A Scientific Approach to the Process Development Bonded Attachments for High-Speed Rotor Application

2000 ◽  
Vol 124 (1) ◽  
pp. 190-195
Author(s):  
R. R. Cairo ◽  
K. A. Sargent
Keyword(s):  
High Speed ◽  
Process Development ◽  
Dead Load ◽  
Stress Concentrations ◽  
Blade Loading ◽  
Pressure Profiles ◽  
Scientific Approach ◽  
Deformable Bodies ◽  
Bond Plane ◽  
Tool Stresses

The quest for increased work per stage of compression to reduce overall gas turbine engine system cost has placed extreme demands on the high-pressure turbine (HPT) system. As an example, the HPT is required to operate at unprecedented levels of AN2 (the product of turbine annulus area and mechanical speed squared) to enable compressor performance goals to be met. The typical approach of mechanically attaching blades via firtree or dovetail configured mechanical attachments, limits rotor speed because of the life limiting broach slots (stress concentrators) in the disk rim. Exacerbating this problem is the fact that the disk lugs, which react the blade loading, impose a dead load. Higher disk speed results in higher blade loading requiring a deeper or wider lug to support the blade. This in turn results in a wider disk bore to support the deeper, dead load lug region. The dilemma is that higher speed results in larger stress concentrations at the rim and a wider disk bore to support the added parasitic rim load. The answer to this dilemma lies in creating an integrally bladed rotor (IBR) in which the blades are integral with the disk. Since typically, for an HPT, the blades are single crystal and the disk equiaxed nickel alloys, the IBR design suggested precludes absolute machining as the fabrication approach. A solution lies in metallurgically bonding the blades to the disk rim. Bonded airfoil attachments have the potential to increase AN2 and component life by 9–10 percent by eliminating broach induced stress concentrations as noted. Moreover, bonded attachments can reduce external rim loading by upward of 15 percent with a corresponding reduction in disk weight. The key to the solution is a controlled, economical process to concurrently join a full complement of HPT blades in a repeatable manner. This paper discusses how a scientific approach and creative design practice can lead to such a process. Three alternative tooling concepts, and one universal tool that allows independent use of two of these concepts, were developed. Tool stresses and deflections, tool load paths, and bond pressure profiles were all quantified through ANSYS finite element analyses and closed-form analytical solutions. Prior experience has shown that joint strength is sensitive to the bond pressure level. Therefore, the tool materials and geometry were iterated upon until the pressure applied to the blade bond plane was as uniform as possible. Since absolute uniformity is elusive when deformable bodies are part of the bond load train, accurately determining the maximum and minimum bond plane pressure is absolutely essential for subsequent joint characterization and design allowable determination. This allows localized working stresses in the designed attachment to be compared to specific, bond pressure driven, allowable strengths rather than an average strength. This paper will show how applying a scientific approach to the development of a critical technology process can reduce both the cost and risk of process development.

A Scientific Approach to the Process Development of Bonded Attachments for High Speed Rotor Application

2000 ◽  
Author(s):  
Ronald R. Cairo ◽  
Kathleen A. Sargent
Keyword(s):  
High Speed ◽  
Process Development ◽  
Dead Load ◽  
Stress Concentrations ◽  
Blade Loading ◽  
Pressure Profiles ◽  
Scientific Approach ◽  
Deformable Bodies ◽  
Bond Plane ◽  
Tool Stresses

