Blade Production Research Articles

Finite Element Analysis of CM247LC Superalloy for Gas Turbine Blade Application

The objective of this article is to conduct a comparative analysis of the various materials used in the production of gas turbine blades. The materials under investigation include CM247LC, Nimonic 80A, and Inconel 738. The selected blade materials are required to demonstrate exceptional resistance to high temperatures and corrosion. It is determined that the most appropriate material for the construction of a gas turbine blade is a nickel-based superalloy. For the purposes of Finite Element Analysis (FEA), the aforementioned materials are defined as nickel-based superalloys. A comprehensive analysis of these materials was conducted using the ANSYS 2024 R2 student edition and a combination of structural and vibrational analyses was carried out. The deformation observed in CM247LC and Nimonic 80A exhibited nearly identical values of 0.965 mm and 0.884 mm, respectively. The results of the vibrational analysis indicated that all materials successfully circumvented the natural frequency as well as the operational natural frequency of 50 Hz, thereby ensuring the safe operation of the gas turbine blade. The findings demonstrated that the CM247LC satisfied both criteria for material selection, making it the most suitable material for gas turbine blade applications when compared to alternative materials. This is due to its comparatively lower deformation despite experiencing a greater magnitude of centrifugal force.

Aeroelastic Simulation of Full-Machine Wind Turbines Using a Two-Way Fluid-Structure Interaction Approach

Two-way fluid–structure interaction (FSI) simulation of wind turbines has gained significant attention in recent years due to the growth of offshore wind energy development. Strong coupling procedures in these simulations predict realistic behavior with higher accuracy but result in increased computational costs and potential numerical instabilities. This paper proposes a mixed weak and strong coupling approach for the FSI simulation of a 5 MW wind turbine. The deformation of the turbine blade is calculated using a weak coupling approach, ensuring blade deflection meets a convergence criterion before rotating to the next azimuthal position. Fluid and solid solvers are partitioned, utilizing the commercial software packages STAR-CCM+ and Abaqus, respectively. Flexible and rigid blade cases are modeled, and the calculated loads, power, and blade tip displacement for the rotor at a constant rotating speed are compared. The proposed model is validated, showing good agreement with the existing literature and results comparable to those from another validated wind turbine simulator. The effect of rotor–tower interaction is evident in the results. Based on our calculations, the power production of flexible blades is evaluated to be 9.6% lower than that of rigid blades.

Cognitive digital twin in manufacturing process: integrating the knowledge graph for enhanced human-centric Industry 5.0

Industry 5.0 emphasises human-centric intelligent manufacturing, posing challenges in integrating human expertise with advanced machine capabilities. To address these challenges, a novel three-layer cognitive digital twin model based on knowledge graphs is proposed, designed to integrate workers’ knowledge and experience into intelligent manufacturing processes. This model comprises three layers: an ontology layer that constructs a foundational process knowledge ontology library; a knowledge layer that maps real-time data to dynamically update digital models; and a cognitive layer that utilises machine learning, knowledge reasoning, and knowledge mining for advanced analysis, state understanding, and model evolution. The model promotes user interaction through intuitive interfaces and a Q&A system, leveraging techniques such as knowledge reasoning and querying to support decision-making and enhance worker engagement. Validated through a system implemented for aero-engine blade production, this cognitive digital twin model leverages human expertise and machine capabilities to enhance process control, quality management, and overall efficiency. The proposed approach demonstrates significant potential for advancing personalised human-machine interaction in manufacturing, truly embodying the value of a human-centric approach and paving the way for future developments in the field.

Static solid cooling (SSC) method for directional solidification and single crystal production: A CAFE Simulation Approach

Static solid cooling (SSC) method for directional solidification and single crystal production: A CAFE Simulation Approach

Heterogeneous graph neural network for modeling intelligent manufacturing systems

Abstract Currently, manufacturing systems have become more and more complex, often involving multiple machines, systems and processes to produce workpieces. In order to facilitate comprehensive analysis and control of manufacturing processes, the integration of connections between machine level, system level, and process level in manufacturing process modeling is needed. However, traditional graph deep learning models are unable to take into account the heterogeneity of different machines in the system when modeling manufacturing systems. To address this problem, this paper proposes a new approach: modeling manufacturing systems using the heterogeneous graph neural network sample and aggregate algorithm based on cutting-edge Bayesian neural networks and graph deep learning. This method considers the connection between different manufacturing system levels, treats machine operations as nodes, and connects different nodes through material flow and operational similarity. The effectiveness of the method is demonstrated through its application to model an aero-engine blade production line. Extensive numerical experiments show that the proposed graph modeling method is effective in expressing the heterogeneity of different machines and multi-level manufacturing processes. By integrating machine heterogeneity into the modeling of a manufacturing system, it not only facilitates comprehensive analysis and control of the manufacturing process, but also lays the foundation for cost savings and productivity improvements in the manufacturing system.

