NUMERICAL ESTIMATION OF FATIGUE LIFE OF

AEROENGINE FAN BLADES

Binesh philip1, *N. C. Mahendra Babu2
Student, M. Sc. [Engg.], Professor, M.S. Ramaiah School of Advanced Studies, Bangalore 560 054
*Contact Author e-mail: mahendrababu@msrsas.org

Abstract
During every startup and shutdown of an aviation gas turbine, the fan blades are subjected to centrifugal, gas
bending and vibratory loads. This repeated loading and unloading can reduce the life of fan blades. Previous works on fan
blades have focused mainly on fatigue life estimation in the vicinity of foreign object damage. There is no evidence of
fatigue life estimation from centrifugal, gas bending load and dynamic load.
As it is important to assess the fatigue life of the blade subjected to static and dynamic loads, the analysis is divided
into two parts. In the first part, the blade is subjected to static loading that is centrifugal and gas bending load. Based on
stress results, a decision is made whether to proceed with stress based fatigue life assessment or strain based fatigue life
assessment. In case of dynamic loading, the blade is subjected to a tip load. Harmonic analysis is carried out to study the
alternating stresses. The equivalent endurance stress obtained is checked against the S-N curve to obtain the HCF life
under dynamic loading.
Results obtained are based on the above process. In case of static loading, it is observed that the dovetail regions will
have a minimum life in LCF. And in case of dynamic loading, it is observed that the maximum speed of the fan blade is
close to one of the blade passing frequencies. Hence, the deflections are predominantly similar. It is also observed that
under dynamic loading, the aerofoil is having a minimum life in HCF.
Keywords: Fan, Compressor, High Cycle Fatigue, von Mises Stress, Modal and Harmonic Analysis
Aeromechanical instability in blades is accompanied by
aerofoil flutter and acoustic fatigue of sheet metal
components in the combustor, nozzle and augmenter.
The steady loads induce a permanent damage into the
blade. The fatigue life of the blade under such
conditions is computed by Low Cycle Fatigue (LCF)
analysis. In case of vibration loads, the fatigue life of
the blade is computed by High Cycle Fatigue (HCF)
analysis.

1. INTRODUCTION
Aircraft engines or otherwise known as gas
turbines are power plants that suck in air, compress it,
mix the compressed air with the right proportion of fuel,
burn the mixture in the combustor and expand it in the
turbine. All these processes are driven by large number
of rotating parts. When a gas turbine is in operation, the
different parts of the engine are subjected to extreme
loading such as centrifugal loads, thermal loads, gas
bending loads, aerodynamic loads, vibration loads, etc.
these loads can induce a plastic damage into the
components. During each operation, there is a certain
amount of permanent damage induced in the system.
This could ultimately lead to fatigue failure. Such a
failure, if not predicted, can results in catastrophic
damage leading to loss of both human and property.
Engine designers, therefore, design their components for
safe life, that is the components are designed to survive
a definite period of time. During every maintenance
cycle, the components are either replaced or repaired.
This decision is either based on past experience or
fatigue calculation.

Low cycle fatigue is due to high amplitude low

frequency loading, comprising one startup-shutdown
cycle. It is also known as a stress block. During each
LCF, certain regions of the blade undergo plastic
deformation. Hence, the life of such the regions is
assessed by strain based approach. But in case of
regions that are elastically deformed, a stress based
approach is used to compute the fatigue life.
Unprecedented failures in the past have led to
research on fatigue life estimation. Both experimental
and numerical fatigue life estimation has been carried
out. Dungey and Bowen [1] carried out experimental
studies on a cross-rolled Ti-6Al-4V plate to assess the
effect of HCF on LCF. In this study, it is concluded that
large vibrational amplitude reduced the fatigue life
considerably. Ren and Nicholas [2] carried out
experimental analysis to study the effect of prestrain on
subsequent HCF cycles. They carried out tests on
Nickel-based superalloy, Udiment-720. From this test it
was concluded that 10% prior LCF consumption could
reduce the HCF limit by 33%. Russ [3] also studied the
effect of LCF cycles on subsequent HCF cycles. From
the study it is concluded that the introduction of LCF
effectively increased the FCG rate of subsequent high R
cycles. From this study it is also concluded that the load
interactions have lower life as compared to the one with
higher no-load interaction. Byrne et al [4] also observed
similar behaviour on Ti-6Al-4V specimens. From the

