1

CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION
Gas turbines are used extensively for aircraft propulsion, power generation and industrial applications. In recent years, there has been an increased interest in the design and analysis of critical components in gas turbines. Rotor blade is the very critical component in the field of turbo machines. The stress and displacement analysis of the rotor blade of any turbo machine in the field of design played a very important role. The major cause of break down is due to different loadings such as fluid or gas forces, inertia load, centrifugal forces are acting on the turbo machines rotor blades Hence, the proper mechanical design of the turbo machine blade plays an important role in the proper functioning of the turbo machine. Finite element analysis is used to calculate the stresses for complex geometry of rotor blades. The stress analysis is performed to determine the critical section as well as the stressing pattern. 1.2 The finite element method The finite element method has become a powerful tool for the numerical solution of a wide range of engineering problems. Applications range from deformation and stress analysis of automotive, aircraft, building, and bridge structures to field analysis of heat flux, fluid flow, magnetic flux, seepage, and other flow problems. The finite element method includes with three basic features that account for its superiority over other competing methods: Geometrically complex domain of the problem is represented as a function of geometrically simple sub domains called finite elements. Over each finite element the approximation, functions are derived using the basic idea that any continuous function can be represented by a linear combination of algebraic polynomials. Algebraic relations among the undetermined co efficient are obtained by satisfying the governing equation often in a weighted integral sense over each element.

1.3 GAS TURBINE AND THEIR COMPONENTS Gas turbine is a rotating internal combustion engine, which takes air from the atmosphere and compresses it to high pressure in a compressor and the compressed air flows into the combustion chamber, where fuel is admitted and ignited with the help of a spark plug, the products of combustion are used as a working fluid for developing power in the turbine section of the gas turbine.

3 Working principle of gas turbine

Figure 3.1 Indicator diagram of gas turbine 1-2 isentropic compression (in a compressor) 2-3 Constant pressure heat addition 3-4 isentropic expansion (in a turbine) 4-1 Constant pressure heat rejection (cooling process)

Figure 3.2 Simple open cycle gas turbine The key components are: The Compressor The Combustor and The Turbine

4 Compressor usually sits at the front of the engine. There are two main types of compressor, the centrifugal compressor and the axial compressor. The compressor will draw in air and compress it before it is fed into the combustion chamber, to obtain the required high pressure. The turbine drives the compressor so it is coupled to the turbine shaft. The combustor module contains the combustion chambers, igniter plugs, and fuel nozzles. It burns the fuel-air mixture and delivers the products of combustion to the turbine at temperatures within design range. The turbine obtains its power by utilizing the energy of burnt gases and the air which is at high temperature and pressure by expanding through the several rings of fixed and moving blades. The turbine consists of several stages. Each stage comprises of a stationary blow of nozzles where, the velocity of the high energy gases is increased and directed towards a rotating row of buckets (aero foils) attached to the turbine shaft. The high velocity gases impinge on the buckets, converting kinetic energy of gas to shaft power The rotor blades of the turbo machine are very critical components and reliable operation of the turbo machine as a whole depends on their repayable operation. The major cause of break down in turbo machine is the failure of rotor blade. The failure of the rotor blade may lead to catastrophic consequences both physically and economically. Hence, the proper design of the turbo machine blade plays a vital role in the proper functioning of the turbo machine. 1.2 NEED AND OBJECTIVE: The main cause of turbine blade failure is high cycle fatigue. The fatigue life of a structural member i.e. the number of load cycles it can survive is in general determined by the magnitude of the stress cycles. The exact relation between the magnitude of the stress and the fatigue life depends on the material properties of the structural member In the present work the first stage rotor blade of a two-stage gas turbine has been analyzed for structural, thermal using ANSYS 12, which is a powerful Finite Element Software, for different materials, so as to obtain an optimum blade design, without an actual model making. 1.3 PROBLEM DEFINITION The present study attempts to understand and analyze the turbine blade subjected to centrifugal forces due to rotational speed and gas forces through Finite Element Modeling with a view to determine the stresses and displacement for complex geometry of rotor blades. Stress and displacement analysis can be viewed by postprocessor phase

CHAPTER 2

LITERATURE REVIEW
2.1 LITERATURE REVIEW Moving blades in the turbine are meant for conservation of the kinetic energy of the flowing gas into the mechanical work on the turbine shell, the work done by working fluid is transmitted to the shaft through the disc on which the blades are mounted. Turbo machine rotor blades are subjected to different types of loading such as fluid or gas forces, inertia loads and centrifugal forces. Due to these forces various stresses are induced in rotor blades. So stress and strain mapping on a rotor blade provide a vital information concerning the turbo machine design and lead to the detection of critical blade section. Analysis of static and dynamic behavior of a rotor blade is a basic problem in aero elasticity of turbo machine blades. The present paper deals with the stress analysis of a typical blade made up of nickel super alloy, which is subjected to centrifugal loading. The analysis results shows that stress is sever due to centrifugal forces, when compared, due to dynamic gas forces. Here in this case the effect of thickness, twist and taper of the blade was considered at the root of the blade where generally failure is occurring. The various blade shapes viz. rectangular, aerofoils with some angle twist, taper aerofoil are taken into consideration. In this paper linear static analysis for determining von mises stresses, deformation in Z direction was determined using Finite element analysis software. The Solid brick 20-node element is used. Turbine blades operate at speed range 5000 to 15000 r.p.m., with temperature ranging from 50 to 900 degree centigrade. Hence depending on the stage of operation, blading material is usually an AL alloy, stainless steels, titanium alloys and nickel-based alloys. The tolerances on the blades are usually in the range of 0.05 mm to 0.15 mm on the aerofoil. The blades have a complex aerofoil structure and with varying aerofoil shape at different sections along the length of blade. There is always twisting in the aerofoil sometimes of the order 60 degrees. These complex configurations are required as the gases are to be smoothly guided along the different stages of the compressor and turbine without turbulence to achieve maximum thrust from the engine.

