Innovation Through Simulation 1

Blade Root Shape Optimization

Dr. J. S. Rao
Director - Advanced Engineering
Altair Engineering India Pvt. Ltd.
#65 13th Cross Rd.
Sarakki Industrial Layout
J.P Nagar, 3rd Phase
Bangalore 560 078
js.raoaltair.com
S. Suresh
Profect Engineer
Altair Engineering India Pvt. Ltd.
#65 13
th
Cross Rd.
Sarakki Industrial Layout
J.P Nagar, 3
rd
Phase
Bangalore 560 078
suresh.raoaltair.com


Keywords: Turbine Blade, Blade Root, Elasto-Plastic analysis, Optimization, Mesh morphing

Abstract

Turbomachinery bladed disks in Low Pressure stages are subjected to severe centriIugal loads. The severe
loading leads to large peak stresses at the stress raiser locations, oIten into plastic conditions. In early
design practice, the root design was based on experience and extensive testing to keep peak stresses as low
as possible in achieving crack Iree blades during their liIe time. Today`s modern DOE and optimization
commercial codes allow an optimum design oI the shape to keep the peak stresses to as low as possible
peak values. In this paper, we demonstrate the application oI HyperWorks tools, HyperMesh, OptiStruct
and HyperStudy in achieving an optimum blade root shape that gives minimum possible plastic stress and
strain Iield in the dovetail region.
Introduction

Bladed Disks are most Ilexible elements in high speed rotating machinery. Due to rotation, the blade root
gets tightened in the disk slot and transmits the centriIugal load. The mating contact surIaces could be just 2
Ior high pressure turbine blades a Iew centimeters long and may increase to six or more Ior low pressure
1m long turbine blades. While the average stress in the mating areas is Iully elastic and well below yield,
the peak stress at singularities in the groove shape can reach yield values and into local plastic region. Last
stage LP turbine blades are the most severely stressed blades in the system. Usually these are the limiting
cases oI blade design allowing the peak stresses to reach yield or just above yield conditions. Failures can
occur with crack initiation at the stress raiser location and propagation, two cases can be cited. The last
stage blades in an Electricite de France B2 TG Set Iailed in Porcheville on August 22, 1977 during over
speed testing |1|. On March 31, 1993 Narora machine LP last stage blades suIIered catastrophic Iailures,
see |2|. These blades have stresses well beyond yield. On Narora machine blade, initial Iully elastic
analysis has shown a peak stress value 3253 MPa though the average stress is only 318 MPa. An elasto
plastic analysis Ior the same case showed that the peak stress is 1157 MPa well beyond the yield. While it
is not possible to eliminate the yield and keep the structure Iully elastic to achieve the last stage blades in
limiting cases, it will be advisable to achieve the yield conditions to be as low as possible. It should be
noted that the local plastic conditions are conIined to a small region around the discontinuity.

Until recently, the dynamic stress Iield under nonlinear conditions is determined using energy methods and
one dimensional beam models as given in |3|. With the advent oI high speed computation and commercial

Innovation Through Simulation 2
Iinite element codes that can handle large mesh sizes, it has become possible to accurately assess the stress
Iield in the regions oI discontinuity oI the disk grooves, see |4|. Invariably all the earlier long blade designs
in last stage LP turbines or Iirst stage LP compressors operate in local plastic regions. Now DOE
techniques and optimization methods have become available to optimize the shape and minimize the peak
stress values so as to improve the blade disk structural integrity.

The shape optimization in recent years depended on determining strain energy density and based on the
location where it is high, diIIerent shapes were chosen and models are generated. Rao |5| discussed these
developments Irom an industry perspective. Because the problem is highly nonlinear due to centriIugal
stiIIening and spin soItening, considerable time is taken to achieve an optimized root.

Optimization has become a necessity in the recent years because oI advances in the design as well as
availability oI commercial codes. In earlier practices, dedicated codes are developed to achieve a speciIic
optimization problem. For example, Bhat, Rao and Sankar |6| used the method oI Ieasibility directions |7|
to achieve optimum journal bearings Ior minimum unbalance response. While every commercial code has
an optimization module built in to them in recent years, Altair OptiStruct |8| has been developed recently
to perIorm structural optimization. This has been successIully applied Ior topology, topography, gauge and
shape optimizations oI automotive and airIrame structures, e.g., Schuhmacher |9|, Taylor et. al., |10|
discussed the weight optimization achieved in aircraIt structures. The method adopted in Optistruct, viz.,
gradient based optimization algorithm, see Vanderplaats |11| is used in achieving the required structural
optimization. While OptiStruct is limited to structural analysis, recently Altair has developed a multi
purpose DOE/Optimization/Stochastic tool, HvperStudv |12| that can perIorm a wide cross-section oI
optimizations in CFD, Heat TransIer, Structures or multi physics problems using available commercial
code platIorms.

