Higher aircraft energy efficiency may be achieved by minimizing the clearance between the rotating blade tips and respective surrounding casing. A common technical solution consists in the implementation of an abradable liner which improves both the operational safety and the efficiency of modern turbomachines. However, unexpected abradable wear removal mechanisms were recently observed in experimental set-ups as well as during maintenance procedures. Based on a numerical strategy previously developed, the present study introduces a numerical-experimental comparison of such occurrence.Attention is first paid to the review and analysis of existing experimental results. Good agreement with numerical predictions is then illustrated in terms of critical stress levels within the blade as well as final wear profiles of the abradable liner. Numerical results suggest an alteration of the abradable mechanical properties in order to explain the outbreak of a divergent interaction. New blade designs are also explored in this respect and it is found that the interaction phenomenon is highly sensitive to (1) the blade geometry, (2) the abradable material properties and (3) the distortion of the casing.

In the field of turbomachines, better engine performances are achieved by reducing possible parasitic leakage flows through the closure of the clearance distance between blade tips and surrounding stationary casings and direct structural contact is now considered as part of the normal life of aircraft engines. In order to avoid catastrophic scenarios due to direct tip incursions into a bare metal housing, implementation of abradable coatings has been widely recognized as a robust solution offering several advantages: reducing potential nonrepairable damage to the incurring blade as well as adjusting operating clearances, in situ, to accept physical contact events. Nevertheless, the knowledge on the process of material removal affecting abradable coatings is very limited and it seems urgent to develop dedicated predicting numerical tools. The present work introduces a macroscopic model of the material removal through a piecewise linear plastic constitutive law which allows for real time access to the current abradable liner profile within a time-stepping approach of the explicit family. In order to reduce computational loads, the original finite element formulation of the blade of interest is projected onto a reduced-order basis embedding centrifugal stiffening. First results prove convergence in time and space and show that the frequency content of the blade response is clearly sensitive to the presence of abradable material. The continuous opening of the clearance between the blade tip and the casing due to the material removal yields larger amplitudes of motion and new scenarios of structural divergence far from the usual linear conditions provided by the well-known Campbell diagrams.

International audienceMinimizing the operating clearance between rotating bladed-disks and stationary surrounding casings is a primary concern in the design of modern turbomachines since it may advantageously affect their energy efficiency. This technical choice possibly leads to interactions between elastic structural components through direct unilateral contact and dry friction, events which are now accepted as normal operating conditions. Subsequent nonlinear dynamical behaviors of such systems are commonly investigated with simplified academic models mainly due to theoretical difficulties and numerical challenges involved in non-smooth large-scale realistic models. In this context, the present paper introduces an adaptation of a full three-dimensional contact strategy for the prediction of potentially damaging motions that would imply highly demanding computational efforts for the targeted aerospace application in an industrial context. It combines a smoothing procedure including bicubic B-spline patches together with a Lagrange multiplier based contact strategy within an explicit time-marching integration procedure preferred for its versatility. The proposed algorithm is first compared on a benchmark configuration against the more elaborated bi-potential formulation and the commercial software Ansys. The consistency of the provided results and the low energy fluctuations of the introduced approach underlines its reliable numerical properties. A case study featuring blade-tip/casing contact on industrial finite element models is then proposed: it incorporates component mode synthesis and the developed 3D contact algorithm for investigating structural interactions occurring within a turbomachine compressor stage. Both time results and frequency-domain analysis emphasize the practical use of such a numerical tool: detection of severe operating conditions and critical rotational velocities, time-dependent maps of stresses acting within the structures, parameter studies and blade design tests