CHAPTER 1

INTRODUCTION
1.1 GAS TURBINE ENGINE
Gas turbine engine is the most commonly used type of engine in aircrafts.
These engines are classified into many types depending on its design and
operation. Its operation is based on Baryton cycle. The key components of gas
turbine engine are inlet, compressor, combustor, turbine, and nozzle. It uses air
as its working fluid.
1.2 OPERATING PRINCIPLE
The atmospheric air with low pressure and temperature enters through the
inlet section which is known as ram air or bleeds air. The air then enters into the
compressor region. The compressor consists of serious of blades such as rotors
(moving blades) and stators (stationary blades) which compresses the air and
increases its pressure. The high pressure air from the compressor gets mixed
with the fuel in the combustor or combustion chamber the next section of the
engine. The fuel is injected from the injectors present inside the walls of the
combustion chamber. Then the mixture gets ignited to produce high temperature
gas. The gas comes out through the nozzle or exhaust which is diverging section
which helps to decrease the pressure and increase the velocity as the pressure
and velocity are inversely proportional. The velocity exhaust from the nozzle
produces thrust to give propulsive power to the aircraft. Between the combustor
and the nozzle a turbine is present which thought not involved in the process but
helps to drive the compressor with a rotating shaft which it connected to the
compressor from the turbine. The shaft rotates when the high pressure and high
temperature gas from the combustor enter into the turbine section i.e, by
transformation of enthalpy. As like the compressor, turbine also consists of
blades which pushes the air into the nozzle.

FUEL
COMBUSTOR

WORK OUT

COMPRESSO
R

TURBINE

FRESH AIR

EXHAUST GASES

Fig 1.1 Schematic diagram of gas turbine engine

1.3 FUNCTIONS OF TURBINE

Gas turbines can be used to produce torque (by the rotating shaft), thrust
(by high speed gas exhaust), or both in combination. In the first case, as in the
steam turbine, the mechanical work delivered by the shaft is merely a
transformation of enthalpy (pressure) of the high temperature and pressure gas.
Part of the shaft work is used to drive the compressor through an internal
mechanism. This form of the gas turbine is used mainly for electric power
generation and as power plants for vehicles such as tanks and even cars. An
average size gas turbine produces shaft rotation rates as high as 10,000 RPM,
while smaller turbines may produce 5 times as much. In the second case, the
high pressure gas is directed through a converging nozzle to increase velocity,
and the thrust is generated by the exhaust gas. This type of gas turbine is often
called Jet engine or turbojet engine, which powers the military fighter aircraft.
The combination of both thrust and work generation is used in turboprop
engines, where shaft work is used to drive a propeller.

1.4 TURBINE BLADE FAILURE:

The service life of critical aerospace components is governed by the
modes of degradation and failure such as: fatigue, fracture, yielding, creep,
corrosion, erosion, wear, etc. In that fatigue is the main cause for turbine blade
failure. Fatigue failure is related to repeat cycling of the load on a structural
member. The fatigue life of a structural member i.e. the number of load cycles it
can survive is in general determined by the magnitude of the stress cycles.
1.5 TYPES OF FATIGUE FAILURES
1.5.1 High Cycle Fatigue:
When the fatigue occurs above 103 cycles (usually 104 or more), it is
called high cycle fatigue. The material is subjected to lower loads, normally less
than 2/33 of the yield stress the deformation will be in elastic range. Then
fatigue life will be high cycle (103-106).
1.5.2 Low Cycle Fatigue:
The S-N curve estimate the service life of materials above 103 (often
>104) cycles in nature. The corresponding stress levels are usually below 2/3 of
the yielding stress. The low cycle fatigue model, on the other hand, it is made
for 104 and below that. The stress level usually steps into plastic range.
1.6 S-N curves:
The S-N curve is the basic method presenting the fatigue failure in high
cycles (N > 105) which implies the stress level is relatively low and the
deformation occurs in elastic range.
The S-N curve for a specific material is the curve of nominal stress S (y axis)
against the number of cycles to failure N(x axis). A log scale is almost always
used for N. The stress is usually nominal stress and is no adjustment for stress
concentration. The curve is usually obtained one by reversed bending
experiments with zero mean stress.
3

The S-N curve of 1045 steel and 2014-T6 aluminium alloy is enclosed
below to represent two typical S-N curves of metal materials.

