Unilateral contact induced blade/casing vibratory interactions in impellers: Analysis for rigid casings

This contribution addresses the vibratory analysis of unilateral-contact induced structural interactions between a bladed impeller and its surrounding rigid casing. Such assemblies can be found in helicopter or small aircraft engines for instance and the interactions of interest shall arise due to the always tighter operating clearances between the rotating and stationary components. The investigation is conducted by extending to cyclically symmetric structures an in-house time-marching based tool dedicated to unilateral contact occurrences in turbomachines. The main components of the considered impeller together with the associated assumptions and modelling principles considered in this work are detailed. Typical dynamical features of cyclically symmetric structures, such as the aliasing effect and frequency clustering are explored in this nonlinear framework by means of thorough frequency-domain analyses and harmonic trackings of the numerically predicted impeller displacements. Additional contact maps highlight the existence of critical rotational velocities at which displacements potentially reach high amplitudes due to the synchronization of the bladed assembly vibratory pattern with the shape of the rigid casing. The proposed numerical investigations are also compared to a simpler and (almost) empirical criterion: it is suggested, based on nonlinear numerical simulations with a linear reduced order model of the impeller and a rigid casing, that this criterion may miss important critical velocities emanating from the unfavorable combination of aliasing and contact-induced higher harmonics in the vibratory response of the impeller. Overall, this work suggests a way to enhance guidelines to improve the design of impellers in the context of nonlinear and nonsmooth dynamics.