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Turbomachinery Laboratory, Department of Mechanical Engineering, Michigan State University, East Lansing, MI 48824-1226, USA
Institute of Aeronautics and Applied Mechanics, Warsaw University of Technology, Warsaw, Poland
a r t i c l e
i n f o
Article history:
Received 3 August 2010
Accepted 23 November 2010
Available online 2 December 2010
Keywords:
Composite axial impeller
Fatigue
Finite element method
Damage accumulation
a b s t r a c t
Centrifugal forces are generated by a spinning impeller, of magnitudes that create large stresses. Aerodynamic forces are also imparted on an impeller blade, which varies with time and position. These two
forces play different roles during compressor events. Damage accumulated from these events results in
the fatigue failure of impeller material and structure. Therefore, it is important to design an impeller
against dynamic and fatigue failure. The nite element method has been used in the study of impeller
fracture mechanics and is regarded as an important tool in the design and analysis of material and structures.
Novel axial composite impellers, manufactured through lament winding technology, were invented
and studied at Michigan State University. These impellers will be used to compress water vapor so as
to use it as a refrigerant. In this study dynamic and fatigue behavior of two types of composite impellers
8B and 8C, were analyzed using commercial code ANSYS. Firstly, load cases were identied calculated and
evaluated. Static analysis was then performed with a full 3-D nite element model. The critical zone
where fatigue failure begins was extracted and used to determine life assessment positions. Secondly,
aerodynamic forces imparted on the blade were obtained from FLUENT, so that damage from dynamic
stresses could be calculated. Finally, based on the FEM and FLUENT simulation results, a linear damage
accumulation model was employed as a damage estimation rule to predict life of the two composite
impellers. A conservative life of 6498 h for 8B was calculated by this method, as was a life of 5435 h of
8C. Based on the method, safe fatigue life reduces for about 32% in case of 8B and 40% in case of 8C compared with conventional approaches where aerodynamic forces are omitted.
2010 Elsevier Ltd. All rights reserved.
1. Introduction
Of all the statistical data regarding fracture failure, the study of
these events in rotating parts and structures account for more than
80% of the cases [1]. This relates to the high degree of interest in
the failure of complicated rotating and moving systems. The root
causes behind these failures vary a lot based on different operating
conditions, such as high rotational speed and elevated temperature. In general, compressor blade failures can be grouped into
two categories: (a) fatigue, including both high-cycle fatigue
(HCF) and low-cycle fatigue (LCF) [26] and (b) creep rupture [7].
Blade fatigue failures are often related to anomalies in mechanical
behaviors and manufacturing defects. Because the mechanical performance requirements of compressor blades have high theoretical
signicance and application value, a precise life prediction is very
important. Fig. 1 shows a comparison between different industrial
components and their expected life cycles.
Considering centrifugal stresses for the life prediction of impeller blade components, we examine the non-steady-state usage.
Corresponding author.
E-mail address: liqubo@egr.msu.edu (Q. Li).
0261-3069/$ - see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2010.11.051
2059
2. Modeling
research, aerodynamic force has been obtained from calculation
[9], yet its discussion is typically just limited to the case of steady-state. Dynamic forces from the oscillating pressure forces were
not included to evaluate fatigue behavior of impeller blades. To the
authors knowledge, there are few studies that have been conducted considering inuence of both oscillating aerodynamic
forces and centrifugal forces on a compressor blades fatigue life
study.
At Michigan State University, a novel method has been developed to manufacture a composite impeller using lament winding
technology for water chillers [10]. A schematic structure for the
chiller is shown in Fig. 2. Here impeller wheels can be actuated
from an external shaft, or from a magnetic force between poles
in the outer shroud and coil poles on a stationary device surrounding the impeller and housing. Through this approach to wheel production, several threads such as Kevlar and carbon bers can be
used to weave a composite impeller impregnated with epoxy
through an automated process. A myriad of patterns have also
been developed by Eyler [11]. Of these patterns, two patterns with
the greatest potential of structure stability and aerodynamic performance have been selected for compressing water vapor as
refrigerant [12].