2.2 CRITICAL REVIEW The free and mapped mesh is taken into consideration. By studying lot of literature and critical review of them, I conclude 1) To determine thermal stresses due to high temperature gradient. 2) To determine maximum stress induced in blades. 3) To determine the temperature distribution along the blade profile. 4) To maintain temperature and stresses within limits. 5) To determine the parameters influencing the stress concentration in rotor blades. 6) To determine the effect of change of material properties. This enables the designers to develop the analysis of gas turbine rotor blade more effectively and easily.

CHAPTER 3

METHODOLOGY

3.1 INTRODUCTION The purpose of turbine technology is to extract the maximum quantity of energy from the working fluid to convert it into useful work with maximum efficiency by means of a plant having maximum reliability, minimum cost, minimum supervision and minimum starting time. The stress analysis of the rotor blade being the key phase of the turbo machine design, requires careful determination of the blade loading to get realistic results. As the blade vibration is also a cause of failure in many cases, the determination of natural frequencies is considered, so as to avoid resonance, which is an undesirable phenomenon.
Turbine Blade Failure

The main cause of turbine blade failure is high cycle fatigue. Fatigue failure is related to repeated cycling of the load on a structural member. The fatigue life of a structural member i.e. the number of load cycles it can survive is in general determined by the magnitude of the stress cycles. The exact relation between the magnitudes of the stress and the fatigue life depends on the material properties of the structural member. In general higher stresses lead to a shorter fatigue life The Fatigue failure results from a combination of steady stress, vibratory stress, and material imperfections. However, the size of microscopic imperfections is difficult to control. Hence, stress-range diagrams are used to quantify the allowable vibratory stress amplitudes to avoid fatigue damage. It is initiated by the formation of a small, oftenmicroscopic crack. The vibratory stress levels required to produce a fatigue crack at a specific mean stress level are then determined from stress-range diagrams, as shown .

Figure 2.1 stress range diagram Advanced turbo machinery blading is designed to have high steady stress levels. Thus high cycle fatigue occurs because of high mean stress low amplitude vibratory loading of aerofoils, as shown.

Figure 2.2

Advanced Airfoil stress range diagram

Due to corrosion and corrosion deposits turbine blades fail. To protect it from corrosion, the uses of pack-aluminized coatings are used. The main elements used are aluminium, nickel, and chromium A good design of the turbo machine rotor blading involves the following : 1) Determination of geometric characteristics from gas dynamic analysis. 2) Determination of steady loads acting on the blade and stressing due to them. 3) Determination of natural frequencies and mode shapes. 4) Determination of unsteady forces due to stage flow interaction. 5) Determination of dynamic forces and life estimation based on the cumulative damage fatigue theories. 3.2.1 PRODUCTION OF BLADES Blades may be considered to be the heart of turbine and all other member exist for the sake of the blades. Without blading there would be no power and the slightest fault in blading would mean a reduction in efficiency and costly repairs. The following are some of the methods adopted for production of blades. 1) Rolling: - Sections are rolled to the finished size and used in conjunction with packing pieces. Blades manufactured by this method do not fail under combined bending and centrifugal force. 2) Machining: - Blades are also machined from rectangular bars. This method has more or less has the same advantage as that of first. Impulse blading are manufactured by this technique.

9 3) Forging: - Blade and vane sections having airfoil sections are manufactured by specialist techniques. The simplest way is to determine the profile required at the hub and tip and join then by straight ruled lines. Once the geometry of the ruled line is established they may be machined by a milling machine, rest carefully by each line to generate the shape required in a master block from which the forging die may be copy machined. This method ensures the accurate forging of blades to their finished size, requiring only finishing. Broaching often does the machining of the fir-tree root and electrochemical machining may be used in some parts to avoid the conventional cutting processes. In advance methods, computers are used to determine the blade shape required by aerodynamic and stress criteria. The computer may then instruct a numerically controlled milling machine to prepare the dies. 4) Extrusion: - Blades are sometimes extruded and the roots are left on the subsequent machining. This method is not reliable as rolled sections, because of narrow limits imposed on the composition of blade material. 3.2.2 BLADE MATERIALS Proper selection of blade material plays an important role in blade design. The factors that influence the selection of blade materials are: 1) Method of manufacture 2) Ease of machining 3) The ability to produce blade sections free from flaws. 4) Ductility both allow of rolling of shapes. 5) The capacity for being welded. 6) Ease of forging easily. 7) Condition of operations. 8) Suitable tensile strength at high temperature. 9) Resistance to creep. 10) Cost. The commonly used blade materials are: Brass: - Brass (70 to 72 % Cu and 28 to 30 % Zn) is suitable for temperature up to 230 deg. This is rarely used now days. Copper Nickel: - This is an alloy containing about 80 % Cu, 19 % Ni and fraction of iron and magnesium. Nickel Brass: - It is suitable for temperature range up to 230 and contains 50 % Cu, 40 % Zn and 10 % Ni.It may be cold drawn. Manganese copper: - Its composition is 95 to 96 % Cu, 4 to 5 % Mn and small amounts of iron, carbon and leads. It is not suitable for high stress and temperature .It may be cold drawn and cold rolled. Phosphor Bronze: - This is copper tin alloy with a small amount of phosphorous. Its composition is 86 % Cu, 14 % tin and 1 % phosphorous for hard bronze.