This paper deals with an analytical procedure to

quantify the fatigue life of a 1st stage fan blade. This
blade, being at the starting of the engine, is subjected to
centrifugal, gas bending and dynamic loads. All the
loads are dependent on the speed of the engine. As the
speed increases, the centrifugal force, gas bending load
and dynamic load also increase. Dynamic load arises
from pressure fluctuations between blade tip and casing.
During every startup and shutdown of the engine,
the fan blade is subjected to steady and vibration loads.
Steady loads arise from the centrifugal and gas bending
loads whereas vibration loads arise from blade row
interactions. Vibration can also arise from rotor
instability, aerodynamic excitation occurring in
upstream vanes, downstream struts and blades.
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experiments it was concluded that periodic LCF

overloads reduced the effect of FCG rate. Another
observation in these experiments was that an increase in
the prior LCF cycles to the loading block increased the
FCG rates proportionately prior to the onset of HCF
activity and reduced the effect of HCF at onset. Byrne
et al [5] studied the effect of FOD on subsequent low
and high cycle fatigue crack growth behaviour. From
this study, they concluded that the residual stress from
FOD played an important role in fatigue life. It is also
concluded that the FOD damages are preferred sites of
crack propagation.

Certain assumptions are considered

inadequacy of data

due to

The loading conditions are with respect to sea

level.

Only structural damping is considered in the

analysis.

Table 1 Range of axial flow compressor design

parameters [9].

Several theoretical studies have also been carried

out in the past to study the fatigue life estimation. Li et
al [6] studied fatigue life models subjected to multiaxial
loading. They carried out elastoplastic analysis on Steel
specimens to determine fatigue life. The theoretical
studies were supported by experimental approach. From
this study it was concluded that multilinear kinematic
hardening was best suited for fatigue life estimation.
Mall et al [7] carried out hybrid experimentalnumerical studies on fatigue life of Ti-6Al-4V plates
subjected to Foreign Object Damage (FOD). From the
study it was observed that there was sufficient reduction
on fatigue strength from a prior FOD. Dowson et al [8]
studied the effects of cyclic loading on elastic modulus,
yield strength and plastic strain development. The
theoretical analysis was supported by experimental
studies and they found a good match in results. The
above study addressed the complete failure of the
component and did not differentiate between crack
initiation and crack propagation. Fatigue life estimation
is addressed in the vicinity of the FOD and none of the
published papers address the fatigue life estimation of
the fan blades. Component based fatigue life estimation
is not addressed in any of these papers. In the current
study a numerical approach is developed to evaluate the
fatigue life of fan blades.

3. METHODOLOGY
As the fan blade is spinning at full speed, it is
subjected to steady centrifugal and gas bending loads.
This can lead to low cycle fatigue, whereas excitation
from secondary flows between blade and casing lead to
high cycle fatigue. The procedure for fatigue life
estimation is represented as a flow chart in Fig. 2.

4. FINITE ELEMENT MODEL

As depicted in the methodology flow chart (Fig. 2),
it is important to have a finite element model. The
quality of results is dependent on the quality of FE
model. Denser the mesh used for analysis, better will be
the results. The FE model is generated in
HYPERMESH. The FE element library contains a
variety of element types. The use of these elements is
governed by the type of problem, time for solving the
problem and quality of results. It is also advisable to
have best quality mesh for fatigue life assessment. For
the current problem, a mesh convergence study was
carried out to decide on the quality of mesh.

Fig. 1 Overall dimension of fan blade

2. GEOMETRIC MODEL

4.1 Mesh Convergence Studies

The part considered for fatigue life estimation is a

fan blade taken from a turbojet aviation gas turbine.
Made of Ti-6Al-4V material, each blade weighs about
687grams. The overall dimensions of the fan blade are
shown in Fig. 1. The maximum rotational speed of the
blade is 10,600 rpm, with corresponding tip speed of
429.58 m/s. The speed falls within the range given in
Table 1.

