International Journal of Advances in Science and Technology, Vol. 4, No.
1, 2012
Analysis of Gas Turbine Blades with materials N155 & INCONEL718
[Link] 1, [Link] Rao2,[Link] Babu3,[Link] rao4
1
Department of Mechanical Engineering, GMRIT, Srikakulam, AP, India anilnatas@[Link] 2 Department of Mechanical Engineering, JNTU, Kakinada, AP, India venkatmtechmd@[Link] 3 Department of Mechanical Engineering, GMRIT, Srikakulam, AP, India rameshbabu.p@[Link] 4 Department of Mechanical Engineering, GMRIT, Srikakulam, AP, India umamaheswararao.r@[Link]
Abstract
The analysis of Stress values that are produced while the turbine is running are the key factors of study while designing the gas turbines. A gas turbine Rotating system is loaded with time by the changes in stress levels as a result of start up and shut down procedures. Hot section blades typically fail because of creep, oxidation, low cycle fatigue and High cycle fatigue. Therefore this report has primarily focused on heat transfer characteristics, centrifugal and thermal stresses in the blade. The maximum stresses obtained from different analysis by using innovative high heat resistant material N155 are found to be within the yield strength of the material. Results are obtained interms of thermal stresses,Vonmisses stress are compared with high heat resistant material INCONEL [Link] of all operating conditions the blade with material INCONEL 718 is expected to perform well .The object is to improve the life and efficiency of future generation of engines. Key words: Axial flow gas turbine, Centrifugal Forces, Convective Heat Transfer Coefficients, FEM.
1. Introduction
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 the several rings of fixed and moving blades to get a high pressure of order 4 to 10 bar of working fluid which is essential for expansion. The pressure and Speed required at the inlet is very high so a centrifugal or axial compressor is required at the inlet. 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. The Finite Element Method [1] has now become a very important tool of engineering analysis. In the modern technological environment the conventional methodology of design cannot compete with the modern trends of Computer Aided Engineering (CAE) techniques. The constant search for new innovative design packages have been developed by software professional and technologist.
Special Issue
Page 46 of 99
ISSN 2229 5216
International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012
2. Nomenclature
P Far Fc Ft E I U W Ux Uy [K] N E T C1 C2 A1 K M Re Nu Pr Load Axial force Centrifugal force Tangential force Coefficient of thermal expansion Youngs Modulus Moment Of Inertia Internal strain Energy External work done Displacement along X-direction Displacement along Y-direction Poissons ratio Stress Stiffness matrix RPM of turbine Strain Torque transmitted by shaft Approach Velocity Theoretical exit velocity Absolute air velocity Thermal conductivity Total mass of rotor blade Reynolds Number Nusselt number Prandtl number
3. Details and Design Criteria
3.1.1 Material The turbine blade is simultaneously subjected to high temperature gradients and centrifugal forces that require a unique blend of material properties such as high strength. The materials chosen for the application are N155 and INCONEL 718 .INCONEL 718 is niobium, chromium and Nickel alloy .N155 is Nickel based Super alloy .INCONEL 718 have high strength at elevated temperatures, corrosion resistance and the relative ease of manufacturing. And N155 has high temperature properties and do not depend upon Age hardening it has good ductility, strength, corrosion resistance and excellent oxidation. 3.1.2 Blade Details The turbine blade dimensions are as follows: Diameter of blade midspan D=1.3085m Blade height h=117mm Base I_Section =49mm27mm Speed of rotor is 3,426 rpm 3.1.3 Mechanical properties The physical properties of the materials such as Elastic modulus, Poisson ratio, Coefficient of thermal expansion vary with the temperature. Accurate stress calculations would therefore require accurate data of the elastic properties of the material.