10 Monel Metal: - The composition of Monel metal is 67 % Ni and 28 % Cu with a small amount of iron, carbon, manganese. It is resistant to corrosion and is suitable for high temperature. It is used for marine work. Mild steel: - In the past, it was used in many turbines but now it is rarely used. It corrodes very soon with wet steam but it is very inexpensive. Nickel steel: - This alloy is more resistant to corrosion than is mild steel. It may be forged or machined but not welded. Generally steel with 3 to 5 % Ni is used. It is used in many turbines. Stainless steel: - It is an alloy of iron, chromium and carbon containing 12 to 14 % chromium and normal percentage of carbon. It is very resistant to corrosion and erosion. It is also very hard. It may be rolled, easily machined and welded.

material

Elastic modulus (n/mm2) 2.10*10E5 0.75*10e5 1.20*10e5 1.25*10e5

Table 3.1 Material properties Poissons Density Yield Ratio (tonne/mm3) Strength (n/mm2) 0.3 0.33 0.34 0.33 7.89*10E-9 2.79*10e-9 9.10*10e-9 9.75*10e-9 250 165 70 150

Ultimate strength (n/mm2) 420 260 240 400

Steel Aluminium alloy copper Copper alloy

3.2.3 TURBINE BLADE COOLING: Unlike steam turbine blading, gas turbine blading need cooling. The objective of the blade cooling is to keep the metal temperature at a safe level to ensure a long creep life and low oxidation rates. Although it is possible to cool the blades by liquid using thermo syphon and heat pipe principal, but the universal method of blade cooling is by cool air or working fluid flowing through internal passage in the blades.

11 The mean rotor blade temperature is about 3500 c below the prevailing gas temperature after efficient blade cooling.

Figure 3.4 Turbine blade cooling .

SOLUTION PHASE OF THE ANALYSIS

3.2.5 WHAT IS SOLUTION In the solution phase of the analysis, the computer takes over and solves the simultaneous equations that the finite element method generates. The results of the solution are - a) nodal degree of freedom values which form the primary solution and b) derived values, which form the element solution. The element solution is usually calculated at the element integration points. Several methods of solving the simultaneous equations are available in the ANSYS program, frontal solution, sparse direction solution, Jacobi Conjugate Gradient solution, Precondition Conjugate Solution and an automatic iteration solver option. The frontal solver is the default. 3.2.6 SELECTING A SOLVER The following table provides general guidelines you may find useful in selecting which solver to use for a given problem is shown in the table 3.2. 3.3 WHAT IS MODEL GENARATION The ultimate purpose of a finite element analysis is to re-create mathematically the behavior of an actual engineering system. In other words, the analysis must be an accurate mathematical model of a physical prototype. In the broadest sense, this model comprises all the nodes, elements, material properties, real constants, boundary conditions and other features that are used to represent the physical system.

12 In ANSYS terminology, the term model generation usually takes on the narrower meaning of generating the nodes and elements that represents the spatial volume and connectivity of the actual system. The ANSYS program offers you the following approaches to model generation. Creating a solid model within ANSYS. Using direct generation Importing a model created in a computer aided three dimensional interactive applications (CATIA) system.

Solver

Table 3.2 Different Solvers Typical Model Applications Size Under 50,000 DOFS

Memory Disk Requirement requirement Low High

Frontal solver When robustness is required (Direct i.e. nonlinear analysis or elimination when memory is limited. solver Sparse Direct When robustness and solution solver (direct speed are required i.e. for elimination nonlinear analysis solver)

10,000 to Medium 500,000 DOFS more for shells

High

PCG solver- When solution speed is Iterative solver crucial linear analysis of large models. Especially suited for large models with solid elements ICCG iterative When solution speed is solver crucial. Handles models that are harder to converge in other iterative solvers

50,000 to High 1,000,000 DOFS

Low

50,000 to High 1,000,000 DOFS

Low

13

3.3.1 TYPICAL STEPS INVOLVED IN MODEL GENARATION WITHIN ANSYS: A common modeling session might follow this general outline. Begin by planning your approach-Determine your objectives, decide what basic form your model will take, choose appropriate element types and consider how you will establish an appropriate mesh density. Enter the preprocessor to initiate your model building session. Establish a working plane Generates basic geometric features using geometric primitives and Boolean operators. Activate the appropriate coordinate system Generate other solid model features from the bottom up. That is creating keypoints, and then defines lines, areas, and volumes as needed. Create table of element attributes (element types, real constants, material properties and element coordinate system) Set elemenent attribute pointers. Set meshing controls to establish your desired mesh density. Create nodes and elements by meshing your solid model. Save your model as jobname.db 3.4 FINITE ELEMENT FORMULATION OF ELEMENTS PLANE 82 2-D 8-NODE STRUCTURAL SOLID ELEMENT Plane 82 is a higher order version of the two dimensional four-node element. It provides more accurate results for mixed (quadratic-triangular) automatic meshes and can tolerate irregular shapes without as much loss of accuracy. The 8-node elements have compatible shapes and are well suited to model curved boundaries. The 8-node element is defined by 8-nodes having two degrees of freedom at each node-translations in the nodal x and y directions. As shown below the element may be used as a plane element or as an axis syymetric element. The element has plastically creep, stress stiffening, large deflection, and large strain capabilities. The following table provides the summary of element input.

14

Figure 3.5 plane 82 2-d structural solid

3.4.1 PLANE 82 INPUT SUMMARY: Element Name Plane 82 Nodes I, J, K, L, M, N, O, P Degrees of Freedom UX, UY Real constants none Material Properties EX, EY, EZ (PRXY, PRYZ, PRXZ NUXY, NUYZ, NUXZ) ALPX, ALPY, ALPZ, DENS Surface loads Pressure Body loads Temperatures Special features Plasticity, creep, stress stiffening, large deflection, and large strain. 3.4.2 SOLID 95 3D 20-NODE STRUCTURAL SOLID ELEMENT Solid 95 is higher order version of the 3-D 8-node solid element. It can tolerate irregular shapes without as much loss of accuracy. Solid 95 elements have compatible displacement shapes and are well suited to model curved boundaries as shown. The element is defined by 20 nodes having three degrees of freedom per node, translations in the nodal x, y, and z directions. The element may have any spatial orientation. The element has plastically creep, stress stiffing, large deflection and large strain capabilities.

