CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION TO THE TURBINE BLADES

The purpose of turbine technology are 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 gas turbine obtains its power by utilizing the energy of burnt gases and the air which is
at high temperature and pressure by expanding through combination of several fixed and moving
blades. To get a high pressure of order 4 to 10 bar of working fluid, which is essential for
expansion a compressor, is required. The quantity of ten working fluid and speed required are
more so generally a centrifugal or axial compressor is required. The turbine drives the
compressor so it is coupled to the turbine shaft. If after compression the working fluid were to be
expanded in a turbine, then assuming that there were no losses in either component, the power
developed by the turbine can be increased by increasing the volume of working fluid at constant
pressure or alternatively increasing the pressure at constant volume. Either of these may be done
by adding heat so that the temperature of the working fluid is increased after compression. To get
a higher temperature of the working fluid a combustion chamber is required where combustion
of air and fuel takes place giving temperature rise to the working fluid.
Gas turbines have been constructed to work on the following: -oil, natural gas, coal gas,
producer gas, blast furnace and pulverized coal. Gas turbines may be classified on the basis of
following: -

a) On the basis of combustion process the gas turbine is classified as follows: -

i) Continuous combustion or constant pressure type -The cycle working on this

principal is called Joule or Brayton cycle.

ii) The explosion or constant volume type -The cycle working on this principal is called
Atkinson cycle.

b) On the basis of the action of expanding gases similar to steam turbine is classified as: -

i) Impulse turbine or Impulse-reaction turbine.

c) On the basis of path of working substance the gas turbine is classified as

i) Open cycle gas turbine (working fluid enters from atmosphere and exhaust to
atmosphere.

1
 ii) Closed cycle gas turbine (Working fluid is confined in the plant)

iii) Semi closed cycle (part of the working fluid is confined within the plant and another
part flows from and o the atmosphere.

d) On the basis of direction of flow Axial flow and Radial flow

A gas turbine is an engine where fuel is continuously burnt with compressed air to
produce a steam of hot, fast moving gas. This gas stream is used to power the compressor that
supplies the air to the engine as well as providing excess energy that may be used to do other
work.

The engine consists of three main parts.

The Compressor

The Combustor and

The Turbine

Figure 1.1 Simple open Cycle gas turbine

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. In both types, the compressor
rotates and it is driven by a shaft that passes through the middle of the engine and is attached to
the turbine as shown in fig 1.1.

2
 The combustor is where fuel is added to the compressed air and burnt to produce high
velocity exhaust gas as shown in fig 1.2.

Figure 1.2 Indicator diagram of gas turbine

The turbine extracts energy from the exhaust gas. The turbine can, like the compressor,
be centrifugal or axial. In each type the fast moving exhaust gas is used to spin the turbine. As
the turbine is attached to the same shaft as the compressor at the front of the engine, the turbine
and compressor will turn together. The turbine may extract just enough energy to turn the
compressor. The rest of the exhaust gas is left to exit the rear of the engine to provide thrust as in
a pure jet engine. Or extra turbine stages may be used to turn other shafts to power other
machinery such as the rotor of a helicopter, the propellers of a ship or electrical generators in
power stations.

Figure 1.3 Turbine blade coupled to centrifugal compressor

3
 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.

A good design of the turbo machine rotor blading involves the following

i) Determination of geometric characteristics from gas dynamic analysis.

ii) Determination of steady loads acting on the blade and stressing due to them.

iii) Determination of natural frequencies and mode shapes.

iv) Determination of unsteady forces due to stage flow interaction.

v) Determination of dynamic forces and life estimation based on the cumulative damage
fatigue theories.

The stress analysis of the rotor blade being the key phase of the turbo machine design
requires much attention and careful determination of the blade loading to get realistic results.
The stress analysis is performed to determine the critical section as well as the stressing pattern.
As the blade vibration is also a cause of failure in many cases, the determination of natural
frequencies and mode shapes is also of paramount importance. The designer should take care of
dynamic forces such that the frequencies of these must be away from those of the rotor blades to
avoid resonance, which is an undesirable phenomenon.

1.2 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.

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
4
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.