Fig 1.2 Schematic diagram of S-N Curve

CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
The complexity while analyzing the low cycle fatigue and high cycle
fatigue in Gas turbine blades can be minimized in many ways that can be
explained in below followed survey.
2.2 SUMMARY
[1]

Aarash Rahman (2013) used different failure mechanisms; resonant

vibration of blades has a major role and therefore is the subject of many recent
research works. Therefore, in this paper, modal analysis of a first stage blade in
ALSTOM gas turbine is investigated and natural frequencies and vibration
modes of blade are found in various conditions. For this purpose, a cloud -point
model of a gas turbine blade has been created using 3D Laser Digitizer. Then
the numerical calculation by finite element method using ANSYS software
based on experimental test conditions is utilized and Experimental natural
frequencies have been obtained. The results show acceptable agreement
between the experimental and FEM results.

[2]

Dianyin Hu (2013) focused on a crack growth life assessment method for a

turbine component under high low combined cycle fatigue (HLCCF) loading
through experimental and numerical methods. Crack growth tests under HLCCF
loading on five full scale turbine components, attached to actual turbine discs,
were conducted at elevated temperature by using a Ferris wheel combined
fatigue system to simulate the stress under HLCCF loading and temperature
distributions.

[3]

Mirzaei M (2014 ) described the stress analysis and life assessment of a first-

stage air-cooled blade made of the super alloy IN738LC. Three-dimensional

5

finite element thermal and stress analyses of the blade were carried out for the
steady-state full load operation. The results of these analyses were used for
determination of the regions where the combination of high temperature and
high tensile stress was sufficient for significant creep-fatigue crack growth.
Accordingly, a critical point at the leading edge of the airfoil, near the root, was
selected for crack modeling. An incremental crack growth scheme was
considered and the total life for the growth of a 0.5mm surface crack to a 5mm
through-thickness crack was calculated.

[4]

Madan Kumara M C(2014) analyzed Nickel base single crystal material is

used due to the effectiveness over polycrystalline blade materials. HCF caused
by large resonance stresses is one of the main problems in turbine blade design.
Fatigue analysis is done for the notched linearly varying rotating blade, the
alternating stress, strain energy, stress intensity and life of the rotating blade is
found. Influence of size and location of the damage on blades life is reported.
Failure analysis of the rotating blade is carried to know the effect of the notch
on the damaged blade and use it in critical conditions.

[5]

Binesh Philip (2010) studied the fatigue life of the blade subjected to static

and dynamic loads, the analysis is divided into two parts. In the first part, the
blade is subjected to static loading that is centrifugal and gas bending load.
Results obtained are based on the above process. In case of static loading, it is
observed that the dovetail regions will have a minimum life in LCF. And in case
of dynamic loading, it is observed that the maximum speed of the fan blade is
close to one of the blade passing frequencies. Hence, the deflections are
predominantly similar. It is also observed that under dynamic loading, the
airfoil is having a minimum life in HCF.

[6]

Nandish R.V (2008) explained the severity of Foreign Object Damage

induced notches can vary significantly, depending on their geometry and

location on the airfoil caused by large resonance stresses is one of the main
problems in turbine blade design. Fatigue analysis is done for the notched
rotating blade, the alternating stress, fatigue stress concentration factor and life
of the rotating blade is found for the known stress concentration factor. Failure
analysis of the rotating blade is carried to give the information to maintenance
engineer for critical usage of turbine blades.

[7]

Patil A.A (2011) described the failure of a second stage blade in a gas turbine

was investigated by mechanical examinations of the failed blade. The blade was
made of a nickel-base alloy Inconel 738LC. The turbine engine has been in
service for about 73,500 hrs. An analytical calculation parallel to the finite
element method was utilized to determine the static stresses due to huge
centrifugal force. The dynamic characteristics of the turbine blade were
evaluated by the finite element mode and harmonic analysis. Finally according
to the log sheet records and by using a Campbell diagram there was a good
agreement between the failure signs and FEM results which showed the broken
blade has been resonated by the third vibration mode occasionally before the
failure occurred.

[8]

Tulsidas (2014) focused in utilizing a technique to assess low cycle fatigue

life of stream turbine blade. Two approaches are employed here, first is based
on the linear elastic finite element analysis. Fictive elastic results are
recalculated using Neubers rule. Second approach is based on elastic -plastic
finite element analysis. Strain amplitude approach is followed through universal
slop method and coffin- Manson equation to determine the number of start-up
and shut down cycles.

[9]

WassimMaktouf and KacemSa (2006) studied the failure of a first stage

compressor blade of a Gas Turbine Generator in a Gas Treatment plant caused

severe mechanical damage to the compressor section and power supply
troubles. In this paper, the blade failure is investigated by mechanical,
metallographic and chemical analysis. A finite element analysis is performed on
the blade geometry to identify the stress concentration areas and the stress/strain
values. The investigation outcomes provided the most probable cause of the
premature blade failure and the recommendations to mitigate such incidents.

