Finite element analysis of fir tree region of Low pressure

turbine blade disc assembly using Ansys & Hyper mesh.

GTRE DRDO (Bangalore)

Meshing :Iges file is imported in hyper mesh

Entity set created in hyper mesh along with

there name are given below which are to be
used in ANSYS to apply boundary condition
Procedure to define entity set in hyper
mesh:Analysis>entity sets > give the name &
select entity either node or element

Disc_cp
Finite element modal is build In hyper mesh
using 20 node hexahedral element, ANSYS
element SOLID 186 we will get .hm file that
is hyper mesh file
Total number of nodes= 274869
Total number of elements = 251100

Top_firtree

Procedure to define element type :Utility >ET type > define element (solid186)
Component manager >define element to
components

Constrain
t

High_l_d

Low_l_b

Similar way we have two more node sets on

right side of fir tree
Low_r_b
High_r_b

Make sure that at contact region of blade

and disc should have one to one matching
of nodes/elements to each other .
one fine way to do that is first mesh the
blade contact>find the face > project it on
the surface of disc > create 3D element
matching with them

Note :- before exporting it in to ANSYS

delete all the 2d component ,line surface,
free node, in other words as per the
geometry & finite model is concern you
should have only 3D elements .

High_l_b

We will get a file with .cdb extension

Low_l_d

Similar way we have two more node sets on

right side of fir tree
Low_r_d
High_r_d

Material property:Material property for fir tree disc : UDIMET 720

Mass density : 8.2e-9tonne/mm
Poissons ratio .30

S.NO Property Temperature (k)

293 673 773 823 923
1

E(Gpa)

227 193 192 188 184

7
8
9

1073
1173
1273

93398
87394
81390

Specifications properties
Specifications properties
Temp(k)
293

823

property
.2%
proof strength,
(Mpa)
Ultimate
tensile
strength ,( Mpa)
Reduction in area ( %)
.2%
proof strength,
(Mpa)
Ultimate
tensile
strength ,( Mpa)
Reduction in area ( %)

value
1060
1400
10
1000

Temp(k) property
293
.2% proof strength ,
(Mpa)
Ultimate
tensile
strength , (Mpa)
823
.2% proof strength ,
(Mpa)
Ultimate
tensile
strength , (Mpa)

Value
878.1
948.9
866.3
922.3

1350
10

Note:- ANSYS command are

not case

sensitive .

Material property for fir tree blade : CM 247 LC DS- properties of blade
Mass density : 8.53e-9tonne/mm
Poissons ratio : .30
S.NO
Temperature(k) E(Mpa)
1
473
116750
2
573
114750
3
673
111410
4
773
107410
5
873
103400
6
973
98736

! Set of command to apply material

property to blade and disc
CMSEL,S,blade
CMPLOT
Eplot
/prep7 ! activate the pre processor
! Material for blade CM 247 LC DS
MP,DENS,1,8.53e-9 ! density
MPTEMP,,,,,,,,
MPTEMP,1,473
! temperature
MPTEMP,2,573
MPTEMP,3,673

MPTEMP,4,773
MPTEMP,5,873
MPTEMP,6,973
MPTEMP,7,1073
MPTEMP,8,1173
MPTEMP,9,1273
MPDATA,EX,1,,116750 ! modulus
elasticity
MPDATA,EX,1,, 114750
MPDATA,EX,1,, 111410
MPDATA,EX,1,,107410
MPDATA,EX,1,,103400
MPDATA,EX,1,, 98736
MPDATA,EX,1,,93398
MPDATA,EX,1,,87394
MPDATA,EX,1,, 81390
MPDATA,PRXY,1,,.3 ! Poissons ratio
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
MPDATA,PRXY,1,,.3
CMSEL,S,disc
CMPLOT
Eplot
Mat,2
! Material for disc UDIMET 720
MP,DENS,2,8.2e-9 ! density
MPTEMP,,,,,,,,
MPTEMP,1,293
! temperature
MPTEMP,2,673
MPTEMP,3,773
MPTEMP,4,823
MPTEMP,5,923
MPDATA,EX,2,,227000
! modulus
elasticity
MPDATA,EX,2,,193000
MPDATA,EX,2,,192250
MPDATA,EX,2,,188750
MPDATA,EX,2,,184000
MPDATA,PRXY,2,,.3 ! Poissons ratio