1.3 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: -

NI55: It is an Nickel based super alloy and it is composed of mainly Carbon, Chromium, Cobalt
and it has trace amounts of Manganese, Molybdenum, Nickel, Silicon, Tungsten. It is commonly
used for high-temperature bolts and aircraft parts, including:

Tail pipes and cones,

Exhaust manifolds,
Nozzles,
Turbine, combustion chamber and afterburner components.

A Super alloy or high-performance alloy is an alloy that exhibits excellent mechanical strength,
resistance to creep (tendency for solids to slowly move or deform under stress) at high
temperatures; good surface stability; and corrosion and oxidation resistance. Super alloys
typically have a matrix with an austenitic face-centered cubic crystal structure.

5
1. Aluminum: - Aluminum is remarkable for the metal's low density and for its ability to resist
corrosion due to the phenomenon of passivation. Structural components made from aluminum
and its alloys are vital to the aerospace industry and are important in other areas of transportation
and structural materials. The most useful compounds of aluminum, at least on a weight basis, are
the oxides and sulfates.

2. Silicon carbide: - Silicon carbide (SiC), also known as carborundum, is a compound of

silicon, carbon with chemical formula SiC It occurs in nature as the extremely rare mineral
moissanite. Silicon carbide powder has been mass-produced since 1893 for use as an abrasive.
Grains of silicon carbide can be bonded together by sintering to form very hard ceramics which
are widely used in applications requiring high endurance, such as car brakes, car clutches and
ceramic plates in bulletproof vests.

3. 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.

4. Copper Nickel: - This is an alloy containing about 80 % Cu, 19 % Ni and fraction of iron and
magnesium.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

6
11. 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.

1.4 TURBINE BLADE COOLING

Unlike steam turbine blades, gas turbine blades 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-siphon 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 as shown fig 1.4. The mean rotor blade temperature is
about 623.15K below the prevailing gas temperature after efficient blade cooling.

Figure 1.4 Turbine blades cooling

7
 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 aluminum, nickel,
chromium.

1.5 APPLICATIONS OF GAS TURBINE

The following are the applications of gas turbine
1) Locomotive propulsions.
2) Central power stations.
a) Standby plants for hydro installations.
b) Fully automatic booster stations at end of transmission lines.
c) Standby and peak load plants for small system.
d) Bomb proof power plants.
e) At location where water is not available.
3) Industrial.
a) Pumping stations.
b) Space applications-Turbo jet, Turbo propulsion, marine applications.

8
 CHAPTER-2

LITERATURE REVIEW

2.1 LITERATURE REVIEW

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[8].

Aero engine turbine and compressor blades operate at speed range 5000 to 15000 rpm.
While the temperature limits may vary from 323.15K to 1173.15K [9] [10]. 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 15-35 degrees [7] [10].
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
as shown in fig 2.1. Advanced turbo machinery blading is designed to have high steady stress
levels [4]. Thus, HCF occurs because of high mean stress - low amplitude vibratory loading of the
airfoils. It is initiated by the formation of small often-microscopic cracks.

Figure 2.1 stress range diagram

9
 Figure 2.2 Advanced Airfoil 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 in fig 2.2.

A.K.Matta [10] studied the stress analysis for Inconel 718 material. On solid blades it is
reported that Inconel 718 is better suited for high temperature operation

They have chosen Inconel 718, a high heat resistant alloy of chromium, nickel &
niobium. The study was focused on centrifugal & thermal stress arising in the disk

Deepanraj [9] have considered titanium aluminium alloy as the blade material and
performed structural and thermal analysis.

In this study, blade operating and service conditions are taken into consideration [10]. The
factors are inspection results, coating stripping, and cracks due to thermo mechanical stresses
during operation likely to be located on airfoil and on fillet radius, mechanical deformation
modifications of design profile mainly on trailing edge, corrosion, and erosion, coating and
surface degradation due to high temperature on airfoil.

Therefore in terms of maintained requirements, manufacturing difficulties and costs, the

blades are the most critical item of the today gas turbines.

10
 CHAPTER-3

PROBLEM DEFINITION

3.1 PROBLEM DEFINITION

The modern gas turbine is a complex machine, the design and development of which
takes many months and costs millions. The gas turbine manufacturing industry is under pressure
to minimize the resources required to bring a new design to market due to global competitive
pressure and increasing customer expectations. Accurate design and prediction tools are going to
play key role to success in this process.

