American Journal of Aerospace Engineering

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Erosion of an Axial Transonic Fan due to Dust Ingestion

Received: 29 September 2014    Accepted: 05 October 2014    Published: 16 October 2014
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Abstract

This paper deals with the prediction of the particle dynamic and erosion characteristics due to dust ingestion in an axial flow fan, installed in a high bypass-ratio turbofan engine that operates in a dusty environment. Dynamic behavior comprises the particle trajectory and its impact velocity and location. While the erosion characteristics are resembled by the impact frequency, erosion rate, erosion parameter and the penetration rate. The study was carried out in two flight regimes, namely, takeoff, where the sand particles are prevailing, and cruise, where the fly ashes are dominated. In both cases, the effect of the particle size on its trajectory, impact location, and the erosion characteristics was studied. To simulate the problem in a more realistic manner, a Rosin Rambler particle diameter distribution was assumed at takeoff and cruise conditions. At takeoff, this distribution varies from 50 to 300 μm with a mean diameter of 150 μm sand particles. While at cruise, this distribution varies from 5 to 30 μm with a mean diameter of 15 μm fly ash particles. The computational domain employed was a periodic sector through both the fan and its intake bounding an angle of (360/38) where the number of fan blades is (38). The intake is a stationary domain while the fan is a rotating one and the FLUENT solver is used to solve this problem. Firstly, the flow field was solved in the computational domain using the Navier-Stokes finite- volume supported by the Spalart-Allmaras turbulence model. The governing equations, representing the particle motion through the moving stream of a compressible flow are introduced herein to calculate the particle trajectory. The solution of these equations is carried out based on the Lagrangian approach. Next, empirical equations representing the particle impact characteristics with the walls are introduced to calculate the rebound velocity, the erosion rate, erosion parameter, impact frequency and penetration rate. Moreover, a method to smoothen the irregularity in the calculated scattered data was discussed as well. During takeoff flight regime, the pressure side of fan blade experienced higher particle impact and erosion damage. The highest erosion rate was found at the corner formed by blade tip and trailing edge of pressure side. During cruise conditions, less erosion rates resulted. Maximum erosion rates are found at the leading edge of the pressure side.

DOI 10.11648/j.ajae.s.2015020101.15
Published in American Journal of Aerospace Engineering (Volume 2, Issue 1-1, January 2015)

This article belongs to the Special Issue Hands-on Learning Technique for Multidisciplinary Engineering Education

Page(s) 47-63
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Turbomachinery Erosion, Transonic Axial Fan, Fan Erosion, Particulate Flow

