CHAPTER-1

INTRODUCTION
With the advent in Gas turbine technology, its usage as a prime mover has
become prominent, since last few decades. One of the most important applications
of gas turbines is in power generation, though it has been in use for aircraft
propulsion since long time. The efficiency and power output of gas turbine plants is
dependent on the maximum temperatures attained in the cycle.
Advanced gas turbine engines operate at high temperatures (1200–15000C)
to improve thermal efficiency and power output. With the increase in temperatures
of gases, the heat transferred to the blades will also increase appreciably resulting in
their thermal failure. With the existing materials, it is impossible to go for higher
temperatures.
Taking into account the metallurgical constraints, it is necessary to provide
cooling arrangement for turbine blades to keep their metal temperature with in
allowable limits. Therefore, developments in turbine cooling technology play a
critical role in increasing the thermal efficiency and power output of advanced gas
turbines. The following three types of cooling methods have been adapted to varying
degree of success.
1. Convection cooling
2. Film cooling
3. Transpiration cooling
While all three methods have their difference, they all work by using cooler air (bled
from the compressor) to remove heat from the turbine blade.
Convection cooling works by passing cooling air though passages internal to
the blade. Heat is transferred by conduction to the blade and then by convection into
the air flowing inside of the blade. A large internal surface area is desirable for this
method, so the cooling passages are generally provided with small fins.

1
1.1. THE GAS TURBINE CYCLE
Impingement cooling is often used on certain areas of the turbine blade, like
the leading edge with standard convection cooling used in the rest of the blade. The
second type of cooling is film cooling. This type of cooling works by pumping cool
air out of the blade through small holes in the blade. This air creates a thin layer of
cool air on the surface of the blade, protecting it from the high temperature gases.
The air holes are most often located along the leading edge. One consideration
with film cooling is that injecting the cooler air into the gas flow reduces turbine
efficiency. The drop in the efficiency increases as the amount of cooling flow
increases. The drop in efficiency however is usually compensated by the increasing
overall performance produced by the higher turbine temperature.
Transpiration cooling is the third major type of cooling and is similar to film
cooling as it creates a thin film of cooling air on the blade, but it is different in that
that air is lead though a porous shell rather than injected through holes. This type of
cooling is effective at high temperature asit uniformly covers the entire blade with
cool air.
The analysis of turbine blade mainly consists of the following two parts:
Structural and thermal analysis. The analysis is carried out under steady state
conditions using Ansys software. The study has been conducted with two different
classes of Nickel based alloys i.e., Inconel 718 and N-155.

1.2. FUNDAMENTALS OF GAS TURBINE ENGINES

The gas turbine is an internal combustion engine that uses air as the working
fluid. The engine extracts chemical energy from fuel and converts it to mechanical
energy using the gaseous energy of the working fluid (air) to drive the engine and
propeller, which, in turn, propel the airplane.

2
The basic principle of the airplane turbine engine is identical to any and all engines
that extract energy from chemical fuel. The basic 4 steps for any internal combustion
engine are:
1. Intake of air (and possibly fuel).
2. Compression of the air (and possibly fuel).
3. Combustion, where fuel is injected (if it was not drawn in with the intake air) and
burned to convert the stored energy.
4. Expansion and exhaust, where the converted energy is put to use.

In the case of a piston engine, such as the engine in a car or reciprocating

airplane engine, the intake, compression, combustion, and exhaust steps occur in the
someplace (cylinder head) at different times as the piston goes up and down. In the
turbine engine, however, these same four steps occur at the same time but indifferent
places. As a result of this fundamental difference, the turbine has engine sections
called:
1. The inlet section
2. The compressor section
3. The combustion section (the combustor)
4. The turbine (and exhaust) section.
The turbine section of the gas turbine engine has the task of producing usable
output shaft power to drive the propeller. In addition, it must also provide power to
drive the compressor and all engine accessories. It does this by expanding the high
temperature, pressure, and velocity gas and converting the gaseous energy to
mechanical energy in the form of shaft power.
A large mass of air must be supplied to the turbine in order to produce the
necessary power. This mass of air is supplied by the compressor, which draws the
air into the engine and squeezes it to provide high-pressure air to the turbine. The

3
compressor does this by converting mechanical energy from the turbine to gaseous
energy in the form of pressure and temperature.
If the compressor and the turbine were 100% efficient, the compressor would
supply all the air needed by the turbine. At the same time, the turbine would supply
the necessary power to drive the compressor. In this case, a perpetual motion
machine would exist. However, frictional losses and mechanical system
inefficiencies do not allow a perpetual motion machine to operate.

