<p>Advanced composite materials, particularly carbon fibre-reinforced polymers (CFRPs), offer significant advantages over conventional metallic materials in centrifugal compressor impellers, addressing limitations. In this study, ansys composite prepost (ACP) is used to design and analyse a closed-centrifugal-compressor impeller under realistic boundary conditions. The analysis integrates advanced failure criteria, including Tsai–Wu, Hashin, maximum strain, maximum stress, and maximum shear stress to comprehensively evaluate the structural integrity and performance of the composite impeller under dynamic operational loads. The results indicate a peak axial deformation of 2.4848 mm at the shroud and blades, with the maximum shear stress of 47.035 MPa remaining significantly below the CFRP’s allowable shear strength of 75 MPa. Failure indices calculated using Tsai–Wu and Hashin failure criteria confirm the impeller’s structural reliability and robustness under operational conditions. Tsai–Wu failure index remained below 1 across most regions, with a peak value of 1 at the leading-edge fillets and blade roots, indicating localized stress concentrations without immediate structural failure. The Hashin failure criterion indicated a fibre tension failure index of 1.25 at the blades and leading-edge fillets, suggesting potential fibre failure due to high centrifugal forces that induce axial tensile stresses. Overall, the majority of the impeller structure exhibited failure indices below unity, verifying the composite material’s structural adequacy under the specified operating conditions. However, localized high-stress regions at the hub base, shroud, and blade roots indicate potential risks of material degradation and progressive damage under prolonged cyclic loading or extreme operational conditions. The study highlights the effectiveness of composite layups and optimized stacking sequences in maintaining structural stability under centrifugal and aerodynamic loads.</p>

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Structural integrity assessment of carbon fibre composite centrifugal compressor impeller using FEA

  • Abhishek Kumar,
  • Abhimanyu Chaudhari,
  • Ketan Borate

摘要

Advanced composite materials, particularly carbon fibre-reinforced polymers (CFRPs), offer significant advantages over conventional metallic materials in centrifugal compressor impellers, addressing limitations. In this study, ansys composite prepost (ACP) is used to design and analyse a closed-centrifugal-compressor impeller under realistic boundary conditions. The analysis integrates advanced failure criteria, including Tsai–Wu, Hashin, maximum strain, maximum stress, and maximum shear stress to comprehensively evaluate the structural integrity and performance of the composite impeller under dynamic operational loads. The results indicate a peak axial deformation of 2.4848 mm at the shroud and blades, with the maximum shear stress of 47.035 MPa remaining significantly below the CFRP’s allowable shear strength of 75 MPa. Failure indices calculated using Tsai–Wu and Hashin failure criteria confirm the impeller’s structural reliability and robustness under operational conditions. Tsai–Wu failure index remained below 1 across most regions, with a peak value of 1 at the leading-edge fillets and blade roots, indicating localized stress concentrations without immediate structural failure. The Hashin failure criterion indicated a fibre tension failure index of 1.25 at the blades and leading-edge fillets, suggesting potential fibre failure due to high centrifugal forces that induce axial tensile stresses. Overall, the majority of the impeller structure exhibited failure indices below unity, verifying the composite material’s structural adequacy under the specified operating conditions. However, localized high-stress regions at the hub base, shroud, and blade roots indicate potential risks of material degradation and progressive damage under prolonged cyclic loading or extreme operational conditions. The study highlights the effectiveness of composite layups and optimized stacking sequences in maintaining structural stability under centrifugal and aerodynamic loads.