TITLE: Damper Valve Blade Crack Case Study & New

Modification Analysis Report

Contents

1 General ................................................................................................................................................. 5

Forward ......................................................................................................................................... 5

Reference Documents ................................................................................................................... 5

Material Used ................................................................................................................................ 5

Material Properties ........................................................................................................................ 6

1.4.1 Material : SS316.................................................................................................................... 6

1.4.2 Material : SS304.................................................................................................................... 6

1.4.3 Material : Teflon ................................................................................................................... 7

2 Finite Element Model ............................................................................................................................ 7

Software Detail ............................................................................................................................. 7

Geometry Model. .......................................................................................................................... 7

Analysis Setup ............................................................................................................................... 7

2.3.1 Setting ................................................................................................................................... 7

2.3.2 Static Structural Analysis ...................................................................................................... 7

2.3.3 Modal Analysis ..................................................................................................................... 7

2.3.4 Harmonic Analysis Structural ............................................................................................... 8

Finite Element Meshing Properties ............................................................................................... 8

Boundary Condition .................................................................................................................... 10

Applied Load Detail .................................................................................................................... 12

Acceptance Criteria (for Plate & Shaft Modification Analysis Report) ..................................... 14

3 Step-1-Crack Study for Exiting Blade ................................................................................................. 15

Geometry..................................................................................................................................... 15

Mesh ............................................................................................................................................ 15
 Crack Location ............................................................................................................................ 16

Applied Pressure ......................................................................................................................... 16

Applied Boundary ....................................................................................................................... 17

Stress ........................................................................................................................................... 17

Stress in Cracked Location ......................................................................................................... 17

Shear ........................................................................................................................................... 18

Shear in Cracked Location .......................................................................................................... 18

Deflection .................................................................................................................................... 19

Deflection in Cracked Location .................................................................................................. 19

4 Step-2- Manual Calculation for Bending & Companied Stress for Damper vane .............................. 20

5 Step-3- FEA Calculation for Bending & Companied Stress for Damper vane ................................... 24

Equivalent Stress ......................................................................................................................... 24

Max Shear Stress......................................................................................................................... 25

Total Deflection .......................................................................................................................... 26

Max Bending Stress .................................................................................................................... 27

Max Companied Stress ............................................................................................................... 28

6 Step-4- FEA for Modal & Harmonic Analysis ................................................................................... 29

Modal Equivalent Stress at 91.625 Hz ........................................................................................ 29

Modal Max Deflection at 91.625 Hz .......................................................................................... 31

Harmonic Max Deflection at 10 Hz ............................................................................................ 32

Harmonic Max Equivalent Stress at 10 Hz ................................................................................. 32

Harmonic Max Deflection at 20 Hz ............................................................................................ 33

Harmonic Max Equivalent Stress at 20 Hz ................................................................................. 33

Harmonic Max Deflection at 30 Hz ............................................................................................ 34

Harmonic Max Equivalent Stress at 30 Hz ................................................................................. 34

 Harmonic Max Deflection at 40 Hz ............................................................................................ 35

Harmonic Max Equivalent Stress at 40 Hz ................................................................................. 35

Harmonic Max Deflection at 50 Hz ............................................................................................ 36

Harmonic Max Equivalent Stress at 50 Hz ................................................................................. 36

Harmonic Max Deflection at 60 Hz ............................................................................................ 37

Harmonic Max Equivalent Stress at 60 Hz ................................................................................. 37

Harmonic Max Deflection at 70 Hz ............................................................................................ 38

Harmonic Max Equivalent Stress at 70 Hz ................................................................................. 38

Harmonic Max Deflection at 80 Hz ............................................................................................ 39

Harmonic Max Equivalent Stress at 80 Hz ................................................................................. 39

Harmonic Max Deflection at 90 Hz ............................................................................................ 40

Harmonic Max Equivalent Stress at 90 Hz ................................................................................. 40

Harmonic Max Deflection at 100 Hz .......................................................................................... 41

Harmonic Max Equivalent Stress at 100 Hz ............................................................................... 41

7 Step-5- FEA for housing & Vane Support .......................................................................................... 42

Equivalent Stress ......................................................................................................................... 42

Max Shear Stress......................................................................................................................... 43

Total Deflection .......................................................................................................................... 44

8 Result & Conclusion ........................................................................................................................... 45

Result Table ................................................................................................................................ 45