1.3. Turbine
This example engine has a four-stage turbine. The turbine converts the
gaseous energy of the air/burned fuel mixture out of the combustor into mechanical
energy to drive the compressor, driven accessories, and, through a reduction gear,
the propeller. The turbine converts gaseous energy into mechanical energy by
expanding the hot, high-pressure gases to a lower temperature and pressure. Each
stage of the turbine consists of a row of stationary vanes followed by a row of
rotating blades. This is the reverse of the order in the compressor. In the compressor
energy is added to the gas by the rotor blades, then converted to static pressure by
the stator vanes. In the turbine, the stator vanes increase gas velocity, and then the
rotor blades extract energy. The vanes and blades are air foils that provide for a
smooth flow of the gases. As the airstream enters the turbine section from the
combustion section, it is accelerated through the first stage stator vanes. The stator
vanes (also called nozzles) form convergent ducts that convert the gaseous heat and
pressure energy into higher velocity gas flow (Pi). In addition to accelerating the gas,
the vanes "turn" the flow to direct it into the rotor blades at the optimum angle. As
the mass of the high velocity gas flows across the turbine blades, the gaseous energy
is converted to mechanical energy. Velocity, temperature, and pressure of the gas
are sacrificed in order to rotate the turbine to generate shaft power.

4
1.4. EFFECTS OF TURBINE TEMPERATURE
The materials used in the turbine section of the engine limit the maximum
temperature at which a gas turbine engine can operate. The first metal the hot gases
from the combustion section strike is the turbine inlet. The temperature of the gas
stream is carefully monitored to ensure that over temperature does not occur.

1.5. GAS TURBINE BLADE

In a gas turbine engine, a single turbine section is made up of a disk or hub
that holds many turbine blades. That turbine section is connected to a compressor
section via a shaft (or "spool"), and that compressor section can either be axial or
centrifugal. Air is compressed, raising the pressure and temperature, through the
compressor stages of the engine. The temperature is then greatly increased by
combustion of fuel inside the combustor, which sits between the compressor stages
and the turbine stages. The high temperature and high pressure exhaust gases then
pass through the turbine stages. The turbine stages extract energy from this flow,
lowering the pressure and temperature of the air and transfer the kinetic energy to
the compressor stages along the spool. This process is very similar to how an axial
compressor works, only in reverse.

The number of turbine stages varies in different types of engines, with high
bypass ratio engines tending to have the most turbine stages. The number of turbine
stages can have a great effect on how the turbine blades are designed for each stage.
Many gas turbine engines are twin spool designs, meaning that there is a high
pressure spool and a low pressure spool. Other gas turbines use three spools, adding
an intermediate pressure spool between the high and low pressure spool. The high
pressure turbine is exposed to the hottest, highest pressure air, and the low pressure
turbine is subjected to cooler, lower pressure air. That difference in conditions leads

5
the design of high pressure and low pressure turbine blades to be significantly
different in material and cooling choices even though the aerodynamic and
thermodynamic principles are the same.

How does it work?

6
 CHAPTER-2

LITERATURE REVIEW

1. S.Gowreesh et.al (1) studied on The first stage rotor blade of a two stage
gas turbine has been analysed for Structural, thermal, modal analysis using ANSYS
11.0.which is a powerful Finite Element Method Software. The temperature
distribution in the rotor blade has been evaluated using this software. The design
features of the turbine segment of the gas turbine have been taken from the
preliminary design of a power turbine for maximization of an existing turbo jet
engine. It has been felt that a detail study can be carried out on the temperature
effects to have a clear understanding of the combined mechanical and thermal
stresses
2. Kauthalkaret.al (2) the purpose of turbine technology is to extract,
maximum quantity of energy from the working fluid to convert it into useful work
withmaximum efficiency. That means, the Gas turbine 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. This is at high
temperature and pressure by expanding through the several rings of fixed and
moving blades. A high pressure of order 4 to 10 bar of working fluid which is
essential for expansion, a compressor is required.
3. John.v et.al (3) studied on the design and analysis of Gas turbine blade,
CATIA is used for design of solid model and ANSYS software for analysis for F.E.
model generated, by applying boundary condition, this paper also includes specific
post-processing and life assessment of blade .HOW the program makes effective use
of the ANSYS pre-processor to mesh complex turbine blade geometries and apply
boundary conditions. Here under we presented how Designing of a turbine blade is
done in CATIA with the help of co-ordinate Generated on CMM. And to
7
demonstrate the pre-processing capabilities, static and dynamic stress analysis
results, generation of Campbell and Interference diagrams and life assessment. The
principal aim of thisPaper is to get the natural frequencies and mode shape of the
turbine blade.
4. V.Raga Deepu et.al (4) StudiedonaGas turbine is adevice designed to
convert the heat energy of fuel in touseful work such as mechanical shaft
power.TurbineBlades are most important components in a gas turbinePower plant.
A blade can be defined as the medium oftransfer of energy from the gases to the
turbinerotor.Theturbine blades are mainly affected due to staticloads. Also the
temperature has significant effect on theBlades. Therefore thecoupled (static and
thermal)analysis of turbine blades is carried out using finite element analysis
software ANSYS.
5. V.Veeraragavan [5]had mainly done the research on the aircraft turbine
blades; his main focus was on 10 C4/ 60 C50 turbine blades models. He had used
the conventional alloys such as titanium, zirconium, molybdenum, and super alloys
were chosen for the analysis. He had analyzed the effect of the temperature on the
different material for the certain interval of times. And conclude the molybdenum
alloys had better temperature resistance capability.
6. R D V Prasad, G Narasa Raju, M S S Srinivasa Rao, N Vasudeva Rao [6]
had done research on different types of the cooling technique which maintain
temperature of the blade to allowable limits, Finite element analysis is used to
examine steady state thermal & structural performance for N155 & Inconel 718
nickel-chromium alloys. Four different models consisting of solid blade and blades
with varying number of holes (5, 9 & 13 holes) were analyzed to find out the
optimum number of cooling holes. They had used two material Inconel 718 and
Inconel 155 for their research work and found out Inconel 718 has the better thermal
properties as the blade temperature and the stress induce is lesser.