15

Figure 3.6 Solid 95 3-D structural solid 3.4. 3 SOLID 95 INPUT SUMMARY Element t Name Nodes Degrees of Freedom Real constants Material Properties Surface loads Body loads Special features Solid 95 I, J, K, L, M, N, O, P, Q, R, S, T, U, V, V, W, X, Y, Z, A,B. UX, UY, UZ none EX, EY, EZ (PRXY, PRYZ, PRXZ NUXY, NUYZ, NUXZ) ALPX, ALPY, ALPZ, DENS Pressure Temperatures Plasticity, creep, stress stiffening, large deflection, and large strain.

3.4.4 WHAT IS THE FINITE ELEMENT METHOD The FEM has become a powerful tool for numerical solution of wide range of engineering problems. The advance in computer technology and high-speed electronic computers enables complex problems to model easily. This makes to test in computers before the first prototype is built. In this method of analysis, a complex continuum is defined into simple geometric shapes called FEM. The material properties and governing relationship are considered over these elements and expressed in term of unknown values at elemental corners 3.4.5 FINITE ELEMENT ANALYSIS OF GAS TURBINES BLADE

16
A turbine blade is analyzed for its thermal as well as structural performance due to the loading condition. It can be done by

(a) Finite difference and (b) finite element discretizations of a turbine Blade profile.

Figure 3.7 Discretizations of turbine blade profile Finite difference model of a problem gives a point wise approximation and finite element model of a problem gives a piecewise approximation. Finite difference techniques become hard to use for irregular geometries where as the finite element method is particularly well suited for problems with complex geometries as they give better approximation to the boundary shape.

HOW THE FINITE ELEMENT METHOD WORKS 1. Discretize the Continuum. The first step is to divide the continuum or solution region into elements, that is turbine blade has to be divided into triangular elements that might be used to find the temperature distribution or stress distribution in the blade. 2. Select Interpolation Functions: Assign nodes to each element and then choose the interpolation function to represent the variation of the field variable over the element. The field variable may be a scalar, a vector, or a higher-order tensor. 3. Find the Element Properties. For this task one of the three approaches must be mentioned: the direct approach, the variational approach, or the weighted residuals approach, to determine the matrix equations expressing the properties of the individual elements 4. Assemble the Element Properties to Obtain the System Equations: combine the matrix equations expressing the behavior of the elements and form the matrix equations expressing the behavior of the entire system. The matrix equations for the system have the same form as the equations for an individual element except that they contain many more terms because they include all nodes.

17 5. Impose the Boundary Conditions. Before the system equations are ready for solution they must be modified to account for the boundary conditions of the problem imposing known nodal values of the dependent variables or nodal loads. 6. Solve the System Equations. The assembly process gives a set of simultaneous equations to obtain the unknown nodal values of the problem, by solving them. 7. Make Additional Computations. Faster automatic calculations, which are repetitive in nature, simultaneous display of modifications & post processing results, are done For example, in a structural problem the nodal unknowns are displacement components. From these displacements we calculate element strains and stresses. Similarly, in a heatconduction problem the nodal unknowns are temperatures, and from these we calculate element heat fluxes. 3.5 EVALUATION OF GAS FORCES ON THE ROTOR BLADES Gas forces acting on the blades of the rotor in general have two components namely tangential (Ft) and axial (Fa). These forces result from the gas momentum changes and from pressure differences across the blades. These gas forces are evaluated by constructing velocity triangles at inlet and outlet of the rotor blades. The rotor blades considered for analysis are untwisted and same profile is taken throughout the length of the blade. If the gas forces are assumed to be distributed evenly then the resultant acts through the centroid of the area. 3.5.1 EVALUATION OF GAS FORCES ON THE FIRST STAGE ROTOR BLADE At the inlet of the first stage rotor blades, Absolute flow angle 2 = 23.850 Absolute velocity V2 = 462.21 m/s The velocity triangles at inlet of first stage rotor blades were constructed as shown.

Figure 3.8 Inlet velocity triangles of I-stage rotor blades Diameter of blade midspan D = 1.3085 mt. Design speed of turbine N = 3426 r.p.m.

18

Peripheral speed of rotor blade at its midspan U = DN/60 ------------------ (1) From the velocity triangles in figure we get, Whirl velocity Vw2 = 422.74 m/s Flow Velocity Vf2 = 186.89 m/s Relative velocity Vr2 = 265.09 m/s Blade angle at inlet 2 = 135.017 0 At the exit of first stage rotor blades, Flow velocity Vr3 = 180.42 m/s Relative flow angle 2 = 37.88 0 The velocity triangles were constructed at the exit of the first stage rotor blades as shown.

Figure 3.9 Exit velocity triangles of I-stage rotor blades From the velocity triangles (Figure), we get Whirl velocity Vw3 = 2.805 m/s Relative velocity Vr3 = 293.83 m/s Finding tangential Force (Fr) and Axial force (Fa) on each rotor Tangential force In Newtons Axial Force In Newtons

Ft = M (Vw2 (+Vw3)]. (2) FA = M (Vf2 (+Vf3)]. (3)

Where m represents mass flow rate of gases through the turbine in kgs / sec.

19

Figure 3.10 First stage rotor Referring to Figure 3.10 M = p2 x (D0-Di)/4 x V f2. (4) Where p2 is the density of gases at the entry of first stage rotor P2 = 0.8234 kg/m3 Using equation (4), M = 70.925 kgs/sec Using equations (2) and (3) Total tangential force on first stage rotor Fr = 29783.88 Newtons. Total axial force on first stage rotor Fa = 458.88 Newtons. Number of blade passages in first stage rotor = 120 Tangential force on each rotor blade FT Ft = -----------------------------------------. No. of blade passages

(5)

Axial forced on each rotor blade FA Fa = -----------------------------------------. No. of blade passages Using equation (5) Ft = 248.199 Newtons Using equation (6)

(6)

20 Fa = 3.82 Newtons Power developed (p) in the first stage rotor From Eulers energy equation, P = m {Vw2 U (+Vw3 U)}. (7) Using equation (7) P = 6.991 Mega Watts 3.5.2 EVALUATION OF GAS FORCES ON SECOND STAGE ROTOR BLADES The gas forces and power developed in second stage rotor blades were evaluated using the same procedure and similar equations that were used for first stage rotor blades as shown in figure 2.4.