Conclusion .................................................................................................................................. 47
1 General
Forward
Purpose of this Strength Calculation & Damaged Case Study report is to know the Strength for
Damper Valve Blade have adequate strength to support for Air Control Operation,
This Report Contains 4 Steps which are following below
1. Step-1-Crack Study for Exiting Blade.
Crack Study for Exiting Blade will explain the in detail of Vane cracked location, using FEA
Method
2. Step-2-Manual Calculation Bending & Companied Stress for New Damper vane

Manual Calculation for Bending & Companied Stress for Damper vane, use to cross check the
FEA calculation report

3. Step-3-FEA Calculation Bending & Companied Stress for New Damper vane

FEA Calculation for Bending & Companied Stress for Damper vane, use to cross check the
Manual calculation report

4. Step-4-FEA Calculation Modal & Harmonic Response

FEA Calculation to detect resonant response and avoid it if necessary

5. Step-5-FEA for housing & Vane Support.

To check the Housing Strength when the total load acting on the housing & vane

Reference Documents
V-2158-050-4-903-(Test Report For Fan performance Test)
6937-201-(Detail Of Damper Valve)
Power Plant Engineering-Black & Veatch 5th Edition

Material Used
For this structural Analysis all the material used
Housing (Outside & Inside) : SS 304 Material
Blade & Shaft : SS316 Material
Bush : Teflon
 Material Properties
ANSYS Default material Settings for stainless steel

1.4.1 Material : SS316

Reference: https://www.ezlok.com/technical-info/mechanical-properties/316-stainless-steel

Modulus of Elasticity : 200000 N /mm

Yield Strength : 206.9 N /mm (all thickness is <16mm)
Tensile Strength : 517.1 N /mm
Poissons ratio : 0.3
Density : 7750 kg/m^3

1.4.2 Material : SS304

Reference: http://www.azom.com/properties.aspx?ArticleID=965

Modulus of Elasticity : 200000 N /mm

Yield Strength : 206.9 N /mm (all thickness is <16mm)
Tensile Strength : 517.1 N /mm
Poissons ratio : 0.3
Density : 7750 kg/m^3

1.4.3 Material : Teflon

Yield Strength : 9 N /mm (@ 23C)
Poissons ratio : 0.46 (@ 23C)
Density : 2160 kg/m^3

2 Finite Element Model

Software Detail
` Finite Element Geometry Model has been carried out through Solidworks Surface & Beam
modeling for Step-1 & Solid Modeling for Step -3 & 4, after completed the in solidwork, the model had
been imported to ANSYS workbench Design Molder using Parasolid Format (.x_t) as Surface & Beam
for Step-1 and Solid Element for Step -3&4.
The FEA analysis has been carried out using ANSYS Workbench. Static Structural Analysis

Geometry Model.
Please refer drawing No: 6937-201-Rev-C (Detail of Damper Valve)

Analysis Setup
2.3.1 Setting

2.3.2 Static Structural Analysis

To check the Strength of the Selected Material

2.3.3 Modal Analysis

Refer Shock & Vibration using ANSYS Mechanical - April 27, 2015
A modal analysis is a technique used to determine the vibration characteristics of structures:
Natural frequencies
At what frequencies the structure would tend to naturally vibrate
Mode shapes
In what shape the structure would tend to vibrate at each frequency
Mode participation factors
The amount of mass that participates in a given direction for each mode
2.3.4 Harmonic Analysis Structural
Refer Shock & Vibration using ANSYS Mechanical - April 27, 2015
Why should you do a harmonic analysis?
To make sure that a given design can withstand sinusoidal loads at different frequencies (e.g, an engine
running at different speeds).
To detect resonant response and avoid it if necessary (by using dampers, for example).

Finite Element Meshing Properties

The element is defined by 8 nodes having three degrees of freedom per node: translations in the nodal x,
y, and z directions.
All the geometries are mapped meshed. The necessary partitions are made to make Accurate meshing
which satisfies the quality check on the elements.
The detail of meshing for Structural analysis (Vane Blade / Housing & Support) is as given below:
Damper Vane Analysis

Object Name Face Sizing Edge Sizing

State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face 1 Edge
Definition
Suppressed No
Type Element Size
Element Size 3. mm 5. mm
Behavior Soft
Curvature Normal Angle Default
Growth Rate Default
Local Min Size Default (3. mm)
Bias Type No Bias
Nodes 11149
Elements 10828
Housing & Support Analysis