References
[1] Montgomery, J. E., and Clark, J. M., Jun., “Dust Erosion Parameters for a Gas Turbine,” Soc. of Automotive Engineers Summer Meeting, 1962, Preprint 538A.
[2] Tabakoff, W., and Hamed, A., “ Temperature Effect On Particle Dynamics And Erosion In Radial Inflow Turbine,” J. Turbomachinery, Vol. 110, APRIL 1988, PP. 258-264 .
[3] Tabakoff, W., Hamed, A., and Metwally M., “ Effect Of Particle Size Distribution On Particle Dynamics And Blade Erosion In Axial Flow Turbines,” J. Engineering For Gas Turbines And Power, October 1991, Vol. 113.
[4] Hamed, A. “An Investigation In The Variance In Particle Surface Interactions And Their Effects In Gas Turbines,”. Journal of Engineering For Gas Turbines And Power, APRIL 1992, Vol. 114, PP. 235-241.
[5] Hamed, A., Tabakoff, W., Richard B. Rivir, Kaushik Das, and Puneet Arora, ”Turbine Blade Surface Deterioration By Erosion”, Journal of Turbomachinery, July 2005, Vol. 127, Issue 3, pp. 445-452.
[6] Japikse, D., "Review- Progress in Numerical Turbo-machinery Analysis" ASME J. of Fluids Engineering, pp 592-606, 1976.
[7] Wulf, R. H., Kramer, W. H., and Paas, J. E., "CF6-6D Jet Engine Performance Deterioration" NASA/CR-159786, NASA, 1980.
[8] Peterson, R. C., "Design Features for Performance Retention in the CFM56 Engine " Turbomachinery Performance Deterioration FED, Vol. 37, the AIAA/ASME 4th Joint Fluid Mechanics Plasma Dynamics and Lasers Conference, Atlanta, Georgia, 1986.
[9] Neilson J. H. and Gilchrist A., “Erosion By A Stream Of Solid Particles “, Wear, Π , 1968 .
[10] Tabakoff, W., and Hussein, M. F., "Computation and Plotting of Solid Particle Flow In Rotating Cascades" Computers and Fluids, Vol. 2, 1974.
[11] Elsayed, A. F., and Brown, A., "Computer Prediction of Erosion Damage in Gas Turbine" ASME Paper 87-GT-127, 32nd ASME Int. Gas Turbine Conf., California, USA, 1987.
[12] Hamed, A., "Particle Dynamics of Inlet Flow Fields with Swirling Vanes" Journal of Aircraft, Vol. 19, No. 9, pp 707-712, 1982.
[13] Beacher B., Tabakoff W. and Hamed A. "Improved Particle Trajectory Calculations through Turbo-machinery Affected by Coal Ash Particles.",ASME Journal of Engineering for Power, vol. 104, pp 64-68, 1982.
[14] Hamed, A., and Fowler, S., "Erosion Pattern of Twisted Blades by Particle Laden Flows" ASME J. of Engineering for Power, Vol.105, pp839-843, 1983.
[15] Clevenger, W. B., Jr., and Tabakoff, W., "Similarity Parameters for Comparing Erosive Particle Trajectories in Hot Air and Cold Air Radial Inflow Turbines", ASME Paper 74-GT-65, 1974.
[16] Hussein, M. F., and Tabakoff, W., "Computer Program for Calculations of Particle Trajectories through a Rotating Cascade" Univ. of Cincinnati, Cincinnati, Ohio, USA, Tech. Report 76-47, 1976.
[17] Elsayed, A. F., and Rashed, M. I. I., "Erosion in Centrifugal Compressors" Paper No.55, Proc. 5th Int. Conf. on Erosion by Liquid and Solid Impact (ELSI V), Newnham Collage, Cambridge Univ., Uk, 1979.
[18] Elsayed, A. F., and Rashed, M. I. I., "Computation of Gas Flow in Centrifugal Compressors Used in Helicopters." Proc. of 5th Int. symposium on Air Breathing Engines, Bangalore, India, 1980.
[19] Maxwell, B. R., "Particle Flow in Blade Passage of Turbo-machinery with Application of Laser-Doppler Velocimetry", NASA CR-134543, 1974.
[20] Elsayed, A. F., and Rouleau, W. T., "Three Dimensional Viscous Particulate Flow in a Typical Turbo-expander", Int. J. of Energy Systems, Vol.5, No.2, 1985.
[21] Elsayed A. F., "Aerodynamics/Aero-elastic Behavior of Eroded Axial Turbines" 2nd Int. Symposium on Transport Phenomena, Dynamics and Design of Rotating Machinery, Honolulu, Hawaii, USA, 1988.
[22] Suzuki, M., Inaba, K., and Akoto Yamamoto, M.” Numerical Simulation of Sand Erosion Phenomena in Rotor/Stator Interaction of Compressor”, Proceedings of the 8th International Symposium on Experimental and Computational Aerothermodynamics of Internal Flows, Lyon, July 2007.
[23] Corsini, A., Marchegian, A., Rispoli, F., Venturini, P., and Sheard, A. “Predicting Blade Leading Edge Erosion in an Axial Induced Draft Fan”, Journal of Engineering for Gas Turbine and Power, published online January 30, 2012.
[24] Brun, K., Nored , M., and Kurz, R. “ Analysis of Solid Particle Surface Impact Behavior in Turbo-machines to Assess Blade Erosion and Fouling”, Proceedings of the Forty-First Turbo-machinery Symposium September 24-27, 2012, Houston, Texas.
[25] Carbonetto, B. and Hoch, V.” Advances in Erosion Prediction of an Axial Flow Expander”, Proceeding of The 28th Turbo-machinery Symposium.
[26] Zhang, J., Han, Z., Cao, H., Yin, W., Niu, S., and Wang, H. “Numerical Analysis of Erosion Caused by Biomimetic Axial Fan Blade”, Hindawi Publishing Corporation, Advances in Materials Science and Engineering, Volume 2013, Article ID 254305, 9 pages.
[27] Fluent 6.1 Documentation (User Guide Manual).
[28] Zohier, H. Z., "Solid Particulate Flow in an Axial Transonic Fan In a High Bypass Turbofan Engine", M.Sc. Thesis, Zagazig University, Egypt, 2006.
[29] Elsayed, A. F, Gobran M. H., and Zohier H., "Three-Dimensional Flow in A Transonic Axial Flow Fan of A High Bypass Ratio Turbofan Engine", 11th International Conference On Aerospace Science and Aviation Technology, Military College, Cairo, Egypt, 17-19, May 2005.
Author Information
  • Mechanical Power Eng. Dept., Zagazig University, Zagazig, Egypt