The quest for increased work per stage of compression to reduce overall gas turbine engine system cost has placed extreme demands on the high-pressure turbine (HPT) system. As an example, the HPT is required to operate at unprecedented levels of AN2 (the product of turbine annulus area and mechanical speed squared) to enable compressor performance goals to be met. The typical approach of mechanically attaching blades via firtree or dovetail configured mechanical attachments, limits rotor speed because of the life limiting broach slots (stress concentrators) in the disk rim. Exacerbating this problem is the fact that the disk lugs, which react the blade loading, impose a dead load. Higher disk speed results in higher blade loading requiring a deeper or wider lug to support the blade. This in turn results in a wider disk bore to support the deeper, dead load lug region. The dilemma is that higher speed results in larger stress concentrations at the rim and a wider disk bore to support the added parasitic rim load. The answer to this dilemma lies in creating an Integrally Bladed Rotor (IBR) in which the blades are integral with the disk. Since typically, for an HPT, the blades are single crystal and the disk equiaxed nickel alloys, the IBR design suggested precludes absolute machining as the fabrication approach. A solution lies in metallurgically bonding the blades to the disk rim. Bonded airfoil attachments have the potential to increase AN2 and component life by 9–10% by eliminating broach induced stress concentrations as noted. Moreover, bonded attachments can reduce external rim loading by upward of 15% with a corresponding reduction in disk weight. The key to the solution is a controlled, economical process to concurrently join a full complement of HPT blades in a repeatable manner. This paper discusses how a scientific approach and creative design practice can lead to such a process. Three alternative tooling concepts, and one universal tool that allows independent use of two of these concepts, were developed. Tool stresses and deflections, tool load paths, and bond pressure profiles were all quantified through ANSYS Finite Element Analyses and closed form analytical solutions. Prior experience has shown that joint strength is sensitive to the bond pressure level. Therefore, the tool materials and geometry were iterated upon until the pressure applied to the blade bond plane was as uniform as possible. Since absolute uniformity is elusive when deformable bodies are part of the bond load train, accurately determining the maximum and minimum bond plane pressure is absolutely essential for subsequent joint characterization and design allowable determination. This allows localized working stresses in the designed attachment to be compared to specific, bond pressure driven, allowable strengths rather than an average strength. This paper will show how applying a scientific approach to the development of a critical technology process can reduce both the cost and risk of process development.

A New Shaft Coupling Design for a High-Speed Rotor Wheel

1995 ◽  
Author(s):  
Tibor Kiss ◽  
Wing-Fai Ng ◽  
Larry D. Mitchell
Keyword(s):  
High Speed ◽  
High Stress ◽  
Critical Issue ◽  
Working Environment ◽  
Outer Diameter ◽  
Stress Concentrations ◽  
Coupling Region ◽  
Rotor Wheel ◽  
High Stress Concentration ◽  
Safety Margins

Abstract A high-speed rotor wheel for a wind-tunnel experiment has been designed. The rotor wheel was similar to one in an axial turbine, except that slender bars replaced the blades. The main parameters of the rotor wheel were an outer diameter of 10“, a maximum rotational speed of 24,000 RPM and a maximum transferred torque of 64 lb-ft. Due to the working environment, the rotor had to be designed with high safety margins. The coupling of the rotor wheel with the shaft was found to be the most critical issue, because of the high stress concentration factors associated with the conventional coupling methods. The efforts to reduce the stress concentrations resulted in an advanced coupling design which is the main subject of the present paper. This new design was a special key coupling in which six dowel pins were used for keys. The key slots, now pin-grooves, were placed in bosses on the inner surface of the hub. The hub of the rotor wheel was relatively long, which allowed for applying the coupling near the end faces of the hub, that is, away from the highly loaded centerplane. The long hub resulted in low radial expansion in the coupling region. Therefore, solid contact between the shaft and the hub could be maintained for all working conditions. To develop and verify the design ideas, stress and deformation analyses were carried out using quasi-two-dimensional finite element models. An overall safety factor of 3.7 resulted. The rotor has been built and successfully accelerated over the design speed in a spin test pit.