The major problem associated with this Gas turbine rotor blade is that the vibrations and
thermal fluxes will combine together and lead to catastrophic event. There are many instances of
engine failures which were direct result of this combination. In many engine models the
maintenance of this portion is very costly event due to the restricted access to this section so
many industries will not go for this check up periodically and they hope that this rotor blade
section will work to a certain period of time before going for maintenance of this section.

But the ambient conditions and air intakes will not be as always as we expected some
times the air from combustor chamber entering turbine chamber will more turbulent and may
contain Thermal fluxes more than we expected. Under these circumstances the blade will
sometimes snap right off this will lead to the total loss of the entire engine sometimes even the
aircraft. This breaking of rotor blade will cost dearly to the company as a single gas turbine
engine will cost at least 50-75 million .

So it is absolutely necessary to make sure that our rotor blades have wide range of
operating conditions that will enable us to avoid unnecessary disturbances. In order to achieve
this we must conduct intensive Thermal and Modal analysis of the rotor blades along with
Structural analysis in simulation software before going to test the prototypes.

This is what we do in this present study in order to understand about the behavior of the
rotor blade under a set of boundary conditions and a given value of frequency range.

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3.2 BLADE DETAILS AND DESIGN CRITERIA
3.2.1 BLADE DETAILS

The turbine blade dimensions are as follows [10]:

Diameter of blade mid span D= 1.3085
Blade height h = 110 mm
Blade I- Section = 49 mm27 mm,
Speed of rotor is 3,426

Figure 3.1 3-D Model of Rotor Blade

3.2.2 MATERIAL
The turbine blade is simultaneously subjected to high temperature gradients that require a
unique blend of material properties such as high strength [8]. The materials chosen for the
application are N155 [9]. It is Nickel based Super alloy has high temperature properties and do not
depend upon Age hardening it has good ductility, strength, corrosion resistance and excellent
oxidation.

3.2.3 MECHANICAL PROPERTIES [9]

The physical properties of the materials such as Elastic modulus, Poissons ratio,
Certificate of thermal expansion vary with the temperature. Accurate stress calculations would
therefore require accurate data of the elastic properties of the material. The mechanical properties
we considered for our Turbine rotor blade are given in Table 1.

TABLE 1 Mechanical Properties of N155 material [9]

Property Units N155 at 839.5310C
E Pa 143E09
Kg/cu m 8249
K W/m-K 20.0
----- 0.344
0
E-06/ C 17.7
Cp J/KgK 435
0
Melting point C 1354
Yield stress Mpa 550

12
 CHAPTER 4
METHOD OF ANALYSIS

4.1 NUMERICAL METHODS

We cannot solve the above basic heat conduction equation by ordinary analytical methods
because of complexity arising from non-linearity due to radiant boundary conditions. Hence
numerical methods are used for solving the problem.

Numerical methods allow evolution of reasonably accurate results. However, the

accuracy strongly depends on physical considerations, but not on mathematical manipulations.
There are number of numerical methods to solve the transient heat transfer problems.
They are
1. Finite Difference method
2. Finite Element Method
3. Finite Volume Method

4.2 FINITE DIFFERENCE METHOD [3]:

One of the most widely used numerical techniques for solving the differential equations
is the finite difference method. Analytical methods provide solution at every point in time and
space within the problem boundaries and therefore it is only an approximation of the exact
solution. Representing the problem at only a finite number of points simplifies the solution
procedure. If more discrete points are used in finite difference calculation, the solution will be
closer to exact solution.

4.3 FINITE ELEMENT METHOD: (FEM) [1] [6]

A method for solving an equation by approximating continuous quantities as a set of

quantities at discrete points, often regularly spaced into a so-called grid or mesh. Because finite
element methods can be adapted to problems of great complexity and unusual geometry, they are
an extremely powerful tool in the solution of important problems in heat transfer, fluid
mechanics and mechanical systems. Furthermore, the availability of fast and inexpensive
computers allows problems which are intractable using analytic or mechanical methods to be
solved in a straight forward manner using finite element methods.