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In order to mesh the fan blade, a mesh convergence

study was carried out. It was for the type of the element
used and the density of the mesh. A cantilever beam
was considered for the study, as shown in Fig. 3.

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Fig. 2 Flowchart of HCF- LCF assessment

Table 2 Mesh information

Fig. 3 Cantilever beam

Linear static analysis was carried out for all these

cases and bending stress was plotted against analytical
results. X-direction stress results are captured at each
node on the top face, from the fixed to the free end. The
results are plotted on a graph and are verified against the
theoretical calculations has shown in Fig. 6.

It was subjected to its own weight of 1G load, and

material properties of Ti-6Al-4V were considered for
the analysis. Five FE models of the beam were
generated using:

Only first order hexagonal element (8-Node)

Only first order tetrahedral element (4-Node)

Only second order tetrahedral element (10Node)

The element shapes are shown in Fig.4.

Fig. 4 Element shapes

Case (iii) is further analysed with increased mesh
density. Summary of different cases analysed is shown
in Table 2. Corresponding FE models are shown in
Fig.5.

Fig. 6 Bending stress for different cases and

analytical results
From the graph it is observed that as the mesh
density increases the results get closer to the theoretical
results. Based on these results, the fan blade is meshed
with 10- Node tetrahedron element and with a density of
around 0.36 mm. Regions such as fillets of airfoilplatform interface, fillets at neck of dovetail and other
fillet regions are more densely meshed for better
prediction of results. The total number of elements in
the fan blade is 125 332 and the total number of nodes is
202 349. FE model of the fan blade is shown in Fig. 7.

Fig. 5 FE models for 5 cases

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secondary flow between the blade tip and casing. This

can induce a vibratory load in radially downward
direction. This load determines the life of the fan blade.
Analysis is carried out taking into consideration the
above loads.

5. ANALYSIS
5.1 Static Analysis
Static analysis is carried out to determine the LCF.
Stress distribution is also studied from static analysis.
The results from this analysis determine whether to
proceed with stress based approach or strain-based
approach. In case of a strain based approach, stressstrain curve is also input to the analysis [10].
Multilinear kinematic hardening model is considered for
the analysis as it takes into account the cyclic effects
[14]. The stress-strain curve is shown in Fig. 9.

Fig. 7 FE model of fan blade

4.2 Material Property
A widely used material for fan and compressor
blades is Ti-6Al-4V because of its low density and high
strength. The material properties [10], considered at
room temperature, are given in the Table 3.

Table 3 Material properties of Ti-6Al-4V

4.3 Boundary Conditions

Another important input to the analysis is the
application of boundary conditions. In reality, the blade
is clamped to the disc at the dovetail. The rotation of the
disc spins the blade. Boundary conditions are shown in
Fig. 8.

Fig. 9 Stress-strain plot from MIL handbook

5.2 Dynamic Analysis
As discussed in the loading section, the fan blade is
also subjected to pressure fluctuations at the blade tip in
the radial direction. Vibration characteristics of the
blade are studied from modal analysis. Prestressed
modal analysis is carried out at different speeds ranging
from 0 to 10600 rpm [14]. The natural frequencies from
the analysis are plotted on a Campbell diagram. As there
are 24 blades in the first stage fan, a 24X line is drawn
to check for interactions. Campbell diagram and mode
shapes give a better understanding of the response of the
blade. The amplitude of the response is determined from
harmonic analysis.
Loading for harmonic analysis is obtained from
pressure fluctuations between the blade tip and the
casing. Analysis is carried out for full speed. Radial
force equivalent to pressure fluctuations is applied in the
downward direction [15], as shown in Fig.10. Structural
damping of 20% is considered for the analysis.

