3D MODELLING AND ANALYSIS OF MICRO GAS TURBINE COMPRESSOR .
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014ISSN 2278 – 0149 www.ijmerr.comVol. 3, No. 4, October 2014 2014 IJMERR. All Rights ReservedResearch Paper3D MODELLING AND ANALYSIS OF MICRO GASTURBINE COMPRESSOR BLADEAjin Elias Alex1* and Nadeera M1*Corresponding Author: Ajin Elias Alex, ajinelias@gmail.comMicroturbines can be utilized in refrigerator, generator, air drier, etc., Micro turbine being small insize as compared to large turbine, such that less weight which reflects on pressure ratio, lowcost and easy maintenance. Design and analyze of the micro turbine compressor blade iscarried out in this thesis. With different material and rotational speed, compressor blade of themicro turbine is analyzed. A 3D Structural design of microturbine generating 120 KW of outputpower is modeled in Solidworks. Based on the given microturbine output power, the dimensionsand physical properties of the compressor blade were calculated. Titanium, Aluminium andStainless steel alloys, this materials effect on compressor blade are found out by carrying stressand modal analysis. Microturbine systems claimed many advantages over reciprocating enginegenerators, such as higher power to weight ratio, low pollution and having few moving part.Microturbines have many advantages, such that it may be designed with foil bearings and aircooling operating without lubricating oil, coolants or other hazardous materials. Microturbinesare quicker to respond to output power requirement and also more efficient. Microturbines alsohave more efficiency at low power levels than reciprocating engines. The variation of rotationalspeed is a representation of various operating conditions, depending on the required output. Byanalysis software ANSYS 12, stress and modal analysis are done.Keywords: Compressor blade, Microturbine, Vibrational analysisINTRODUCTIONchallenge, both aerodynamically andmechanically. The aerodynamic compressordesign process basically consist of mean lineprediction is the first step during compressorblade design.Axial flow compressors are used in mediumto large thrust gas turbine and jet engines. Thecompressor rotates at very high speeds addingenergy to the air flow while at the same timecompressing it into a smaller space. Thedesign of axial flow compressors is a great1Nowadays, the need of energy productionto be used for either industrial or severalDepartment of Computer Integrated Manufacturing, T.K.M College of Engineering, Kollam, India.493
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014transportations is in great demand. The typeof power generation has become the majorconcern because of its widespread need. Forthe concern of recent time needs, the suitablepower generation type is one which achievesa relatively better efficiency, low in cost, andsatisfied the demanding criteria.down from the large industrial gas turbine.Microturbines are quicker to respond tooutput power requirement and also moreefficient. The microturbine took in placebecause of the emerging need of innovationto the existing large gas turbine power plant,especially for the application of remote andlimited area to be placed. Microturbines areoperated at lower pressure ratios than largergas turbines.Because of its critical role, it isunderstandable that innovation to a step furtheris needed. In a field where the major roleneeded and development costs both are themajor concerns, it was thought to build thesmallest possible gas turbine, and to explorewhether the device could be made into smallersize. The micro turbine is actually the scaledown of the large ordinary gas turbine system.Objective of StudyThe objective of this study is to model a microturbine compressor blade and conduct stressanalysis as well as vibration analysis basedon its rotation per minutes.MaterialsThis is what gave birth to this project sincethe advantages of gas turbines are alreadyknown compared to other. This project dealswith designing of micro turbine compressorand the corresponding overall integrity analysisof the designated compressor. Aluminum alloy. Stainless steel alloy. Titanium alloy.Rotational Speed 40000 rpmMicroturbine is definitely different from theusual large industrial gas turbine, althoughit has the same principal work and scale- 50000 rpm 60000 rpmFigure 1: MicroturbineScope of StudyThe design and the analysis of the structuresintegrity using finite element method isconducted. It is expected that the project willprovide the recommendation that can help toimprove the performance of compressordesign base on the previous analysis.The scope of study consists of two majorparts. The first is to design the dimension ofthe compressor based on the given outputpower. The design is expected to be the mostoptimal dimension to that proposed output.494