  • Mechanical Power Eng. Dept., Zagazig University, Zagazig, Egypt

  • Mechanical Power Eng. Dept., Zagazig University, Zagazig, Egypt

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  • APA Style

    Ahmed Fayez EL-Saied, Mohamed Hassan Gobran, Hassan Zohier Hassan. (2014). Erosion of an Axial Transonic Fan due to Dust Ingestion. American Journal of Aerospace Engineering, 2(1-1), 47-63. https://doi.org/10.11648/j.ajae.s.2015020101.15

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    ACS Style

    Ahmed Fayez EL-Saied; Mohamed Hassan Gobran; Hassan Zohier Hassan. Erosion of an Axial Transonic Fan due to Dust Ingestion. Am. J. Aerosp. Eng. 2014, 2(1-1), 47-63. doi: 10.11648/j.ajae.s.2015020101.15

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    AMA Style

    Ahmed Fayez EL-Saied, Mohamed Hassan Gobran, Hassan Zohier Hassan. Erosion of an Axial Transonic Fan due to Dust Ingestion. Am J Aerosp Eng. 2014;2(1-1):47-63. doi: 10.11648/j.ajae.s.2015020101.15

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  • @article{10.11648/j.ajae.s.2015020101.15,
      author = {Ahmed Fayez EL-Saied and Mohamed Hassan Gobran and Hassan Zohier Hassan},
      title = {Erosion of an Axial Transonic Fan due to Dust Ingestion},
      journal = {American Journal of Aerospace Engineering},
      volume = {2},
      number = {1-1},
      pages = {47-63},
      doi = {10.11648/j.ajae.s.2015020101.15},
      url = {https://doi.org/10.11648/j.ajae.s.2015020101.15},
      eprint = {https://download.sciencepg.com/pdf/10.11648.j.ajae.s.2015020101.15},
      abstract = {This paper deals with the prediction of the particle dynamic and erosion characteristics due to dust ingestion in an axial flow fan, installed in a high bypass-ratio turbofan engine that operates in a dusty environment.  Dynamic behavior comprises the particle trajectory and its impact velocity and location. While the erosion characteristics are resembled by the impact frequency, erosion rate, erosion parameter and the penetration rate. The study was carried out in two flight regimes, namely, takeoff, where the sand particles are prevailing, and cruise, where the fly ashes are dominated. In both cases, the effect of the particle size on its trajectory, impact location, and the erosion characteristics was studied. To simulate the problem in a more realistic manner, a Rosin Rambler particle diameter distribution was assumed at takeoff and cruise conditions.  At takeoff, this distribution varies from 50 to 300 μm with a mean diameter of 150 μm sand particles. While at cruise, this distribution varies from 5 to 30 μm with a mean diameter of 15 μm fly ash particles. The computational domain employed was a periodic sector through both the fan and its intake bounding an angle of (360/38) where the number of fan blades is (38). The intake is a stationary domain while the fan is a rotating one and the FLUENT solver is used to solve this problem. Firstly, the flow field was solved in the computational domain using the Navier-Stokes finite- volume supported by the Spalart-Allmaras turbulence model. The governing equations, representing the particle motion through the moving stream of a compressible flow are introduced herein to calculate the particle trajectory. The solution of these equations is carried out based on the Lagrangian approach. Next, empirical equations representing the particle impact characteristics with the walls are introduced to calculate the rebound velocity, the erosion rate, erosion parameter, impact frequency and penetration rate. Moreover, a method to smoothen the irregularity in the calculated scattered data was discussed as well.  During takeoff flight regime, the pressure side of fan blade experienced higher particle impact and erosion damage. The highest erosion rate was found at the corner formed by blade tip and trailing edge of pressure side. During cruise conditions, less erosion rates resulted. Maximum erosion rates are found at the leading edge of the pressure side.},
     year = {2014}
    }
    

