• Journal of Power System Engineering
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• v.15 no.4
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• pp.37-41
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• 2011

This paper introduces the special eddy current sensor and its characteristic for bolt hole defect evaluation in gas turbine rotor. In the past, Fluorescent penetration inspection method was used for qualitative defect evaluation in gas turbine rotor bolt hole. This method can defect the bolt hole defect but can not evaluate the defect size. Nowadays, eddy current method is used quantitative defect evaluation due to advanced sensor design technology. And eddy current method is more time and cost saving than the old method. We developed bolt shape eddy current sensor for the rotor bolt hole defect detection and evaluation. The eddy current sensor moves to the bolt hole guided by screw nut and detects the defect on the bolt hole. The bolt hole mock-up and artificial defects were made and used for the signal detection & resolution analysis of eddy current sensor. The results show that signal detection capability is enough to detect 0.2 mm depth defect. And the resolution capability is enough to differentiate 02, 0.5, 1.0 and 2.0 mm depth defect.

• Journal of Power System Engineering
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• v.15 no.3
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• pp.65-69
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• 2011

This paper introduces the multi-coil eddy current sensor and its characteristic in magnetic material gas turbine rotor. In the past, magnetic particle inspection method was used for qualitative defect evaluation in magnetic material gas turbine rotor. And the ultrasonic inspection method was used for quantitative defect evaluation. Nowadays, eddy current method is used in magnetic gas turbine rotor inspection due to advanced sensor design technology. We developed multi-coil eddy current sensor for the rotor dovetail inspection. At first, rotor stress is analyzed for the determination of sensor position and number. The sensor coils are designed to cover the stress concentration area of rotor dovetail. We select optimum frequency according to material standard penetration data and experiment results. The rotor mock-up and artificial defects were made for the signal detection and resolution analysis of multi-coil eddy current sensor. The results show that signal detection and resolution capabilities are enhanced in comparison to the commercialized sensor enough for the gas turbine rotor inspection. So, this developed multi-coil eddy current sensor substituted for commercialized one and it applied in real gas turbine rotor inspection.

• Journal of Power System Engineering
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• v.14 no.4
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• pp.63-67
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• 2010

This paper introduces the eddy current signal characteristic of magnetic and non-magnetic gas turbine rotor. In the past, Magnetic particle inspection method was used in magnetic material for qualitative defect evaluation and the ultrasonic test method was used for quantitative evaluation. Nowadays, eddy current method is used in magnetic gas turbine rotor inspection due to advanced sensor design technology. We are studying on the magnetic gas turbine rotor by using eddy current method. We prepared diverse depth specimens made by magnetic and non-magnetic materials. We select optimum frequency according to material standard penetration data and experiment results. We got the signal on magnetic and non-magnetic material about 0.2 mm, 05 mm, 1.0 mm, 1.5 mm 2.0 mm and 2.5 mm depth defects and compare the signal amplitude and signal trend according to defect depth and frequency. The results show that signal amplitudes of magnetic are bigger than non-magnetic material and the trends are similar on every defect depth and frequency. The detection and resolution capabilities of eddy current are more effective in magnetic material than in non-magnetic materials. So, the eddy current method is effective inspection method on magnetic gas turbine rotor. And it has the merits of time saving and simple procedure by elimination of the ultrasonic inspection in traditional inspection method.

• Journal of the Korean Society for Nondestructive Testing
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• v.25 no.6
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• pp.483-486
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• 2005

The relationship between the EFBH (Equivalent Flat-Bottom Hole) size measured by non-destructive method and the actual size by destructive method in many rotors manufactured at Doosan Heavy Industries & Construction Co. Ltd. was investigated. In this investigation. "the Master Curve" compensating the differences between UT reported sizes and actual sizes of defects in our rotor forgings were obtainable. The applicability of this "Master Curve" as a way of calculating the actual defect size was also investigated. For the evaluation of rotor forgings, it is expected that this "Master Curve" may be used to determine the accurate actual sizes of defects.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.233-236
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• 2005

Rotor in small-medium induction motor has been usually manufactured by aluminum diecasting. In order to improve efficiency of induction motors, newly developed Cu-Ca alloys have been investigated. The electrical conductivity in the Cu alloys containing Ca less than $1.0wt\%$ was higher than $80\%$ IACS. Cu-Ca alloy is desirable for the thixoforming process because it has wide semi-solid range over $150^{\circ}C$. In this study, Cu-rotor with thixoforming process was developed to replace the conventional aluminum diecasting rotor. Analysis microstructure of thixoforming rotor. effect of incomplete filling defect on the efficiency of induction motor was discussed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.10a
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• pp.115-116
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• 2009