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014AnalysisThe second part is the analysis of thedesigned dimension of the compressor. Thispart is investigating the stress acting on thecompressor and conducting vibrationalanalysis of the model using the finite elementanalysis program. ANSYS is the software usedfor analysis. 3D model obtained from SolidWorks is imported to ANSYS in IGES format.ANSYS Workbench 12 is the software usedfor analysis. 3D model obtained from SolidWorks is imported to ANSYS in IGES format.Compressor MaterialsThe material properties are assigned as partof the analyses. The material for thecompressor blade is chosen into threedifferent materials.METHODOLOGYGeometrical ModellingTable 2: Different Material and its DetailsSolidworks is used for the modelling purpose.This are the geometric parameter used formodelling.MaterialsItemsParameterValueTitanium AlloyTi-b-120UCAElastic modulusE(MPa)0.102E6Poisson ratioN0.3Density (kgm 3)4850Figure 2: MethodologyUltimate c modulusE(MPa)0.717E5Poisson ratioN0.33Density (kgm 3)2740Ultimate TensileStrengthUTS(MPa)Stainless SteelAlloy 304Elastic modulusTable 1: Compressor GeometryParameterItemsParameterValueShaft DiameterD(mm)20Impeller Inner DiameterD 1(mm)55Impeller Outer DiameterD 2(mm)136Impeller Thickness to Shafth(mm)42Impeller Outflow Thicknessb(mm)4.825Blade Degree (degree)23.20Blade Number-110.193E6Poisson ratioN0.29Density (kgm )3Source: Vyas and Basia (2013)Various conditions for analysis are:Rotational Speed 40000 rpm 50000 rpm 60000 rpm495558E(MPa)Ultimate TensileStrengthUTS(MPa)Source: Vyas and Basia (2013)167580301147
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014MaterialsThe Titanium alloy material at 60000 rpmcreates maximum strain of 0.0061 m/m andminimum strain of 2.18 10-5 m/m. Aluminum alloy Stainless steel alloyThe Aluminium alloy material at 60000 rpmcreates maximum stress of 3.51 108 Pa andminimum stress of 1.10 106 Pa. Titanium alloy– Stress Analysis– Vibrational AnalysisFigure 5: Stress Analysis of AluminiumAlloy at 60000 rpmRESULTSAnalysis Result of 60000 rpmThe Titanium alloy material at 60000 rpmcreates maximum stress of 6.178 108 Paand minimum stress of 2.22 106 Pa.Figure 3: Stress Analysis of Titanium Alloyat 60000 rpmFigure 6: Strain Analysis of AluminiumAlloy at 60000 rpmFigure 4: Strain Analysis of Titanium Alloyat 60000 rpmThe Aluminium alloy material at 60000 rpmcreates maximum strain of 0.00489 m/m andminimum strains of 1.54 10-5 m/m.The Stainless steel material at 60000 rpmcreates maximum stress of 1.02 108 Pa andminimum stress of 3.89 106 Pa.496
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Titanium Alloy Material (Ti-b-120UCA) UTS/FmaxFigure 7: Stress Analysis of StainlessSteel 60000 rpm 1147 106 Pa/6.177 108 Pa 1.857Aluminium Alloy Material (AL-a7079) UTS/Fmax 558 106 Pa/3.509 108 Pa 1.590Stainless Steel Alloy Material (STLAISI-304) 1675 106 Pa/1.021 108 Pa 1.640Analysis Result of 50000 rpmFigure 8: Strain Analysis of StainlessSteel 60000 rpmThe Titanium alloy material at 50000 rpmcreates maximum stress of 4.33 108 Pa andminimum stress of 1.56 106 Pa.The Titanium alloy material at 50000 rpmcreates maximum stress of 0.0042 m/m andminimum stress 1.53 10-5 m/m.The Aluminium alloy material at 50000 rpmcreates maximum stress of 2.46 108 Pa andminimum stress of 7.75 105 Pa.Figure 9: Stress Analysis of TitaniumAlloy at 50000 rpmThe Stainless steel material at 60000 rpmcreates maximum stress of 0.0052 m/m andminimum stress of 2.019 10-5 m/m.Table 3: Analysis Result of 60000 rpmTitaniumAlloyAluminiumAlloyStainlessSteel AlloyMaximumStress (Pa)6.177 1083.509 1081.021 109MaximumStrain (m/m)0.006060.004890.00529Safety Factor of this compressor model is:497