The disadvantage of the FEM is that it obtains only approximate solutions. The FEM has
inherent errors and mistakes by users can be fatal. It is more suitable for a complex geometry.

13
4.3.1 FINITE ELEMENT METHOD WORKS

Figure 4.1 Discretizations of turbine blade profile

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

On the other hand, the finite element. Model gives a better approximation to the region. Also,
a better approximation to the boundary shape results because straight lines of any inclination
represent the curved boundary. This example is not intended to suggest that finite element
models are decidedly better than finite difference models for all problems. The only purpose of
the example is to demonstrate that the finite element method is particularly well suited for
problems with complex geometries. Still another numerical analysis method is the boundary
element method (boundary integral equation method) this method uses Greens theorem to
reduce the dimensionality of the problem; a volume problem is reduced to a surface problem, a
surface problem is reduced to a line problem.

We have been alluding to the essence of the finite element method, but now we shall discuss
it in greater detail. In a continuum problem of any dimension the field variable (whether it is
pressure, temperature, displacement, stress, or some other quantity) possesses infinitely many
values because it is a function of each generic point in the body or solution region. Consequently,
the problem is one with an infinite number of unknowns. The finite element discretization
procedures reduce the problem to one of a finite number of unknowns by dividing the solution
region into elements and by expressing the unknown field variable in terms of assumed
approximating functions within each element. The approximating functions (sometimes called
interpolation functions) are defined in terms of the values of the field variables at specified
points called nodes or nodal points.

Regardless of the approach used to find the element properties, the solution of a continuum
problem by the finite element method always follows an orderly step-by-step process. To
summarize in general terms how the finite element method works we will succinctly list these
steps now.

14
4.3.2 FEM WORKING STEPS
1. Discretize the Continuum: The first step is to divide the continuum or solution region into
elements. In the example of Figure the turbine blade has been divided into triangular elements
that might be used to find the temperature distribution or stress distribution in the blade. A
variety of element shapes may be used, and different element shapes may be employed in the
same solution region. Indeed, when analyzing an elastic structure that has different types of
components such as plates and beams, it is not only desirable but also necessary to use different
elements in the same solution.

2. Select Interpolation Functions: The next step is to 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. Often, polynomials are
selected as interpolation functions for the field variable because they are easy to integrate and
differentiate. The degree of the polynomial chosen depends on the number of nodes assigned to
the element, the nature and number of unknowns at each node, and certain continuity
requirements imposed at the nodes and along the element boundaries. The magnitude of the field
variable as well as the magnitude of its derivatives may be the unknowns at the nodes.

3. Find the Element Properties: Once the finite element model has been established (that is,
once the elements and their interpolation functions have been selected), we are ready to
determine the matrix equations expressing the properties of the individual elements. For this task
we may use one of the three approaches just mentioned: the direct approach, the variation
approach, or the weighted residuals approach.

4. Assemble the Element Properties to Obtain the System Equations: To find the properties
of the overall system modeled by the network of elements we must assemble all the element
properties. In other words, we 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. The basis for the assembly
procedure stems from the fact that at a node, where elements are interconnected, the value of the
field variable is the same for each element sharing that node. A unique feature of the finite
element method is that assembly of the individual element equations generates the system
equations.

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. At this stage we impose
known nodal values of the dependent variables or nodal loads.

6. Solve the System Equations: The assembly process gives a set of simultaneous equations that
we solve to obtain the unknown nodal values of the problem. If the problem describes steady or
equilibrium behavior, then we must solve a set of linear or nonlinear algebraic equations.

15
7. Make Additional Computations: If Desired. Many times we use the solution of the system
equations to calculate other important parameters. For example, in a structural problem the nodal
unknowns are displacement components. From these displacements we calculate element strains
and stresses.

4.4 FINITE VOLUME METHOD: (FVM) [2]

The finite volume method is a numerical method for solving partial differential equations
that calculates the values of the conserved variables averaged across the volume. One advantage
of the finite volume method over finite difference methods is that it does not require a structured
mesh (although a structured mesh can also be used). Furthermore, the finite volume method is
preferable to other methods as a result of the fact that boundary conditions can be applied
noninvasive. This is true because the values of the conserved variables are located within the
volume element, and not at nodes or surfaces.