8
 CHAPTER-3

LIST OF TURBINE BLADE MATERIALS AND COOLING SYSTEM

Note: This list is not inclusive of all alloys used in turbine blades.

 U-500this material was used as a first stage (the most demanding stage)
material in the 1960s, and is now used in later, less demanding, stages.
 Rene 77
 Rene N5
 Rene N6
 PWA1484
 CMSX-4
 CMSX-10
 Inconel
o IN-738 - GE used IN-738 as a first stage blade material from 1971 until
1984, when it was replaced by GTD-111. It is now used as a second
stage material. It was specifically designed for land-based turbines
rather than aircraft gas turbines.
 GTD-111 Blades made from directionally solidified GTD-111 are being using
in many GE Aviation gas turbines in the first stage. Blades made from equated
GTD-111 are being used in later stages.
 EPM-102 (MX4 (GE), PWA 1497 (P&W)) is a single crystal superalloy
jointly developed by NASA, GE Aviation, and Pratt & Whitney for the High
Speed Civil Transport (HSCT). While the HSCT program was cancelled, the
alloy is still being considered for use by GE and P&W.

9
3.1 COOLING

For same pressure ratio at high maximum temperature thermal efficiency is

high. But the high temperature can lead to the damage of the turbine. So the cooling
of blade becomes essential.

Thermal efficiency vs. pressure ratio

3.2. METHODS OF COOLING

Cooling of components can be achieved by air or liquid cooling. Liquid

cooling seems to be more attractive because of high specific heat capacity and
chances of evaporative cooling but there can be problem of leakage, corrosion,
choking, etc. which works against this method. On the other hand air cooling allows
discharging air into main flow without any problem. Quantity of air required for this
purpose is 1-3% of main flow and blade temperature can be reduced by 200-300°C.
There are many types of cooling used in gas turbine blades; convection, film,
transpiration cooling, cooling effusion, pin fin cooling etc. which fall under the
categories of internal and external cooling. While all methods have their differences,
they all work by using cooler air (often bled from the compressor) to remove heat
from the turbine blades.

10
3.3. INTERNAL COOLING

Convection cooling it works by passing cooling air through passages internal to the
blade. Heat is transferred by conduction through the blade, and then by convection
into the air flowing inside of the blade. A large internal surface area is desirable for
this method, so the cooling paths tend to be serpentine and full of small fins. The
internal passages in the blade may be circular or elliptical in shape. Cooling is
achieved by passing the air through these passages from hub towards the blade tip.
This cooling air comes from an air compressor. In case of gas turbine the fluid
outside is relatively hot which passes through the cooling passage and mixes with
the main stream at the blade tip.

Fig.3.1.Internal Cooling

Fig.3.2.Rendering of a turbine blade with cooling holes for film cooling.

11
3.4. Blade cooling by convection
Impingement cooling variation of convection cooling, impingement cooling,
works by hitting the inner surface of the blade with high velocity air. This allows
more heat to be transferred by convection than regular convection cooling does.
Impingement cooling is used in the regions of greatest heat loads. In case of turbine
blades, the leading edge has maximum temperature and thus heat load. Impingement
cooling is also used in mid chord of the vane. Blades are hollow with a core. There
are internal cooling passages. Cooling air enters from the leading edge region and
turns towards the trailing edge.