Object Name Mesh

State Solved
Display
Display Style Body Color
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Coarse
Element Size 10
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 9.5423e-002 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Elements 370463
Mesh Metric 189241
 Boundary Condition
Fixed Boundary Condition applied for Bearing Location and Damper Valve Body
Step-1 for Exiting Blade

Fixed Boundary

Step-2 , 3 & 4 for Damper Vane

Fixed Boundary
Step-5 for Housing & Support

Fixed Boundary

Fixed Boundary
 Applied Load Detail

As per above Image

Static Pressure = 4578 PA

= 0.004578 MPa

Step-1 , 2, 3 & 4 for Exiting Blade

Step-5 for Damper Vane FEA
 Acceptance Criteria (for Plate & Shaft Modification Analysis Report)
For Damper Vane

Reference: Power Plant Engineering-Black & Veatch 5th Edition

Max Allowable Bending Stress 60% of Yield Strength =207 N/mm * 60 % =124.2 N/mm (MPa)
Max Allowable Combined Stress 60% of Yield Strength =207 N/mm * 60 % =124.2 N/mm (MPa)
Max Deflection = length /360 (Refer Deflection Calculation in Step-2)
For Housing & Support

Reference: ASCE 13th Edition

Stress Factor : 0.5

Shear Factor : 0.4
Displacement : L/200 (L= Housing Height)
Displacement Calculation
Max Displacement : H/200 mm
: 300 /200
Max Allowable : 1.5
Von misses Stress
Stress should be >205*0.6

Material Allowable stress N/mm2

SS316 103.5
Shear Stress

Shear Stress should be >205*0.4

Material Allowable Shear stress N/mm2

SS316 82
3 Step-1-Crack Study for Exiting Blade
Geometry

Mesh
Crack Location

Applied Pressure
Applied Boundary

Stress

Stress in Cracked Location

Shear

Shear in Cracked Location

Deflection

Deflection in Cracked Location

4 Step-2- Manual Calculation for Bending & Companied Stress for
Damper vane
5 Step-3- FEA Calculation for Bending & Companied Stress for Damper
vane
Equivalent Stress
Max Shear Stress
Total Deflection
Max Bending Stress
Max Companied Stress
6 Step-4- FEA for Modal & Harmonic Analysis
Modal Equivalent Stress at 91.625 Hz
Modal Max Deflection at 91.625 Hz
Harmonic Max Deflection at 10 Hz

Harmonic Max Equivalent Stress at 10 Hz

Harmonic Max Deflection at 20 Hz

Harmonic Max Equivalent Stress at 20 Hz

Harmonic Max Deflection at 30 Hz

Harmonic Max Equivalent Stress at 30 Hz

Harmonic Max Deflection at 40 Hz

Harmonic Max Equivalent Stress at 40 Hz

Harmonic Max Deflection at 50 Hz

Harmonic Max Equivalent Stress at 50 Hz

Harmonic Max Deflection at 60 Hz

Harmonic Max Equivalent Stress at 60 Hz

Harmonic Max Deflection at 70 Hz

Harmonic Max Equivalent Stress at 70 Hz

Harmonic Max Deflection at 80 Hz

Harmonic Max Equivalent Stress at 80 Hz

Harmonic Max Deflection at 90 Hz

Harmonic Max Equivalent Stress at 90 Hz

Harmonic Max Deflection at 100 Hz

Harmonic Max Equivalent Stress at 100 Hz

7 Step-5- FEA for housing & Vane Support

Equivalent Stress
Max Shear Stress
Total Deflection
 8 Result & Conclusion
Result Table
1. Step-1-Table_1Crack Study for Exiting Blade.

Description Allowable Stress Analysis Result Remark Reference Image

3.6 Stress,
Von misses Stress 123.5 805.15 Fail
3.7 Stress In cracked Location
3.8 Shear
Shear Stress 82.8 470.91 Fail
3.9 Shear in Cracked Location
3.10 Deflection
Displacement 1.5 9.05 Fail
3.11Deflection in Cracked Location
2. Step-2- Table_2 Manual Calculation Bending & Companied Stress for New Damper vane
 3. Step-3-Table_3 FEA Calculation Bending & Companied Stress for New Damper vane

Allowable
Description Analysis Result Remark Reference Image
Stress
Max Bending Stress 123 24.802 Pass 5.4 Max Bending Stress
Max Companied Stress 123 24.802 Pass 5.5 Max Companied Stress
Deflection 1.47 ~0 .01 0.464 ~ 0.05 Pass 5.3 Total Deflection