Simulation of Multi-Stage Compressor at Off-Design Conditions

2017 ◽  
Author(s):  
Feng Wang ◽  
Mauro Carnevale ◽  
Luca di Mare ◽  
Simon Gallimore
Keyword(s):  
Mass Flow ◽  
High Speed ◽  
Eddy Viscosity ◽  
Turbulence Models ◽  
Viscosity Model ◽  
Eddy Viscosity Model ◽  
Multi Stage ◽  
Pressure Profiles ◽  
Non Linear ◽  
The Right

Computational Fluid Dynamics (CFD) has been widely used for compressor design, yet the prediction of performance and stage matching for multi-stage, high-speed machines remain challenging. This paper presents the authors’ effort to improve the reliability of CFD in multistage compressor simulations. The endwall features (e.g. blade fillet and shape of the platform edge) are meshed with minimal approximations. Turbulence models with linear and non-linear eddy viscosity models are assessed. The non-linear eddy viscosity model predicts a higher production of turbulent kinetic energy in the passages, especially close to the endwall region. This results in a more accurate prediction of the choked mass flow and the shape of total pressure profiles close to the hub. The non-linear viscosity model generally shows an improvement on its linear counterparts based on the comparisons with the rig data. For geometrical details, truncated fillet leads to thicker boundary layer on the fillet and reduced mass flow and efficiency. Shroud cavities are found to be essential to predict the right blockage and the flow details close to the hub. At the part speed the computations without the shroud cavities fail to predict the major flow features in the passage and this leads to inaccurate predictions of massflow and shapes of the compressor characteristic. The paper demonstrates that an accurate representation of the endwall geometry and an effective turbulence model, together with a good quality and sufficiently refined grid result in a credible prediction of compressor matching and performance with steady state mixing planes.

scholarly journals Effects of a Single Blade Incidence Angle Offset on Adjacent Blades in a Linear Cascade

Processes ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 1974
Author(s):  
Jiří Fürst ◽  
Martin Lasota ◽  
Jan Lepicovsky ◽  
Josef Musil ◽  
Jan Pech ◽  
...  
Keyword(s):  
High Speed ◽  
Static Pressure ◽  
Incidence Angle ◽  
Blade Loading ◽  
Linear Cascade ◽  
Pressure Distributions ◽  
Blade Cascade ◽  
Loading Function ◽  
Stationary Approach ◽  
Dimensional Section

The paper presents a numerical and experimental investigation of the effect of incindence angle offset in a two-dimensional section of a flat blade cascade in a high-speed wind tunnel. The aim of the current work is tp determine the aerodynamic excitation forces and approximation of the unsteady blade-loading function using a quasi-stationary approach. The numerical simulations were performed with an in-house finite-volume code built on the top of the OpenFOAM framework. The experimental data were acquired for regimes corresponding to the numerical setup. The comparison of the computational and experimental results is shown for the static pressure distributions on three blades and upstream and downstream of the cascade. The plot of the aerodynamic moments acting on all five blades shows that the adjacent blades are significantly influenced by the angular offset of the middle blade.

Web-Based, Interactive Laboratory Experiment in Turbomachine Aerodynamics

2009 ◽  
Vol 132 (1) ◽  
Author(s):  
Nalin Navarathna ◽  
Vitalij Fedulov ◽  
Andrew Martin ◽  
Torsten Fransson
Keyword(s):  
High Speed ◽  
Communication Technologies ◽  
Web Based ◽  
Laboratory Exercise ◽  
Pressure Profiles ◽  
Laboratory Facility ◽  
Stepper Motors ◽  
Loss Coefficients ◽  
And Control ◽  
Local Laboratory

Remote laboratory exercises are gaining popularity due to advances in communication technologies along with the need to provide realistic yet flexible educational tools for tomorrow’s engineers. Laboratory exercises in turbomachinery aerodynamics generally involve substantial equipment in both size and power, so the development of remotely controlled facilities has perhaps not occurred as quickly as in other fields. This paper presents an overview of a new interactive laboratory exercise involving aerodynamics in a linear cascade of stator blades. The laboratory facility consists of a high-speed fan that delivers a maximum of 2.5 kg/s of air to the cascade. Traversing pneumatic probes are used to determine pressure profiles at upstream and downstream locations, and loss coefficients are later computed. Newly added equipment includes cameras, stepper motors, and a data acquisition and control system for remote operation. This paper presents the laboratory facility in more detail and includes discussions related to user interface issues, the development of a virtual laboratory exercise as a complement to experiments, and comparative evaluation of virtual, remote, and local laboratory exercises.