Effect of Al(OH)3 on the properties of silica-based ceramic cores prepared by laser powder bed fusion combined with vacuum infiltration

Effect of Al(OH)3 on the properties of silica-based ceramic cores prepared by laser powder bed fusion combined with vacuum infiltration

A study of Early Upper Paleolithic blade production in the third cultural layer at Suyanggae Locality VI, Republic of Korea

A study of Early Upper Paleolithic blade production in the third cultural layer at Suyanggae Locality VI, Republic of Korea

Priority-based two-phase method for hierarchical service composition allocation in cloud manufacturing

Priority-based two-phase method for hierarchical service composition allocation in cloud manufacturing

Economic Impact Assessment of Structural Health Monitoring Systems on the Lifecycle of a Helicopter Blade

Structural Health Monitoring Systems (SHMS) are currently widely investigated in the literature, however, their application to the aerospace industry is still limited. One of the reasons lies in the lack of methods aimed at evaluating their economic impact on the lifecycle of the structural element to be monitored [1]. In this work the economic impact of FBG-based SHMS was evaluated on a composite helicopter rotor blade, considering two perspectives: Beginning Of Life (BOL), concerning the blade production, and Middle Of Life (MOL), concerning its usage. The processes were modeled using the IDEF0 methodology, which allowed deriving the cost models for two scenarios: the current one, and the one including the SHMS. In BOL, the SHMS was supposed providing support to the development of new composite rotor blades, including the curing cycle definition and certification tests. In MOL the SHMS was supposed performing automatic scheduled inspections coupled with the traditional ones. The cost model was implemented in the Probabilistic Damage Tolerance Analysis [2] to compare the scenarios having the same blade Probability Of Failure and considering the performances of the SHMS in terms of Probability Of Detection and Probability of False Alarm. Results show that an economic benefit may be achieved using the SHMS in the development of new blades, potentially reducing the number of blades tested and number of autoclave cycles. Moreover, it was found that the traditional scheduled detailed inspection intervals could be extended if automatic SHMS inspections are performed in addition, maintaining the same Probability Of Failure. [1] Büchter, K. D. et al. (2022). Modeling of an aircraft structural health monitoring sensor network for operational impact assessment. Structural Health Monitoring, 21(1), 208-224. [2] Lin, K. Y., & Styuart, A. V. (2007). Probabilistic approach to damage tolerance design of aircraft composite structures. Journal of Aircraft, 44(4), 1309-1317.

Correlation analysis of primal cuts weight, fat contents, and auction prices in Landrace × Yorkshire × Duroc pig carcasses by VCS2000.

Currently, in pork auctions in Korea, only carcass weight and backfat thickness provide information on meat quantity, while the production volume of primal cuts and fat contents remains largely unknown. This study aims to predict the production of primal cuts in pigs and investigate how these carcass traits affect pricing. Using the VCS2000, the production of shoulder blade, loin, belly, shoulder picnic, and ham was measured for gilts (17,257 pigs) and barrows (16,365 pigs) of LYD (Landrace × Yorkshire × Duroc) pigs. Single and multiple regression analysis were conducted to analyze the relationship between the primal cuts and carcass weight. The study also examined the correlation between each primal cut, backfat thickness (1st thoracic vertebra backfat thickness, grading backfat thickness, and Multi-brached muscle middle backfat thickness), pork belly fat percentage, total fat yield, and auction price. A multiple regression analysis was conducted between the carcass traits that showed a high correlation and the auction price. After conducting a single regression analysis on the primal cuts of gilt and barrow, all coefficients of determination (R2) were 0.77 or higher. In the multiple regression analysis, the R2 value was 0.98 or higher. The correlation coefficient between the carcass weights and the auction price exceeded 0.70, while the correlation coefficients between the primal cuts and the auction prices were above 0.65. In terms of fat content, the backfat thickness of gilt exhibited a correlation coefficient of 0.70, and all other items had a correlation coefficient of 0.47 or higher. The correlation coefficients between the Forequarter, Middle, and Hindquarter and the auction price were 0.62 or higher. The R2 values of the multiple regression analysis between carcass traits and auction price were 0.5 or higher for gilts and 0.4 or higher for barrows. The regression equations between carcass weight and primal cuts derived in this study exhibited high determination coefficients, suggesting that they could serve as reliable means to predict primal cut production from pig carcasses. Elucidating the correlation between primal cuts, fat contents and auction prices can provide economic indicators for pork and assist in guiding the direction of pig farming.

