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Danuţa-Aurica GRAD et al.

/ (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES


Vol No. 5, Issue No. 2, 333 - 338

A correlation method between erosion and the


acoustic properties of bladed turbomachinery

Danuţa-Aurica GRAD Valeriu DRĂGAN


―Politehnica‖ University of Bucharest, Faculty of ―
POLITEHNICA‖ University Bucharest, Faculty of
Mechanical Engineering and Mechatronics Aerospace Engineering
Str. Independentei nr.313 sector 6,Bucharest, Building CD Str. Gheorghe Polizu, nr. 1, sector 1, 011061
Bucharest, Romania Bucharest, Romania
danielapopescu20@gmail.com drvaleriu@gmail.com

Abstract— This paper studies the influence of erosion and impinging particles and the breaking of material due to
corrosion on the acoustics of bladed turbomachinery. It is well repeated deformation caused by particle impact to the
known that eroded airfoils, such as the ones found in

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material. Reference 2 gives equations to predict erosion trough
turbomachinery, will tend to have an altered flow pattern, more these mechanisms, based on mass and velocity of the particles
turbulent than the ideal airfoil and ideal rugosity. By studying and also the angles of impact and physical proprieties of the
the turbulence parameters of the flow we can determine the particles and eroded material.
Sound Power Levels (SPL) of different blades – be it stators or
Experimental results of particles in gas streams are
rotors- and thus establish a reference to use in operating
conditions. given in Ref.3 by J.H. Neilson. Neilson factors in the shape,
size velocity and angles of attack in the effort to determine the
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Air breathing turbo machineries operate in various
conditions, some of which in erosive and/or corrosive
environments. It is important, especially under those conditions
to have a constant monitoring of the conditions of the blades
during operation. While it is known that only boroscopic
erosion-angle of attack characteristic for different specimen
materials.
For aluminum surfaces, Shelson and Kanhere give
out in Ref. 4 the erosion process equations for large particles.
examinations are to be used to decide the true condition of a The mathematical model derived there is based on the
bladed stage, we could use the complementary method of indentation hardness theory. It is shown that said model is
recording the sound emerging from different isolated
valid for relatively low velocities.
components of the machinery and compare it to a set of estimated
SPLs, that an erosion damaged blade would have.
-leveled equations, graphics, and tables are not prescribed,
This complementary method would be useful especially although the various table text styles are provided. The
in the cogeneration industry where shutting down a power plant formatter will need to create these components, incorporating
for inspections is necessary for boroscopy. Another use would be the applicable criteria that follow.
A
in the airliner industry where maintenance could have a Another important study is given by Hutchins, Ref 5
redundant system to look over the turbomachinery while in use,
in which the author presents a theoretical analysis of spherical
and gather relevant data for future inspections.
particle impinging at normal incidence-quite useful in
modeling the erosion patterns of the leading edges. The study
Keywords-turbomachinery; erosion; acoustics; is particularly of interest since it deals with aluminum alloy
specimens. Also, Ref. 6 offers a theoretical model for metal
erosion by particles at normal incidence. Sundararajan and
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I. INTRODUCTION Shewmon use criterion of critical plastic strain to show that


The causes of erosion are many and diverse ranging the localization model is more useful than the fatigue models
from solid particles suspended in air such as sand, dust, described in the early literature.
volcanic ash, ice and hail to liquid particles such as water
droplets in air breathing engines or condensation droplets in The matter investigated in this paper is weather or not
steam turbine installations. aerodynamic parameters of the eroded airfoil will have a
In order to understand erosion, various mathematical significant impact on the acoustics of the flow. In order to
models have been devised. achieve this we used Computational Fluid Dynamics software
Finnie, discusses in Ref.1 the prediction models for to simulate flow conditions around the considered shapes: the
both ductile ad brittle materials although stating that he baseline airfoil and the eroded airfoil. The viscosity model
quantitative aspects of erosion are difficult to calculate. J.G.A. used is a standard k-epsilon.
Bitter points out that the erosion process is caused by two
types of wear: the direct cutting of the material by the

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Danuţa-Aurica GRAD et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 5, Issue No. 2, 333 - 338