Influences of Obstacles Installed in the Container on the Superheated Liquid Boiling

2012 ◽  
Vol 429 ◽  
pp. 62-66 ◽  
Author(s):  
Si Ning Chen
Keyword(s):  
Storage Tank ◽  
High Speed ◽  
Process Development ◽  
Control Measures ◽  
Movement Speed ◽  
Superheated Liquid ◽  
Two Phase ◽  
Microscopic Mechanism ◽  
Boiling Process ◽  
And Control

During the accident mechanism investigation of Boiling Liquid Expanding Vapor Explosion (BLEVE), numerous dada shows that overheated liquid explosive boiling is the main reason and driving force to cause accidents. Research on the micro-process of overheated liquid instant boiling in BLEVE as well as the microscopic mechanism to influence this process development under different device conditions is favorable to seek the preventive and control measures for this accident. In this paper, regarding the mesh obstacle provided inside the storage tank, high-speed camera technology has been utilized to shoot the boiling process during continuous leakage of the storage tank, and the influence of the obstacle on the overheated liquid boiling has been tested and analyzed. It is found out that the boiling process of overheated liquid has been delayed. When the bubbles are rising, the growth process has been suppressed, after passing the obstacle, the movement speed and volume has been decreased, and the upward expansion speed of two-phase flow has also been decreased.

Size Effects in Cutting With a Diamond-Coated Tool

2011 ◽  
Author(s):  
Feng Qin ◽  
Xibing Gong ◽  
Kevin Chou
Keyword(s):  
Residual Stresses ◽  
Size Effect ◽  
Normal Stress ◽  
High Speed ◽  
Chip Thickness ◽  
Tool Geometry ◽  
Uncut Chip Thickness ◽  
Edge Radius ◽  
Coated Tool ◽  
Tool Stresses

In machining using a diamond-coated tool, the tool geometry and process parameters have compound effects on the thermal and mechanical states in the tools. For example, decreasing the edge radius tends to increase deposition-induced residual stresses at the tool edge interface. Moreover, changing the uncut chip thickness to a small-value range, comparable or smaller than the edge radius, will involve the so-called size effect. In this study, a developed 2D cutting simulation that incorporates deposition residual stresses was applied to evaluate the size effect, at different cutting speeds, on the tool stresses, tool temperatures, specific cutting energy as well as the interface stresses around a cutting edge. The size effect on the radial normal stress is more noticeable at a low speed. In particular, a large uncut chip thickness has a substantially lower stress. On the other hand, the size effect on the circumferential normal stress is more noticeable at a high speed. At a small uncut chip thickness, the stress is largely compressive.

Visualization of Supercritical Carbon Dioxide Flow Through a Converging-Diverging Nozzle

2019 ◽  
Author(s):  
Chang Hyeon Lim ◽  
Gokul Pathikonda ◽  
Sandeep Pidaparti ◽  
Devesh Ranjan
Keyword(s):  
Carbon Dioxide ◽  
Supercritical Carbon Dioxide ◽  
Critical Point ◽  
High Speed ◽  
Operating Conditions ◽  
Higher Plant ◽  
Two Phase ◽  
Pressure Profiles ◽  
Flow Through ◽  
Supercritical Carbon

Abstract Supercritical carbon dioxide (sCO2) power cycles have the potential to offer a higher plant efficiency than the traditional Rankine superheated/supercritical steam cycle or Helium Brayton cycles. The most attractive characteristic of sCO2 is that the fluid density is high near the critical point, allowing compressors to consume less power than conventional gas Brayton cycles and maintain a smaller turbomachinery size. Despite these advantages, there still exist unsolved challenges in design and operation of sCO2 compressors near the critical point. Drastic changes in fluid properties near the critical point and the high compressibility of the fluid pose several challenges. Operating a sCO2 compressor near the critical point has potential to produce two phase flow, which can be detrimental to turbomachinery performance. To mimic the expanding regions of compressor blades, flow through a converging-diverging nozzle is investigated. Pressure profiles along the nozzle are recorded and presented for operating conditions near the critical point. Using high speed shadowgraph images, onset and growth of condensation is captured along the nozzle. Pressure profiles were calculated using a one-dimensional homogeneous equilibrium model and compared with experimental data.