Impingement revised
EXTERNAL COOLING film cooling Film cooling (also called thin film
cooling) is a major type of cooling which works by pumping cool air out of the blade
through small holes in the blade. This air creates a thin layer (the film) of cool air on
the surface of the blade, protecting it from the high temperature air. The air holes
can be in many different blade locations, but they are most often along the leading
edge. A United State Air Force program in the early 1970s funded the development
of a turbine blade that was both film and convection cooled, and that method has
become common in modern turbine blades. There are orifices on the surface through
which the cool air flows on the surface and makes a film on the surface which acts
as a barrier to heating and provides effective cooling. Besides cooling blade surface
it decreases heat transfer from metal surface to the hot fluid. One consideration with
film cooling is that injecting the cooler bleed into the flow reduces turbine efficiency.
12
That drop in efficiency also increases as the amount of cooling flow increases. The
drop in efficiency, however, is usually mitigated by the increase in overall
performance produced by the higher turbine temperature.

Film cooling revised

Cooling effusion Blade surface is made of porous material which means

having infinite number of small orifices on the surface. Cooling air is forced through
these porous holes which form a film or cooler boundary layer. Besides this uniform
cooling is caused by effusion of the coolant over the entire blade surface.

13
Cooling by effusion
Pin fin cooling in the narrow trailing edge film cooling is used to enhance heat
transfer from the blade. There is an array of pin fins on the blade surface. Heat
transfer takes place from this array and through the side walls. As the coolant flows
across the fins with high velocity, the flow separates and wakes are formed. Many
factors contribute towards heat transfer rate among which the type of pin fin and the
spacing between fins are the most significant.

Transpiration cooling it is similar to film cooling in that it creates a thin film

of cooling air on the blade, but it is different in that air is "leaked" through a porous
shell rather than injected through holes. This type of cooling is effective at high
temperatures as it uniformly covers the entire blade with cool air. Transpiration-
cooled blades generally consist of a rigid strut with a porous shell. Air flows through
internal channels of the strut and then passes through the porous shell to cool the
blade. As with film cooling, increased cooling air decreases turbine efficiency,
therefore that decrease has to be balanced with improved temperature performance.

14
 CHAPTER-4
MODELING AND ANALYSIS OF GAS TURBINE BLADE
The blade model profile is generated by using CATIA software. Key points are
created along the profile in the working plane. The points are joined by drawing B
spline curves to obtain a smooth contour. The contour (2D model) is then converted
into area and then volume (3D model) was generated by extrusion. The hub is also
generated similarly. These two volumes are then combined into single volume.
This model of turbine blade is then imported into ANSYS software. The blade is
then analysed sequentially with thermal analysis preceding structural analysis. The
model is discretized using 10 nodes tetrahedral solid element (Solid 87).The surface
of the blade is applied with Surface element (Surf 152) for applying the convection
loads. The temperatures of blade are then determined by thermal analysis. Followed
by this, the structural analysis is carried out by importing the temperatures
determined in thermal analysis. 10 nodes tetrahedral solid element (Solid 187) was
used for structural analysis. The loads considered for structural analysis are
centrifugal, axial & tangential forces.

Nomenclature
α Coefficient of thermal expansion
E Young’s Modulus
μ Poisson’s ratio
L Length
D Diameter of shaft
N Speed of turbine in RPM
K Thermal conductivity
D Diameter of cooling air passage

15
Mechanical properties of TitaniumT6, Inconel 718, N155

Titanium T
Properties Units N 155 Inconel 718
6
1.06 E5
Pa 143 E09 149 E09
E Mpa
Poisson‘s
- 0.3 0.31 0.3
Ratio

ρ Kg/cu m 8249 8220 4420 kg/m3

K W/m-K 20 25 10
μ --- 0.344 0.331 ---
α E-06/0C 17.7 16.0 8.8
Cp J/Kg K 435 586.2 544
Melting
0C 1354 1344 1649
Point
Yield stress MPa 550 1067 ---

4.1. SOFTWARE TOOLS USED FOR MODELING

System software
System software is the collection of system program that perform a variety of
functions viz. File editing, I/O management, Storage management etc. It aids the
user in effective execution of computer graphics system and implementing certain
specialized functions.
The term execution here includes all activities concerned with initial input of the
program, Text and the various stages of processing by computer system namely,
editing, storage, translation, relocation etc.

16
 The operating system (OS) is the major system software element in a CAD
system. It is a software link between the computer hardware and software and also
links user with hardware and software. The OS also controls the peripheral devices.