In order to evaluate fatigue life to these two novel axial composite impellers, an investigation was conducted to calculate dam-
Rotor wrapped
with stator
Cooling
Water Loop
Condenser
Counter-rotating
Compressor
Cooled Air
2060
Shroud deflection
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
20,000
40,000
60,000
Number of elements
2.2E+08
2.0E+08
1.8E+08
1.6E+08
1.4E+08
1.2E+08
1.0E+08
8.0E+07
0
20,000
40,000
60,000
Number of elements
Fig. 4. Convergence graphs of FE model.
were used as composite constituents; a similar ber volume fraction of 30% can be obtained using this novel manufacturing method. According to mechanics of composite materials [15],
unidirectional (U-D) composites mechanical properties can be
determined from micromechanics model from:
E1 Ef 1 V f Em V m
1
Vf Vm
E2
Ef
Em
v 12 v f V f v m V m
G12
1
Vf Vm
Gf Gm
Table 1
Material mechanical properties (GPa).
Material
E11
E22 = E33
G12 = G13
G23
Carbon ber
Epoxy
U-D composite
231
26.2
87.64
15
26.2
22.84
15
9.17
14.52
7
9.17
8.52
0.2
0.35
0.31
4. Loading
shroud
Fracture blade root 1
Centrifugal force
Aerodynamic force
blade
Fracture blade root 2
hub
Table 2
Static analysis of blade under different events 8B.
Start-up
Compression
Shut down
Shroud
deection
(mm)
Maximum
longitudinal
stress (MPa)
(safety factor)
Maximum
transverse
stress (MPa)
(safety factor)
1.95
1.84
2.10
240 (5.85)
208 (6.75)
253 (5.55)
51.3 (1.17)
48.1 (1.25)
53.2 (1.13)
22 (3.64)
20.3 (3.94)
24.5 (3.27)
Table 3
Static analysis of blade under different events 8C.
Events
Start-up
Compression
Shut down
The loading cases were determined by inspection of the different operating conditions. There are four main operating conditions
according to different impeller working periods: (1) start-up, (2)
steady-state, (3) standby compression, and (4) shut down. These
loading cases were used for fatigue analysis and were treated inter-connectedly since damage accumulated from a previous working period is able to initiate or enlarge crack growth rate for the
next one. All of the load cases that occur during the aforementioned events can be categorized as follows:
(1)
(2)
(3)
(4)
(5)
Events
2061
Shroud
deection
(mm)
Maximum
longitudinal
stress (MPa)
(safety factor)
Maximum
transverse
stress (MPa)
(safety factor)
1.23
0.87
1.35
320 (4.38)
281 (4.99)
341 (4.11)
52.3 1.19)
51.2 (1.33)
54.8 (1.16)
28.7 (4.75)
25 (4.85)
30.3 (4.04)
2062
9000. When the tip clearance is 4 mm, for the maximum shroud
deection case the impeller shroud will not hit the cylinder wall.
Fig. 6 shows that the Von Mises stress distribution on the impeller blade 8B and it is shown that maximum Von Mises stress exists
at the fracture blade root 1 between blade body and shroud which
is supposed to be the critical zone. In addition, considering vibrations of blades, the connection root between blade body and
shroud is also a dangerous area where an interaction of low cycle
and high-cycle fatigue exists. This critical surface results in most
fracture failure in service mainly due to the inuence of stress con-
113
111
116
117
114
119
115
118
120
122
121
123
124
Fig. 7. Keypoint location in the critical section.
112
2063
centration factors. As it is illustrated in Fig. 7, positions at keypoints 114 and 121 have equal, and the largest, stress concentra-
Fig. 10. FLUENT static pressure distribution on the blade for 8C.
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
0
30
60
90
120
150
180
210
240
270
300
330
360
390
Table 4
Linear elastic FEM analysis results for 8B.
