The design of bladed disks with contact interfaces typically requires analyses of the resonant forced response and flutter-induced limit cycle oscillations. The steady-state vibration behavior can efficiently be calculated using the Multi-Harmonic Balance method. The dimension of the arising algebraic systems of equations is essentially proportional to the number of harmonics and the number of degrees of freedom (DOFs) retained in the model. Extensive parametric studies necessary e.g. for robust design optimization are often not possible in practice due to the resulting computational effort.

In this paper, a two-step nonlinear reduced order modeling approach is proposed. First, the autonomous nonlinear system is analyzed using a Complex Nonlinear Modal Analysis technique based on the work of Laxalde and Thouverez [1]. The methodology in [1] was refined by an exact condensation approach as well as analytical calculation of gradients in order to efficiently study localized nonlinearities in large-scale systems. Moreover, a continuation method was employed in order to predict nonlinear modal interactions. Modal properties such as eigenfrequency and modal damping are directly calculated with respect to the kinetic energy in the system. In a second step, a reduced order model is built based on the Single Nonlinear Resonant Mode theory. It is shown that linear damping and harmonic forcing can be superimposed. Moreover, similarity properties can be exploited to vary normal preload or gap values in contact interfaces. Thus, a large parameter space can be covered without the need for re-computation of nonlinear modal properties. The computational effort for evaluating the reduced order model is almost negligible since it contains a single DOF only, independent of the original system.

The methodology is applied to both a simplified and a large-scale model of a bladed disk with shroud contact interfaces. In contrast to [1], the contact constraints account for variable normal load and lift-off in addition to dry friction. Forced response functions, backbone curves for varying normal preload and excitation level as well as flutter-induced limit cycle oscillations are analysed and compared to conventional methods. The limits of the proposed methodology are indicated and discussed.

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