Structural Design and Analysis of Gas Turbine Blade using CAE tools

Structural Design and Analysis of Gas Turbine Blade using CAE tools

Nithin Kumar K C1, Tushar Tandon2, Praveen Silori3, Amir Shaikh4

Assistant Professor1, UG students2, 3, Professor4 Department of Mechanical Engineering, Graphic Era University,

Dehradun, India

Abstract In todays industrial scenario, gas turbine is one of the most important parts of a power plant. In order to maximize the overall performance and efficiency of all modern turbines, it should operate at high temperatures and speeds. Due to high operating temperatures and speeds, failure of the turbine blades is inevitable. Hence there is a pressing need for analysis of turbine blades. The steady state thermal and static structural analysis of turbine blade is carried out using ANSYS 14.0 for different titanium alloys.

In the analysis, it is observed that the bottom trailing edge of the blade section has higher stress value than the tip of the blade. The value of Von-Mises stress and deformation is obtained and it is seen that at 10000C, Alloy 685 and at 20000C, Ti 6242S exhibits least amount of stress and undergoes less deformation for a constant turbine speed of 10000 rpm with a pressure of 3.06 MPa.

KeywordsTurbine Blade, Titanium alloys, Von-Mises stress, Ansys 14.0.

1. INTRODUCTION

   The turbine is a mechanical power generating rotary device which uses energy of flowing fluid and convert it into useful work. The turbine is designed to extract maximum amount of energy to produce maximum thermal efficiency [1].

   In the turbine, a rotary compressor compresses the working fluid and then sends it into the combustion chamber where it gets mixed with the fuel and is heated at elevated temperatures. Now these hot gases are passed on to the turbine blades where they expand and the heat energy gets converted to rotary motion of turbine shaft. The generator coupled to turbine shaft converts mechanical work to electrical output [2].

   The thermal efficiency and power output of gas turbine varies directly with the increasing blade inlet temperature. The current inlet temperature is far more than the melting point of blade material. Hence the blade material should sustain the high temperature to increase the thermal efficiency [3].

   In a gas turbine, high temperature is created by flowing fluid which tends to fail the blade after some time. Some types of failure are being discussed here: When 150 MW gas turbine was analyzed, it failed by highly intensified vibrations. All blades including stationary blades were damaged. The blade completed 1800 Hrs of life in running mode. More important is that there is no damage to any other section in the securing pin hole located at the root [4].

2. LITERATURE REVIEW

   Zuniga [5] explains the design of a turbine in detail and the trajectory of air flow along the blades with various angles of fluid flow with respect to blade are schematically shown thus aiding in development of the blade profile of rotor and stator of turbine through various blade parameters.

   Patsa and Mohammed [6] presented analysis of turbine blade geometries, by applying boundary conditions to various blade materials like Monel-400, Haste alloy x & Inconel 625, steady state thermal and structural performance is carried out.

   The works of Homji and Gabriles [7] provides an insight to various modes of failures of gas turbine blades. The prominent of these are fatigue, creep, erosion wear and environmental attacks and combined failure mechanisms.

   Jianfuhou, Bryon J. Wicks, Ross A. Antoniou [8] did an investigation of fatigue failures of turbine blades in a gas turbine engine by mechanical analysis which categorized that (i) Fatigue includes both HCF (high cycle fatigue) & LCF (low cycle fatigue) & also (ii) Creep. Which upon investigation by FE (finite element) modelling showed results that the maximum stress occurs at the tip, it indicates thermal expansion, centrifugal load & gas pressure during operation & crack propagation.

   G. Narendranath, S. Suresh analyzed [9] the result of gas forces namely tangential and axial which is constructed using velocity triangle by ANSYS. Material of blade is iron based super alloy. They have used finite element method for obtaining approximate results. They found that the thermal stress is less than the yield strength value.

3. MODELLING AND ANALYSIS

   The blade model profile is generated by using Solid Edge software. This model of turbine blade is then imported into ANSYS software. Meshing of the model is performed using SOLID 186 elements (since the element supports creep, stress stiffening, large deflection, and strain capabilities).

   The bottom edge is fixed and a pressure load of 3.06 MPa and speed is 10000 RPM are taken as boundary conditions along with varying temperatures (10000C and 20000C) for different Titanium alloys.

   Fig 1. Total Deformation in Ti6242 at 1000o C

   Fig 2. Total Deformation in Ti6242 at 2000o C

   Fig 3. Total Deformation in Ti6242S at 1000o C

   Fig 4. Total Deformation in Ti6242S at 2000o C

   Fig 5. Total Deformation in Alloy 832 at 1000o C

   Fig 6. Total Deformation in Alloy 832 at 2000o C

   Fig 7. Total Deformation in Alloy 685 at 1000o C

   Fig 8. Total Deformation in Alloy 685 at 2000o C

   Fig 9. Directional Deformation in Ti6242 at 1000o C

   Fig 10. Directional Deformation in Ti6242 at 2000o C

   Fig 11. Directional Deformation in Ti6242S at 1000o C

   Fig 12. Directional Deformation in Ti6242S at 2000o C

   Fig 13 Directional Deformation in Alloy 832 at 1000o C

   Fig 14. Directional Deformation in Alloy 832 at 2000o C

   Fig 15. Directional Deformation in Alloy 685 at 1000o C

   Fig 16. Directional Deformation in Alloy 685 at 2000o C

   Fig 17. von-Mises Deformation in Ti6242 at 1000o C

   Fig 18 von-Mises Deformation in Ti6242 at 2000o C

   Fig 19. von-Mises Deformation in Ti6242S at 1000o C

   Fig 20. von-Mises Deformation in Ti6242S at 2000o C

   Fig 21. von-Mises Deformation in Alloy 832 at 1000o C

   Fig 22. von-Mises Deformation in Alloy 832 at 2000o C

   Fig 23. von-Mises Deformation in Alloy 685 at 1000o C

   Fig 24. von-Mises Deformation in Alloy 685 at 2000o C

4. RESULTS AND DISCUSSION

   From the steady state thermal and static structural analysis of turbine blade the following results are obtained. The results are tabulated in Table I, II and Table III.

