Modeling and Simulation of Sand Particle Trajectories and Erosion in a Transonic Fan Stage

In desert regions, there is a significant presence of dust and sand particles lifted by storms and drawn into aircraft engines, resulting in considerable erosion. This numerical study investigates the dynamics of sand particles affecting the front components of a high-bypass turbofan engine (HBTFE). The components under consideration include a Pitot intake, a spinner, a fan rotor, inlet guide vanes (IGVs), and outlet guide vanes (OGVs). This research focuses on the engine's operating conditions during takeoff from a Saharan airfield. The flow field is solved separately, and the data are transferred to an in-house particle trajectory code based on the Lagrangian model. The finite element method (FEM) is used to track sand particles as they move through the mesh cells, facilitating an accurate assessment of impacts and conditions necessary for calculating erosion rates. The results obtained indicate that a significant number of sand particles frequently impact the rotor blade, from the hub to approximately 80% of its span, due to deflection by the Pitot intake lip and outer contour. The pressure side (PS) of the rotor blade experiences severe erosion, with the highest erosion rates occurring at the leading edge (LE) and toward the trailing edge (TE). At the exit of the rotor, a substantial amount of particles flows through the OGVs and erode the PS, while fewer particles from the lower sections of the fan blade pass via the IGVs to the engine's core. These findings highlight erosion-prone regions that require special protective coatings.