With additional advances in mesh morphing techniques, see |13| it has become somewhat easier to
generate several shapes. Taking advantage oI these developments, we demonstrate here an eIIective method
oI shape optimization oI blade roots and keep the peak stress and strain levels to a minimum in the plastic
region oI limiting blade cases. An existing blade example is chosen and the possibilities oI improving its
perIormance through shape optimization Irom OptiStruct and HvperStudv are examined.

Blade Model

For the present study an existing axial entry LP turbine blade is chosen and having a Iir tree root design to
assemble in a rotor disc. A sector oI rotor disc is modeled to make use oI cyclic symmetry condition. The
Blade is pre-twisted with a height oI 290 mm. There are 60 blades in this LP stage and are placed on the
disk with the bottom oI the blade root at a radius oI 248 mm Irom the axis oI the rotor. A 3-D Iinite element
model oI the bladed disc is generated as shown in Fig. 1. Using mapped meshing options a solid element
mesh with 8 nodes is generated, by capturing all the critical regions with Iiner mesh. Mesh around the
singularities, blade and disc dovetail root Iillet regions at higher radius, where the peak stresses are
expected are captured with 2 to 3 layers oI elements with element size as low as 0.235 mm. The mesh
shown in Fig. 1 consists oI 305524 elements and 344129 nodes.

Baseline Analvsis

For the analysis the blade along with disk eIIect is considered by modeling a 1/60 sector oI the disk with
one blade and using cyclic symmetry boundary conditions applied on both the partition surIaces as shown
in Fig. 1. The common nodes on the pressure Iaces at six positions, shown in Fig. 1, where the load
transIer between blade and disc takes place are joined together to make it as a single entity. The blade and
disc are assumed to be made up oI same material with Yield stress oI 585 MPa, Young`s Modulus 210
GPa, Density 7900 Kg/m
3
and Poisson`s Ratio 0.3.


Innovation Through Simulation 3
X
Y
Z
X
Y
Z
X
Y
Z
Blade
Wheel
LE
TE
Cyclic Symmetry
Boundary Conditions
Pressure Iaces
1825 MPa at node 153608
Average Stress 256 MPa
An elastic stress analysis is conducted Ior a centriIugal load at Iull speed 8500 RPM, using ANSYS solver
|14|. The Von Mises elastic stress Iield near the root region is shown in Fig. 2. The root Iillet in the Iirst
landing area experiences a severe stress oI 1825 MPa at node 153608 well beyond Yield 585 MPa, with an
average sectional stress 256 MPa. Stress contour beyond yield is shown to be spread across 3 elements over
a depth oI 1.22 mm.

The hardening property oI the material in the plastic region is given in Fig. 3. To have a better
understanding on the plastic region, next an elasto-plastic stress analysis is carried out. The elasto-plastic
analysis result Ior the von Mises stress is given in Fig. 4. The stress region beyond yield is also deIined in
the same Iigure. The root Iillet now experiences a peak Von Mises stress 768 MPa at a node 176017 in the
same region which is beyond the yield value 585 MPa. From Fig. 4, it is observed that the plastic region
has not changed Irom the simple elastic analysis result in Fig. 2. The peak stress value has dropped
considerably Irom the elastic analysis result 1825 MPa to a value 768 MPa just above the yield.




















Fig.1: Bladed Disk Model Showing the FE Mesh







Fig.2: Von Mises Stress in Elastic domain at 8500 RPM

Innovation Through Simulation 4
768 MPa
Average Stress 216.86 MPa
0
100
200
300
400
500
600
700
800
900
1000
0 0.002 0.004 0.006 0.008 0.01 0.012
Strain
S
t
r
e
s
s

(
M
P
a
)
EP
Elastic

The material in the root region around the stress raiser location Ilows thus easing the stress and raising the
strain in accordance to the hardening law given in Fig. 3. The peak strain observed at the node 153608 in
the same region closer to peak stress location is 0.0153.


















