DOI: 15, 2021Proceedings Paper

Optimization of Airfoil Blend Limits With As-Manufactured Geometry Finite Element Models

Emily B. CarperJoeseph A. Beck


Conventional airfoil blend repair limits are established using nominal, design intent geometry. This convention does not explicitly consider the inherent blade-to-blade structural response variation associated with geometric manufacturing deviations. In this work, we explore whether accounting for these variations leads to significant differences in blend depths and develop a novel approach to effectively predict blade-specific blend allowables. These blade-specific values maximize the part repairability according to their proximity to defined structural integrity constraints. The methodology is demonstrated on the as-manufactured geometry of an aerodynamic research rig compressor rotor. Geometric point cloud data of this rotor is used to construct as-built finite element models (FEMs) of each airfoil. The effect of two large blends on these airfoils demonstrates the opportunity of blade-specific blend limits. A new approach to determine each airfoil’s blend repair capacity is developed that uses sequential least squares quadratic programming and a parametric blended blade FEM that accounts for manufacturing geometry variations and variable blend geometry. A mesh morphing algorithm modifies a nominal geometry model to match the...Continue Reading

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