CHAPTER 3
DESIGN CONSIDERATION
3.1 TURBINE BLADE AIRFOIL COORDINATES

S.NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Table 3.1 Turbine blade airfoil coordinates

X
Y
35
36.298
coordinate coordinate
36
37.364
0.363
1.022
37
38.431
0.941
1.94
38
39.497
1.667
2.744
39
40.563
2.487
3.459
40
41.629
3.358
4.107
41
42.694
4.273
4.694
42
43.759
5.233
5.202
43
44.824
6.238
5.613
44
45.887
7.277
5.428
45
46.95
8.338
6.162
46
48.01
9.411
6.335
47
49.066
10.49
6.45
48
50.096
11.575
6.521
49
49.113
12.661
6.536
50
48.029
13.746
6.496
51
46.946
14.829
6.407
52
45.864
16.988
6.162
53
44.783
18.067
6.038
54
43.703
19.147
5.914
55
42.602
20.225
5.783
56
41.538
21.302
5.641
57
40.457
22.378
5.486
58
39.374
23.452
5.321
59
38.292
24.524
5.148
60
37.21
25.526
4.972
61
36.127
26.668
4.794
62
35.044
27.74
4.616
63
33.96
28.812
4.374
64
32.878
29.883
4.258
65
31.759
30.954
4.076
66
30.711
32.025
3.891
67
29.628
33.095
3.701
68
28.543
34.163
3.504
69
27.459
35.231
3.302
70
26.373
9

3.098
2.891
2.683
2.475
2.265
2.054
1.842
1.627
1.41
1.188
0.961
0.725
0.47
0.135
0.039
0.11
0.201
0.299
0.402
0.506
0.61
0.713
0.815
0.913
1.006
1.099
1.187
1.272
1.358
1.445
1.532
1.616
1.694
1.764
1.824
1.873

71
72
73
74
75
76
77
78
79
80
81
82
83
84
85

25.287
24.201
23.115
22.029
20.942
19.857
18.772
17.69
16.608
15.529
14.453
13.382
12.317
11.262
10.223

1.91
1.933
1.942
1.935
1.944
1.869
1.808
1.725
1.621
1.492
1.338
1.357
0.942
0.683
0.365

86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

9.208
8.223
7.266
6.33
5.406
4.487
3.563
2.621
1.646
0.607
-0.36
-0.608
-0.51
-0.288
0

-0.23
-0.481
-0.994
-1.545
-2.117
-2.696
-2.267
-2.696
-2.267
-3.81
-4.287
-3.587
-2.233
-1.048
0

3.2 DESCRIPTION OF GAS TURBINE BLADE

From the above coordinate points the root of the turbine blade was
designed and the tip is designed with the scale ratio of 0.5 with various stagger
angles. And the following four different design of turbine blade are given in
below table.
Table 3.2 Description of gas turbine blade
Straight
Tapered
Blade
Straight Blade
Blade
S.No Description
Without
With Twist
Without
Twist
Twist
1
Blade high
100 mm
100 mm
100 mm
Root chord
2
50.13 mm
50.13 mm
50.13 mm
length
Tip chord
3
50.13 mm
25.065 mm
50.13 mm
length
4
Stagger angle
00
50, 100 ,150
00
Dove tail
5
Fir tree
Fir tree
Fir tree
type

