Equivalent Bird-Strike Test Method and Fixture Design for the Trailing Edge of Aero-Engine Composite Fan Blades
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摘要: 为了研究航空发动机复合材料叶片在鸟撞事件中的响应与损伤行为，提出了一种使用元件级平板试样替代全尺寸风扇叶片的等效鸟撞试验方法，旨在通过元件级平板试验再现全尺寸叶片在鸟撞过程中出现的尾缘分层损伤。通过开展不同夹持方案下平板试样的鸟撞试验和数值仿真，系统分析了不同方案下平板试样的冲击响应特点及分层损伤的起始和扩展过程，进而提出了一种能够有效模拟叶片鸟撞过程中尾缘分层损伤的元件级等效试验方法，并确定了可诱导典型复合材料层合板产生单侧尾缘分层的基准冲击工况，包括冲击高度、冲击速度以及切鸟量（鸟弹撞击试件时有效撞击体积占鸟弹总体积的百分比）。此外，通过对比不同冲击工况下的试验与仿真结果，验证了数值模型的准确性。基于已验证的数值模型，针对冲击高度、冲击速度及切鸟量等试验参数分别开展了敏感性分析，得出在试验可控的参数波动范围内，3个参数引起的复合材料平板关键冲击响应指标（平板上侧尾缘峰值位移、平板下侧尾缘峰值位移及平板上沿位移差）相对基准工况的变化幅度均小于5%。研究表明，所提出的等效试验方法可以通过复合材料平板试验模拟全尺寸叶片鸟撞时的局部位移响应和分层损伤模式，且试验结果具有良好的鲁棒性。Abstract: To investigate the response and damage behavior of composite aero-engine blades under bird-strike events, an equivalent bird-strike testing method was proposed in which a component-level flat plate specimen was used to replace a full-scale fan blade. The method aims to reproduce the trailing-edge delamination damage observed in full-scale blades during bird strike. Bird-strike tests and corresponding numerical simulations on the plate specimens under different clamping configurations were conducted, and the impact response characteristics as well as the initiation and propagation processes of delamination were systematically analyzed for each configuration. Based on these results, a component-level equivalent test methodology capable of effectively simulating trailing-edge delamination in blade bird-strike scenarios is proposed. A baseline impact condition that induces single-side trailing-edge delamination in a representative composite laminate is identified, including impact height, impact velocity, and the bird-cut ratio (defined as the percentage of the effective impacting volume of the bird projectile relative to its total volume at the instant of impact). In addition, by comparing test and numerical results under various impact conditions, the accuracy of the numerical model is validated. Using the experimentally validated model, sensitivity analyses were performed with respect to the test parameters (impact height, impact velocity, and bird-cut ratio). The results show that, within the controllable ranges of parameter variation in the tests, the changes in key impact response metrics of the composite plate—namely the peak displacement at the upper trailing edge, the peak displacement at the lower trailing edge, and the displacement difference along the upper edge—are all less than 5% relative to the baseline condition. This study demonstrates that the proposed equivalent testing method enables a composite plate test to replicate the local displacement response and delamination pattern of a full-scale blade under bird strike, and the test outcomes exhibit good robustness.
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Key words:
- composite fan blade /
- bird strike /
- equivalent test /
- fixture design /
- interlaminar delamination
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图 1 真实叶片鸟撞模型的仿真结果(a)、位移分布(b)、应变分布(c)和应力分布(d)
Figure 1. Simulation result (a), displacement distribution (b), strain distribution (c), and stress distribution (d) of actual blade bird strike model
图 4 单边夹持刚性夹具鸟撞模型
Figure 4. Bird-strike model with a single-sided rigid clamping fixture
图 5 双边夹持夹具构型Ⅰ(a)、Ⅱ(b)、Ⅲ(c)及单边夹持夹具(d)的应力云图
Figure 5. Stress contours of the double-sided clamping fixture configurations Ⅰ (a), Ⅱ (b), and Ⅲ (c), and the single-sided clamping fixture (d)
图 6 2种方案的DIC计算结果与叶片尾缘处局部位移云图
Figure 6. DIC results of the two test configurations and the local displacement contour at the blade trailing edge
图 7 采用2种方案时试验及仿真分层损伤云图
Figure 7. Test and numerical damage contours for the two configurations
图 8 单边夹持方案的分层损伤发展过程
Figure 8. Evolution of delamination damage in the single-sided clamping configuration
图 9 复合材料典型件鸟撞冲击测试系统
Figure 9. Bird strike impact test system for a representative composite component
图 10 数据采集系统中各相机的功能
Figure 10. Roles of individual cameras in the data acquisition system
图 12 试验及仿真的面外位移云图（左）及分层损伤分布（右）
Figure 12. Out-of-plane displacement contours (left) and delamination damage distributions (right) from tests and simulations
表 1 试验工况参数
Table 1. Parameters of test conditions
Case Impact velocity/(m·s−1) Impact height/mm Bird-cut ratio/% Ⅰ 173.5 88 93.0 Ⅱ 195.4 88 94.1 
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表 2 各冲击参数的归一化斜率
Table 2. Normalized slopes of various impact parameters
Impact parameter ${S}_{ p} $ $\Delta$Xu $\Delta$Xd $\varDelta $u Impact height 0.08 −0.42 −0.36 Bird-cut ratio 0.83 0.64 0.83 Impact velocity 1.13 0.96 1.09
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