Sunil Kumar

Bio: Sunil Kumar is an academic researcher from Gas Turbine Research Establishment. The author has contributed to research in topics: Catastrophic failure & Rotor (electric). The author has an hindex of 1, co-authored 1 publications receiving 1 citations.

Rotor Blade Vibration Measurement on Aero Gas Turbine Engines

Abstract: Rotor blade vibration in turbomachinery has been a major cause of failure due to HCF, often resulting in catastrophic damage. The primary aeromechanical design concerns are blade flutter and forced vibration that need to be quantified. The severity of blade vibratory response is almost impossible to predict using theoretical tools as it depends on the strength of excitation. Hence in order to evaluate the HCF characteristics of rotating blades, aero industry depends on measurements for actual vibratory response during engine tests. Various methods are used for measurement of rotor blade vibration. Conventionally strain gauges are extensively used for characterizing vibratory signatures of rotating blades. However, the strain gauges have their own limitations posed by operating temperatures and high-end technology is required to transmit signal from rotating components. Hence only a few blades in a rotor can be instrumented resulting in limited data capture. This paper presents a non-contact type of measurement technique using blade tip timing to capture vibratory signatures of all the blades of the rotor stage. This method is used to characterize monitor rotor blade vibrations of Low-Pressure Compressor and Low-Pressure Turbine of a developmental gas turbine engine. It has provided valuable data with respect to incipient damages, preventing catastrophic failure.

Experimental and Numerical Vibration Analysis of Octet-Truss-Lattice-Based Gas Turbine Blades

Abstract: This paper aims to investigate the utilization of octet truss lattice structures in gas turbine blades to achieve weight reduction and improvement in vibration characteristics, which are desired for turbine blades to improve the efficiency and load capacity of turbines. A solid blade model using NACA 23012 airfoil was designed as reference. Three lattice-based blades were designed and manufactured via additive manufacturing by replacing the internal volume of solid blades with octet truss unit cells of variable strut thickness. Experimental and numerical vibration analyses were performed on the blades to establish their suitability for potential use in turbine blades. A maximum weight reduction of 24.91% was achieved. The natural frequencies of lattice blades were higher than those of solid blades. A stress reduction up to 38.6% and deformation reduction of up to 21.5% compared with solid blades were also observed. Both experimental and numerical results showed good agreement with a maximum difference of 3.94% in natural frequencies. Therefore, apart from being lightweight, octet-truss-lattice-based blades have excellent vibration characteristics and low stress levels, thereby making these blades ideal for enhancing the efficiency and durability of gas turbines.

The location method of blade vibration events based on the tip-timing signal

Abstract: Tip-timing technology has been widely used to monitor blade vibration of the aeroengine. In the off-line analysis of tip-timing signals, it is key and a prerequisite in blade fault diagnosis to locate the vibration event accurately. It is the most common method used to locate abnormal vibration based on the correlation of tip-timing data in adjacent revolutions. However, the data in the adjacent revolutions only include little vibration information, which results in the location performance being susceptible to noise. This paper located the vibration event using the area of the ellipse calculated based on the two-parameter plot. The relationship between the area of the fitted ellipse and the blade vibration parameters was derived for the first time in this paper. The feasibility of the method was verified using the tip-timing data of the low-pressure fan of an aeroengine. The results showed that the method can locate both synchronous resonance and rotating stall accurately. Its performance in anti-noise interference was far superior to the correlation coefficient methods due to enough information provided by multi-revolutions rather than only two revolutions. The work in this paper is of great significance for the realization of automatic processing of tip-timing signals.

Exploration of an unconventional validation tool to investigate aero engine transonic fan flutter signature

Abstract: Abstract Flutter, an aeroelastic blade vibration phenomena, experienced by the fan of an developmental aero gas turbine engine, result in blade failure. Hence, suitable flutter detection instrumentation is required during engine testing. Flutter signature capture from revolving blades is a challenging task that necessitates either a complicated strain gauge-based rotating instrumentation or a noncontact tip timing system. Authors investigated a unique way for identifying, measuring, and validating flutter signature by assessing wall static pressure pulsations produced during blade tip transit across a casing mounted high bandwidth sensor during this research. The authors devised a mathematical model to explain signal spectrum components that feature both amplitude and angle modulation properties at the same time. The theory was tested using first-stage fan rotor blades that were fluttering in the first flexural mode (1F) and forming the second nodal diameter (2ND). The approach’s estimated blade deflection was compared to measurements taken using a traditional tip timing method up to 7 mm and determined to be within 1% inaccuracy. This research provides a low-cost, easy alternative technique for measuring flutter during engine development testing.

Assessment of Substrate and TBC Damage Effects on Resonance Frequencies for Blade Health Monitoring

Abstract: The reliability of critical aircraft components continues to shift towards onboard monitoring to optimize maintenance scheduling, economy efficiency and safety. Therefore, the present study investigates changes in dynamic behavior of turbine blades for the detection of defects, with focus on substrate cracks and TBC spallation as they relate to vibration modes 1 to 6. Two‐dimensional and three-dimensional finite element simulation is used. The results indicate that TBC spallation reduces natural frequencies due to the ensuing hot spot and overall increase in temperature, leading to drops in blade stiffness and strength. Cracks cause even larger frequency shifts due to local plastic deformation at the crack that changes the energy dissipation behavior. Mode 1 vibration shows the largest shifts in natural frequencies that best correlate to the size of defects and their position. As such, it may be most appropriate for the early assessment of the severity and location of defects.