Application software
Application software is developed to meet the user requirement. Some of
these software are of a general nature and can be purchased as a package, while other
software are developed to meet the specific need of the user. There are number of
general purpose CAD packages are available which may be categorized as

1. Computer Aided Drawing.

2. Geometric modelling.
3. Finite Element Analysis Packages.

Application software should be more machine independent. Special purpose

programs can be developed by the using high level languages like FORTRAN, C++,
and Visual Basic etc. Example: optimization of engineering design problems.

Computer Aided Drafting

The most commonly used computer aided drafting software is AUTO CAD.
Using which 2D drawing and limited 3D models can be generated. It is a powerful
drafting tool that has flexible features for drawing, editing, plotting etc.

Basic concepts of Pro-Engineer

Pro-engineer uses parametric design principles for solid modelling. Pro/
Engineer provides mechanical engineers with an approach to mechanical design
automation based on solid modelling technology. This chapter explains Pro-
Engineer modelling philosophies and introduces key program capabilities.

17
3D modelling
The essential difference between Pro/Engineer and traditional CAD systems
is that models created in Pro/Engineer exist as three dimensional solids. Other 3-D
modellers represented only the surface boundaries of the model. Pro-Engineer
models the complete solid. This not only facilities the creation of realistic geometry,
but also allows for accurate model calculations, such as those for mass properties.

Parameter design
Dimensions such as angle, distance and diameter control Pro-E model
geometry. You can create relationships that allow parameters to be automatically
calculated based on the value of other parameters. When you modify the dimensions,
the entire model geometry can update according to the relations you created.

Features- Based modelling

You create models in Pro-Engineer by building features. These features have
intelligences, in that they contain knowledge of their environment and adapt
predictably to change. Each feature asks the user for specific information based on
the feature type. For example, a hole has a diameter, depth and placement, while a
round has a radius and edges to round.

Pro-Engineer is a fully-associated system. This means that changes in the

design model any time on the development process is propagated throughout the
design automatically updating all engineering deliverables including assemblies,
drawing and manufacturing data. Associatively makes concurrent engineering
possible by encouraging change, without penalty, at any point in the development
cycle. This enables downstream functions to contribute their knowledge and
expertise in the development cycle.

18
Solid modelling
Solid modelling contains geometrical information’s necessary to
unambiguously describe a 3D object: It is a well advanced geometric modelling
technique.

Geometric modelling
The geometric modelling is in the computer compatible mathematical
description of the geometry of the object. This mathematical description allows the
image of the object to be displayed and manipulated on the computer screen and also
it can be stored in the memory and retrieved back and displayed on the computer
screen whenever required.

The geometric modelling can be classified into

 Wire frame modelling

 Surface modelling
 Solid modelling

Wire frame modelling

Wire frame modelling is the simplest method of modelling of the object. Wire
frame models can be considered as networks of inter connected lines to the edges of
the physical objects being modelled. A typical wire frame may consist of points,
lines, arcs, circles, conics, and curves.

Surface modelling
The ambiguities of wire frame modelling are overcome with surface models.
The surface modelling takes the modelling of an object one step beyond wire frame
model by providing information on surfaces connecting the object edges. i.e., a

19
surface model can be built by defining the surface on the wire frame. This is
analogous to stretching a thin material over frame work.
Solid modelling
Solid modelling is the most powerful 3 D modelling technique. There is more
number of methods available to generate solid models. Out of which two basic
approaches are important from our subject point of view.
They are
1. Constructive solid geometry (CSG).
2. Boundary representation (B-Rep.)

Constructive solid geometry

A solid modeller has a library of set of basis element shapes known as
primitives like, cuboids, cylinder, sphere, cone, wedge, torus etc.

Basic elements in a typical 3D model modelling software.

In this approach, the physical objects are modelled by combining the
primitives by a set of Boolean operations. The type of Boolean operations is used in
CSG are union (U), difference (-) and intersections (੯).
Here, directed graph (Binary tree) scheme is used to store the model in the
data structure.
Any node may have one parent node and two-child node. The root node (R)
has no parent and leaf node (L) has no children.

Boundary representation (B-rep)

This approach is widely used in most of solid modellers. The solid model
created by using B-rep technique may be stored in graph based on data structure
system. This is illustrated with a simple example of tetrahedron.

20
 The tetrahedron is composed of four varieties namely A, B, C and D. The co-
ordinate of these vertices is stored in the database.

Advantages of solid modelling

1. Mass properties such as area, volume, Weight, centre of gravity and moment of
inertia of physical model can be calculated quickly.
2. Solid models are un-ambiguous models.
3. Cross-section views of models can be obtained easily.
4. It can be used for interference / clearance checking of moving parts.
5. Aesthetic look of finished object can be visualized in the computer screen itself
with colour shading, high-lighting, and facilities available in solid modellers.
6. Different views of the object (Isometric, perspective, and Orthographic view) can
be obtained easily.
7. Solid model is very much useful for finite element analysis.
8. They can help to produce NC machining instruction automatically.

