3D Crack Growth Modelling In Gas Turbine Engines

Dr J. Hou
Air Vehicles Division, DSTO, Australia

MSC.Software VPD Conference 2006, Sydney, Australia, July 25-26, 2006

Presentation Title: 3D Crack Growth Modelling in Gas Turbine Engines
DSTO has been continuously enhancing its capability to provide through-life support to the ADF in aircraft engine component life management. One of the major requirements is an enhancement in computational 3D crack growth modelling and analysis. During service, gas turbine engine components experience both cyclic and sustained thermal and mechanical loadings which may result in fatigue and creep damage. As the damage sustained is highly dependent on the variations in both operating stresses and temperatures, finite element analyses (FEA) of the components can be very useful. This presentation outlines the critical issues involved in 3D crack growth and evaluates the results of a 3D crack growth capability in the ZENCRACK software with an emphasis on its validity and applicability to engine components. The primary issues to be dealt with in practice for 3D crack modelling are outlined, and the methodology and techniques implemented in ZENCRACK are described and discussed. Practical applications of ZENCRACK and individual evaluations for particular problems are presented. The various limitations and uncertainties encountered in the practical applications are identified. In particular, it is found that ZENCRACK is a useful tool for the calculation of stress intensity factors. Conclusions and recommendations are made for more accurate 3D crack growth modelling.