4. Step-4-Table_4 FEA Calculation Bending & Companied Stress for New Damper vane

Modal Analysis
Analysis Reference Image
Description Allowable Stress Remark
Result
For Shape Mode
24.696 at As advised by SRC 6.2 Modal Max Deflection
Max Deflection In-between 0 Hz
to 100 Hz
91.625 Hz Max up to 100 Hz at 91.625 Hz
Max Stress 393.17is 6.1 Modal Equivalent
Max Stress 123 110.13 inside the place this will Stress at 91.625 Hz
be removed in welding

Harmonic Analysis
6.3Harmonic Max
Deflection at 10 Hz 1.47 0.4769 Acceptable
Deflection at 10 Hz
6.4 Harmonic Max
Stress at 10 Hz 123 7.0063 Acceptable
Equivalent Stress at 10 Hz
6.5 Harmonic Max
Deflection at 20 Hz 1.47 0.50354 Acceptable
Deflection at 20 Hz
6.6 Harmonic Max
Stress at 20 Hz 123 7.3977 Acceptable
Equivalent Stress at 20 Hz
6.7 Harmonic Max
Deflection at 30 Hz 1.47 0.55522 Acceptable
Deflection at 30 Hz
6.8 Harmonic Max
Stress at 30 Hz 123 8.157 Acceptable
Equivalent Stress at 30 Hz
6.9 Harmonic Max
Deflection at 40 Hz 1.47 0.64839 Acceptable
Deflection at 40 Hz
6.10 Harmonic Max
Stress at 40 Hz 123 9.52258 Acceptable
Equivalent Stress at 40 Hz
6.11 Harmonic Max
Deflection at 50 Hz 1.47 0.82678 Acceptable
Deflection at 50 Hz
6.12 Harmonic Max
Stress at 50 Hz 123 12.14164 Acceptable
Equivalent Stress at 50 Hz
6.13 Harmonic Max
Deflection at 60 Hz 1.47 1.2456 Acceptable
Deflection at 60 Hz
6.14 Harmonic Max
Stress at 60 Hz 123 18.3 Acceptable
Equivalent Stress at 60 Hz
6.15 Harmonic Max
Deflection at 70 Hz 1.47 3.1039 Shall be advise by SRC
Deflection at 70 Hz
6.16 Harmonic Max
Stress at 70 Hz 123 45.601 Acceptable
Equivalent Stress at 70 Hz
 6.17 Harmonic Max
Deflection at 80 Hz 1.47 4.3026 Shall be advise by SRC
Deflection at 80 Hz
6.18 Harmonic Max
Stress at 80 Hz 123 63.2111 Acceptable
Equivalent Stress at 80 Hz
6.19 Harmonic Max
Deflection at 90 Hz 1.47 1.1615 Acceptable
Deflection at 90 Hz
6.20 Harmonic Max
Stress at 90 Hz 123 17.064 Acceptable
Equivalent Stress at 90 Hz
6.21 Harmonic Max
Deflection at 100 Hz 1.47 0.63962 Acceptable
Deflection at 100 Hz
6.22 Harmonic Max
Stress at 100 Hz 123 9.3968 Acceptable
Equivalent Stress at 100 Hz

5. Step-5 Table_5 FEA for housing & Vane Support.

Description Allowable Stress Analysis Result Remark Reference Image

Von misses Stress 103.5 21.555 Pass 7.1Equivalent Stress
Shear Stress 82.8 11.585 Pass 7.2Max Shear Stress
Displacement 0.218 1.5 Pass 7.3Total Deflection

Conclusion
From Setp-1- Table_1 all the stress & Deflection if higher than the allowable limit and more than
the ultimate / point of rupture , so blade will be crack or broken , therefore this blade / damper vane
have no adequate strength to support for air controlled operation

From Step-2-Table_2 & Step-3-Table_3 all the stress with in the allowable limit and comparison
Between Manual Calculation and FEA Calculation similar equal, so the new Damper vane /Blade have
adequate strength to support for Air Control Operation,

Step-4-Table_4 Deflection at 70 Hz & 80 Hz is higher than 50 % & 75 % higher than the allowable
limit, if we change the Round bar size also the deflection is same, & this deflection is not permanent
deflection because the stress is within the limit, SRC shall be advise accordingly.

From Step-5-Table_5 all the stress & Deflection are within the allowable limit, so the Housing
and Support have adequate strength to support damper Vane/Blade