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An Introduction to
Dynamic Spin Testing
 An Introduction to Dynamic Spin Testing 2

An Introduction to Dynamic Spin Testing

In high-performance gas turbines, the design of a blade is a crucial element. It must be

lightweight, meet the aerothermal performance and manufacturing feasibility criteria, and
be robust enough to survive an arduous operating environment with a safety margin. A
combination of the intricate blade geometry, punishing operating environment, the use of
cutting-edge materials, and complex manufacturing processes (including emerging non-
metallics, additive manufacturing/3D printing) results in complexity and design challenges
for engineers and designers.

Many failure modes for gas turbines are related to the dynamic behavior of compressor
and turbine blades. High stress from blade resonance and vibration in the operating part
of the machinery rapidly consumes the fatigue life and often leads to catastrophic damages.
Studies of turbine blade damage mechanisms, failure modes, and damper design have
been an active field of research for over five decades.

As a part of the design process, an extensive structural dynamic analysis is carried

out to predict the natural frequencies, mode shapes, and damping properties. Due to
the complexity of several intertwined factors in the blade design and its attachment
constructions, development of a sound engineering modeling involves in-depth
understanding of non-linear factors and judgments.

Test data for validating and tuning the model is a critical step in assuring a successful
and robust design.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 An Introduction to Dynamic Spin Testing 3

What Is Dynamic Spin Rig (DSR)?

Accurately characterizing and validating the dynamic behavior of blades and the HCF damage
models has been an important part of bladed disk design development. TD has been the leader in
dynamic spin testing and uses a unique method that excites the parts while spinning.

Dynamic Spin Testing enables the CF driven body load on the blades, which cannot be done in
static bench tests. In some cases, the presence of the body load, as opposed to mechanically
pulling, could have an important implication on accurately capturing the behavior of a test blade.
For example, the presence of a stress gradient and the manner of blade deformation (e.g.
untwisting) could affect the level, and sometimes the location, of a critical stress feature. The
difference in the blade loading condition is also known to affect the interface at the blade to disk
attachment, which could influence the damping and dynamic response of the test blades.

Dynamic Spin Rig (DSR) is a patented technology that Test Devices has been pioneering since
2004. DSR is a spin test system that can excite blades under centrifugal loading. Since its
inception, Test Devices has been continuously improving the technology and the method through
numerous tests over the last 15 years.

DSR is a fully integrated spin test system designed to handle highly instrumented and sophisticated
tests, such as High Cycle Fatigue (HCF) test, damping characterization studies, and blade crack
propagation studies. Test Devices offers two proven blade excitation technologies: Liquid Jet
Excitation System and Aeropulse Excitation System.

Test Devices© DSR System (Illustration) An example of a Campbell Diagram

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 An Introduction to Dynamic Spin Testing 4

These two technologies were proven through numerous tests at our facility in Massachusetts, USA.
Some examples of the different types of dynamic spin tests include:

• Validation of new manufacturing process or method

• Blade resonance frequency survey and mode shape study. Validation and tuning of
Campbell diagrams and FEA models.

• In-situ blade deflection measurement; the study of structural strain. HCF life validation.

• Characterization of blade damping & amplification factor (Q) at different modes.

• Study of wear damage in the blade attachment and evaluation of the efficacy of the
anti-wear coatings.

• Study of mistuning effect, especially in integral bladed rotors (IBR) or blisks.

• Crack propagation study—By monitoring the blade resonance frequency shift due to a crack.

Successful implementation of complex technology such as DSR requires more than a purchase of
the equipment. It takes training and guidance of the new test technologist to develop the expertise.
Our experienced test experts are available to assist you by supporting your testing needs or training
your staff.

Key Ingredients for Successful

Dynamic Spin Testing

Precision Speed Control

Controlling speed is one of the key

components of the DSR system. The ability
to precisely control the speed enables
efficient targeting of blade resonances.
This lets us obtain a greater blade response
in a consistent and repeatable manner.
An example of close-coupled modes captured by the use of Precision Speed Control System consists of
accurate speed controlling via DSR.
add-on equipment to the Test Devices© air
drive and control systems.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 An Introduction to Dynamic Spin Testing 5

Without the ability to control the speed accurately, the resulting blade responses will be smeared,
making it impossible to articulate the dynamic properties of the bladed rotor. An example of
close-coupled resonances clearly captured by TD’s DSR is shown on the previous page.