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Figure 10: Strain Analysis of TitaniumAlloy at 50000 rpmFigure 13: Stress Analysis of StainlessSteel at 50000 rpmFigure 11: Stress Analysis of AluminiumAlloy at 50000 rpmFigure 14: Strain Analysis of StainlessSteel at 50000 rpmFigure 12: Strain Analysis of AluminiumAlloy at 50000 rpmThe Aluminium alloy material at 60000 rpmcreates maximum strain of 0.0034 m/m andminimum strain of 1.80 10-5 m/m.The Stainless Steel alloy material at 50000rpm creates maximum stress of 7.16 108 Paand minimum stress of 2.73 106 Pa.The Stainless Steel material at 50000 rpmcreates maximum strain 0.0037 m/m andminimum strain of 1.42 10-5 m/m.498
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014The Titanium alloy material at 40000 rpmcreates maximum strain of 0.0027 andminimum strain of 9.78 10-6 m/m.Table 4: Analysis Result of 50000 rpmTitaniumAlloyAluminiumAlloyStainlessSteel AlloyMaximumStress (Pa)4.332 1082.461 1087.159 108MaximumStrain (m/m)0.004250.003430.00371Figure 16: Strain Analysis of TitaniumAlloy at 40000 rpmSafety Factor of this compressor model is:Titanium Alloy Material (Ti-b-120UCA) UTS/Fmax 1147 106 Pa/4.332 108 Pa 2.65Aluminium Alloy Material (AL-a7079 UTS/Fmax 558 106 Pa/2.461 108 Pa 2.27The Aluminium alloy material at 50000 rpmcreates maximum stress of 1.57 108 Pa andminimum stress of 4.96 105 Pa.Stainless Steel Alloy Material (STLAISI-304) UTS/Fmax 1675 106 Pa/7.159 108 PaFigure 17: Stress Analysis of AluminiumAlloy at 40000 rpm 2.34Analysis Result of 40000 rpmThe Titanium alloy material at 40000 rpmcreates maximum stress of 4.58 108 Pa andminimum stress of 1.75 106 Pa.Figure 15: Stress Analysis of TitaniumAlloy at 40000 rpmThe Aluminium alloy material at 40000 rpmcreates maximum strain of 0.0021m/m andminimum stress of 6.91 10-6 m/m.The Stainless Steel material at 40000 rpmcreates maximum stress of 4.58 108 Pa andminimum stress of 1.75 106 Pa.499
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Table 5: Analysis Result of 40000 rpmFigure 18: Strain Analysis of AluminiumAlloy at 40000 rpmTitaniumAlloyAluminiumAlloyStainlessSteel AlloyMaximumStress (Pa)2.772 1081.575 1084.582 108MaximumStrain (m/m)0.002720.002200.00240Safety Factor of this compressor model is:Titanium Alloy Material (Ti-b-120UCA) UTS/Fmax 1147 106 Pa/2.772 108 Pa 4.138Figure 19: Stress Analysis of StainlessSteel at 40000 rpmAluminium Alloy Material (AL-a7079) UTS/Fmax 558 106 Pa/1.575 108 Pa 3.54Stainless Steel Alloy Material (STLAISI-304) UTS/Fmax 1675 106 Pa/4.582 108 Pa 3.66Various Rotational Speed ResultsTitanium Alloy AnalysisTable 6: Analysis Result of Titanium AlloyFigure 20: Strain Analysis of StainlessSteel at 40000 rpmSpeed400005000060000MaximumStress (Pa)2.772 1084.332 1086.177 108Safety factor4.132.651.86Figure 21: Graph Showing Analysis Resultof Titanium AlloyThe Stainless Steel material at 60000 rpmcreates maximum stress of 0.0024 m/m andminimum strain of 2.22 10-6 m/m.500
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Aluminium Alloy AnalysisVibrational AnalysisThe Titanium alloy material at 4428.3 rpmcreates vibration of 4428.3 Hz frequency andmaximum deflection of 1.69 mm.Table 7: Analysis Result of Aluminium AlloySpeed400005000060000MaximumStress (Pa)1.575 1082.461 1083.509 108Safety factor3.542.271.59Figure 24: Vibrational Analysisof Titanium Alloy at 40000 rpmFigure 22: Graph Showing Analysis Resultof Aluminium AlloyStainless Steel Alloy MaterialAnalysisThe Aluminium alloy material at 40000 rpmcreates vibration of 4940.8 Hz frequency andmaximum deflection of 3.20 mm.Table 8: Stainless Steel Alloy MaterialAnalysisSpeed400005000060000MaximumStress (Pa)4.582 1087.159 1081.021 109Safety factor3.662.341.64Figure 25: Vibrational Analysisof Aluminium Alloy at 40000 rpmFigure 23: Graph Showing Analysis Resultof Stainless Steel AlloyThe Stainless Steel alloy material at 40000rpm creates vibration of 4940.8 Hz frequencyand maximum deflection of 1.53 mm.501
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014as compared to Aluminium Alloy and Stainlesssteel.Figure 26: Vibrational Analysisof Stainless Steel at 40000 rpmThe Titanium alloy material at 50000 rpmcreates vibration of 4462.8 Hz frequency andmaximum deflection of 2.02 mm.The Aluminium alloy material at 50000 rpmcreates vibration of 4971.4 Hz frequency andmaximum deflection of 1.97 mm.Figure 28: Vibrational Analysisof Aluminium Alloy at 50000 rpmComparison Table of VariousMaterials at 40000 rpmThe Titanium alloy material at 40000 rpmcreates a low vibration of 4428.3 Hz frequencyTable 9: Comparison Table of VariousMaterials at 40000 53The Stainless Steel alloy material at 50000rpm creates vibration of 4462.4 Hz frequencyand maximum deflection of 1.25 mm.Figure 29: Vibrational Analysisof Stainless Steel at 50000 rpmFigure 27: Vibrational Analysisof Titanium Alloy at 50000 rpm502
