger order k, the excitation spectrum kn TC
mn DE is obtained from the Fourier decomposition of the CFD
results. An example for the sixth turbocharger order is shown in
Journal of Turbomachinery
leads to the conclusion, that for the described example case threedimensional effects are small and the value of the damping ratio
was well chosen.
To prove the numerical results Fig. 12, left diagram, measured
vibration amplitudes are shown in Fig. 13. The similarity between
the measured and calculated spectrums is obvious and shows the
capability of the unidirectional coupled numerical procedure to
predict vibrations of turbocharger turbine blades.
Fig. 12 Calculated blade amplitudes at the trailing edge versus exciting frequency left; and contour plot of qualitative
stress distribution in the turbine blade with the damping wire
right
Fixed contact between the lacing wire and the airfoil was assumed in the steady state vibration analyses. The frictional as well
as the aerodynamic energy dissipation are only included by the
introduction of the equivalent damping ratio. To illustrate all this,
Fig. 11 shows the computed minor resonance responses of the
second and third blade modes related to the resonance of the fundamental blade mode.
The difference between the first computed and measured blade
eigenfrequency was below 2 percent. To illustrate the results of
the forced response analysis, the calculated relative amplitudes at
the tip of the blade trailing edge are shown over the exciting
frequencies on the left side of Fig. 12. The trailing edge was
chosen because it exhibits the highest airfoil oscillations for the
first blade mode. The right side of Fig. 12 displays the dynamic
stress distribution. Additionally, the resulting circumferential and
axial forces imposed on the blade are indicated in Fig. 12. The
calculated peak stress was validated with the help of strain gage
measurements. In spite of the simple model of the blade loading,
fairly good agreements for the highest measured and computed
stresses are obtained. The differences were below 25 percent. This
Acknowledgments
The authors would like to thank ABB Turbo Systems Ltd. for
the encouragement and the permission to publish this work. The
authors are also in debt of Dr. P. Neuenschwander, who performed
the SiSy calculations.
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