Preface |
|
xi | |
Authors |
|
xiii | |
|
|
1 | (22) |
|
1.1 Background and Motivation |
|
|
1 | (1) |
|
|
2 | (2) |
|
1.3 Initial Phase of Aero Engine Development |
|
|
4 | (2) |
|
1.4 Working Principle of Aero Gas Turbine Engines |
|
|
6 | (1) |
|
1.5 Critical Components of an Aero Engine |
|
|
7 | (1) |
|
1.6 Aero Engine Compressor |
|
|
7 | (3) |
|
1.7 Aero Engine Combustion Chamber |
|
|
10 | (1) |
|
|
10 | (2) |
|
1.9 Aero Engine Propelling Nozzle |
|
|
12 | (2) |
|
1.10 Design Philosophy of an Aero Engine Combustion Chamber |
|
|
14 | (1) |
|
1.11 Types of Combustion Chamber in Aero Engines |
|
|
15 | (2) |
|
1.11.1 Multiple Combustion Chambers |
|
|
15 | (1) |
|
1.11.2 Tubo-Annular Combustion Chamber |
|
|
16 | (1) |
|
1.11.3 Annular Combustion Chamber |
|
|
16 | (1) |
|
1.12 Complexities in Combustion Chamber Design |
|
|
17 | (2) |
|
1.13 Materials Used for Combustion Chamber |
|
|
19 | (1) |
|
1.14 Significant Contributions |
|
|
20 | (1) |
|
|
21 | (2) |
|
2 Fatigue Design Philosophy of an Aero Engine Combustor Casing |
|
|
23 | (30) |
|
|
23 | (1) |
|
2.2 Combustion Chamber Design |
|
|
23 | (2) |
|
2.3 Fatigue Failure in Aero Engines |
|
|
25 | (4) |
|
2.4 Fatigue Cycle Counting Methods |
|
|
29 | (5) |
|
2.5 Fatigue Life Evaluation Methods |
|
|
34 | (3) |
|
2.6 Fatigue Damage Assessment |
|
|
37 | (2) |
|
2.7 Nondestructive Testing Methods |
|
|
39 | (10) |
|
2.7.1 Radiography Inspection |
|
|
40 | (2) |
|
2.7.2 Magnetic Particle Inspection |
|
|
42 | (2) |
|
2.7.3 Dye Penetrant Inspection |
|
|
44 | (1) |
|
2.7.4 Ultrasonic Inspection |
|
|
45 | (2) |
|
2.7.5 Eddy Current and Electromagnetic Inspection |
|
|
47 | (2) |
|
2.8 Summary of the Design Philosophy |
|
|
49 | (1) |
|
2.9 Important Design Considerations for Combustor Casing |
|
|
50 | (1) |
|
|
51 | (2) |
|
3 Development of Test Facility and Test Setup |
|
|
53 | (16) |
|
|
53 | (2) |
|
3.2 Airworthiness and Certification |
|
|
55 | (1) |
|
3.3 Description of the Test Facility and Its Subsystems |
|
|
56 | (4) |
|
3.3.1 Hydraulic Power Supply |
|
|
57 | (1) |
|
3.3.2 Servo Valve with Manifold |
|
|
58 | (1) |
|
3.3.3 Safety Relief Valve |
|
|
59 | (1) |
|
|
59 | (1) |
|
3.3.5 Pressure Transducer |
|
|
59 | (1) |
|
3.4 Integration of the Subsystems |
|
|
60 | (1) |
|
3.5 Design and Manufacturing of Adaptors |
|
|
61 | (7) |
|
3.5.1 Bottom Fixing Plate |
|
|
62 | (1) |
|
3.5.2 Bottom Sealing Drum |
|
|
62 | (1) |
|
3.5.3 Inner Bottom Fixing Plate |
|
|
63 | (1) |
|
|
64 | (1) |
|
|
65 | (1) |
|
|
65 | (1) |
|
|
65 | (1) |
|
|
66 | (1) |
|
|
67 | (1) |
|
|
68 | (1) |
|
|
68 | (1) |
|
4 Manufacturing of an Aero Engine Combustor Casing, the Experimental Evaluation of Its Fatigue Life, and Correlation with Numerical Results |
|
|
