This work develops a methodology for full engine FEA simulation of the fan blade off containment test for a jet engine using LS-Dyna. The fan blade off containment test is a safety requirement involving the intentional release of a fan blade when the engine is running at full power. The released blade must not pierce or fracture the engine cases during the impact or rotating unbalance. The novel feature of the LS-Dyna simulation is the extensive full engine geometry as well as the widespread use of nonlinearities (mainly plasticity and friction) to absorb the large kinetic energies of the engine rotors. The methodology is simple to use, runs quickly and is being recognized by industry as a contender for widespread implementation. Future applications look promising enough that the methodology warrants further development and refinement.

This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm. A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps. A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values. Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path. Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis.

This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm. A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps. A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values. Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path. Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis.

This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm. A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps. A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values. Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path. Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis. / Applied Science, Faculty of / Mechanical Engineering, Department of / Graduate

A new method and mechanism for generating non-uniform, or distorted, aircraft engine inlet flow is being developed in order to account for dynamic changes during the creation and propagation of the distortion. Total pressure distortions occur in gas turbine engines when the incoming flow is disturbed. Dynamic total pressure changes may happen slowly, or may occur very rapidly. The disturbance of the incoming flow can change engine operating characteristics, including lowering the surge limit and creating High Cycle Fatigue incidents. In order to create a distorted flow with dynamic characteristics, a mechanism must be developed that when actuated, can change the distortion pattern and intensity with respect to time. This work covers the initial design of both the distorting and actuating device. The design chosen is a low force design that is practically independent of flow forces. This allows the system to be easily sized for all flow conditions. The study also includes developing the working design into an overall prototype. Testing is also performed to validate the design as the most advantageous choice. / Master of Science

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Multidisciplinary design optimization (MDO) is a technique that has found use in the field of aerospace engineering for aircraft design. It uses optimization to simultaneously solve design problems with several disciplines involved. In order to predict aircraft performance an engine performance simulation model, also called “rubber engine”, is vital. The goal of this project is to validate and integrate a rubber engine model into an MDO environment. A method for computer simulation of gas turbine aero engine performance was created. GasTurb v11, a commercial gas turbine performance simulation software, was selected for doing the simulation models. The method was validated by applying it to five different jet engines of different size, different type and different age. It was shown that the simulation engine model results are close to the engine manufacturer data in terms of SFC and net thrust during cruise, maximum climb (MCL) and take off (MTO) thrust ratings. The cruise, take off and climb SFC was in general predicted within 2% error when compared to engine manufacturer performance data. The take off and climb net thrust was in general predicted with less than 5% error. The integration of the rubber engine model with the MDO framework was started and it was demonstrated that the model can run within the MDO software. Four different jet engine models have been prepared for use within the optimization software. The main conclusion is that GasTurb v11 can be used to make accurate jet engine performance simulation models and that it is possible to incorporate these models into an MDO environment.