Fig.3: Material hardening characteristic in the plastic region





Fig.4: Results oI Elasto-Plastic analysis at 8500 RPM

Optistruct is a linear stress analysis code and optimization is possible when the structure is wholly elastic as
against the globally elastic and locally plastic condition as in Fig. 4. The location where peak stress occurs
remains almost the same depending on the stress raiser location irrespective oI the loading condition.
ThereIore, the shape optimization can be as well conducted at a speed where the structure is wholly elastic
and veriIy the conditions at Iull speed under elasto plastic conditions. This will also reduce the
computational time.

ThereIore an elastic stress analysis is carried out Ior centriIugal load at 4000 RPM. Fig. 5 shows the Von
Mises stress distribution obtained which is completely elastic. The peak stress observed is 404 MPa in the
root Iillet oI the blade at the same node number as observed beIore.

Innovation Through Simulation 5
404 MPa
Average Stress 54.4 MPa

Fig.5: Von Mises Stress in Elastic domain at 4000 RPM

Optimi:ation through OptiStruct

The optimization problem is Iormulated to Iind the shape oI the blade root proIile such that the peak Von
Mises stress is minimized when subjected to centriIugal load using OptiStruct code. An optimization
problem in general requires, deIining an objective Iunction, design constraints and design variables. In a
limiting design oI the blade root where the peak stress is close to yield, it may not be possible to achieve
the peak value to be completely within yield condition making the structure wholly elastic. II one tries to
attempt an optimization to achieve such an elastic condition, the optimization Iails and the results obtained
will be above the speciIied stress value. The objective oI the problem here is thereIore set to minimize the
peak stress with shape variables as design variables and having no design constraints; however, the shape is
constrained within available design space.

Shape variables are generated using mesh morphing technique in HyperMesh. Using the baseline Iinite
element model in Fig. 1, a suitable number oI shapes in the vicinity oI baseline consistent with the available
design space is deIined by modiIying the grid point locations, which are saved as perturbation vectors. The
shapes generated are combinations oI parameters shown in Fig. 6. Shapes are then deIined as variables by
assigning the lower and upper bounds to it. Table 1 gives the minimum and maximum values adopted Ior
deIining the shape variables. Shape variables can then be assigned as indicated to perturbation vectors,
which control the shape oI the model within a given bound. This is helpIul in generating the required shape
bounds without re-meshing the model. A shape optimization is then carried out using OptiStruct code.

OptiStruct uses an iterative procedure known as the local approximation method to solve the optimization
problem. The design update is computed using the solution oI an approximate optimization problem, which
is established using the sensitivity inIormation. OptiStruct has three diIIerent methods implemented: the
optimality criteria method, a dual method, and a primal Ieasible directions method. The primal method |11|
is more common in shape optimizations. This approach is based on the assumption that only small changes
occur in the design with each optimization step. This method determines the solution oI the optimization
problem using the Iollowing steps:

1. Analysis oI the physical problem using Iinite elements.
2. Convergence test, whether or not the convergence is achieved.
3. Design sensitivity analysis.
4. Solution oI an approximate optimization problem Iormulated using the sensitivity inIormation.
5. Back to 1.


Innovation Through Simulation 6
323 MPa
Minimum Value (mm) Maximum Value (mm)
W1 22.17 W1 25.76
W2 13.65 W2 13.86
R1 1.70, H 5.67,
V 4.13, R2 4.0
R1 2.14, H 4.85,
V 4.06, R2 3.37
0 29.86
0
0 16.25
0

Fig. 6: Parameters Used For DeIining The Shape Variables

Table 1: Shape Variable DeIinitions








Shape Optimization is then carried out at two speeds, 4000 and 8500 RPM. The cyclic symmetry boundary
conditions are simulated by using enIorced displacements obtained Irom baseline analysis. The optimized
result Ior 4000 RPM is shown in Fig. 7. The peak stress obtained is 323 MPa as against the base line value
404 MPa given in Fig. 5 giving a drop oI 20 in the optimized shape.

The optimized result Ior 8500 RPM is shown in Fig. 8. The peak stress obtained is 1466 MPa as against the
base line value 1825 MPa given in Fig. 2 giving a drop oI 19.5 similar to 4000 RPM run in the optimized
shape.












