DEVELOPMENT OF SIMULATION METHODOLOGY FOR THE INTERACTION BETWEEN A SEPARATED FAN BLADE AND THE ABRADABLE RUB STRIP IN TURBOFAN ENGINES EXPERIENCING A FAN BLADE-OFF EVENT

温莎大学和加拿大普惠公司（P&WC）之间的这项合作研究项目的目标是开发一种精确的仿真方法，以模拟与涡轮风扇发动机转子分离的风扇叶片对发动机可磨损摩擦条的高速冲击。模拟方法将包括开发可磨损材料的本构材料模型，并结合能够表示风扇叶片高速相互作用和摩擦条穿透力学的数值方法。普惠加拿大公司将把这项技术作为其全发动机数值模型的组成部分，用于支持发动机认证计划的叶片密封评估。开发模拟方法的方法将包括(i)在不同载荷、温度和应变率条件下广泛表征可磨损材料，（ii）本构材料建模，以及（iii）研究多种高级数值方案的适用性，以模拟风扇叶片/可磨损条的相互作用。将进行广泛的测试程序，包括高速撞击和摩擦测试，以促进开发的模型的验证。除了模拟方法之外，本项目创造的新知识将包括推进对非均质多孔材料（如用于制造耐磨条的材料）的温度和应变率依赖行为的基本理解，理解此类材料的渗透力学，以及包含耐磨条材料多种特征的本构模型。P&WC开发这项新技术的一个主要好处是提高了全发动机数值模型预测风扇叶片脱落事件结果的准确性。这将最大限度地减少新发动机认证所需的物理测试数量，从而节省数百万美元的成本，减少发动机开发成本和交货时间，使加普惠在全球市场上更具竞争力，并更快地部署新产品。

The objective of this collaborative research project between the University of Windsor and Pratt & Whitney Canada (P&WC) is to develop an accurate simulation methodology to model the high-speed impact of a fan blade separated from the rotor of a turbofan engine on the abradable rub strip of the engine. The simulation methodology will include the development of a constitutive material model for abradable material combined with a numerical method capable of representing the mechanics of high-speed interaction and penetration of the rub strip by the fan blade. Pratt & Whitney Canada will use this technology as an integral part of their full-engine numerical models developed for blade containment evaluation in support of engine certification programs. The approach to developing the simulation methodology will include (i) extensively characterizing the abradable material at different loading, temperature, and strain-rate conditions, (ii) constitutive material modeling, and (iii) investigating the applicability of multiple advanced numerical schemes to simulate the fan blade/abradable strip interaction. An extensive testing program, including high-speed impact and rub tests, will be conducted to facilitate validation of the developed modeling. Besides the simulation methodology, new knowledge created in this project will include advancing the fundamental understanding of the temperature- and strain rate-dependent behavior of heterogeneous porous materials, such as the material used in making of abradable strips, understanding the penetration mechanics of such materials, and a constitutive model incorporating multiple features of the abradable strip material. A major benefit to P&WC from developing this new technology will be increased accuracy of their full-engine numerical models in predicting the outcomes of fan blade-off events. This will enable minimizing the number of physical tests required for new engine certification, thus providing multimillion-dollar cost avoidance and decreasing engine development costs and lead-time, allowing P&WC to be more competitive in the global market and deploy new products much faster.