CONCEPT OF FVM:
The concept of control volume formulation circles around derivatives of finite difference
equations for a domain which is divided into number of non overlapping control volume
surrounding each grid point. The differential equation is integrated over each control volume.
Piece wise profiles expressing the variation of temperature between the grid points are used to
evaluate the required integrals. The results are the discretised equation contains the values of
temperature for a group of grid points.

4.5 SOLID 45 3D 8-NODE STRUCTURAL SOLID ELEMENT [9]

Solid 45 is higher order version of the 3-D 8-node solid element. It can tolerate irregular
shapes without as much loss of accuracy. Solid 45 elements have compatible displacement
shapes and are well suited to model curved boundaries as shown. The element is defined by 10
nodes having three degrees of freedom per node, translations in the nodal x, y, and z directions.

Figure 4.2 Solid 45 3-D Structural solid

16
 CHAPTER 5

MODELING AND ANALYSIS OF GAS TURBINE ROTOR BLADE

The solution procedure of this project work involves the following steps:
5.1 Modeling of the rotor blade
5.2 Brick mesh gas turbine rotor blade
5.3 Modal analysis
5.4 Thermal analysis
5.1 MODELING OF THE ROTOR BLADE
The geometry of the Gas turbine rotor blade is quite complex and solid modeling is done
by modeling tools. Modeling is done step by step as shown in figures.

5.1.1 I-SECTION BASE SKETCH

Figure 5.1 I-Section Base line sketch

The designing of the turbine rotor blade will consist of several steps and we first start our design
by creating a rectangle section of dimensions 49 mm x27 mm in sketcher module.

17
5.1.2 I-SECTION BASE PAD DESIGN

Figure 5.2 I-Section Base Pad design

In next step we will exit sketcher and we will pad our base by adding material up to a length of
8mm.
TABLE 2 List of selected key points
NO(Z=0) X Y
1 0 20
2 2 22
3 6 24.5
4 18 26
5 20 25.5
6 30 21
7 36 16.6
8 40 12.5
9 44 8
10 49 0
11 44 5
12 40 8
13 36 10.5
14 30 13
15 25 14.3
16 20 15
17 16.5 15.3
18 10 15.5
19 6 16
20 2 18

The above indicated are the list of selected key points which are used for generating an
airfoil. Our airfoil is NACA-2413

18
5.1.3 AIRFOIL SKETCH ON I-SECTION BASE

Figure 5.3 Airfoil sketch on I-Section base

In this step we will create airfoil on our rectangular base with respect to the values
specified in table no 2. This airfoil section which we created is nothing but NACA-2413

5.1.4 SURFACE PROJECTION

Figure 5.4 Surface Projection

We have created an airfoil section now we try to create an entire blade profile. In order to this we
will create a reference plane at a height of 110mm+8mm.

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5.1.5 WIRE FRAME SURFACE DESIGN

Figure 5.5 Wireframe design

We will create the blade profile at a required height and we will try to give important twist angle
to our blade

5.1.6 BLADE TWIST ANGLE ROTATION

Figure 5.6 Blade twist angle rotation

In this section we will complete our modeling portion by using multi-section option to fill the
area between two blade profiles (twisted and on base profiles). The twist angle we used is in
order of 15 degrees. [10]

20
 Figure 5.7 Rotor blade with 3 D 8 Node element

5.1.7 TURBINE BLADE I-SECTION DESIGN

Figure 5.8 Turbine Blade I-Section design

We will create complete base for our turbine blade.

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5.1.8 GAS TURBINE BLADE TOTAL DESIGN

Figure 5.9 Turbine blade total design

This is the total design profile of the turbine rotor blade which is used for thermal as well as
modal analysis.

5.1.9 TURBINE ROTOR BLADE FOUR VIEWS

Figure 5.10 Turbine rotor blade 4 views

22
5.2 BRICK MESH GAS TURBINE ROTOR BLADE

A mesh is a network of line elements and interconnecting nodes used to model a

structural system and numerically solve for its simulated behavior under applied loading. First,
computational techniques create an analytical model by populating the material domain with a
finite-element mesh in which each line element is assigned mathematical attributes (axial,
bending, shear, and torsional stiffness, etc.) which simulate the material and geometric properties
of the structural system. The system is then restrained within boundary conditions and subjected
to mechanical or thermal loading.