Fig 7. Von Mises Stress At 4000 RPM For Optimized ConIiguration




Innovation Through Simulation 7
1466 MPa
Baseline Configuration
(mm)
Optimized Shape (mm)
4000RPM
Optimized Shape (mm)
8500RPM
W1 22.17 W1 25.72 W1 25.72
W213.65 W2 13.86 W2 13.86
R1 1.70, H 5.67,
V 4.13, R2 4.0
R1 1.95, H 5.05,
V 4.03, R2 3.97
R1 2.10, H 4.91,
V 4.04, R2 3.98
0 29.86
0
0 16.25
0
0 16.25
0
Optimized Shape
Baseline Shape
Region oI
interest













Fig. 8. Von Mises Stress At 8500RPM For Optimized ConIiguration

In both the cases, the optimized shape obtained is same as given in Fig. 9 where the result is compared with
the baseline and in Table 2 where the shape variable values achieved Ior both the speeds are presented. This
can be expected as basically the phenomenon oI stress concentration at the dovetail discontinuity. The
stress concentration Iactor obtained in either oI the speeds is around 7.12 as can be seen Irom Figs. 2 and 5.
When linear elasticity is adopted Ior calculations, the peak stress is magniIied by the stress concentration
Iactor irrespective oI the local condition elastic or plastic. Under plastic conditions, we have to account Ior
material Ilow that relaxes the stress and raises the strain.

Table 2: Optimized Shapes at 4000 and 8500 RPM






















Fig. 9. Blade Root ProIiles OI Baseline And Optimized ConIiguration


Innovation Through Simulation 8
325 MPa
1501

Fig. 9 gives the baseline and optimized shapes obtained by Optistruct under elastic conditions. The shape
variables achieved are same Ior either speed as shown in Table 2.

Optimi:ation through HvperStudv

Optistruct is specially designed as a linear Iinite element solver Ior optimization oI general structures, see
|9, 10|. Altair developed a multipurpose DOE/Optimization/ stochastic tool HvperStudv that can be applied
in the multi-disciplinary optimization oI a design combining diIIerent analysis types. Once the Iinite
element model and shape variables are developed, an optimization can be perIormed by linking HvperStudv
to a particular solver oI choice that can include nonlinear analyses.

HvperStudv uses global optimization methods which is very general in that they can be used with any
analysis code, including non-linear analysis codes. Global optimization methods use higher order
polynomials to approximate the original structural optimization problem over a wide range oI design
variables. The polynomial approximation techniques are reIerred to as Response Surface methods. A
sequential response surIace method approach is used in which, the objective and constraint Iunctions are
approximated in terms oI design variables using a second order polynomial. One can create a sequential
response surIace update by linear steps or by quadratic response surIaces. The process can also be used Ior
non-linear physics and experimental analysis using wrap-around soItware, which can link with various
solvers.

The inability oI using cyclic symmetry boundary conditions discussed in the previous section is now
overcome by linking HvperStudv with ANSYS solver. Here shape optimization by using elastic and elasto-
plastic material properties is discussed.

Shape optimization is carried by using the baseline model, having the cyclic symmetry boundary conditions
imposed on the disc, with the objective to minimize the peak stresses. Shape variables generated in the
previous section are used as design variables. Optimization is carried out at two speeds, 4000 and 8500
RPM, with elastic properties.




















Fig. 10: Von Mises Stress At 4000 & 8500RPM For Optimized ConIiguration

Innovation Through Simulation 9
Objective value
Shape Variables
Optimized Shape
Baseline Shape
Region oI
interest













Fig 11. Blade Root ProIiles OI Baseline And Optimized ConIiguration

The variation oI the peak stress and shape variables during each iterative step is shown in Fig. 12.






























Fig. 12. Variation OI Objective And Shape Variables During Optimization

Innovation Through Simulation 10
Von Mises Stress 746 MPa
BaseIine Configuration
(mm)
Optimized Shape (mm)
4000RPM
Optimized Shape (mm)
8500RPM
Optimized Shape (mm)
8500RPM - EP
W1 = 22.17 W1 = 25.36 W1 = 25.43 W1 = 25.48
W2 = 13.65 W2 = 13.86 W2 = 13.86 W2 = 13.82
R1 = 1.70, H = 5.67,
V = 4.13, R2 = 4.0
R1 = 1.74, H = 5.29,
V = 3.90, R2 = 4.0
R1 = 1.89, H = 5.17,
V = 4.01, R2 = 4.0
R1 = 2.08, H = 4.96,
V = 4.07, R2 = 4.0
0 = 29.86
0
0 = 16.25
0
0 = 16.50
0
0 = 17.15
0

Next, a shape optimization was carried out using elasto-plastic material properties at 8500 RPM to asses the
actual optimization result under plastic conditions. The Von Mises stress distribution Ior the optimized
shape is shown in Fig. 13. Maximum stress has decreased marginally Irom 768 to 746 MPa by 22 MPa
(2.86) Irom baseline elasto-plastic analysis Ior 8500 RPM; however the peak plastic strains reduced Irom
0.0153 to 0.01126 by 26.4. This is the major advantage in optimization Ior a blade root shape. Many
existing machines have roots designed by experience and there can be considerable margin in lowering
peak strains and thereIore enhanced liIe. Table 3 shows the optimized shapes obtained Irom elastic and
elasto-plastic analyses which are in close match.
