Figure 3.11 inlet velocity triangles of II-stage rotor blades We get, Tangential force Axial force Power developed Ft = 244.49 Newtons Fa = 0.944 Newtons P = 13.972 Mega Watts

Figure 3.12 Exit velocity of stage -II rotor blades

21 3.5.3 CENTRIFUGAL FORCES EXPERIENCED BY THE ROTOR BLADES

Figure 3.13 3-D view of rotor blades showing position of centroid G 3.5.3.1 EVALUATION OF CENTRIFUGAL FORCE EXPERIENCED BY FIRST STAGE ROTOR BLADES

M1x1 + m2x2 + m3x3 The distance x = --------------------------------- (8) M1 + m2 + m3 Where m1, m2, m3 are masses of volumes 1,2 and 3 and x1, x2 and x3 are distances of the centroid of volumes 1,2 and 3 from axis of revolution. The density of material was graphically measured to be p = 7136.52 kg/m3 as shown. m1 = 0.382 kgs m2 = p x V2 m3 = p x V3 Where V2 and V3 are volumes of portions 2 and 3 of rotor blades. Using equation (8), x = 648.85 mm Total mass M = m1+m2+m3 Centrifugal force Fc Fc= M x {2 N/60)2 x (x) ..(9) Where M = Total mass of rotor blade N = Rotor r.p.m. (x) = Distance of centroid from the axis of revolution Using equation (9)

22 Fc = 38038.73 Newtons. 3.5.3.2 EVALUATION OF CENTRIFUGAL FORCE EXPERIENCED BY SECOND STAGE ROTOR BLADES Using the same methodology that was used for the first stage for the second stage rotor blades we get, X = 657.77 mm Fc = 35164.39 Newtons. 3.5.4 CONVECTIVE HEAT TRANSFER COEFFICIENTS OVER THE BLADE SURFACES

Figure 3.14 gas flow over suction and pressure side of rotor blade 3.5.4.1 EVALUATION OF CONVECTIVE HEAT TRANSFER COEFFICIENTS (hs) ON SUCTION SIDE OF FIRST STAGE ROTOR BLADES For first stage rotor blades, as shown. Temperature of gases at inlet Ti = 839.220 c Temperature of gases at exist Te = 732.880 c Mean fluid temperature Tmf = Ti + Te .. (10) 2 The flowing properties of air at Tmf were noted. Kinematic viscosity (v) Prandtl Number (Pr) Thermal Conductivity (K) On suction side the flow is approximated to the flow across a cylinder whose diameter (D) is equal to the chord length (l) of the aerofoil. Reynolds number Re = Vr * D..(11) v Average relative velocity

23

Vr = Vr2 + Vr3.(12) 2 Using equation (11) Re = 97881.14 The Nusselt number (Nu) is calculated using the empirical relation for flow across cylinders. The generalized equation is NuD = C ReD.m Pr0.333.(13) The values of C and M are selected from the table below. Table no 3.3 Reynolds Number C M 0.989 0.330 0.911 0.683 0.193 0.0266 0.385 0.4666 0.618 0.805

ReD 0.4 4.0

4.0 4.0 40.0 4000 4000 40000 40000 4000000 Using equation (13) NuD = 247.329

NuD = hs * D..(14) K Using equation (14) Hs = 379.92 w/m2 k 3.5.4.2 EVALUATION OF CONVECTIVE HEAT TRANSFER COEFFICIENTS (hp) ON THE PRESSURE SIDE OF FIRST STAGE ROTOR BLADES. For first stage rotor blades, Ti = 839.220 c Te = 732.880 c Tmf = Ti + Te (11) 2 Kinematic viscosity (v), Prandtl number (Pr) and thermal conductivity (k) of air at Tmf are noted down form air tables. On pressure side, the flow is approximated to the flow over a flat plate whose length (L) along the flow direction is equal to chord length (l) of the aerofoil blade. Reynolds number Re = Vr * L..(11)

24 v Using equation (16), Re = 97881.14 Since Re< 5 * 10 5 flow is laminar on pressure side. Following is the empirical relation for laminar flow over a flat plats. Nu = 0.664 Pr 1/3 Re 1/2 (17) Using equation (17) Nu = 241.983 For flat plate, Nu = hp * L.. (18) K Hp = 284.95 w/m2 K 3.5.4.3 EVALUATION OF CONVECTIVE HEAT TRANSFER COEFFICIENT (HR) ON THE TWO RECTANGULAR FACES AT INLET AND EXIST OF FIRST STAGE ROTOR BLADES. In figure 2.8 and 2.9.the shaded rectangles are the ones which heat transfer coefficients are calculated. The gases sweep the rectangular faces with a velocity V = u = D N/60 (16)

Figure 3.15 Inlet of first stage rotor blade

25

Figure. 3.16 Exit of first stage rotor blade The flow can be approximated to the flow over a flat plate whose length is equal to the length (L) of the rectangular face. Gas temperature at inlet T I = 839.220 c Gas temperature at exist Te = 7320 c V, Pr and K of air are noted at temperature Ti and Te from the air table Re = V * L .(17) v At inlet Re =20325.197 At exist Re = 23785.71 For laminar flow over a flat plate Nu = 0.664 Pr 1/3 Re ..(18) Nu = hL.. (19) K Convective heat transfer coefficients on the rectangular face at inlet hfi = 231.195 w/m2 K Convective heat transfer coefficients on the rectangular face at exist hfe = 224.73 w/m2 K 3.6 COMPUTER AIDED STRUCTURAL ANALYSIS OF A GAS TURBINE ROTOR BLADE Element Type 1: Element type 2: 8 node quadrilateral element 10 node Brick solid element.