Figure 5.11 Brick mesh gas turbine rotor blade

5.3 MODAL ANALYSIS

Modal analysis, or the mode-superposition method, is a linear dynamic-response

procedure which evaluates and superimposes free-vibration mode shapes to characterize
displacement patterns. Mode shapes describe the configurations into which a structure will
naturally displace. Typically, lateral displacement patterns are of primary concern. Mode shapes
of low-order mathematical expression tend to provide the greatest contribution to structural
response. As orders increase, mode shapes contribute less, and are predicted less reliably. It is
reasonable to truncate analysis when the number of mode shapes is sufficient.

This kind of analysis is used for finding out natural frequency of the material within the
given frequency limits and also to find out deformations respectively.

23
5.4 THERMAL ANALYSIS

From the post processing, the temperature variation obtained as shown in fig. From
figure, it is observed that the temperature variations from leading edge to the trailing edge on the
blade profile is varying from 1059.76K to 1094.201K throughout the blade and the variation is
linear along the path from both inside and outside of the blade.

5.4.1 CONVECTIVE HEAT TRANSFER COEFFICIENTS OVER THE

BLADE SURFACES

Figure 5.12 Gas flow over suction and pressure side of rotor blade

5.4.2 EVALUATION OF CONVECTIVE HEAT TRANSFER

COEFFICIENTS (hs) ON SUCTION SIDE OF FIRST STAGE ROTOR
BLADES

For the first stage rotor blades is as shown.

Temperature of gases at inlet Ti = 839.220 c

Temperature of gases at exist Te = 732.880 c

Mean fluid temperature

+
Tmf = (5.1)
2
The flowing properties of air at Tmf were noted.

Kinematic viscosity (v)

Prandtl Number (Pr)
Thermal Conductivity (K)

24
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 = (5.2)

Average relative velocity

2 +
Vr = (5.3)
2

Using equation (5.2)

Re = 97881.14

The Nusselt number (Nu) is calculated using the empirical relation for flow across cylinders.

The generalized equation is

NuD = C*Re*Dm*Pr0.333 (5.4)

Using equation (5.4)

NuD = 247.329

+
NuD = (5.5)

Using equation (5.5)

hs = 379.92 w/m2 k

5.4.3 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 = (5.6)
2

25
Kinematic viscosity (v), Prandtl number (Pr) and thermal conductivity (k) of air at T mf is 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 = (5.7)

Using equation (5.7), 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*Pr1/3*Re1/2 (5.8)

Using equation (5.8) Nu = 241.983

For flat plate,

Nu = (5.9)

hp = 284.95 w/m2 K

5.4.4
EVALUATION OF CONVECTIVE HEAT TRANSFER COEFFICIENT (HR) ON THE
TWO RECTANGULAR FACES AT INLET AND EXIST OF FIRST STAGE ROTOR BLADES.

Figure 5.13 Inlet of first stage rotor blade Figure 5.14 Exit of first stage rotor blade

In figure 5.13 and 5.14.the shaded rectangles are the ones which heat transfer coefficients are calculated.

26
The gases sweep the rectangular faces with a velocity

V=u= (5.10)
60

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 = (5.11)

At inlet Re =20325.197

At exist Re = 23785.71

For laminar flow over a flat plate

Nu = 0.664*Pr1/3*Re1/2 (5.12)

Nu = (5.13)

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

5.4.5 EVALUATION OF CONVECTIVE HEAT TRANSFER

COEFFICIENTS ON SECOND STAGE ROTOR BLADES.
HS = 486.28 W/M2 K

Hp = 308.37 w/m2 K

Hfi = 4234.82 W/M2 K

Hfc = 238.162 W/M2 K

27
 The following material properties were defined in the material property table named as
material type 1.

Youngs Modulus of Elasticity (E) = 143e5 N/mm2

Density () = 8249e-9 Kg/mm3

Coefficient of thermal expansion () = 5.45e-6

5.4.6 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 files 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 fig 4.15

Heat flux = 0 for 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.

