Dynamic test and fatigue life evaluation of compressor blades
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DOI 10.1007/s12206-014-0917-5
Dynamic test and fatigue life evaluation of compressor blades†Kyungkook Kim1 and Young Shin Lee2,* 1
Doosan Heavy Industries & Construction, 555, Changwon, Kyungnam 641-712, Korea 2 Dept. of Mechanical Design Engineering, Chungnam National University, Korea
(Manuscript Received December 24, 2013; Revised June 12, 2014; Accepted June 19, 2014) ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Abstract High-cycle fatigue (HCF) has been identified as one of the primary causes of gas turbine engine failure. To verify the reliability of the high cycle fatigue fracture of the 5 MW gas turbine engine blade being developed by Doosan Heavy Industries & Construction Co., Ltd., dynamic tests were conducted using real size compressor rigs according to previous studies. The dynamic safety margin of the 5MW gas turbine engine blade was calculated on the basis of the ratio between the dynamic stress and endurance limit stress respectively determined through the compressor rig and fatigue tests. The HCF characteristics and the fatigue life stability of the DGT-5 compressor blades were verified through these processes. A fatigue life design procedure for the gas turbine compressor blade was established on the basis of the design, analysis, and test processes implemented in a previous study. In sum, the 5 MW class gas turbine compressor blades were found to be well designed in terms of resonance stability and fatigue life. Keywords: Gas turbine; Natural frequency; High cycle fatigue; Fatigue test; Dynamic test; Safety margin ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Introduction Industrial or aero gas turbine engines consist of numerous blades. The blades take on a variety of shapes according to the fluid, temperature, pressure, and output power. The blade design factor is specified for each developer. However, a critical factor that affects blade life is related to the material strength and the vibration prevention technique. Turbine blade damage is the leading cause of operational gas turbine failure. Incidents of gas turbine blade breakdown pose a high risk of chain breakdown to peripheral blades. Moreover, these incidents have a strong possibility of damaging the entire gas turbine engine, specifically in the gas turbine blade [1-4]. High cycle fatigue (HCF) destruction is a representative blade damage pattern that accounts for 55% of gas turbine engine mishaps. The erroneous prediction of the excitation force and resonance, design system error, mechanical material defect and damage, galling, and fretting can cause a
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