Predictive dynamic modeling and analysis of blisks through digital representations constructed upon precise geometry measurements

Blade geometric variations generally have a significant impact on the structural dynamics of integrally bladed disks widely used in the advanced aero-engines. This paper presents a holistic research in regard to the predictive dynamic modeling, analysis and experimental verification for a blisk by taking advantage of the advanced 3D optical geometry measurement technology. Geometrically mistuned models (GMMs) are semi-automatically constructed upon the precisely measured blisk geometry by an efficient FE mesh updating strategy. They provide explicit, high-fidelity digital representations of the geometric variations within the integrally manufactured blisk. A 'Sector Mode Assembling Reduction Technique' is developed and specifically tailored for efficient dynamic analysis of the large-sized GMMs at a relatively low computational cost and memory requirement. Intensive test campaigns, including forced response tests in the stationary/spinning rig under well-controlled laboratory conditions, are carried out for a full assessment of the GMMs' dynamic prediction capability. Experimental verification results show that the GMM is able to capture the modal dynamics and resonant vibration of the stationary/rotating blisk with satisfactory accuracy. The physical-reality-based GMM converted directly from the precise geometry measurement data can be considered as a viable and valuable tool for predictive vibration evaluation of blisks. However, its model accuracy exhibits a mode-related dependence on the mesh density. The tradeoff between model accuracy and prohibitive computational cost proved to be the bottleneck of this promising blisk modeling approach.