   TABLE I. TOTAL AND DIRECTIONAL DEFORMATION

   Material	Result For 1000°C		Result For 2000°C
   	Total Deformation (mm)	Directional Deformation (mm)	Total Deformati on (mm)	Directional Deformation (mm)
   Ti6242	11.408	1.5143	14.687	2.8012
   Ti6242S	11.12	1.3581	13.529	2.3438
   Alloy 832	11.761	1.6743	15.669	3.125
   Alloy 685	10.899	1.4991	14.266	2.7897

   TABLE II. VONMISES STRESS

   Material	von-Mises stress
   	Result For 1000°C		Result For 2000°C
   	Throughout the body (MPa)	At a point in Bottom Trailing Edge (MPa)	Throughout the body (MPa)	At a point in Bottom Trailing Edge (MPa)
   Ti6242	1.6671	6365.3	1.6774	13713
   Ti6242S	1.7251	5369.6	1.7308	10787
   Alloy 832	1.5773	6960.6	1.5924	15551
   Alloy 685	1.6367	6646.2	1.6411	14475

   TABLE III. HEAT FLUX (THERMAL ANALYSIS)

   Material	Static Thermal Analysis
   	Result For 1000°C		Result For 2000°C
   	Total Heat flux (W/mm2)	Directional Heat flux (W/mm2)	Total Heat flux (W/mm2)	Directional Heat flux (W/mm2)
   Ti6242	1.08E-11	5.62E-12	2.16E-11	1.13E-11
   Ti6242S	1.08E-11	5.67E-12	2.16E-11	1.13E-11
   Alloy 832	1.08E-11	5.63E-12	2.16E-11	1.13E-11
   Alloy 685	1.08E-11	5.63E-12	2.16E-11	1.13E-11

   Fig 25. Total Deformation at 1000o C

   Fig 26. Total Deformation at 2000o C

   Fig 27. Directional Deformation at 1000o C

   Fig 28. Directional Deformation at 2000o C

   Fig 29. von-Mises Stress throughout the body at 1000o C

   Fig 30. von-Mises Stress throughout the body at 2000o C

   Fig 31. von-Mises stress in bottom trailing edge at 1000o C

   Fig 32. von-Mises stress in bottom trailing edge at 2000o C

   From the above results, it is observed that, the fixed end exhibits maximum stress and deformation compared with the overall blade. From the above used materials Alloy 685 has the least deformation at 10000C and Ti6242S has the least deformation at 20000C (Fig. 1-16).

   It can be seen that for 10000C and 20000C, Alloy 685 and Ti 6242S respectively exhibit least stress as compared to other materials (Fig 17-24).

5. CONCLUSION

From the above study it can be observed that the bottom trailing edge of the blade is prone to failure. The top trailing edge of the blade exhibits large deformation as compared to overall blade. For the temperature range for 7500C-12500C, Alloy 685 is best suited and from temperature range of 12500C-22000C, Ti6242S is suited and can be used. It is also found that with the use of thermal barrier coatings the above materials will exhibit greater stability and longer life.

REFERENCES

1. G D Ujade And M B Bhambere Review Of Structural And Thermal Analysis Of Gas Turbine Blade, Ijmerr

2. Shreya Nair, Tanya Chhabra, Priyanka Verma, Shruti Mittal Steady State Structural Analysis Of High Pressure Gas Turbine Blade, Ijerr

3. Deepanraj And P. Lawrence, Theoretical Analysis Of Gas Turbine Blades By Finite Element Method, Journal Of The Institute Of Engineering, Vol. 8, No.1, Pp. 1-11.

4. Bhupendra E. Gajbhiye, Sachin V. Bhalerao, Amit G. Pdgelwar Fluid Flow Analysis And Velocity Distribution Along A Gas Turbine Blade Profile Using Cfd Technique And Tool,Ijirse

5. Yoshio Samaizu Perez Zuniga, June 2011, Design Of Axial Turbine And Thermodynamic Analysis And Testing Of K03 Turbocharger.

6. Chaitanya Krishna Patsa, Subhani Mohammed, Structural Analysis Of Super Alloy Gas Turbine Blade Using Fea, Ijert, Vol3 Issue 1,January 2014.

7. Cyrus B.Meher-Homji, George Gabriles, Gas Turbine Failures- Cause, Avoidance And Troubleshooting

8. Jianfuhou, Bryon J. Wicks, Ross A. Antoniou, An Investigation Of Fatigue Failures Of Turbine Blades In A Gas Turbine Engine By Mechanical Analysis, Engineering Failure Analysis 9 (2002) 201- 211.

9. G.Narendranath, S.Suresh, Thermal Analysis Of A Gas Turbine Rotor Blae By Using Ansys, Internaltional Journal Of Engineering Research And Applications, Vol. 2,Issue 5, September October 2012, Pp.2021-2027