Higher aircraft energy efficiency may be achieved by minimizing the clearance between the rotating blade tips and respective surrounding casing. A common technical solution consists in the implementation of an abradable liner which improves both the operational safety and the efficiency of modern turbomachines. Recently, unexpected abradable wear removal mechanisms were observed in experimental set-ups and during maintenance procedures. The present study introduces a numerical strategy capable to address this occurrence.

After focusing on the analysis of the experimental results, the good agreement between experimental observations and numerical results is illustrated in terms of critical stress levels within the blade as well as final wear profiles of the abradable liner. New blade designs are also explored in order to assess the impact of blade design on the outbreak of the interaction phenomenon. The prevalence of three dominant parameters in the interaction onset is shown: (1) blade design, (2) abradable material mechanical properties and (3) the need for a global distortion of the casing to synchronize blade-tip/abradable coating contacts.

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