In Ref. 7 the most obvious erosion pattern were


observed at the trailing edge of the tip of the blade. This can [m]
be explained in two ways: f= centered frequency of the 1/3 octave [Hz] (applicable for
1.The thickness of the blade is lower near the trailing the BPF harmonics)
edge than near the leading edge therefore the same material N=rpm
loss will result in more radical airfoil changes. β=blade angle of attack at ¾ of its height
2. Near the walls washed by any two-phase flow, the The broadband noise is slightly more intuitive and it is
suspended aerosol is subject to both impingement and lift. The generated by the turbulence that arises near the blades due to
lift force that a suspended particle is subjected to has a it’s perturbation of the flow. It too has been mathematically
fundamentally different origin than conventional lift, i.e. shear described by various models of which we will mention
layer lift described by Saffman in 1965. Proudman’s and Lilley’s
It is hence to be expected that the walls to which the
flow is substantially laminar and tangential will have less B. The Proudman and Lilley Equations
erosion than those nearer the trailing edge which are Proudman(1953) gives the following equation for the total
substantially turbulent. acoustic power radiated by a volume unit that contains
Bladed rotating machinery noise is generally turbulent flow:
composed by two components : the broadband and the pure
tones or rotor harmonics, which peek above the baseline sound
pressure level. The general prescription when designing rotary

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bladed stages is to adapt the stator vane number to reach an (5)
evanescence criterion of the desired harmonic frequency of the where u=turbulent velocity
rotor, typically the second or third. Tyler and Sofrin ε=turbulent dissipation
demonstrated that the ideal number of vanes is given by Eq.1: c=sound velocity
(1) ρ=reference density
V is the number of stator vanes α= Proudman’s constant
B is the number of rotor blades
n is the order of the harmonic frequency
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The stator rotor interaction is the main theme in evaluating
turbomachinery noise, various formulations have been made:
is the turbulent Strouhal number
(6)

(7)
(2)
(8)
BPF is the by-pass frequency, i.e. the first natural harmonic
of the rotor Ф=0,42
N is the number of rotations per minute
Lilley gives the equation :
The acoustic mode radiated by the stator-rotor interaction, (9)
m is given by:
A
(3)
(10)

III. THE CFD SETUP


II. SPECTRAL ANALISYS OF THE FAN NOISE
The airfoil used for this particular investigation was a
A. General Aspects NACA 2406-43 – Fig.1a for the baseline and, by interpolation
of photographies given in Ref 7, we have obtained the eroded
There are two different aspects of the noise spectrum of
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airfoil seen in Fig.1d. Also Fig. 1b and 1c depict airfoils


any bladed machinery: eroded at the leading edge with and without trailing edge
-Pure tones – in fact very narrow band with-represent damage. The SPL plots of the four considered airfoils are
the harmonics of the rotor, which are the peeks in SPL. obtained with the Proudman formalism which was found to be
-Broad band noise, generated by the turbulent wakes more realistic than the Lilley equation which is more suited
at the trailing edge of the blades. rather for nonstationary simulations.
For pure tones, Soderman and Mort (1983) give the The flow parameters are presented below:
following semi-empirical equation:
X velocity=200 m/sec
Y velocity=25m/sec
(4) Angle of attack=7.125 deg
Temperature=293.15 K
Static Pressure=101325 Pa
Rugosity=0

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ISSN: 2230-7818 @ 2011 http://www.ijaest.iserp.org. All rights Reserved. Page 334


Danuţa-Aurica GRAD et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 5, Issue No. 2, 333 - 338

IV. RESULTS AND CONCLUSIONS


Figures 3 trough 6 depict the Sound Power Level calculated
with Eq.5, the common scale is given in Fig.2.
It can be seen that the aerodynamic turbulent noise
generated by the eroded airfoil is significantly higher than the
noise generated by the baseline airfoil. This will yield an
increase in the broadband noise. The most influence on noise
production is that of the eroded leading edge.
This aerodynamic turbulence is directly linked to the loss of
aerodynamic lift to drag ratio and hence, can be correlated
with the efficiency of the compressor stage.
The velocity deficit, which is the aerodynamic reason for
the stator-rotor interaction, is illustrated in figures 5 and 6.
The flow field downstream of the eroded blade is highly
distorted but with a much thicker velocity deficit area.
Therefore the stator rotor interaction will have a longer time
hence producing additional tones around the natural harmonics
of the rotor.
Figure 1. The NACA 2406-43 airfoil (a), with leading edge erosion (b), with

