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Project Overview Project broken into 3 parts : Part 1: Baseline design 3D model

Thermo-Mechanical Fatigue Optimization of Three Dimensional Stress Concentration Features in a Tangentially Bladed Rotor by Nicholas D. Aiello. Project Overview Project broken into 3 parts : Part 1: Baseline design 3D model Create 3D CAD model of slot area in NX Mesh model in ANSYS

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Project Overview Project broken into 3 parts : Part 1: Baseline design 3D model

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  1. Thermo-Mechanical Fatigue Optimization of Three Dimensional Stress Concentration Features in a Tangentially Bladed RotorbyNicholas D. Aiello

  2. Project OverviewProject broken into 3 parts: • Part 1: Baseline design 3D model • Create 3D CAD model of slot area in NX • Mesh model in ANSYS • Apply boundary conditions and interface definition • Run and post process results • Part 2: 2D optimization routine • Create 2D CAD plate model of slot area in NX • Determine 2D-3D stress factors for each mission point using 3D model and TMF lifing file • Vary thickness of plane stress elements to replicate 2D-3D stress factors at each mission point • Create iSight DOE to map effect of change of slot shape on TMF life of slots • Review DOE map to determine optimal solution that meets design constraints • Part 3: Result verification 3D model • Create 3D model of optimized geometry • Repeat steps from part 1 • Compare stress concentrations predicted by 2D model to 3D results

  3. Geometry Summary • 3D rotor model created • 3D model includes upper portion of disk web and full disk rim area • 3D stress concentration features are load slots, lock slots, and shield slots • Model is cut up for ease of meshing/applying BC’s in ANSYS

  4. Mesh Summary • Blade Definition • Blade “stump” used to model correct interface with disk • Mass point at CG represents the upper portion of the blade • Stiff, massless spring elements connect mass points to blade stumps Model meshed using 3 types of 3D elements 10 node tetrahedron: for the complex geometry of the area surrounding the 3D slots 8 node brick: for axi-symmetric portions of the disk to help keep the element count down/increase run speed 20 node brick: collapse to form the pyramid shaped elements that connect the other 2 element types

  5. Boundary Condition Summary • Mapped/cut boundaries • Nodes exported from 3D FE mesh • Exported nodes compressed onto mid-plane, file created for use in thermal mapping • Compressed mid-plane nodes not on cut boundaries deleted, additional file created for mapping displacements on model boundaries • Other boundaries/interfaces • Contact elements used for blade stub to disk interface • Blades constrained for no circumferential motion • “Roller” constraints applied to disk sector boundaries

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