The following material properties were defined in the material property table named as material type 1. Youngs Modulus of Elasticity (E) = 2e5 N/MM2

26 Density () = Coefficient of thermal expansion () = 7136.52 e-9 6.12e-6

The aerofoil profile of the rotor blade was generated on the XY plane with the help of key points defined by the coordinates as given below. Then a number of splines were fitted through the keypoints. A rectangle of dimensions 49*27 mm was generated as shown.

Figure 3.17 Boundary of aerofoil section Table no:-3.4 LIST OF SELECTED KEYPOINTS X Y LOCATION (Z=0) 0.00 2.6 5.85 10 14.8 22.9 28 33.4 38 42 45.5 49 6.18 11.2 16.18 21.1 26 0.00 17.3 21 25 26.6 25.3 22.2 18.5 14.4 10.9 5.70 0.00 12.4 14.4 15.5 14.9 13.6

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

27 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38.2 45 49 49 0.00 19.8 1.00 29.2 29.2 19.8 15.2 18.08 49.00 48.90 29.2 19.8 19.8 29.2 0.00 19.8 19.8 8.77 3.95 0.00 27.00 27.00 0.00 13.6 0.00 27 27.00 27.00 27.00 0.27E-1 0.288E-1 12.49 26.62 15.12 21.25 0.30E-1 0.30E-1 15.12

Using splines and lines 9 different areas were generated which was shown.

Figure 3.18 areas of turbine rotor blade In the shape and size option, the number of element edges along the lines, surrounding the areas 1 to 9 was specified. In the attribute option element type 1 and material type 1 were assigned to all the areas. Using the mesh option all the areas were meshed with 8-node quadrilateral element.

28 Areas 1 to m9 were extruded upwards in the positive Z direction through a height of 5mm.Before the extrusion option, the element and material type have to be assigned to the areas to be extruded. Element type 2 and material type 1 +were assigned to these areas. After extrusion, the rectangular block as shown was generated which was meshed with 3-D 20 node Brick element.

Figure 3.19 turbine rotor block Again using the extrusion option, the shaded area as shown in figure 3.2 was extruded upwards through the blade height (117 mm) along the positive Z direction using 3 D

. Figure 3.20 rotor blade with 3 D 8 Node element Areas 4,5,6 were extruded downwards along the negative direction through a distance 14.5 mm using 3-D 20 node Brick elements as shown in figure 3.4

Figure 3.21 Volume of rotor blade The shaded areas shown in figure were extruded along the X-direction through a distance of 3.8 mm using 3-D 20 node Brick elements. The model was generated in the preprocessor of ANSYS 9.0

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Figure 3.22 3-D model of rotor blade 3.7 STRUCTURAL BOUNDARY CONDITIONS TO BE APPLIED ON THE ROTOR BLADE MODEL Two structural boundary conditions namely displacement and force were applied on the rotor blade model. The solution part of ANSYS was opened and the displacement constraints (U) were imposed on the areas shaded and numbered.

Figure 3.23 Structural boundary conditions on rotor blade Ux = 0 for areas 4,5,6,7 and 11,12,13,14 Uy = 0 for areas 1,2,3 and 8,9,10 Uz = 0 for areas 5 and 12 U represents displacement and suffix X, Y, Z represents the direction in which the displacement was constrained. Since the gas forces were assumed to be distributed evenly, the tangential and axial forces acts throughout the centroid of the blade. The centrifugal force also acts through the centroid of the blade and in radial direction. For first stage rotor blades, Tangential force ft = 248.199 Newtons. Axial force Fa = 3.82 Newtons. Centrifugal force Fc = 38038.73 Newtons. In the solution part of Ansys the blade forces namely tangential, axial and centrifugal were applied on the node located at the centroid of the blade as shown.

30

Figure 3.24 Static loading on rotor blade 3.7.1 ANALYSIS OF STRESSES ANDS ELONGATIONS The ANSYS software then analyzed the mechanical stresses and elongations experienced by the rotor blade. The results were viewed in the post processor part of ansys. The geometry, loads and results were stored in a file named X. 3.8 THERMAL BOUNDARY CONDITIONS APPLIED ON THE ROTOR BLADE MODEL A new file was opened in ANSYS and the thermal module of ANSYS was activated. The rotor blade model was copied into this file from which the previous structural analysis file X. The structural boundary conditions that were applied previously on the rotor blade model were deleted. The element type was stitched from structural to its equivalent thermal element type. The material properties were same as those in the previous file of structural analysis. Two boundary conditions namely Heat flux and Convection were applied on the rotor blade model. The solution part of ANSYS was opened and Heat flux = 0 was applied on the areas shaded and numbered in figure Heat flux = 0 fro areas 1,2 to 16 Areas 1,2,3 and 8,9,10 come in contact with similar areas on the adjacent rotor blades. Hence due to symmetry boundary conditions, these areas are assumed to be insulated. Areas 4,5,6 and 11,12,13,15 on account of their small dimensions are assumed to be insulated. In the convective boundary condition, the convective heat transfer coefficient (h) and temperature of surrounding gases (T) have to be specified on the areas subjected to convection.

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Figure 3.25 Thermal Boundary conditions The following have been the convective boundary conditions for the areas For area A, h = (hs + hp)/2 = 332.43 w/m2 K and T = 839.220 c For area B, h = hp = 248.95 w/m2 K and T = 7860 c For area C, h = hs = 379.92 w/m2 K and T = 7860 c For area D, h = 248.95 w/m2 K and T = 7860 c For area E, h = 379.92 w/m2 K and T = 7860 c For area F h = 231.19 w/m2 K and T = 7330 c

CHAPTER 4

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STRUCTURAL AND THERMAL ANALYSIS 4.1 ANALYSIS OF TEMPERATURE DISTRIBUTION The temperature distribution on the rotor blade was then analyzed by using the ANSYS software. The calculations were carried out in the solution part of Ansys. The results were viewed in the postprocessor part of software. The geometry, loads and results were stored in a separate file y. 4.2 ANALYSIS OF STRESSES ANSD ELONGATIONS TAKING TEMPERATURE EFFECT INTO CONSIDERATION The thermal analysis file y was reopened. The element type was switched from thermal to its equivalent structural element type. The structural boundary conditions namely displacements and forces were again applied on the model. In the thermal analysis the temperature distribution is stored in a .rth file. The temperature distribution was imposed on the blade by recalling it from .rth file file. The stresses and elongations were then analyzed using software results were viewed in the post processor.