Parametric study on the effect of material properties, tool geometry, and tolerances on preform quality in wind turbine blade manufacturing

Parametric study on the effect of material properties, tool geometry, and tolerances on preform quality in wind turbine blade manufacturing

Core Reduction Methods of Mizyn Industry of Epigravettian Techno-Complex

Mizyn is one of the main sites of the Epigravettian techno-complex of the Middle Dnipro Basin. One of the modern approaches to the study of the material culture of Upper Palaeolithic societies is the study of technological features of flintknapping. The purpose of this study is to determine the core reduction strategy of the Mizyn site in particular and the Mizyn industry in general. To achieve this goal, an attributional analysis of the artefacts from the lithic assemblage of excavation area no. 1 of the Mizyn site was carried out. Fragments of raw material, core-like pieces, and lamellar pieces have been analysed. This paper focuses on the study of the assemblage of core-like pieces, taking into account the imperfections of the 70-year-old field research methodology. The main outcome of this study was the elucidation of discrete core reduction strategies of the Mizyn site. Rounded raw material played a greater role in the production of blades from narrow flaking surface cores and sub-cylindrical cores (fig. 4). Narrow flaking surface cores (fig. 6) made from plate-like raw materials were used to produce blades and micro-blades. Blades were necessary blanks for making a “home” set of tools. Bladelets and micro-blades were used for hunting equipment. Both strategies are characterised by unidirectional splitting and the use of the hard hammer-stone. Crested and débordante lamellar pieces were required to maintain the convexity of the core’s flaking surface. The overhang trimming method was also used, most commonly for bladelets and micro-blade cores. The main reason for core discard was the occurrence of hinge fractures on the flaking surface, which were repaired by using an opposite striking platform. The same features of the lithic assemblage are found at the Barmaky site. As a result, discrete strategies of the core reduction are a typical feature for the Mizyn industry. As Barmaky and Mizyn are the oldest Epigravettian sites in the Middle Dnipro basin, this feature can be explained by a chronological factor. However, the choice of a strategy can also be explained by the regional characteristics of the landscape and the adaptation of the primary inhabitants to them.

Making wind turbine blades more sustainable

Researchers at Virginia Tech’s College of Engineering will use new methods of additive manufacturing, computational design, and a recyclable, high strength thermoplastic material to improve the environmental footprint of wind turbine blade production.

Lithic stories of broken relations after the Storegga tsunami in Mesolithic western Norway?

ABSTRACT Major changes in lithic technologies are often explained by either migration or crisis. Here we argue that continuity and minor adjustments in lithic production can tell equally dramatic tales of altered social situations. We base our interpretations on identified lithic blade production concepts and raw materials at 30 sites dating 7500–5000BC, i.e. from before and after the massive Storegga tsunami hit the coast of western South-Norway around 6150BC. Regional continuation, but also local variations in lithic production are interpreted inspired by a machine-oriented ontological framework. The tsunami disrupts the environment, society and its lithic traditions are affected. Although no immediate major breaks are observed, sometime after the tsunami, societies or lithic production as ‘machines’ in separate regions had begun to hum to different tunes. We suggest that variation in tsunami impact had created differing local social contexts which in turn pushed the lithic traditions down diverging paths.

