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

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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.