Fig. 8 Boundary conditions at dovetail of fan

blade
4.4 Loading Conditions

6. FATIGUE LIFE ASSESSMENT

The blade is subjected to other types of loads when

it is spinning at full speed. One of these is the gas
bending load, which tends to push the blade in
tangential and axial direction. Calculation of gas
bending load is done according to ref [11], [12] and
[13]. Apart from the gas bending load, there is a

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The strains and stresses obtained from static and

dynamic analyses are used for fatigue life assessment.
The strains obtained from static analysis are used for
LCF whereas the vibratory stresses obtained from
harmonic analysis are used for HCF.

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7. RESULTS AND DISCUSSIONS

Analysis is carried to assess the life of the fan
blade. As discussed in the previous section, the LCF is
determined from static analysis, whereas HCF is
determined from dynamic analysis.
7.1 Static Analysis
Different regions of the blade such as dovetail
roots and roots of the aerofoil experience high
centrifugal stresses when the blade spins at 10600 rpm
along with the gas bending load. As the state of stress is
multiaxial, von Mises stress is considered for life
calculation. Figure 12 shows results of static analysis.

Fig. 10 Excitation force applied at blade tip

6.1 Evaluation of LCF for fan blade
Fatigue strength properties are needed for LCF
assessment [16].
Fatigue strength exponent (b ) = 0.1260

= 2.8
f

Fatigue ductility coefficient

Fatigue ductility exponent (c ) = 0.86

The total life is calculated using strain life relation [11]

f
(2 N f )b + f(2Nf)c
=
2
E

plastic

Fig. 12 von Mises stress of full blade

elastic

Maximum von Mises stress of 1740 MPa is

observed at the dovetail root. But the yield strength of
the material is only 985 MPa. Hence, fatigue cannot be
computed considering stress based approach. Material
non-linear analysis is carried out to study the plastic
strain at the dovetail roots as shown in Fig. 13. The total
strain is shown in Fig. 14.

Fig. 11 Goodman diagram

6.2 Evaluation of HCF for fan blade
HCF assessment is carried out based on dynamic
analysis. It is obtained from the equation

en = f (2 N f )b

as per ref. [17] and [18]. Endurance

stress en is obtained from intercept of Goodman

Fig. 13 Plastic strain

diagram, as shown in Fig. 11.

The mean stress and alternating stresses are
obtained from static and dynamic analyses.

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7.3 Modal Analysis

As discussed in the previous section, the modal
analysis is carried out at different speeds to study the
vibration characteristics. Frequencies are plotted on a
Campbell diagram, as shown in Fig. 16.

Fig. 14 Total strain

7.2 LCF Calculation
The life at the dovetail root, calculated based on
Section 6.1, is N f = 3978cycles . LCF cycles at
different regions are shown in Fig. 15.

Fig. 16 Campbell diagram

As there are 24 blades in the first stage disc, each
blade is subjected to 24 excitations during each
revolution. Mode shapes are shown in Fig. 17. It is
observed that at almost all the frequencies, maximum
deflection occurrs only at the tip. The fan blades would
survive only a few seconds if they operate at the blade
passing frequencies. When the blades are spinning at
full speed, the most probable mode shape would be the
14th mode.

Fig. 15 LCF plot of fan blade

Fig. 17 Mode shapes

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8. CONCLUSIONS
Based on this study, a methodology is derived to
analytically compute the fatigue life of typical aero
engine fan blades. Some of the important conclusions
derived from this analysis are:

Fig. 18 Maximum displacement at 4240Hz

7.4 Harmonic Analysis
A force representing the cyclic load is applied at
the tip of the blade in radially downward direction.
Maximum displacement obtained is shown in Fig. 18.
The displacement obtained is similar to the 14th
mode shape. Von Mises stress results are shown in
Fig.19. It is observed that the maximum stress does not
exceed the yield strength of the material.

Failure of dovetail region of the blade is by LCF. It

is also stated in some of the previous works.

Failure of the dovetail is also by HCF and damage

could be immediate if the blade is operated at the
blade passing frequency.

Major source of failure of the blade is by foreign

object damage and there are lots of studies being
carried out on HCF damage from FOD.

Gas bending loads play an important role in the

LCF of the blade.

The gap between the casing and the fan blade tip
can contribute to cyclic loading in the radially
inward direction.