Figure 5.15 Thermal Boundary condition

28
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

5.4.7 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.

5.4.8 ANALYSIS OF STRESSES AND 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. The stresses and elongations were then analyzed using
software results were viewed in the post processor.

Figure 5.16 Line diagram of rotor blade Figure 5.17 Area diagram of rotor blade

29
 CHAPTER 6
RESULTS AND DISCUSSIONS
6.1 MODAL ANALYSIS RESULTS:
Mode 1:

Figure 6.1 Modal 1 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 18.911Hz and the maximum deformation was
found to be 1.03mm in first mode.

Mode 2:

Figure 6.2 Modal 2 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 60.294Hz and the maximum deformation was
found to be 1.133mm in second mode.

30
Mode 3:

Figure 6.3 Modal 3 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 82.238Hz and the maximum deformation was
found to be 1.008mm in third mode.

Mode 4:

Figure 6.4 Modal 4 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 110.86Hz and the maximum deformation was
found to be 1.053mm in fourth mode.

31
Mode 5:

Figure 6.5 Modal 5 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 203.785Hz and the maximum deformation was
found to be 1.288mm in fifth mode.

Mode 6:

Figure 6.6 Modal 6 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 270.129Hz and the maximum deformation was
found to be 1.102mm in sixth mode.

32
Mode 7:

Figure 6.7 Modal 7 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 296.36Hz and the maximum deformation was
found to be 1.097mm in seventh mode.

Mode 8:

Figure 6.8 Modal 8 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 301.694Hz and the maximum deformation was
found to be 1.094mm in eighth mode.

33
Mode 9:

Figure 6.9 Modal 9 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 329.654Hz and the maximum deformation was
found to be 1.415mm in ninth mode.

Mode 10:

Figure 6.10 Modal 10 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 382.857Hz and the maximum deformation was
found to be 1.258mm in tenth mode.

34
Mode 11:

Figure 6.11 Modal 11 Shape of gas turbine rotor blade

We conducted a modal analysis at a frequency of 397.014Hz and the maximum deformation was
found to be 1.232mm in eleventh mode.

Table 3 Modal analysis results

The modal analysis has been carried out to the frequency varying from 18.911Hz to 397.01 Hz in
11modes is observed. The maximum deformation was found to be ranging from 1.03mm to
1.232mm.

35
6.2 THERMAL ANALYSIS RESULTS:

Figure 6.12 Nodal temperatures in the blade

Above figure shows the nodal temperature variations from tip of the rotor blade to the leading
edge and it is varying from 1059.76K to1094.2011K.

Figure 6.13 Thermal flux vector sum in the blade

Having seen the nodal temperature variations now we shift our focus to Thermal flux above fig shows a
Thermal flux vector sum. Having seen that now we may shift our focus to thermal fluxes in each direction
and the shear forces ranges from 0.287E-04N/mm2 to 0.027066 N/mm2.

36
 Figure 6.14 Thermal flux in X-Direction in the blade

Thermal flux in X-Direction in the blade is shown in this figure and the shear forces ranges from
-0.004544N/mm2 to 0.019155N/mm2

Figure 6.15 Thermal flux in Y-Direction in the blade

Thermal flux in Y-Direction in the blade is shown in this figure and the shear forces ranges from
-0.025228N/mm2 to 0.011199N/mm2

37
 Figure 6.16 Thermal flux in Z-Direction in the blade

Thermal flux in Z-Direction in the blade is shown in this figure. With shear forces
-0.21314N/mm2 to 0.004566N/mm2 limits.

Figure 6.17 Thermal gradients in X -Component in the blade

The thermal gradients are studied and are presented in this present section above shows the same
in X-direction. With shear force in -0.957773N/mm2 to 0.227223N/mm2 limits.

38
 Figure 6.18 Thermal gradients in Y-Component in the blade

Thermal gradient in y-direction are shown in above figure. With a shear limits between
0.559932N/mm2 to 1.261N/mm2

Figure 6.19 Thermal gradients in Z-Component in the blade

Thermal gradient in z direction is shown in this figure. With shear force in -0.228278N/mm2
to 1.066N/mm2 limits.