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Figure Diagram

4.1 Line

Figure 4.2 Area diagram of rotor blade

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Figure 4.3 Finite Element model mapped mesh

4.3 G L O B A L S T A T U S FOR STRUCTURAL AND THERMAL ANALYSIS

No Of Nodes = 45934 No of elements = 10392 4.3.1 STRUCTURAL ANALYSIS OF DEFFERENT METERIALS 1)STEEL Table 4.1 Material properties of steel material Elastic modulus (n/mm2) 2.10*10E5 Poissons Ratio Density (tonne/mm3) Yield Strength (n/mm2) Steel 0.3 7.89*10E-9 250 Ultimate strength (n/mm2) 420

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Fig 4.4 Equivalent stress for steel

Fig 4.5 Shear stress in ZX direction

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Fig 4.6 Shear stress in YZ direction

Fig 4.7 Shear stress in XY direction

37

Fig 4.8 Normal stress in Z direction

Fig 4.9 Normal stress in Y direction

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Fig 4.10 Normal stress in X direction

Fig 4.11 Total displacement

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Fig 4.12 Displacement in Z direction

Fig 4.13 Displacement in Y direction

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Fig 4.14 Displacement in X direction

2) Aluminium Alloy Table 4.2 Material properties of Aluminium Alloy material Elastic modulus (n/mm2) Poissons Ratio Density (tonne/mm3) Yield Strength (n/mm2) Aluminium 0.75*10e5 alloy 0.33 2.79*10e-9 165 Ultimate strength (n/mm2) 260

41

Fig 4.15 Equivalent stress for Aluminium alloy

Fig 4.16 Shear stress in ZX direction

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Fig 4.17 Shear stress in YZ direction

43 Fig 4.18 Shear stress in XY direction

Fig 4.19 Normal stress in Z direction

44 Fig 4.20 Normal stress in Y direction

Fig 4.21 Normal stress in X direction

Fig 4.22 Total displacement

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Fig 4.23 Displacement in Z direction

Fig 4.24 Displacement in Y direction

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Fig 4.25 Displacement in X direction

3) Copper Alloy Table 4.3 Material properties of Copper Alloy material Elastic modulus (n/mm2) 1.25*10e5 Poissons Ratio Density (tonne/mm3) Yield Strength (n/mm2) Copper alloy 0.33 9.75*10e-9 150 Ultimate strength (n/mm2) 400

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Fig 4.26 Equivalent stress for Copper Alloy

Fig 4.27 Shear stress in ZX direction

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Fig 4.28 Shear stress in YZ direction

Fig 4.29 Shear stress in XY direction

49

Fig 4.30 Normal stress in Z direction

50 Fig 4.31 Normal stress in Y direction

Fig 4.32 Normal stress in X direction

51 Fig 4.33 Total displacement

Fig 4.34 Displacement in Z direction

Fig 4.35 Displacement in Y direction

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Fig 4.36 Displacement in X direction

4.3.2 THERMAL ANALYSIS OF DEFERENT METERIALS 1)STEEL Table 4.4 Material properties of steel material Elastic modulus (n/mm2) 2.10*10E5 Poissons Ratio Density Yield Ultimate strength (n/mm2) 420

(tonne/mm3) Strength (n/mm2)

Steel

0.3

7.89*10E-9

250

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Fig 4.37 Thermal analysis meshing element

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Fig 4.38 Thermal flux in XYZ direction

Fig 4.39 Thermal flux in Z direction

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Fig 4.40 Thermal flux in Y direction

Fig 4.41 Thermal flux in X direction

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Fig 4.42 Thermal gradient in XYZ direction

Fig 4.43 Thermal gradient in Z direction

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Fig 4.44 Thermal gradient in Y direction

Fig 4.45 Thermal gradient in X direction

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Fig 4.46 Nodal temperature at the airfoil of blade

2) Aluminium Alloy Table 4.5 Material properties of Aluminium Alloy material Elastic modulus (n/mm2) Poissons Ratio Density (tonne/mm3) Yield Strength (n/mm2) Aluminium 0.75*10e5 alloy 0.33 2.79*10e-9 165 Ultimate strength (n/mm2) 260

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Fig 4.47 Thermal flux in XYZ direction

Fig 4.48 Thermal flux in Z direction

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Fig 4.49 Thermal flux in Y direction

Fig 4.50 Thermal flux in X direction

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3) Copper Alloy Table 4.6 Material properties of Copper Alloy material Elastic modulus (n/mm2) 1.25*10e5 Poissons Ratio Density (tonne/mm3) Yield Strength (n/mm2) Copper alloy 0.33 9.75*10e-9 150 Ultimate strength (n/mm2) 400

Fig 4.51 Thermal flux in XYZ direction

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Fig 4.52 Thermal flux in Z direction

Fig 4.53 Thermal flux in Y direction

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Fig 4.54 Thermal flux in X direction

Fig 4.55 Crack on blade

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CHAPTER 5

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RESULTS AND DISCUSSIONS

5.1 STATIC AL ANSYS RESULTS 1) DISPLACEMENT Table:-5.1 Displacement result METERIAL DISPLACEMENT Max X 1 2 3 Steel Alluminium alloy Copper alloy 0.1138 0.1454 0.1539 Y 0.603 0.602 0.609 Z 0.2858 0.135 0.1357 X -0.117 -0.092 -0.091 Min Y -0.121 -0.119 -0.119 Z -0.139 -0.135 -0.285 0.617 0.633 0.656 All DOF