Fig. 13. Results oI Elasto-Plastic analysis at 8500 RPM Ior Optimized conIiguration


Table 3. Comparison oI Baseline and Optimized ConIiguration

Conclusions

Detailed methodology Ior shape optimization oI turbomachine blade roots is presented using Optistruct and
HvperStudv tools. Mesh morphing technology has been adopted Irom HvperMesh to achieve diIIerent
shape variables in perIorming the optimization. It has been demonstrated that the shape optimization
process can be applied in elastic regions as the problem is similar to considering stress concentration in the
peak stress regions.





Innovation Through Simulation 11


In Optistruct linear analysis is conducted. For rotating bladed disk structures where cyclic symmetry
boundary conditions can be used to reduce the analysis eIIort an equivalent stationary structure is
developed using cut boundary displacement conditions. It was shown that a lower speed centriIugal load
(completely elastic condition) can be used to perIorm optimization and the results obtained are valid even
Ior higher speeds where peak stresses cross yield values.

The advantage oI HvperStudv is its capability to handle an optimization problem through any solver and
thereIore elasto-plastic analysis can be adopted in optimization to get the correct picture.

The optimization in globally elastic and locally plastic structures yields very little improvement in the stress
values as the material yields without hardening on stress and relaxes in strain. The improvement in strains
Ior the blade chosen has been shown to be signiIicant oI the order oI 25. This improvement can have
substantial advantages in low cycle Iatigue liIe oI the bladed disk.



ACKNOWLEDGMENTS

The authors are thankIul to Altair Engineering India Ior their support.

REFERENCES

|1| Frank, W., Schaden Speigel, 25, No. 1, 20 (1982)
|2| Rao, J. S., Application oI Fracture Mechanics in the Failure Analysis oI A Last Stage Steam Turbine Blade, Mechanism and
Machine Theorv, vol. 33, No. 5, 1998, p. 9
|3| Rao, J. S. and Vyas, N. S., Determination oI Blade Stresses under Constant Speed and Transient Conditions with Nonlinear
Damping, J of Engng. for Gas Turbines and Power, Trans ASME, vol. 116, 1996, p. 424
|4| Rao, J. S., Ramakrishnan, C. V., Gupta, K. and Singh, A. K., Elastic Plastic Fracture Mechanics oI a LP Last Stage Steam
Turbine Blade Root, ASME-2000-GT-0569
|5| Rao, J. S., Recent Advanced in India Ior AirIrame & Aeroengine Design and Scope Ior Global Cooperation, Societv of Indian
Aerospace Technologies & Industries, 11
th
Anniversarv Seminar, February 8, 2003, Bangalore
|6| Bhat, R. B., Rao, J. S. and Sankar, T. S., Optimum Journal Bearing Parameters Ior Minimum Rotor Unbalance Response in
Synchronous Whirl, Journal of Mechanical Design, Trans ASME, v.104, 1982, p.339
|7| Vanderplaats, G. N., Structural Optimization Methods oI Feasibility Directions, Computers and Structures, vol. 3, 1973, p. 739
|8| Altair Product OptiStruct J7.0 Theory and user manual
|9| Schuhmacher, G., Optimizing AircraIt Structures, Concept to Realitv, Winter Issue 2006, p. 12
|10| Taylor, R. M., et. al., Detail Part Optimization on the F-35 Joint Strike Fighter, AIAA 2006-1868, 47th
AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dvnamics, and Material Conference, May 2006, Newport, Rhode Island.
|11| Vanderplaats, G. N., Numerical Optimi:ation Techniques for Engineering Design With Applications, 3
rd
Edition, Vanderplaats
Research and Development Inc., Colorado Springs, 1999
|12| Altair Product HvperStudv J7.0 Theory and user manual
|13| Altair Product HvperMesh J7.0 Theory and user manual
|14| ANSYS Release 9.0 Documentation