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trailing edge erosion (c) with both trailing and leading edge erosion (d)
A. Conclusions
The mathematical aero-acoustic formalism of Proudman
has been applied in order to evaluate the Sound Pressure
Levels of a baseline airfoil and an eroded airfoil, with good
results on both cases.
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The findings were that an eroded airfoil will develop a
more turbulent flow which in turns will get more erosion
damage to the trailing edge of the foil. In addition to that there
are significant aerodynamic downsides of the eroded profile,
which has a very low lift to drag ratio and is, also prone to
stalling – which can produce the entire compressor stage to
surge.
Aerodynamic noise generated by the eroded airfoil is
significantly higher than the baseline, therefore offering a
perspective for non-invasive investigations during the
turbomachinery operation, cutting maintenance costs trough
the elimination of periodical boroscopic examinations.
A
The leading edge erosion is the most influential in noise Figure 2. The scale of the SPL plots of the airfoils considered
generation although, geometrically the trailing edge erosion is
more spectacular.
The study was carried out with the purpose to investigate if
acoustic measurements would prove useful in investigating the
erosion state of airfoils. However further studies could
improve this method by using the FW-H equations and
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unsteady CFD simulations to determine the frequency


spectrum of the SPL for many more damaged airfoils in order
to establish a database for practical referencing.

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Danuţa-Aurica GRAD et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 5, Issue No. 2, 333 - 338

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Figure 3. The NACA 2406-43 airfoil SPL

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Figure 4. The NACA 2406-43 with leading edge erosion SPL
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Figure 5. The NACA 2406-43 with trailing edge erosion SPL

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Danuţa-Aurica GRAD et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 5, Issue No. 2, 333 - 338

Figure 6. The NACA 2406-43 with leading and trailing edge erosion SPL

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ACKNOWLEDGMENT
The work has been funded by the Sectoral Operational
Programme Human Resources Development 2007-2013 of the
Romanian Ministry of Labour, Family and Social Protection
through the Financial Agreements POSDRU/107/1.5/S/76909
and POSDRU/88/1.5/S/60203.
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A
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Danuţa-Aurica GRAD et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 5, Issue No. 2, 333 - 338

REFERENCES
AUTHORS BIOGRAPHY
[1] I. Finnie „Erosion of surfaces by solid particels‖, Wear, Volume 3, Issue
2, March-April 1960, Pages 87-103;
Danuţa Grad is a Ph.D student with the Department [2] J.G.A. Bitter, in „A study of erosion phenomena‖, Wear,Volume 6, Issue
of Machine Elements and Tribology of the Mechanical 1, January-February 1963, Pages 5-21;
Engineering Faculty of the ― Politehnica‖ University of [3] J.H. Neilson and A Gilchrist, „Erosion by a stream of solid particles‖,
Wear, Volume 11, Issue 2, February 1968, Pages 111-122;
Bucharest in co-tutelle with the Aerospace Sciences ― Elie
[4] G.L. Sheldon si A. Kanhere, „An investigation of impingement using
Carafoli‖ of the Aerospace Engineering Faculty, also of the single particles‖, Wear, Volume 21, Issue 1, August 1972, Pages 195-
―Politehnica‖ University of Bucharest. 209;
Valeriu Drãgan is a Ph.D. with the Aerospace [5] I.M. Hutchings, „A model for the erosion of metals by sherical particles
Sciences ―Elie Carafoli‖ of the Aerospace Engineering at normal incidence‖, Wear, Volume 70, Issue 3, 15 August 1981, Pages
269-281;
Faculty, ―Politehnica‖ University of Bucharest.
[6] G. Sundararajan si P. G. Shewmon, „A new model for the erosion of
metals at normal incidence‖, Wear
Volume 84, Issue 2, 15 January 1983, Pages 237-258;
[7] Gray SimpsSimpson-FOREIGN COMPARATIVE TEST PROGRAM
ON ― RUSSIAN EROSION RESISTANT COATINGS FOR US NAVY
GTE COMPRESSORS‖ JTEG MEETING AT LIMA ARMY TANK
PLANT 24TANK 24--26 JULY 200126 2001

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[8] http://my.fit.edu/itresources/manuals/fluent6.3/help/html/ug/
[9] Thomas Brendel; Dr. Falko Heutling; Wolfgang Eichmann; Markus
Ücker; Dr. Thomas Uihlein "MTU solutions against erosive attack and
loss of EGT margin in turbo engines – ERCoat nt"
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