of

MPDATA,PRXY,2,,.3
MPDATA,PRXY,2,,.3
MPDATA,PRXY,2,,.3
MPDATA,PRXY,2,,.3
MPTEMP,,,,,,,,
MPTEMP,1,293
! temperature
MPTEMP,2,473
MPTEMP,3,673
MPTEMP,4,873
MPTEMP,5,1073
! mpchg,2,all (change disc material to mat 2 )
Allsel,all,all
Eplot

Boundary condition:Preference> structural

1) Coupling to impose cyclic symmetry
Coupling is a way to force set of nodes to
have the same DOF value.
Coupling is from low edge to high edge of
disc sector . low & high edge should have
same number of nodes & should be at equal
distance from the center .
Edges are align along the surfaces of cyclic
symmetry.
The
edge
having
the
algebraically lower in the R-Theta
(cylindrical) coordinate system is called the
low edge and the one having the higher is
called the high edge. The angle between
the two successive surfaces of cyclic
symmetry is called the sector angle.
of

Number of sector will be equal to number

of blades & sector angle will be 360/no of
blade = 360/71 = 5.70423

! Set of command to impose cyclic

symmetry on disc by coupling

cmsel,s,disc_cp ! component disc_cp have

all the nodes of low & high edge of disc
sector
cmplot
/prep7
nplot
Csys,6 ! Cylindrical co ordinate system 6
nrotat,all,all
*get,ncount,node,,count
toler=.0002
*dowhile,ncount
Cpcyc, all, toler, 6,, 360/71 ! Offset in y
dir.
nsel,u,cp,,all
toler=toler+.0002
*get,ncount,node,,count
nplot
*enddo
/pbc,cp,,1
nsel,s,cp,,all
nplot

Note:- we have 3 In build cylindrical co

ordinate system in ANSYS 1,5 & 6,
Use
Csys, 1 ! Z as axial axis or engine axis
Csys,5 ! Y as axial axis or engine axis
Csys,6 ! X as axial axis or engine axis
In the above case we have used csys,6 as
we have X axis as engine axis

High
edge

Low
edge
Angle=
360/71

2) Centrifugal force acting due to mass

of blade on top of fir tree
Mass of one blade 177.185gram(.17718kg)
Cg location of blade from center line
268.75mm (.26875m)
Total centrifugal load acting on a sector
due to mass of 1 blade :
=m*c.g*
M= mass of one blade in kg
c.g = center of gravity of blade from center
line in m
= angular velocity in radian /sec
=.177185*268.75*1157.305
=63778 Newton
Centrifugal force acting per node =
= force/no of nodes
=63778/1545 =41.28026N

But as we have used a portion of blade in

the diagram shown below so we have
approximated 35Newton force per node

! Set of command
centrifugal load

to

apply

/prep7
Csys,0
Cmsel,s,top_firtree
Cmplot
Nplot
! *get,ncount,node,,count
! F,all,fy,63778/ncount
F,all,fy,35
Fini

! Command to save a image

/image,save,bc,png ! this command will
save the bc file in png format .

3) Angular velocity or rotation

command in ANSYS to give rotation
Omega,x,y,z
Rpm =11047
Revolution in radian /sec = rpm*2*pi/60
=11047*2*pi/60 = 1157.305
As revolution is about x axis that is x as
engine axis so we will use
Omega,1157.305
Note:- specify density before giving rotation
4) Four contact at fir tree region by
creating contact & target element .
Contact element use is contact 174 that is
for blade fir tree contact faces .
Target element use is target 170 that is for
disc fir tree contact faces
Contact make the analysis non linear which
is time consuming but it has its own
advantages like we can provide friction
coefficient at contact region between blade
and disc
Other way to give boundary condition at fir
tree contact region is couple the nodes in
tangential & axial direction using coupling
at coincidence nodes , for this Make sure
that at contact region of blade and disc
should have one to one matching of
nodes/elements to each other .
Command in ANSYS
/Cpintf,toler !Toler= 0.0001
but allow them to move /slip in radial
direction .it is linear analysis .

