Computational Mechanics for Turbofan Engine Blade Containment Testing: Fan Case Design and Blade Impact Dynamics by Finite Element Simulations

The harsh environment during airplane take-off and flights with complex operating conditions require a high dynamic and impact resistance capability of airplane engines. The design, development, and performance evaluation of new turbofan engines are generally performed through numerical simulations before a full-scale model or prototype experiment for certification. Simulations of fan blade containment tests can reduce trial–error testing and are currently the most convenient and inexpensive alternative for design; however, certification failure is always a risk if the calibration of material models is not correctly applied. This work presents a three-dimensional computational model of a turbofan for designing new engines that meet the certification requirements under the blade containment test. Two calibrated Johnson–Cook plasticity and damage laws for Ti64 are assessed in a simulation of a turbofan blade containment test, demonstrating the ability of the models to be used in the safe design of aircraft engine components subjected to dynamic impact loads with large deformations and adequate damage tolerance.