Methodology for Modeling Nonlinear Thermomechanical Response With Wear at High-Speed Interactions: Application to a Pin–Disk Configuration

Abstract

An aircraft engine is a complex structure for which some components can come into contact at high speed. Modeling this behavior is very complex as multiple physics must be considered. State-of-the-art methodologies usually account for permanent contact and thermal modeling. In this paper, a new approach is proposed and embeds various phenomena such as nonregular and nonlinear contact mechanics, surface rubbing, wear, and nonlinear heat transfer. A nonlinear version of Moreau–Jean algorithm is employed to compute the transient response of the system and to capture accurately the contact dynamics. Moreover, the full nonlinear coupling between the dynamics and the heating process is taken into account through both a semi-analytical formulation and the finite element (FE) method. At the contact interface, heat flux is generated by dry rubbing and flows into both interacting bodies. The heat flux partition is evaluated thanks to a coefficient that depends on the material properties of the solids in contact. The proposed method also accounts for the adhesive wear between the solids through an energetic approach. This methodology is applied to an academic, yet realistic, disk connected to a rotor shaft that is free to move axially and to rotate around its revolution axis. Gyroscopic effects and variation of the rotation velocity are included leading to a full nonlinear mechanical behavior. The disk undergoes aerodynamic load moving it to contact with a clamped free pin. The rotor shaft and the pin are both modeled as one-dimensional (1D) elastic bodies, while the rotor disk is assumed to be rigid. Through this example, the developed strategy shows its potential to compute the complete transient highly nonlinear response of the breaking phenomenon, in an acceptable time simulation.