69 | (32) |
|
|
69 | (1) |
|
4.2 Manufacturing Method of the Combustor Casing |
|
|
70 | (5) |
|
4.2.1 Metal Spinning Process |
|
|
70 | (1) |
|
4.2.1.1 Advantages of the Metal Spinning Process |
|
|
71 | (1) |
|
4.2.1.2 Disadvantages of Metal Spinning Process |
|
|
72 | (1) |
|
4.2.2 Electron Beam Welding Method |
|
|
72 | (2) |
|
4.2.3 Tungsten Inert Gas Welding Method |
|
|
74 | (1) |
|
4.3 Configuration of the Combustor Casing |
|
|
75 | (1) |
|
4.4 Experimental Evaluation of Fatigue Life |
|
|
76 | (5) |
|
|
77 | (2) |
|
4.4.2 Inspection Methodology |
|
|
79 | (2) |
|
4.5 Mechanical Properties of Combustor Casing Material |
|
|
81 | (1) |
|
4.6 Numerical Analysis of the Combustor Casing |
|
|
82 | (7) |
|
4.6.1 Details of the Finite Element Model |
|
|
83 | (1) |
|
4.6.2 Finite Element Model Quality Parameters |
|
|
84 | (1) |
|
4.6.3 Boundary Conditions |
|
|
85 | (1) |
|
|
85 | (1) |
|
|
85 | (1) |
|
|
85 | (2) |
|
|
87 | (1) |
|
4.6.8 Dittus Boelter Equation |
|
|
87 | (2) |
|
4.7 Numerical Analysis of the Igniter Boss and Its Correlation with Experimental Data |
|
|
89 | (9) |
|
4.8 Results and Discussions |
|
|
98 | (1) |
|
|
98 | (3) |
|
5 Reassessment of Fatigue Life of the Modified Combustor Casing |
|
|
101 | (12) |
|
|
101 | (1) |
|
5.2 Modified Manufacturing Methodology |
|
|
101 | (5) |
|
5.2.1 Forging Process: Benefits and Drawbacks |
|
|
101 | (5) |
|
5.3 Instrumentation of the Modified Combustor Casing |
|
|
106 | (1) |
|
5.4 Assembly and Trial Run |
|
|
106 | (3) |
|
|
109 | (1) |
|
5.6 Results and Discussion |
|
|
109 | (1) |
|
|
110 | (3) |
|
6 Safety Test on Modified Combustor Casing |
|
|
113 | (6) |
|
|
113 | (1) |
|
6.2 Test Component Details |
|
|
114 | (1) |
|
6.3 Instrumentation and Testing |
|
|
115 | (2) |
|
6.4 Results and Discussion |
|
|
117 | (1) |
|
|
118 | (1) |
|
7 Effect of Fatigue on the Proof Strength of an Aero Engine Combustor Casing |
|
|
119 | (20) |
|
|
119 | (1) |
|
7.2 Metallographic Techniques in Failure Analysis |
|
|
120 | (6) |
|
7.2.1 Stereo Zoom Microscopy |
|
|
121 | (1) |
|
7.2.2 Scanning Electron Microscopy |
|
|
121 | (4) |
|
|
125 | (1) |
|
7.3 Details of the Test Component |
|
|
126 | (1) |
|
7.4 Experimental Procedure |
|
|
127 | (1) |
|
|
128 | (9) |
|
|
128 | (1) |
|
7.5.2 Stereo Zoom Microscopy |
|
|
128 | (1) |
|
7.5.3 Scanning Electron Microscopy |
|
|
129 | (1) |
|
|
129 | (2) |
|
7.5.3.2 Energy Dispersive X-Ray Analysis |
|
|
131 | (1) |
|
|
131 | (1) |
|
7.5.5 Microhardness Measurement |
|
|
131 | (6) |
|
|
137 | (1) |
|
|
137 | (2) |
|
|
139 | (4) |
|
8.1 Certification and Acceptance of the Combustor Casing |
|
|
139 | (1) |
|
|
139 | (1) |
|
8.3 Scope for Further Work |
|
|
140 | (3) |
References |
|
143 | (10) |
Index |
|
153 | |