Non-Gaussian Multivariate Process Capability Based on the Copulas Method: An Application to Aircraft Engine Fan Blades

Abstract Process capability indices (PCIs) are major tools in geometric dimensioning and tolerancing (GD&T) for quantifying the production quality, monitoring production, or prioritizing projects. Initially, PCIs were constructed for studying each characteristic of the process independently. Then, they have been extended to analyze several dependent characteristics simultaneously. Nowadays, with the increasing complexity of the production parts, for example, in aircraft engines, the conformity of one part may rely on the conformity of hundreds of characteristics. Also, because those characteristics are dependent, it may be misleading to make decisions based only on univariate PCIs. However, classical multivariate PCIs in the literature do not allow treating such amount of data efficiently, unless assuming Gaussian distribution, which may be false. Regarding those issues, we advocate for PCI based on some transformation of the conformity rates. This presents the advantage of being free from distributional assumptions, such as the Gaussian distribution. In addition, it has direct interpretation, allowing it to compare different processes. To estimate the PCIs of parts with hundreds of characteristics, we propose to use Vine Copulas. This is a very flexible class of models, which gives precise estimation even in high dimension. From an industrial perspective, the computation of the estimator can be costly. To answer this point, one explains how to compute a lower bound of the proposed PCI, which is faster to calculate. We illustrate our method adaptability with simulations under Gaussian and non-Gaussian distributions. We apply it to compare the production of fan blades of two different factories.

Knowledge-based digital twin system: Using a knowlege-driven approach for manufacturing process modeling

Knowledge-based digital twin system: Using a knowlege-driven approach for manufacturing process modeling

A Cold Habitat: Mapping Blade Assemblages Between the Siberian Altai and the Tibetan Plateau During MIS 3

How and why early hunter–gatherers expanded into the challenging environments of the Tibetan Plateau during the Pleistocene remain largely unexplained. The discovery of the archaeological site of Nwya Devu, characterized by lithic blade production, brings new evidence of human expansion to high elevations ca. 40–30 ka. The blade assemblage currently lacks technological antecedents in East Asia. During Marine Isotope Stage 3, the surrounding lowlands to the Plateau were dominated by a distinct type of industry broadly named “core and flake.” It is suggested that the Nwya Devu blade assemblage derives from traditions in the eastern Eurasian Steppe, a clustered hub for Upper Paleolithic blade technology. In contrast to the East Asian lowlands, the Tibetan Plateau shares a number of environmental similarities with North and Central Asia such as low temperature and humidity, long winters, strong seasonality, and grassland landscapes. Blade and core-and-flake technologies tend to be associated with different environments in eastern Asia. We hypothesize that this geographic distribution indicates different sets of behavioral adaptations that map onto distinct ecozones and are relevant to human expansion to the Tibetan Plateau during Marine Isotope Stage 3. To evaluate the working model, we characterized the environmental parameters for both blade and core-and-flake technologies in eastern Asia during the period. The results show that environmental conditions on the Plateau and at the Nwya Devu site align with those of blade assemblages documented in the Eurasian Steppe and contrast with those of core-and-flake assemblages. Blade technology is strongly associated with low-temperature environments. These findings suggest that hunter–gatherers from the steppe belt may have benefited from their behaviorally adaptive advantages when moving into the highland environments of the Tibetan Plateau, 40–30 ka.

Obsidian-tipped Spears from the Admiralty Islands in the Oceania Collection of the Museum of Ethnography in Budapest

The authors studied 36 obsidian-tipped spears in the Oceania collection of the Museum of Ethnography in Budapest. In addition to describing the objects from the Admiralty Islands collected before 1897, the paper provides a summary of the related ethnographic information, including the technological and technical details of spear point making and the characterisation of the obsidian raw material used.The blades used for making the obsidian points presented in this study showed no sign of standardisation (an indicator of advanced blade technology) in the spear point-making process. According to 19th-century ethnographic sources, the functional part of the points was the most important, and much time and effort were invested in ensuring that the blades were effective weapons. Later, as a sign of decline, primary production of obsidian blades ceased, and manufacturers started scavenging old artefacts and utilising waste and by-products. As a result, the blades decreased in size and became more irregular, and an increasingly large number included parts of the cortex, the crust of obsidian. After 1911, the relative importance of decoration increased, and the type became more standardised.The irregular shape of the spear points presented in the study and the thin, weak shafts with an awkward curvature raise questions about whether the spears were actual weapons. At the same time, the artistic decoration of the mounting sockets and ethnographic parallels suggest that the pieces in the collection were likely status objects instead.

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

PurposeThe purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.Design/methodology/approachAn experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.FindingsLarge deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.Originality/valueWhen the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

Orientation control of multiple single crystal blades using a novel high-throughput mold via seeding-grain selection technique

Orientation control of multiple single crystal blades using a novel high-throughput mold via seeding-grain selection technique