! Set of command to create contact

and target elements in fir tree region
MP,MU,1,.1 ! coefficient of friction
MAT,1
R,4
real,4
et,1,186
ET,2,170 ! target 170
ET,3,174 ! contact 174
KEYOPT,3,5,1 ! close initial gap
KEYOPT,3,9,1 ! Exclude both initial
geometrical penetration or gap and offset
KEYOPT,3,12,2 ! no separation can only
slide direction perpendicular to normal of
contact element
! Generate the target surface
NSEL,S,,,HIGH_r_d
TYPE,2
ESLN,S,0
ESURF
! Generate the contact surface
NSEL,S,,,HIGH_r_b
TYPE,3
ESLN,S,0
ESURF
ALLSEL
AT,1
R,5
real,5
! Generate the target surface
NSEL,S,,,HIGH_l_d
TYPE,2
ESLN,S,0
ESURF
! Generate the contact surface
NSEL,S,,,HIGH_l_b
TYPE,3
ESLN,S,0
ESURF
ALLSEL
MAT,1
R,6
real,6

! Generate the target surface

NSEL,S,,,loe_r_d
TYPE,2
ESLN,S,0
ESURF
! Generate the contact surface
NSEL,S,,,low_r_b
TYPE,3
ESLN,S,0
ESURF
ALLSEL
MAT,1
R,7
real,7
! Generate the target surface
NSEL,S,,,low_l_d
TYPE,2
ESLN,S,0
ESURF
! Generate the contact surface
NSEL,S,,,low_l_b
TYPE,3
ESLN,S,0
ESURF
ALLSEL
ESEL,S,TYPE,,2
ESEL,A,TYPE,,3
Eplot

High fir tree

Low fir tree

To check the contact status
/solu
Cncheck

Contact
element
contact 174
Target
element
target 170

5) Constraints in axial & tangential

direction .
Constraint the portion of disc at leading
edge in axial & tangential direction .
make sure that at constraint location it
should not create stress singularity .
Stress singularity:- reasonably higher
amount of stress at the location of point
load or constraint . to avoid this
increase the number of node to be
constraint in axial & tangential direction
for point load you can use equal amount
of pressure load in place of point load .

Solution:Solution> analysis type>soln control> nonlinear>line search <on>

Or
/solu
Lnsrch,1
Other way for non linear analysis that you
can use length arc method

Solution>solve>current ls>ok
Or
Solve

Postprocessor:/post1
Few important command to see the results
Von mises stress :Plnsol,s,eqv ! Nodal solution
Plesol,s,eqv ! Elemental solution
Difference between nodal & elemental
solution is nodal is average & elemental is
non average.
There should not be large difference
between nodal & elemental solution if it is
there that mean mesh needs to be refined
further.
Stress in x,y & z direction:Rsys,6 ! result co ordinate system
Plnsol,s,x ! radial
Plnsol,s,y ! axial
Plnsol,s,z ! tangential
Principal stress :Plnsol,s,1
Plnsol,s,2
Plnsol,s,3
Deflection /growth:Rsys,6 ! result co ordinate system
Plnsol,u,sum
Plnsol,u,x ! radial
Plnsol,u,y ! axial
Plnsol,u,z ! tangential

Prnsol,s,prin ! will print stress at every node

Prnsol,u,sum ! will print deflection at every
node
To count number of node & element in
model :*get,ncount,node,,count
*get,ecount,elem,,count
*stat
! ncount= number of node
! ecount = number of element

Principal stress ( plnsol,s,1)

Von mises stress (plnsol ,s eqv)

------------------------------------------ Prepared by Anil Thakran -------------------------------------------------------------------------------------( 9 Dec 2014 )----------------------------------