S.NO

2) NORMAL STRESS Table:-5.2 Normal stress result NORMAL STRESS Max X 1 2 3 Steel Alluminium alloy Copper alloy 541.21 359.11 637.11 Y 93.58 245.6 461.4 Z 910.202 348.9 579.7 X -229.6 -997.5 -166.1 Min Y -2427 -972.6 -162.11 Z -235.8 -997.5 -166.1

S.NO

METERIAL

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3) SHEAR STRESS

S.NO

Table:-5.3 shear stress result METERIAL SHEAR STRESS Max X Y 176.4 671.3 112.49 Z 576.6 209.6 348.9 X -858.69 -313.0 -521.6 Min Y -956.16 -341.4 -570.0 Z -525.16 -1964 -327.0

1 2 3

Steel Alluminium alloy Copper alloy

707.9 251.1 417.6

4) EQUIVALENT STRESS Table:-5.4 Equivalent stress result METERIAL EQUIVALENT STRESS Max 1 Steel 317.0 Min -0.159

S.NO

Alluminium alloy

120.72

0.441762

Copper alloy

202.26

-0.72088

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5.2 THERMAL ANSYS RESULTS

1) THERMAL FLUX Table 5.5 Thermal flux results THERMAL FLUX MAX 1 2 3 steel Aluminium alloy Copper alloy 1.294 1.226 1.175 MIN -0.517 -0.4912 -0.4685 ALL DOF 1.337 1.212 0.3554

S.NO METERIAL

2) THERMAL GRDIENT

Table 5.6 Thermal gradient results S.NO MATERIAL THERMAL GRDIENT MAX y z 10.53 10.32 MIN x y -13.42 -2.23 ALL DOF 13.927

STEEL

x 5.39

z -4.08

From the post processing, the temperature variation obtained as shown in figure. From figure, it is observed that the temperature variations from leading edge to the trailing edge on the blade profile is varying from 804.567 to 786.005 at the tip of the blade and the variation is linear along the path from both inside and outside of the blade. Considerable changes are not observed from the first 6 mm

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length from the leading edge and from there to next 36 mm length of blade the temperature is gradually decreasing and reaching to a temperature of 796.317 and for another 4 mm length it is almost constant. Again from this point onward it is sloping downwards and reaching795.38 at the trailing edge. Where ever maximum curvature is occurring the temperature variation is less. At the root of the blade i.e. The top flange of base, the temperature variation along X-direction is varying from 800.442 to 786.37 on front side i.e. inside and 802.505 to 790.13 on the backside of the blade. The temperature decreases gradually along X-direction. There is very small temperature gradient is occurring along Y-direction at the blade leading edge, on the suction side of blade and at the exit side of the blade and at the exits side the temperature is varying from 788.067 to 796.317.

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CONCLUSION
1. The finite element analysis of gas turbine rotor blade is carried out using 20 noded brick element. The static and thermal analysis is carried out. 2. The temperature has a significant effect on the overall stresses in the turbine blades. 3. Maximum elongations and temperatures are observed at the blade tip section and minimum elongation and temperature variations at the root of the blade. 4. Temperature distribution is almost uniform at the maximum curvature region along blade profile. 5. Temperature is linearly decreasing from the tip of the blade to the root of the blade section. 6. Maximum stress induced is within safe limit. 7. Maximum thermal stresses are setup when the temperature difference is maximum from outside to inside. 8. Maximum stresses and strains are observed at the root of the turbine blade and upper surface along the blade roots. 9. Elongations in X-direction are observed only at the blade region in the along the blade length and elongation in Y-direction are gradually varying from different sections along the rotor axis. 10. It could be concluded that these contour maps and profiles enables us to ascertain the areas of rotor blades that are vulnerable for failure. 11. For the power turbine used for marine application, the rotor blades were analyzed for mechanical stresses at only a few sections. The temperature has a significant effect on overall stresses in the turbine rotor blades. The

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thermal stress analysis together with the mechanical stress analysis will yield more valuable information about the actual magnitudes of overall stresses encountered by the turbine blades. Hence an attempt is made in the present work to use the ANSYS software to obtain the temperature distribution, thermal and mechanical stresses and radial elongations at several cross sections of the rotor blades of the two stage power turbine selected from the earlier work. The results obtained were pres, radial elonted in the form of contour maps and profiles of temperature distribution sngations and mechanical, thermal stresses for the rotors.

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REFERENCES
1) S.S.Rao,The Finite Element method in Engineering, BH Publications New Delhi, 3rd Edition, 1999. 2) O.C.Zeinkiewicz,The Finite Element method in Engineering Science, Tata McGraw Hill, 2nd Edition, 1992. 3) T.R.Chandrupatla, Belegundu A.D.,Finite Element Engineering, Prentice Hall of India Ltd, 2001. 4) O.P.Gupta,Finite and Boundary element methods in Engineering, Oxford and IBH publishing company Pvt.Ltd.New Delhi, 1999. 5) V.Ramamurti, Computer Aided Design in Mechanical Engineering, Tata McGraw Hill publishing company Ltd.New Delhi, 1987. 6) C.S.Krishnamoorthy,Finite Element Analysis, Theory and Programming, 2nd edition, Tata McGraw Hill publishing company Ltd.New Delhi, 2002. 7) P.Ravinder Reddy,CADA Course Book, AICTE-ISTE sponsored programmer, August 1999. 8) R.Yadav,Steam and Gas turbine, Central Publishing House, Allahabad. 9) ANSYS inc.U.S.A. Help Manual, ANSYS 5.4. 10) Altair Hypermesh,Help Manual, Altair Hypermesh 5.0

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BIBLIOGRAPHY

1) www.altair.com 2) www.femap.com 3) www.ansys.com 4) www.wikipedia.com