• Tribology and Lubricants
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• v.36 no.2
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• pp.105-115
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• 2020

This paper presents a numerical study on the rotordynamic analysis of a dual-spool turbofan engine in the context of blade defect events. The blades of an axial-type aeroengine are typically well aligned during the compressor and turbine stages. However, they are sometimes exposed to damage, partially or entirely, for several operational reasons, such as cracks due to foreign objects, burns from the combustion gas, and corrosion due to oxygen in the air. Herein, we designed a dual-spool rotor using the commercial 3D modeling software CATIA to simulate blade defects in the turbofan engine. We utilized the rotordynamic parameters to create two finite element Euler-Bernoulli beam models connected by means of an inter-rotor bearing. We then applied the unbalanced forces induced by the mass eccentricities of the blades to the following selected scenarios: 1) fully balanced, 2) crack in the low-pressure compressor (LPC) and high pressure compressor (HPC), 3) burn on the high-pressure turbine (HPT) and low pressure compressor, 4) corrosion of the LPC, and 5) corrosion of the HPC. Additionally, we obtained the transient and steady-state responses of the overall rotor nodes using the Runge-Kutta numerical integration method, and employed model reduction techniques such as component mode synthesis to enhance the computational efficiency of the process. The simulation results indicate that the high-vibration status of the rotor commences beyond 10,000 rpm, which is identified as the first critical speed of the lower speed rotor. Moreover, we monitored the unbalanced stages near the inter-rotor bearing, which prominently influences the overall rotordynamic status, and the corrosion of the HPC to prevent further instability. The high-speed range operation (>13,000 rpm) coupled with HPC/HPT blade defects possibly presents a rotor-case contact problem that can lead to catastrophic failure.

• Proceedings of the KSME Conference
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• 2000.04b
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• pp.561-567
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• 2000

This paper is concerned with the viscous interaction between rotor and stator. The viscous interaction is caused by wakes from upstream blades. The rotor cascade in the experiment was composed with five blades, and cylinders were placed to make the stator wakes and their locations were about 50 percent upstream of blade chord. The locations of cylinders were varied in the direction of cascade axis with 0, 12.5, 25, 50, and 75 percent of pitch length. The static pressure distributions on the blade surfaces and the velocity distributions in the cascade flow were measured. From the experimental result it was found that the value of velocity defect by a cylinder wake might vary depending on the wake position within the cascade but the value at the cascade exit approached to some constant value regardless of the difference of wake locus. The momentum defect at the downstream from the cascade and the pressure distribution on the blade surfaces showed that the wake flowing near the blade surfaces caused the decrease of lift and the increase of drag regardless of the disappearance of flow separation.

• The KSFM Journal of Fluid Machinery
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• v.2 no.4 s.5
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• pp.16-23
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• 1999

The characteristic of unsteady flowfields on gas turbine, particularly on a rotor blade surface has been numerically investigated. The unsteady flow in a rotor blade passage as a result of wake/blade interaction is modeled by the inviscid flow approach, and solved by Euler equations using a time accurate marching scheme. Unsteady flow in the blade passage is induced by periodically moving a wake model across the passage inlet. The wake model used in this study is the Gaussian wate model in which the wake flow is assumed to be parallel with uniform static pressure and uniform relative total enthalpy. Numerical results show that for the case of Ps/Pr=1.5, the velocity and pressure distribution on the blade surfaces have much more complex profiles than for the case of Ps/Pr=1.0.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.7
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• pp.347-352
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• 2019

This study focused on improving the cast quality of small-sized induction motor rotors during the die casting process. A new rotor core cast model was proposed based on previous research results and parametric studies. Numerical analyses using 3-dimensional half models were performed to evaluate the filling patterns of aluminum molten metals into a mold and on-site experiment performed to verify the newly proposed cast model. The following were obtained from numerical filling analyses and experimental results. First, molten metals started to fill the lower end ring, then moved on to fill the core slot and upper end ring and finally stopped to fill at the rotor core slot. Second, significant circulation of molten metals was not observed on the lower end ring, resulting in fewer defects at the section of the lower end ring from the experimental results. Third, the new shape of a rotor core cast was effective in producing rotors with sound cast quality, and reducing the end ring cast defect area by approximately 70 %.