4.1.1. Software package for modelling

There are number of software packages available for modelling. Some of the
important packages are

1. Auto cad
2. Pro-E
3. IDEAS
4. Unigraphics
5. CATIA
6. Solid works
7. Solid edge.

21
Soloidworks
Solid Works is a 3D mechanical CAD (computer-aided design) program that
runs on Microsoft Windows and is being developed by DassaultSystemsSolid Works
Corp., a subsidiary of DassaultSystems, S. A. (Vélizy, France). Solid Works is
currently used by over 2 million engineers and designers at more than 165,000
companies worldwide. FY2011 revenue for Solid Works was 483 million dollars.
Parameters refer to constraints whose values determine the shape or geometry of
the model or assembly. Parameters can be either numeric parameters, such as line
lengths or circle diameters, or geometric parameters, such as tangent, parallel,
concentric, horizontal or vertical, etc.
4.2. MODELLING OF THE TURBINE BLADE

4.1. Modelling of Turbine Blade with& without holes using Solid works 2014
(6 Holes)

22
Modelling with 9 Holes Modelling with 12 Holes

23
 CHAPTER-5
ANALYSIS OF TURBINE BLADE
5.1. ANSYS
ANSYS is a general - purpose finite element analysis (FEA) software
package. Finite element Analysis is a numerical method of deconstructing a complex
system into very small pieces called elements. The software implements equations
that govern the behaviour of these elements and solves them all, creating a
comprehensive explanation of how the system acts as a whole. These results then
can be presented in tabulated or graphical forms. This type of analysis is typically
used for the design and optimization of a system far too complex to analyze by hand.
Systems that may fit into this category are too complex due to their geometry, scale,
or governing equations.
ANSYS is the standard FEA teaching tool within the mechanical Engineering
Department at many colleges. ANSYS is also used in civil and Electrical
Engineering, as well as the physics and Chemistry departments.

ANSYS provides a cost effective way to explore the performance of products

or processes in a Virtual environment. This type of product development is termed
virtual prototyping.

With virtual prototyping techniques, users can iterate various scenarios to

optimize the product long before the manufacturing is started. This enables a
reduction in the level of risk, and in the cost of ineffective designs. The multifaceted
nature of ANSYS also provides a means to ensure that the users are able to see the
effect of at design on the whole behaviour of the product, be I electromagnetic,
thermal, mechanical etc.,

24
5.2. Advantages of ANSYS

The ANSYS Mechanical solutions offer best- in -class simulation tools for
product design and optimization that increase productivity, minimize physical
prototyping and help deliver better and innovative products in less time. These
solutions tackle real - world analysis problems by making product development less
costly and more reliable. ANSYS Mechanical includes a full complete of non-liner
elements, material laws ranging from metal to rubber, and the most comprehensive
set of solver available. It can handle even the most complex assemblies especially
those involving nonlinear contact and is the ideal choice for determining stresses,
temperatures, displacements and contact pressures distributions on all your
component and assembly design.

5.3. Optimization through Load Analysis

The finite element method is a numerical method for solving problems of
engineering and mathematical physics. Typical problem areas of interest in
engineering and mathematical physics that are solvable by use of the finite element
method include structural analysis, heat transfer, fluid flow, mass transport, and
electromagnetic potential.

For problems involving complicated geometries, loading, and material

properties, it is generally not possible to obtain analytical mathematical solution.
Analytical solutions are those given by a mathematical expression that yields the
values of the desired unknown quantities at any location in the body (here total
structure or physical systems of interest) and are thus valid for an infinite number of
locations in the body. These analytical solutions generally require the solution of
ordinary or partial differential equations, which, because of the complicated
geometries, loading, and material properties, are not usual obtainable. Hence we

25
need to rely on numerical methods, such as the finite element method, for acceptable
solutions. The finite element formulation of the problem results in a system of
simultaneous algebraic equations for solution, rather than requiring the solution
differential equations. The numerical methods yield approximate values of the
unknown at discrete numbers of points in the continuum. Hence this process of
modelling a body by dividing it into an equivalent system of smaller bodies or units
( finite elements) interconnected at points common to two or more elements (nodal
points or nodes) and / or boundary lines and or surfaces is called discretization. In
the finite element method, instead of solving the problem for the entire body in one
operation, we formulate the equations for each element and combine them to obtain
the solution of the whole body.

Briefly, the solutions for structural problems typically refer to determining the
displacement at each node and stress within each element making up the structure
that is subjected to applied loads. In non-structural problems, the nodal unknown
may, for instance, be temperatures or fluid pressure due to thermal or fluid fluxes.