• +/-1 rpm speed controllability (at steady state dwell)

• Enhanced speed trim and control capability designed specifically for DSR application

• Easy to use precision speed control user interface

Proven Blade Excitation Technologies

The excitation system developed by Test Devices provides a unique approach to excite the
resonant vibration in rotating blades at various speeds and frequency modes. With this technology,
it is possible to characterize the behavior and define the life of blades at various static and dynamic
stress levels, as well as at different temperatures. This technique has been verified through the
successful completion of many experiments on various bladed rotors, carried out at a range of
speeds and temperatures.

Two methods of excitations have been developed and delivered with the Dynamic Spin Rig (DSR):

Liquid Jet System

The Liquid Jets System is designed to perform

HCF testing by using atomized oil jet, which
impacts rotating blades, generating a periodic
excitation force on a rotating blade.

• Excitation EO: 48+ EO exciter system

(depending on the dimensional constraints
associated with the test rotor).

• High blade response (1500με+).

• Exciter oil jet capacity: 6 gal/min @ 200psi

(0.000378541m³/s, 1378kPa).

• Test temperature limit: 204°C (400°F). An example of a liquid jet system.

• Higher EO design available on request.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 An Introduction to Dynamic Spin Testing 6

Aeropulse System

The Aeropulse system is a self-exciter system designed to use the bluff body (or fence) in the
spin chamber to excite the blade. The pit atmosphere inside the spin chamber is maintained by
a specially designed partial atmosphere control system which precisely regulates the air/vacuum
pressure level inside the test chamber.

The aerodynamic mode of excitation is most often used to characterize blade behavior at elevated
temperatures.

• Controlled partial atmospheric test

• Local Aero Impulse from static hardware

• High engine order (54+)

• Aerodynamic heating; additional heating possible (1250F+)

Blade response depends on multiple factors, such as material, geometry, interface with blade
attachment design and damper configuration.

Data Measurements and Instrumentation

• Dynamic Straingage with Slipring (or telemetry)

• NSMS (Non-contact Stress Measurement System) Or BTT (Blade Tip Timing)

Eddy current based blade tip timing probes.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 An Introduction to Dynamic Spin Testing 7

Why Work With Us

Regardless of which blade excitation method is employed, successful testing would require
careful engineering work and test planning. Here are some basic rules to follow in preparation
for HCF testing:
1. Bladed rotors have to be prepared for testing, including:

a.  he rotor interface with the spin rig (arbor) has to be designed

T
and manufactured with tooling integrity as well as taking the
blade and rotor instrumentation into consideration.

b.  otor balancing may need to be performed before installing the

R
rotor in the DSR. This is especially critical for test rotors with
inserted blades, dampers. The effect of unbalances from rotor
instrumentation also should be accounted for.

c.  he rotor should be instrumented (gages, thermocouples,

T
etc) and the appropriate installation method must be selected
to endure the CF load and test environment (including
temperature) throughout the course of the test.

2. For either excitation method, appropriate excitation hardware has to be designed and fabricated.

3. The instrumentation inside the test chamber has to be defined and selected to satisfy the
environmental conditions. It is critically important for any risk of contact between static
instrumentation/hardware (surrounding the rotor) and the rotating assembly to be mitigated to avoid
potential damage to the whole facility.

4. External instrumentation, such as signal conditioners

and data acquisition systems, must be configured, tested,
and fully prepared before testing. Instruction manuals
for each instrumentation system should be reviewed to
ensure proper preparation is done for the intended
testing program.

With over 15 years of experience performing various kinds

of dynamic spin tests, Test Devices is a leader in spin
testing expertise and equipment design and has helped
their customers resolve a range of pressing issues. They
have also designed and installed over a dozen dynamic test
facilities for leading aerospace organizations worldwide.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

Working
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571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017