A model of erosion rate prediction for component with complex geometry based on numerical simulation

Abstract

The structural components prone to erosion damage often exhibit irregular and complex shapes. Predicting erosion rates for such irregular geometries is a field that needs more attention, since it can be used to evaluate the performance of the component. This study aims to develop an evaluation method for predicting erosion rates of components with complex geometry. Standard erosion tests were performed on small plates to investigate the effects of different impact angles and particle velocities on the erosion rate of the target material. Based on these test results, the Newton iteration method was employed to determine the parameters of the Tabakoff and Grant erosion model. Moreover, these parameters were used in computational fluid dynamics simulation of components with complex geometries. Besides, a model was developed to convert the erosion rate density into erosion rate in numerical simulation, allowing quantitative comparison of simulation results with experimental data. The calibration of the erosion model parameters was conducted by using 1060 aluminum alloy specimens. The predicted erosion rate changes with impact angle showed consistency good agreement with the testing data. Subsequently, the erosion rate of a simplified similar structure for aircraft engine blade made of 1060 aluminum alloy was predicted and verified.