Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13

STRUCTURAL ANALYSIS OF MICRO TURBINE BY USING CFD

1

Dr.R.Rajappan, 2K.Chandrasekar
1

Professor, 2PG Students

Department Of Mechanical Engineering, Mailam Engineering College, Mailam E-Mail: 1sssraj2k@gmail.com,2 2sekarsms25@gmail.com

ABSTRACT
A micro turbine can be used in UAV, refrigerator, generator; air drier. A micro turbine being small in size compared to large turbine has less weight which reflects on pressure ratio, low cost, easy maintenance In our project we are going to design and analyze the compressor blade and shaft of a micro turbine. The compressor of the micro turbine is analyzed with different number of blade, with different rotational speed of the shaft. Thus we consider an engine comprising of a single shaft compressor. The various type of impeller model are used in this with four blade, six blade, eight blade, ten blade are been taken in account.

1. INTRODUCTION.
Nowadays, the need of energy production to be used for either industrial or several transportations is in great demand. The type of power generation has become the major concern because of its widespread need. For the concern of recent time needs, the suitable power generation type is one which achieves a relatively better efficiency, low in cost, and satisfied the demanding criteria. For those needs the gas turbine system is the answer. Gas turbines are internal combustion engines that they use a rotating shaft or rotor instead of "reciprocating" in cylinders. It has the advantages of small dimensions, light weight, easy to be serviced (resulting to low maintenance cost), and most of all it can produce more power (relative to the power produced-to-weight ratio) and faster speed spin. They

became practical sixty years ago; today gas turbines are one of the keystone technologies of the civi Micro gas turbines have experienced a growing interest during the last decade. Their large energy density (W hr/kg) makes them attractive for portable power units as well as for propulsion of small airplanes (UAV). They are also of interest for distributed power generation in applications where heat and power generation can be combined. The need for high performance in both applications is at the origin worldwide interest and research on micro (a)objective of study: The objective of this study is to design a compressor shape for micro turbine and conduct stress analysis based on static loading condition to ascertain its structural integrity of shape under the loads experienced in its normal operation

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Scope of study: The project also includes the

dimensional design of the compressor (impeller and its shaft). The design, then, investigated by obtaining the load under various operation conditions, and then the analysis of the structures integrity using finite element method is conducted. It is expected that the project will provide the recommendation that can help to improve the performance of compressor design based on the previous analysis. Simple gas turbine: Gas turbine is the prime mover that uses gas or air as the working fluid to be use to move the turbine, the produced work is also use to drive the electric generator too. A simple gas turbine component consists of compressor, combustion chamber and the turbine as shown in the fig (1.1). Gas turbine deals with the Brayton Cycle for its work as its ideal work Micro turbine: The micro turbine took in place because of the emerging need of innovation Radialcurved blades(=90) - Oftenusedin compressor 1.8. CURVED BLADES: The Compressor has the vane shapes/curves to implement. The vane shapes are made to have the intended outlet velocities. The type of the vane shapes are as shown in the fig (1.6)

to the existing large gas turbine power plant, especially for the application of remote and limited area to be placed. In 1994, when a MIT turbine engineer named Alan Epstein found himself sitting in a jury pool and started to think about what it would take to build the smallest possible jet engine. Then conclusion made that in theory the device could be shrunk a lot. The idea was then started to make realization for a humungous application to appear (a) SHAFT CONSIDERATION: When it is going to design the components in gas turbine, it has to be known the parameters that act on them. For this project designation, the maximum or full power produced. The shaft to be II.DESIGN OF COMPRESSOR BLADE AND SHAFT

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used for generator; this is considered as the net power produced.

= outlet pressure, R = gas constant, = impeller tip speed at outlet diameter

(b)SHAFT POWER: The gas turbine (micro turbine) design here uses the single shaft that attached the compressor, turbine and the shaft for the generator use. So for the work of the shaft is the same, but the transmitted power (by deduction) is different through the used power for attached components along the shaft. For the power generated by gas turbine, 55% to 60% of the power is consumed by the compressor to work. By assuming it would be 60% (taking the greatest power consumed for bigger safety consideration) of the power consumed by compressor work, then the power produced is actually a 40% remaining power from the total shaft power produced by the gas turbine.

This characteristic will be used then for the various condition applied to the Compressor The inlet and outlet area of the impeller must have the same value. Thus the Blade tip width can be calculated as follows: Inducer inlet area = impeller outflow area [ ( [ b = 8.708 X b = 8.708 mm Calculation and assumptions are made for the shaftcompressor assembly; Here are the rough design properties: Shaft diameter = 20 mm r = 10 mm = 150 mm = m ] = ] = 0.15

(c). COMPRESSOR PROPERTIES: The compressor has its own characteristic to the ability of compression ratio. The Characteristic of Pressure Number () for the designated compressor is defined as:

Outer diameter of impeller 75 mm Inner diameter of impeller (

) = 75 mm

= 37.5

Impeller thickness attach to shaft (h) = 40 mm

Fig 3.2 Rough dimensions for shaft-compressor Where: = specific heat = inlet pressure assembly

= inlet temperature,

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III.COMPUTATIONAL FLUID DYNAMICS (CFD) Computational Fluid Dynamics (CFD) (a). STEPS IN CFD ANALYSIS: The CFD analysis involved structural

becomes an essential tool in almost every branch of fluid dynamics, from aerospace propulsion to weather prediction. CFD is commonly accepted as the numerical solution, by computational methods for the governing equations which describe fluid flow, the set of the Navier-Stokes equations, continuity and any

algorithm that can solve the fluid flow problems. To simplify the solution, the following steps are necessary on CFD analysis: Define the geometry system Creating the mesh that determines the boundary area and surfaces of the body so that the flow is in the corresponding boundary. Inputting the calculated pre-defined parameter of fluid dynamics in to the Program Run the simulation program. Getting the result of the simulation. Check and make necessary modification to all parameter or geometry to get the better result.

additional conservation equations, for example an energy concentration.