Special Issue
Page 47 of 99
ISSN 2229 5216
International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012
TABLE1. Mechanical properties of materials N155 and INCONEL718 at 839.5310C Property Unit N155 at 839.5310C
143 550 310 20 5.45 435 8249
INCONEL718 at839.5310C
170.6 1067 890 19.73 14.76 586.2 8220
E K Cp
Gpa Mpa Mpa W/mk 106/0C J/KgK Kg/m3
3.1.4 Temperature gradient The blades are heated by primary flow of gases .The temperature of the combustion gas at nozzle entry is fixed at [Link] the turbine used here is impulse type ,most of the temperature drop takes place within the nozzle is around 735.1620C
4. Finite Element Modeling
The finite Element model used in this analysis. The time steps are varied and the results are stored in load step [Link] allows the thermal analysis to be conducted first and then the results are automatically transferred to the structure model. For the finite element representation of a problem the nodal values of the field variable become the unknowns. Once these unknowns are found, the interpolation functions define the field variable throughout the assemblage of elements. Clearly, the nature of the solution and the degree of approximation depend not only on the size and number of the elements used but also on the interpolation functions selected. As one would expect, we cannot choose functions arbitrarily, because certain compatibility conditions should be satisfied. Often functions are chosen so that the field variable or its derivatives are continuous across adjoining element boundaries. These are applied to the formulation of different kinds of elements. Thus far we have briefly discussed the concept of modeling an arbitrarily shaped solution region with an assemblage of discrete elements, and we have pointed out that interpolation functions must be defined for each element. We have not yet mentioned, however, an important feature of the finite element method that sets it apart from other numerical methods. This feature is the ability to formulate solutions for individual elements before putting them together to represent the entire problem. This means, for example, that if we are treating a problem in stress analysis, we find the forcedisplacement or stiffness characteristics of each individual element and then assemble the elements to find the stiffness of the whole structure. In essence, a complex problem reduces to considering a series of greatly simplified problems. Another advantage of the finite element method is the variety of ways in which one can formulate the properties of individual elements.
Special Issue
Page 48 of 99
ISSN 2229 5216
International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012
5. Structural Analysis
Assumptions 1. The material is completely elastic at the stress distribution induced by the centrifugal and thermal effects. 2. Stress is directly proportional to strain. 3. All the variables of material properties are symmetric about the axes.
6. Results and Discussions
6.1.1 Structural analysis The von misses stresses are obtained as shown in the fig from figure, it is observed that the maximum von mises stress is 296.177, this value is less than the yield strength value. The maximum deformation is [Link] for material INCONEL the maximum deformation is [Link] based on these values the structural analysis for the design of turbine blade with material INCONEL is safe compared to material N155, on the strength criteria and rigidity criteria.
[Link] Analysis of Blade with N155 6.1.2 Thermal Analysis
[Link] Analysis of Blade with INCONEL718
For the thermal analysis for both the materials INCONEL and N155 comparatively deformation is less.
[Link] Analysis of Blade with N155
[Link] Analysis of Blade with INCONEL718
Special Issue
Page 49 of 99
ISSN 2229 5216
International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012
6.1.3Modal Analysis
[Link] Analysis of Blade with N155
[Link] Analysis of Blade with INCONEL718
From the observations we see that the Modal Analysis of Turbine Blades using material N155 varies from 0 to 0.013793,for INCONEL varies from 0 to .003879and maximum deformation of blade at Frequencies 20.122 to 102.58 for materials N155 and INCONEL is 0.013793 and 0.003879mm so from the above the material INCONEL performs well .
7. Conclusions
The results and conclusions are presented for a study concerning the durability problems experienced with gas turbine engines. The investigation encompassed the design and failure history of hot gas path components in the engines. The maximum operational Vonmises Stresses are within the yield strength of the material but the deformation is comparatively better for material INCONEL 718. The present study has conducted detailed heat transfer analysis on the blade using different materials. This study has primarily focused on the centrifugal and thermal stresses arising in the blade for two materials. From the results obtained it is noted that the values are in tolerance limit for material INCONEL 718
8. References
[1] [Link] The Finite Element method in Engineering, BH Publications, New Delhi, 3rd Edition,pp.166555,1999. [2] [Link] The Finite Element method in Engineering Science, Tata McGraw Hill, 2nd Edition,pp312515,1992. [3] Jean-Claude Sabonnadiere and Jean-Louis Coulomb Finite Element method in CAD, North Oxford University,1982.
Special Issue
Page 50 of 99
ISSN 2229 5216