10

Tapered
Blade With
Twist
100 mm
50.13 mm
25.065 mm
50, 100 ,150
Fir tree

3.3 DRAFT VIEW OF GAS TURBINE BLADE

Fig 3.1 Straight Blade without Twist

Fig 3.2 Straight Blade with Twist

12

Fig 3.3 Tapered Blade without Twist

Fig 3.4 Tapered Blade with Twist

13

3.4 ISOMETRIC VIEW OF GAS TURBINE BLADE

Fig 3.5 Straight Blade without Twist

Fig 3.6 Straight Blade with Twist

14

Fig 3.7 Tapered Blade without Twist

Fig 3.8 Tapered Blade with Twist

15

3.5 FOUR VIEWS OF GAS TURBINE BLADE

Fig 3.9 Straight Blade without Twist

Fig 3.10 Straight Blade with Twist

16

Fig 3.11 Tapered Blade without Twist

Fig 3.12 Tapered Blade with Twist

17

CHAPTER 4
METHODOLOGY
4.1 FLOWCHART OF HCF- LCF ASSESSMENT
`

Geometry
model of a Fan
Blade

Mesh
Convergence
Studies

Finite Element
Modelling

Pre-stressing

Metal
Properties

Modal Analysis

Linear
Analysis

Campbell Diagram
Boundary
Conditions

Von Misses
stress>Yield
stress

NO

YES

Harmonic analysis
at blade passing
frequencies

Non Linear
Analysis

Centrifugal
Force

Stress based
Approach

Gas Bending loading

Strain based
Approach

HCF Assessments
LCF
Assessments

Fig. 4.1 Flowchart of HCF- LCF assessment

18

4.2 DESCRIPTION
As depicted in the methodology flow chart, it is important to have a finite
element model. The quality of results is dependent on the quality of FE model.
Denser the mesh used for analysis, better will be the results. The FE model is
generated in ANSYS14.0. The FE element library contains a variety of element
types. The use of these elements is governed by the type of problem, time for
solving the problem and quality of results. It is also advisable to have best
quality mesh for fatigue life assessment. For the current problem, a mesh
convergence study was carried out to decide on the quality of mesh.
The cyclic load leads to high cycle fatigue or low cycle fatigue. Static,
dynamic and fatigue life calculation will be carried out in ANSYS workbench
14.5.Nickel based alloy will be used in the turbine blade analysis, with various
operating conditions.
Linear or non-linear analysis will be carried out on the meshed model. Based on
the static stress analysis result, if the von misses stress is more than the yield
strength LCF occurs and the HCF occur when the von misses stress is less than
yield strength.

19

CHAPTER 5
WORKPLAN
Table 5.1 Phase II Work plan

LIST OF WORK

OCT

NOV

DEC

JAN

FEB

1-31

1-30

1-31

1-30

1-28

Journals For
Fatigue Analysis

Material Selection
Finite

Element

Modeling
Analyzing The
Model With
Various Boundary
Condition
Result

20

REFERENCES
1. Aarash Rahmani modal analysis of a first stage blade in Alstom gas
turbine and comparison with experimental results World of Sciences
Journal; ISSN 2307-3071 in 2013[03].
2. Dianyin Hu.Y, Wang.R.Q, Hoe.G.C, 2013 Combined Fatigue
Experiments on Full Scale Turbine Components", Aircraft Engineering
and Aerospace Technology, p 7-10 in 2013.
3. Mizaei.M, stress analysis and life assessment of a gas turbine blade
ORAL Journal, Reference: ICF100312OR in 2014.
4. Madan kumara.M.C, nandish.R.V, madhu.E ,fatigue failure analysis of
rotating blade of uniform varying cross section with damage at the
leading edge IOSR Journal of Engineering, 2787-7819 PP 17-4 in 2014.
5. Binesh philip, Mahindra babu.N.C numerical estimation of fatigue life
of aero engine fan blades fatigue life Design and analysis, SAS TECH
Journal, Volume 9, Issue 2, September 2010.
6. Nandish.R.V, failure analysis of a gas turbine blade IAJC-IJME
International Conference Paper 120, ENG 108 in 2008.
7. Patil.A.A, Shirsat U.M, Study of Failure Analysis of Gas Turbine
Blade, IOSR Journal of Engineering, 2878-8719 PP 37-43 in 2011.
8. Tulsidas,life estimation of a steam turbine blade by using low cycle
fatigue analysis, prodcedia material science , 2392 2401 in 2014[ 5 ].
9. Wassim Maktouf, Kacem sai , An investigation of premature fatigue
failures of a gas turbine blabe, Engineering Failure Analysis journal
vol.3, p 89101 in 2006.
10.Hoe .N.X, Wen Z.X, Yu .Q.M, Application of a combined high and low
cycle fatigue life model on life prediction of SC blade. International
Journal of Fatigue, 616-619 in 2009.
11.Wang.R.Q, Nie.J.X A new experimental method to study combined
fatigue of actual turbine disk mortise teeth at elevated temperature.
Journal of Engineering for Gas Turbines and Power, Transaction of the
ASME, 119 969-972 in 1997.
12.Wang.R.Q, Cho.C.D, Nia.J.X, Combined fatigue life test and
extrapolation of turbine disk mortise at elevated temperature Journal of
Engineering for Gas Turbine and Power, Transactions of the ASME, 127
863-868 in 2005.
21

13.Bhat.S, Patibandla.R, Metal Fatigue and Basic Theoretical Models: A

Review, Alloy Steel - Properties and Use, Dr. Eduardo Valencia
Morales (Ed.), ISBN: 978-953-307-484-9, Tech, DOI: 10.5772/28911 in
2011.
14.Segersll, Mikael, Nickel-Based Single-Crystal Super alloys: the crystal
orientation influence on high temperature properties, Licentiate Thesis,
Linkping University Electronic Press, Linkping Studies in Science and
Technology. Thesis, ISSN 0280-7971; vol 1568 in 2013.
15. Issler.S, Roos. E, Numerical and experimental investigations into life
assessment of blade-disc connections of gas turbines. Nuclear
Engineering and Design, 226 155-164 in 2003.
16.Tresa M. Pollock, Sammy Tin, Nickel-Based Super alloys for Advanced
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22