5.4. Basic concept of finite element methods

The Finite Element Method (FEM) or Finite Element Analysis (FEA), is
based on the idea of building a complicated object with simple blocks, or, dividing
a complicated object in to small and manageable pieces. Application of this simple
idea can be seen everywhere in everyday life, as well as in engineering.

General steps of the Finite Element Method

Step 1 Discretize and select the element types
Step 2 Select the displacement function
Step 3 Define the strain / displacement and stress / strain relationships.
Step 4 Divine the element stiffness matrix and equations

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 Direct equilibrium method
Work on energy methods
Methods of weighted residuals
Step 5 Assemble the element equations to obtain the global or total equations
and introduce boundary conditions
Step 6 Solve the unknown degrees freedom (or generalized Displacement)
Step 7 Solve for the element strain and stresses
Step 8 Interpret the results

THE NEED OF FEA

 Design analysis
 Hard calculation, experiments and computer simulation.
 Hard calculation, Experiments= Time consuming
 FEM / FEA are the most widely applied computer simulation method in
 Engineering and closely integrated with CAD /CAM packages.

Application of FEM
1. Mechanical / aerospace / Civil / Automobile engineering
2. Structural analysis (Static / Dynamic, Linear/ Non linear)
3. Thermal / fluid flow
4. Electromagnets
5. Geomechanics
6. Biomechanics

Definition
“FEA” is a method of piecewise approximation, in which the approximate
function “” is formed by connecting simple functions. Each defined over a small

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element is such a way that the inter element continuity is maintained is the
assemblage”.
“FEA is a computer aided mathematical technique for obtaining approximate
numerical solution to predict the response of the physical systems subjected to
external influences”
FEM models a structure as an assemblage of the small parts called “elements”
is of small geometry and therefore it’s much simpler to analyze that the actual
structure as a whole.

Three dimensional stress analysis

In this chapter, we consider the three-dimensional, or solid, element. This
element is useful for the stress analysis of general of general three dimensional
bodies that require more precise analysis than is possible through two-dimensional
and / or axis symmetric analysis. Example of three-dimensional problems are arch
dams, thick walled pressure vessels and solid forging parts as used, for instance, in
the heavy equipment and automotive industries.

The tetrahedron is the basic three-dimensional element, and it is used in the

development of the shape functions, stiffness matrix, and force matrices in terms of
a global coordinate systems
To develop the tetrahedral stress elements stiffness matrix we used the
following steps.
1. Select element type.
2. Select displacements functions.
3. Define the strain / displacement and stress / strain relationship.
4. Derive the element stiffness matrix and equations.

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5.5. Thermal analysis in ANSYS
Thermal analysis is a branch of materials science where the properties of
materials are studied as they change with temperature. Several methods are
commonly used – these are distinguished from one another by the property which is
measured:

 Dielectric thermal analysis (DEA): dielectric permittivity and loss factor

 Differential thermal analysis (DTA): temperature difference
 Differential scanning calorimetric (DSC): heat difference
 Dilatometer (DIL): volume
 Dynamic mechanical analysis (DMA) : mechanical stiffness and damping
 Evolved gas analysis (EGA) : gaseous decomposition products
 Laser flash analysis (LFA): thermal diffusivity and thermal conductivity
 Thermo gravimetric analysis (TGA): mass
 Thermo mechanical analysis (TMA): dimension
 Thermo-optical analysis (TOA): optical properties
 Derivatography: A complex method in thermal analysis

Simultaneous Thermal Analysis (STA) generally refers to the simultaneous

application of Thermogravimetry (TGA) and differential scanning calorimetric
(DSC) to one and the same sample in a single instrument. The test conditions are
perfectly identical for the TGA and DSC signals (same atmosphere, gas flow rate,
vapour pressure of the sample, heating rate, thermal contact to the sample crucible
and sensor, radiation effect, etc.). The information gathered can even be enhanced
by coupling the STA instrument to an Evolved Gas Analyzer (EGA) like Fourier
transform infrared spectroscopy (FTIR) or mass spectrometry (MS).