Key positions
B. Aerodynamic mean
bending stress (MPa)
A+B
200
9.3
209.3
S=Stress/Strength
2064
1
0.8
0.6
0.4
0.2
0
0
158
27
185
12
15
18
21
24
27
Table 5
Linear elastic FEM analysis results for 8C.
Key positions
B. Aerodynamic mean
bending stress (MPa)
A+B
278
1.1
279.1
162
5.3
167.3
r rcentrifugal raerodynamic
As it is mentioned at the beginning of this work, the main purpose of this research is to evaluate fatigue life of two patterns of
composite impellers. This is done by calculating damage accumulated during different impeller working stages. Since centrifugal
and aerodynamic stresses are the main loadings considered, load
procedures can be simplied as in Fig. 11. From stress analysis in
previous sections, we have known that there exist stress concentration factors on the fracture blade roots and the critical zone in
facture blade root 1 has the biggest dynamic stress changes. It is
necessary to consider points such as keypoint 114 as the weak
points for structural life prediction. Similar conclusions have been
reached by authors to investigate impeller blades fatigue life
[9,19].
During compressor start-up period, Dtstart, keypoint 114 in fracture blade root 1 is subjected to the heaviest tensile stress. Here
this point also has the largest stress concentration factor compared
to all other keypoints. Local damaging occurs as micro-crack nucleation occurs. Damage caused by the centrifugal stress is reciprocal
to the fatigue resistance of the material at the same load range, Nf,i
according to Miners linear rule [23]:
di
1
N f ;i
The damage due to ni load cycles of the load rang i during different
working range, is given by
di;n ni di
ni
N f ;i
And the total damage caused to the detail by the load cycles of different load levels is thus:
Dtot
X
i
di;n
X ni
Nf ;i
In this case, the total fatigue life the impeller blade can be calculated through:
X ni
1
nstart
ncomp
nshut-down
Dtot
Nf
Nf ;i Nf ;start N f ;comp N f ;shut-down
tshut
tc
tstart
t
Fig. 13. Loadings for blade life determination.
Table 6
Life prediction results of patterns.
Patterns
Life
cycles
Life
in
hour
8B
8C
3.2 105
2.5 105
9455
7390
6498
5077
9500
8500
2065
for nite element analysis and composite micromechanical modeling theory was used to predict composites physical and mechanical properties. Convergence issues were discussed and addressed
before various loading to the blade, and all load cases, were identied calculated and evaluated and negligible cases were ignored.
By performing nite element modeling, the critical zone of the
blade can be obtained at the tip of blade. The impeller rotates at
the designed rpm of 7000 and safety factors for fatigue life have
been calculated based on FE analysis results. In order to better
evaluate impellers fatigue life, this work considered aerodynamic
forces effect to the blade beam. From FLUENT calculation, a transient static pressure trend was obtained which provided information for a further calculation of aerodynamic stress bending effect
in ANSYS. Methodology of combining centrifugal stress and aerodynamic stress from bending effect would improve fatigue lifes
investigation accuracy. Based on this methodology and by using
Miners linear law, fatigue life evaluation was conducted based
on the detailed simulation results. Considering vibration and load
variation effects, the fatigue life was modied. 8B pattern has a fatigue life of 6498 h and 8C pattern has shorter one 5077 h. Compared with conventional approaches where aerodynamic loads
are omitted, safe fatigue life has been reduced for 32% in case of
8B and 40% in case of 8C. It is thus concluded that aerodynamic
loads is important especially when fatigue life is predicted in
sophisticated impeller geometry.
References
9. Conclusion
The aim of this study was to numerically simulate two types of
axial composite impellers fatigue life using both nite element
analysis (FEA) and computational uid dynamic (CFD) method.
This paper presents rst time the consideration of simultaneous
inuence on the predicted safe life of specic impeller, of two types
of load having different features. The low frequency load component is characterized by high load amplitude in contrary to a high
frequency aerodynamic load of small amplitude.
In this work, carbon ber/epoxy composites with ber volume
fraction of 30% were used for blade structure. To simplify the modeling process, linear elastic stress strain relationship was assumed
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