39
 Figure 6.20 Thermal gradients vector sum in the blade

Having seen the Thermal gradients in all the 3 directions now we must see the Thermal gradient
vector sum in the blade in this figure which had Shear force in limits of 0.001436mm to
1.353mm.

40
 CHAPTER 7
VALIDATION

As we have said earlier we are going to study thermal and modal characteristics of a Gas

turbine rotor blade and we used the published papers like Structural and Thermal Analysis of

Gas Turbine Rotor Blade and Analysis of Gas Turbine Blades with materials N155 &

INCONEL 718 as our reference. But instead of following the usual materials and mode of

construction of the turbine blades we have made some changes to our project work. First we

provided a Twist of 150 for our rotor blade model and also we went for a experimental material,

a Nickel based super alloy called N155 which was known to give a better thermal characteristics
[10]
.But we considered the same boundary conditions as for general blade to specify the Bulk

temperature and heat coefficients, using those boundary conditions and material properties of

N155 we found that the temperature variations for our blade were lying between 1094.201 to

1059.76 K which is almost similar to the values found in paper Structural and Thermal

Analysis of Gas Turbine Rotor Blade whose values are lying between 1112.681 to 1008.312 K .

TABLE 4 Comparisons between N155 and INCONEL 718 materials

Material Type Minimum Stress (SMN) Maximum Stress (SMX)

INCONEL 718 1008.312 1112.681

N155 1059.76 1094.201

41
7.1 NODAL TEMPERATURE VALUES

7.1.1 INCONEL 718 MATERIAL

Figure 7.1 Inconel 718 material Nodal temperatures

TABLE 5 INCONEL 718 Nodal temperature values

0
Stress C K

Maximum Stress (SMX) 839.531 1112.681

Minimum Stress (SMN) 735.162 1008.312

42
7.1.2 N155 MATERIAL

Figure 7.2 N155 material Nodal temperatures

TABLE 6 N155 Nodal Temperature Values

0
Stress C K

Maximum Stress(SMX) 821.051 1094.201

Minimum Stress(SMN) 786.61 1059.76

43
 CONCLUSION

The finite element analysis for thermal analysis of gas turbine rotor blade is carried out
using solid 45 elements. The temperature has a significant effect on the overall turbine blades.

Maximum temperatures are observed at the blade tip section and temperature variations
at the root of the blade.

The modal analysis has been carried out to the frequency varying from 18.9 to 397.01 Hz
in 11modes is observed. The deformation ranges from 1.03mm to 1.232mm. It is observed that
the temperature variations from leading edge to the trailing edge on the blade profile is varying
from 1094.201 to 1059.76 K 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 length from the leading edge
and from there to next 36 mm length of blade the temperature gradually decreasing and reaching
to a temperature of 1062.971K and for another 4 mm length it is almost constant.

44
 FUTURE SCOPE

Our project has shown us that turbine rotor blade will undergo Thermal stresses in a very
complicated and unexplained manner which when coupled with vibrations along with gas forces
cause a disastrous result. That is the reason we must go for the use of super alloys in the
manufacturing of Turbine blades. So we have used a Nickel based Super alloy known as N155
for our study. But this alloy will provide us good Thermal characteristics only, but when it comes
to issue of higher durability or strength with Convective cooling provision people will generally
opt for INCONEL 718 which is another super alloy currently utilized in major turbine
manufacturing companies. But this alloy can only give good structural and modal characteristics,
but when we need better thermal characteristics we must go for N155. At present many eminent
organizations are working for a much better alloy which could offer thermal characteristics like
N155 and modal, structural characteristics like INCONEL 718.

45
 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 programme, August
1999.
8) R.Yadav,Steam and Gas turbine, Central Publishing House, Allahabad.
9) G. Narendranath, S. Suresh, IJSRET journal Structural and Thermal Analysis of Gas
Turbine Rotor Blade. Volume 2, Issue2, ISSN 2278 0882, 2013.
10) A.K. Matta, D.Venkata rao, P.Ramesh babu, R.Umamaheshwar rao IJAST journal
Analysis of Gas Turbine Blades with materials N155 & INCONEL 718, Volume 4
No.1, ISSN 2229- 5216, 2012

46