Campbell diagram is important to understand the

blade natural frequencies at the operating speeds.
This could enable the designer to keep the
operating speeds away from the blade natural
frequencies, thereby preventing HCF damage.

9. REFERENCES
[1] Dungey. C and Bowen. P, The effect of combined
cycle fatigue upon the fatigue performance of Ti6Al-4V fan blade material, Elsevier, Journal of
Materials Processing Technology Vol. 153-154 pp.
374-379, 2004.
[2] Weiju Ren, Theodore Nicholas, Effects and
Mechanisms of Low Cycle Fatigue and Plastic
Deformation on Subsequent High Cycle Fatigue
Limit in Nickel-base Superalloy Udimet 720,
Elsevier, Material Science and Engineering A Vol.
332 pp. 236-248, 2002.

Fig. 19 Maximum alternating stress

[3] Stephan M. Russ, Effect of LCF on HCF Crack

Growth of Ti-17, Elsevier, International Journal of
Fatigue Vol. 27 pp. 1628-1636, 2005.
[4] J. Byrne et al., Influence of LCF Overloads on
Combined HCF/LCF Crack Growth, International
Journal of Fatigue Vol. 25 pp. 827-834, 2003.
[5] J. Byrne et al., Fatigue Crack Growth from
Foreign Object Damage under Combined Low and
High Cycle Loading. Part I: Experimental Studies,
Elsevier, International Journal of Fatigue, Vol. 29,
pp. 1339-1349, (2007)
[6] B. Li et al., Simulation of Cyclic Stress/Strain
Evolutions for Multiaxial Fatigue Life Prediction,
Elsevier, International Journal of Fatigue, Vol. 28
pp. 451-458, 2006.

Fig. 20 High cycle fatigue plot

7.5 Stress Based Fatigue Calculation Procedure

[7] Shankar Mall et al., Effect of Predamage from Low

Cycle Fatigue on High Cycle Fatigue Strength of
Ti-6Al-4V, Elsevier, International Journal of
Fatigue, Vol. 25, pp. 1109-1116, 2003.

Alternating stress a from harmonic analysis and

mean stress m from static analysis is plotted on a
Goodman diagram to obtain the endurance stress. The
endurance stress is substituted in the S-N equation to
compute the life. Figure 20 shows the HCF plot of the
fan blade.

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[8] A. L. Dowson et al., Development of a Finite

Element Based Strain Accumulation Model for the
Prediction of Fatigue Lives in Highly Stressed Ti

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Components, International Journal of Fatigue, Vol.

17, No. 6, pp. 385-398, 1995.
[9] Jack D. Mattingly, William H. Heiser, David T.
Pratt, Aircraft Engine Design, 2nd Ed., AIAA, Inc.,
Education Series, 1801, Alexander Bell Drive,
Reston, VA 20191-4344.
[10] Military Handbook, Metallic Materials and
Elements for Aerospace Vehicle Structures, MILHDBK-5H; 1st December 1998.
[11] Kogenhop. O, Propagation Lifetime Calculation of
the P&W Compressor Fan Disc Life Prediction
Based on Crack Growth, NLR-TP-2000-302, 31st
May 2000.
[12] H Cohen et al., Gas Turbine Theory, 4th Edition,
1996, Longman Group Limited, England
[13] Jack D. Mattingly, William H. Heiser, David T.
Pratt, Aircraft Engine Design, Second Edition,
AIAA, Inc., Education Series, 1801, Alexander
Bell Drive, Reston, VA 20191-4344.
[14] Ansys documentation.
[15] Institution of Mechanical Engineers (Great
Britain), International Conference of Fans, Fluid
Machinery Group, WILEY, 1807.
[16] M. P. Szolwinski, J. F. Matlik, T. N. Farris, Effects
of HCF Loading on Fretting Fatigue Crack
Nucleation, ELSEVIER, International Journal of
Fatigue, Vol. 21 671-677, 1999.
[17] Julie. A. Bannantine, Jess J. Comer and James L.
Handrock, Fundamentals of Metal Fatigue
Analysis, Prentice Hall, Upper Saddle River, NJ
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[18] http://www.fatiguecalculator.com
21/10/2009

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