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5.6. ANALYSIS
Boundary conditions of the thermal analysis

Fig.5.1.Boundary condition

Complete mesh model of the Turbine blade material

Fig.5.2. meshing

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5.7. ANALYSIS RESULT
5.7.1 THERMAL ANALYSIS RESULT OF 6 HOLE TITANIUM
Temperature Distribution

Heat Flux

31
Directional Heat flux

Fig.5.3. Temperature Distribution Result of 6 Hole Titanium

5.7.2. THERMAL ANALYSIS RESULT OF 9 HOLE TITANIUM
Temperature Distribution

32
Heat Flux

Directional Heat flux

Fig.5.4.Temperature Distribution Result of 6 Hole Titanium

5.7.3. THERMAL ANALYSIS RESULT OF 12 HOLE TITANIUM
Temperature Distribution

33
Heat Flux

Directional Heat flux

Fig.5.5. Temperature Distribution Result of 12 Hole Titanium

34
5.7.4. THERMAL ANALYSIS RESULT OF 6 HOLE Inconel 716
Temperature Distribution

Heat Flux

35
Directional Heat flux

Fig.5.6. Temperature Distribution Result of 6 Hole Inconel 716

5.7.5. THERMAL ANALYSIS RESULT OF 9 HOLE Inconel 716
Temperature Distribution

36
Heat Flux

Directional Heat flux

Fig.5.7. Temperature Distribution Result of 9 Hole Inconel 716

5.5.6. THERMAL ANALYSIS RESULT OF 12 HOLE Inconel 716
Temperature Distribution

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Heat Flux

Directional Heat flux

Fig.5.8. Temperature Distribution Result of 12 Hole Inconel 716

38
5.8. STRUCTURAL ANALYSIS
Boundary Conditions of the Structural Analysis

5.8.1 STRUCTURAL ANALYSIS RESULT OF 12 HOLE Titanium

Total Deformation

39
Directional Deformation

Stress Distribution

40
Strain Distribution

STRUCTURAL ANALYSIS RESULT OF 12 HOLE Inconel 716

Total Deformation

Directional Deformation

41
Stress Distribution

Strain Distribution

42
 CHAPTER-6
RESULT & DISCUSSION

6.1. TEMPERATURE DISTRIBUTION: MAX 900 OC

Sl.No Temperature Temperature(oc) Temperature (oc)
(oc) (6Holes) (9Holes) (12Holes)
Titanium T6 887.45 876.95 855.73
Inconel 718 885.38 879.68 860.86

6.2. STRUCURAL ANALYSIS RESULTS AT 6 X 105 pa

Total deformation
Sl.No Strain Stress (pa)
(mm )
Titanium T6 0.00029006 2.5934 X10-5 3.0703 X107
Inconel 718 0.00020584 1.8449 x10-5 3.0629x107

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 CHAPTER-7
CONCLUSION

While comparing these materials, it is found that Inconel 718 is better suited
for high temperature applications. On evaluating the contours for temperature
distribution, von-mises stresses and deflection, the blade with 12 holes is considered
as optimum.
This conclusion was drawn based on the fact that the induced stresses are
minimum and the temperature of the blade is close to the required value of 800C.
Any further increase in the number of holes will bring down the temperature below
the required value of 8000 C.

44
 REFERENCES

1. S.Gowreesh, N.SreenivasaluReddy and N.V.Yogananda Murthy.

“CONVECTIVE HEAT TRANSFER ANALYSIS OF an AERO GAS TURBINE
BLADE USING ANSYS”, International journal of Mechanics of solids, vol4, No.1,
March 2009(ppt55-62).
2. P.Kauthalkar, Mr.Devendra S.Shikarwar, and Dr.Pushapendra Kumar Sharma.
“ANLYSIS OF THERMAL STRESES DISTRIBUTION PATTERN ON GAS
TURBINE BLADE USING ANSYS”, International journal of Engineering
Education and technology, Vol.2, No.3, Nov 2010.
3. John’s, T.Ramakrishna. “THE DESIGN AND ANALYSIS OF GAS TURBINE
BLADE”, International Journal of Advanced Research and Studies, Vol 2, No.1,
Dec 2012.
4. V.Raga Deepu, R.P.Kumar Ropichrla.“ DESIGN AND COUPLED FIELD
ANALYSIS OF FIRST STAGE GAS TURBINE ROTOR BLADES”, International
journal of Mathematics and Engineering, Vol 13, No.2, Pages: 1603 -1612.
5. V. Veeraragavan Effect of Temperature Distribution in 10c4/60c50 Gas Turbine
Blade Model Using Finite Element Analysis.
6. R D V Prasad1, G Narasa Raju2, M S S Srinivasa Rao3, N Vasudeva Rao4 Steady
State Thermal & Structural Analysis of Gas Turbine Blade CoolingSystem.
7. B.Deepanraj, P.Larence and G.Sankaranarayanan. “Theoretical Analysis of Gas
Turbine Blade by Finite Element Method”, Scientific world.vol.9.no.9, July 2011.
8. Sukhvinderkaurbhatti, Shyamala kumara, M L Neelapu, C.kedarinath, and Dr.I N
Niranjankumar. “Transient State Stress Analysis on An Axial Flow Gas Turbine
Blade and Disk Using Finite Element Procedure”, Proceedings of the 4th WSEAS
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Greece,Aug21 -23,2006(ppt323 - 330) .

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