A Computational Framework for Predicting Foreign Object Damage in Aero-Engines

  • Albiez, Jürgen (MTU Aero Engines AG)
  • Hörmann, Julia (MTU Aero Engines AG)
  • Leopold, Patrick (MTU Aero Engines AG)
  • Keller, Jan (MTU Aero Engines AG)
  • von Lautz, Julian (MTU Aero Engines AG)

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Foreign Object Damage (FOD) remains a critical challenge for aero-engine durability. This work introduces a computational framework to predict FOD distributions in Low-Pressure Turbines. The approach combines CFD-DEM simulations in Ansys CFX with a variable Coefficient of Restitution (CoR) derived from FE impact simulations in LS-Dyna and ballistic tests. An energetic filter identifies particles capable of causing plastic deformation, while Wasserstein distance metrics enable quantitative comparison of impact patterns. Results show that sub-critical particle trajectories are inertia-driven and largely insensitive to inlet variations. Validation against experimental field data confirms the framework’s potential as a design stage risk assessment tool to predict FOD distributions in Low-Pressure Turbines.