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  • TY  - JOUR
    T1  - Erosion of an Axial Transonic Fan due to Dust Ingestion
    AU  - Ahmed Fayez EL-Saied
    AU  - Mohamed Hassan Gobran
    AU  - Hassan Zohier Hassan
    Y1  - 2014/10/16
    PY  - 2014
    N1  - https://doi.org/10.11648/j.ajae.s.2015020101.15
    DO  - 10.11648/j.ajae.s.2015020101.15
    T2  - American Journal of Aerospace Engineering
    JF  - American Journal of Aerospace Engineering
    JO  - American Journal of Aerospace Engineering
    SP  - 47
    EP  - 63
    PB  - Science Publishing Group
    SN  - 2376-4821
    UR  - https://doi.org/10.11648/j.ajae.s.2015020101.15
    AB  - This paper deals with the prediction of the particle dynamic and erosion characteristics due to dust ingestion in an axial flow fan, installed in a high bypass-ratio turbofan engine that operates in a dusty environment.  Dynamic behavior comprises the particle trajectory and its impact velocity and location. While the erosion characteristics are resembled by the impact frequency, erosion rate, erosion parameter and the penetration rate. The study was carried out in two flight regimes, namely, takeoff, where the sand particles are prevailing, and cruise, where the fly ashes are dominated. In both cases, the effect of the particle size on its trajectory, impact location, and the erosion characteristics was studied. To simulate the problem in a more realistic manner, a Rosin Rambler particle diameter distribution was assumed at takeoff and cruise conditions.  At takeoff, this distribution varies from 50 to 300 μm with a mean diameter of 150 μm sand particles. While at cruise, this distribution varies from 5 to 30 μm with a mean diameter of 15 μm fly ash particles. The computational domain employed was a periodic sector through both the fan and its intake bounding an angle of (360/38) where the number of fan blades is (38). The intake is a stationary domain while the fan is a rotating one and the FLUENT solver is used to solve this problem. Firstly, the flow field was solved in the computational domain using the Navier-Stokes finite- volume supported by the Spalart-Allmaras turbulence model. The governing equations, representing the particle motion through the moving stream of a compressible flow are introduced herein to calculate the particle trajectory. The solution of these equations is carried out based on the Lagrangian approach. Next, empirical equations representing the particle impact characteristics with the walls are introduced to calculate the rebound velocity, the erosion rate, erosion parameter, impact frequency and penetration rate. Moreover, a method to smoothen the irregularity in the calculated scattered data was discussed as well.  During takeoff flight regime, the pressure side of fan blade experienced higher particle impact and erosion damage. The highest erosion rate was found at the corner formed by blade tip and trailing edge of pressure side. During cruise conditions, less erosion rates resulted. Maximum erosion rates are found at the leading edge of the pressure side.
    VL  - 2
    IS  - 1-1
    ER  - 

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