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Frontiers of Structural and Civil Engineering

Front. Struct. Civ. Eng.    2019, Vol. 13 Issue (3) : 505-514     https://doi.org/10.1007/s11709-018-0493-3
RESEARCH ARTICLE
Impact analysis of compressor rotor blades of an aircraft engine
Y B SUDHIR SASTRY1(), B G KIROS2, F HAILU2, P R BUDARAPU3
1. Department of Aeronautical Engineering, Institute of Aeronautical Engineering, Dundigal, Hyderabad 500043, India
2. Department of Aeronautical Engineering, College of Engineering, Defense University, Bishoftu 1041, Ethiopia
3. School of Mechanical Sciences, Indian Institute of Technology Bhubaneswar, Bhubaneswar 752050, India
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Abstract

Frequent failures due to foreign particle impacts are observed in compressor blades of the interceptor fighter MIG-23 aircraft engines in the Ethiopian air force, supplied by the Dejen Aviation Industry. In this paper, we made an attempt to identify the causes of failure and hence recommend the suitable materials to withstand the foreign particle impacts. Modal and stress analysis of one of the recently failed MIG-23 gas turbine compressor blades made up of the following Aluminum based alloys: 6061-T6, 7075-T6, and 2024-T4, has been performed, apart from the impact analysis of the rotor blades hit by a granite stone. The numerical results are correlated to the practical observations. Based on the modal, stress and impact analysis and the material properties of the three considered alloys, alloy 7075-T6 has been recommended as the blade material.

Keywords axial flow compressor      rotor and stator blades      aircraft engine      stress and impact analysis      aluminum alloys     
Corresponding Authors: Y B SUDHIR SASTRY   
Online First Date: 18 September 2018    Issue Date: 05 June 2019
 Cite this article:   
Y B SUDHIR SASTRY,B G KIROS,F HAILU, et al. Impact analysis of compressor rotor blades of an aircraft engine[J]. Front. Struct. Civ. Eng., 2019, 13(3): 505-514.
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http://journal.hep.com.cn/fsce/EN/10.1007/s11709-018-0493-3
http://journal.hep.com.cn/fsce/EN/Y2019/V13/I3/505
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Y B SUDHIR SASTRY
B G KIROS
F HAILU
P R BUDARAPU
Fig.1  MIG-23 gas turbine engine separating from the aircraft. The multistage axial flow compressor is on the right side, whereas the gas turbine is placed on the left side of the engine
Fig.2  Two different views of the multistage axial flow compressor showing the rotor and stator blades in different stages
Fig.3  (a) Front view of the compressor disc showing the bases of fitted rotor blades. Isolated (b) rotor and (c) stator blades of the compressor
Fig.4  (a) A view of the damaged first stage compressor rotor blades along with the rotor disc. (b) A portion of (a) closely showing the damage blades
Fig.5  Geometry of the blade showing the leading and trailing edges, camber line, suction and pressure sides
quantity units alloy
6061-T6 7075-T6 2024-T4
Young’s modulus GPa 68.9 71.7 73.1
shear modulus GPa 26 26.9 28
density kg/m3 2700 2810 2780
Poisson’s ratio 0.33 0.33 0.33
yield strength MPa 275 503 324
ultimate strength MPa 310 572 469
shear strength MPa 207 331 283
specific heat capacity J/(kg·K) 896 960 875
thermal conductivity W/mK 167 130 121
ultimate bearing strength MPa 607 814
bearing yield strength GPa 386 441
fracture toughness MPa√m 29 29 26
fatigue Strength MPa 96.5 159 138
Tab.1  Mechanical properties of the Aluminum alloys 6061-T6, 7075-T6, and 2024-T4 as per ASM Inc [53]
parameter quantity
number of rotor blades (1st stage) 19
number of stator blades (1st stage) 35
number of rotor blades (2nd stage) 29
number of stator blades (2nd stage) 50
blade length (cm) 23 (TE) and 26 (LE)
chord length (cm) 12.3 (root), 14.4 (mean) and 16.4 (tip)
over all pressure ratio 12.9:1
mach number 2.35
rotational speed (RPM) 8464
mass flow rate (kg/s) 105
blade inlet temperature (K) 288
blade tip radius (m) 0.4335
blade mean radius (m) 0.3035
blade root radius (m) 0.1735
blade height (m) 0.260
Tab.2  Compressor data adopted from Ref. [3]
Fig.6  Geometry of the airfoil created in the SOLIDWORKS software
mode natural frequency (Hz)
2024-T4 6061-T6 7075-T6
1 11.22 11.31 11.34
2 30.55 30.79 30.86
3 40.83 41.16 41.25
4 45.58 45.95 46.05
5 66.31 66.84 66.98
6 80.94 81.59 81.77
7 93.36 94.11 94.32
8 94.22 94.97 95.19
9 120.38 121.35 121.62
10 141.85 142.98 143.31
Tab.3  Natural frequencies of the blades made up of Aluminum alloys 6061-T6, 7075-T6, and 2024-T4, estimated based on the finite element analysis
Fig.7  First ten natural frequencies of three alloys considered in this paper
Speed (RPM) Maximum observed
Displacement (mm) von Mises stress (MPa)
5000 1.86 174.48
6000 3.43 152.91
8464 4.41 217.02
Tab.4  Maximum displacements and von Mises stresses at speeds 5000, 6000, and 8464 RPM
Fig.8  Deformed configurations of the rotor blade at (a) mode 1, (b) mode 2, (c) mode 3, and (d) mode 4
Fig.9  Stone impact analysis of compressor rotor blade. (a) Rotor blade and stone after meshing in ANSYS, ready for the impact analysis in LS-DYNA. (b) Displacement plot of the rotor blade showing the maximum displacement at the point of impact. (c) Distribution of the von Mises stress on the blade surface after the stone impact. (d) A close up around the impact point in (c), showing the point of highest stresses
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