scholarly journals A Comprehensive Review of Integrated Hall Effects in Macro-, Micro-, Nanoscales, and Quantum Devices

Sensors ◽  
2020 ◽  
Vol 20 (15) ◽  
pp. 4163
Author(s):  
Avi Karsenty
Keyword(s):  
Hall Effect ◽  
High Speed ◽  
Review Paper ◽  
Process Development ◽  
Analytical Models ◽  
Nanoscale Devices ◽  
Comprehensive Review ◽  
Complex Design ◽  
Hall Effects

A comprehensive review of the main existing devices, based on the classic and new related Hall Effects is hereby presented. The review is divided into sub-categories presenting existing macro-, micro-, nanoscales, and quantum-based components and circuitry applications. Since Hall Effect-based devices use current and magnetic field as an input and voltage as output. researchers and engineers looked for decades to take advantage and integrate these devices into tiny circuitry, aiming to enable new functions such as high-speed switches, in particular at the nanoscale technology. This review paper presents not only an historical overview of past endeavors, but also the remaining challenges to overcome. As part of these trials, one can mention complex design, fabrication, and characterization of smart nanoscale devices such as sensors and amplifiers, towards the next generations of circuitry and modules in nanotechnology. When compared to previous domain-limited text books, specialized technical manuals and focused scientific reviews, all published several decades ago, this up-to-date review paper presents important advantages and novelties: Large coverage of all domains and applications, clear orientation to the nanoscale dimensions, extended bibliography of almost one hundred fifty recent references, review of selected analytical models, summary tables and phenomena schematics. Moreover, the review includes a lateral examination of the integrated Hall Effect per sub-classification of subjects. Among others, the following sub-reviews are presented: Main existing macro/micro/nanoscale devices, materials and elements used for the fabrication, analytical models, numerical complementary models and tools used for simulations, and technological challenges to overcome in order to implement the effect in nanotechnology. Such an up-to-date review may serve the scientific community as a basis for novel research oriented to new nanoscale devices, modules, and Process Development Kit (PDK) markets.

Simulation of Multistage Compressor at Off-Design Conditions

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Feng Wang ◽  
Mauro Carnevale ◽  
Luca di Mare ◽  
Simon Gallimore
Keyword(s):  
Mass Flow ◽  
High Speed ◽  
Eddy Viscosity ◽  
Turbulence Models ◽  
Viscosity Model ◽  
Eddy Viscosity Model ◽  
Pressure Profiles ◽  
Multistage Compressor ◽  
Stage Matching ◽  
The Right

Computational fluid dynamics (CFD) has been widely used for compressor design, yet the prediction of performance and stage matching for multistage, high-speed machines remains challenging. This paper presents the authors' effort to improve the reliability of CFD in multistage compressor simulations. The endwall features (e.g., blade filet and shape of the platform edge) are meshed with minimal approximations. Turbulence models with linear and nonlinear eddy viscosity models are assessed. The nonlinear eddy viscosity model predicts a higher production of turbulent kinetic energy in the passages, especially close to the endwall region. This results in a more accurate prediction of the choked mass flow and the shape of total pressure profiles close to the hub. The nonlinear viscosity model generally shows an improvement on its linear counterparts based on the comparisons with the rig data. For geometrical details, truncated filet leads to thicker boundary layer on the filet and reduced mass flow and efficiency. Shroud cavities are found to be essential to predict the right blockage and the flow details close to the hub. At the part speed, the computations without the shroud cavities fail to predict the major flow features in the passage, and this leads to inaccurate predictions of mass flow and shapes of the compressor characteristic. The paper demonstrates that an accurate representation of the endwall geometry and an effective turbulence model, together with a good quality and sufficiently refined grid, result in a credible prediction of compressor matching and performance with steady-state mixing planes.

Sign in / Sign up

Export Citation Format

Share Document