As a developing science, Computational Fluid Dynamics was given attention throughout the international community since the development of the digital computer.

The attraction of the subject is the desire to be able to model physical fluid phenomena that cannot be easily simulated or measured with a physical experiment. Secondly, the desire to be able to investigate physical fluid systems more cost effectively and more rapidly than with experimental procedures. Shaft diameter Impeller diameter Impeller diameter There has been considerable growth in the development and application of Computational Fluid Dynamics to fluid dynamics. In design and Impeller thickness to shaft Impeller outflow thickness Blade degree There is a considerable demand for Blade number /splitter # 10 /splitter (deg) 90 b(mm) 8.708 h(mm) 40 outer d2 150 inner ITEMS PARAMETER (unit) D(mm) d1 20 75 VALUE

development, CFD programs are now considered to be standard numerical tools, utilized within industry.

specialists in the subject, to apply and develop CFD methods throughout engineering companies and research organizations.

Table 4.1.Compressor Geometry Parameter

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4.3. MODEL: From the geometrical details and the dimensions calculated for the micro turbine

Table 4.2.CFD Parameter Analysis (Pre-solver) 4.5. CFD PROGRAM (FLOTRAN): The properties obtained previously, used in the input of flotran program. The additional properties added to run the program are as follows:

compressor blade in the previous chapter, the modeling of the same had been done. The modeling had been done in the CATIA V5 R17. The modeling had been carried out for four cases. The 4 cases are 4 blades, 6 blades, 8 blades & 10 blades

4.6. CFD ANALYSIS FOR DESIGNED CENTRIFUGAL COMPRESSOR 4.6.1. CFD ANALYSIS FOR 4 BLADES: The fig 4.2(a) is the Velocity contour obtained from ANSYS -FLUENT analysis done for 4-bladed Centrifugal compressor. The analysis had been carried out with a casing aro

4.4. PROPERTIES: PARAMETER(unit ITEMS ) VALUE 1.7894 Air viscosity Inlet pressure Mass flow rate Inlet air velocity(radial ) Outflow air velocity(radial ) Blade /splitter(speed ) red 6283.187 V The figure infers that the maximum velocity around the blade is found to 1179m/s and the minimum velocity experienced is 393.121m/s. Fig 4.2(a).VELOCITY CONTOUR OF 4-BLADE V (m ) 85.860 (kg ) 0.5057 und the model, to neglect the environmental effect over the blade as in the real time situation. (N/mm2) 1.01325

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The fig 4.2(d) is the Pressure contour obtained from ANSYS -FLUENT analysis done for 6-bladed Centrifugal compressor. The analysis had been carried out with a casing around the model, to neglect the environmental effect over the blade as in the real time situation. The figure infers that the maximum pressure around the blade is found to 7.482N/mm2

. CFD ANALYSIS FOR 6 BLADES The fig 4.2(C) is the Velocity contour obtained from ANSYS -FLUENT analysis done for 6-bladed Centrifugal compressor. The analysis had been carried out with a casing around the model, to neglect the environmental effect over the blade as in the real time situation. The figure infers that the maximum velocity around the blade is found to 1986m/s. Fig 4.2(d).PRESSURE CONTOUR OF 6-BLADE CENTRIFUGAL COMPRESSOR

STRUCTURAL ANALYSIS &FINITE ELEMENT METHOD The Finite Element Method (FEM) becomes an important for the numerical solution of some engineering problems. The advantages of computer technology can solve the complex problems in to relatively easy. Thus several alternative

configurations can be figured and tested on computer before the first prototype is built Fig 4.2(c).VELOCITY CONTOUR OF 6-BLADE CENTRIFUGAL COMPRESSOR

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Compressor Efficiency mainly depends on the Compressor blades. Therefore, good

improvement in the compressor blade is mandatory. To achieve high Compressor efficiency, we made a suggestion of increasing the number of blades in the compressor. In order to find the optimized number of blades we worked on four different cases (4, 6, 8 and 10 blades). The analysis had been carried out for all the four cases in ANSYS FLOTRAN and the values of displacement and stress have been found for all cases. Comparing the stress and

displacement values obtained for all the four cases, we could infer that the ten blade-centrifugal compressors have very least displacement and stress values. And the reductions in the value for the ten blade case, compared to the existing case were nearly more than 10%. Thus, we tell that the centrifugal compressor with ten blade would be the apt one to give very high compressor efficiency and thereby very high engine efficiency too.

REFERENCES:

[1] Fred Hap good, Micro turbine,6 ed page(40-86) (1993) vol -3 [2] Jan Peirs, Dominiek Reynaerts, Filip Verplaetsen, Michael Poesen, Pieterja Made Renier by (2002). A

Microturbine

Micro-Electro-

DischargeMachining. The 16th European Conference on Solid-State Transducers.September 15-18. Prague, CONCLUSION: Czech Republic: EC, 790-793. Vol-7

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[3] Colin Rodgers, James Watts,Dan Thoren, Ken Nichols and Richard Brent. Micro turbines, In: CRC Press LLC.Gas Turbine Engineering. 2001. [4] The American Society of Mechanical Engineers. Turbines on a Dime. StevenAshley. 1997. [5] Meherwan P. Boyce. Gas Turbine Engineering Handbook. 2nd ed. Houston, Texas: Gulf

Professional. 2002. [6] Jack D. Mattingly. Elements of Gas Turbine Propulsion. Seattle,Washington: McGraw-Hill. 1996.

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