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Comparison Table of VariousMaterials at 50000 rpmFigure 31: Vibrational Analysisof Aluminium Alloy at 60000 rpmThe Titanium alloy material at 50000 rpmcreates a low vibration of 4462.8 Hz frequencyas compared to Aluminium Alloy and Stainlesssteel.Table 10: Comparison Table of VariousMaterials at 50000 25Figure 32: Vibrational Analysisof Stainless Steel at 60000 rpmThe Titanium alloy material at 60000 rpmcreates vibration of 4540.3 Hz frequency andmaximum deflection of 1.97 mm.Figure 30: Vibrational Analysisof Titanium Alloy at 60000 rpmComparison Table of VariousMaterials at 60000 rpmTable 11: Comparison Table of VariousMaterials at 60000 rpmFrequency(Hz)The Aluminium alloy material at 60000 rpmcreates vibration of 5007.7 Hz frequency andmaximum deflection of 2.66 lessSteel4503.25007.74792.91.972.661.59The Titanium alloy material at 60000 rpmcreates a low vibration of 4503.2 Hz frequencyas compared to Aluminium Alloy and Stainlesssteel.The Stainless Steel alloy material at 60000rpm creates vibration of 4792.9 Hz frequencyand maximum deflection of 1.59 mm.503
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014CONCLUSIONFUTURE SCOPEThe compressor blade is modelled by using3D modeling Software Solid works 2013. Inthis case stress analysis and vibrationalanalysis of different materials is carried outusing analysis software ANSYS 12.Even though Titanium Alloy have betterproperties comparing with others when costfactor come into consideration then it is costly.For future works, new material or compositematerial has to be found out with low cost andmore efficient.This analysis shows that Titanium alloyblade gives better safety factors comparedto other alloys. The vibration characteristicsfrom model analysis were also good for thesame alloy. The simulation showed that thestresses are concentrated on the bladeattachment to the hub. A better safety factorwould be obtained when the rotationalspeed is decreased. The simulationshowed that the stresses are concentratedon the blade attachment to the hub, causedby the centrifugal stresses. The countermeasure for this problem is to apply thef illet rad iu s th icken in g of t he b la deattachment to the hub.REFERENCES1. Amanda (2009), “Design of A MicroTurbine for Energy Scavenging from AGas Turbine Engine”, NASA.2. Brcon Williams and Brandon Howard(2012), “Demonstration of the Design ofA First-Stage Axial-Flow CompressorBlade Using Solid Modeling”, TechnologyInterface International Journal I, Vol. 2.3. Hansjorg Schilp (2000), “Fabrication ofTurbine-Compressor Shaft Assembly forMicro Gas Turbine Engine”.4. Lars Sommer and Dieter Bestle (2011),“Curvature Driven Two Dimensional MultiObjective Optimization of CompressorBlade Sections”, Aerospace Scienceand Technology, Vol. 15, pp. 334-342.Another point observed is that a higherrotational speed will result in greaterstresses to be borne by the structure, whichindicates that a better safety factor would beobtained when the rotational speed isdecreased.5. Lindsay Dempsev (2007), “Life CycleImpact of Steam Injection on theLM6000PC Turbine Blades”, IndustrialApplication of Gas Turbines Committee.Considerations about the limiting rotationalspeed are also of importance. Because of theneed to have a particular output power, thedesignated rotational speed needs to bepredicted, since structural strength is limitedby the various rotational speeds. Thus for thispurpose, Titanium alloy, with a much higherultimate tensile strength compare to StainlessSteel and Aluminium alloy, is thus the safematerial to be used because they have thehigher Young’s modulus (E).6. Pericles Pilidis (2007), “Analysis of GasTurbine Compressor Fouling andWashing on Line”, Cranfield University.7. Peter J Schubel and Richard J Crosslev(2012), “Compressor Blade Design”,March, ISSN: 1996-1073.8. Pradccp A V and Kona Ram Prasad(2012), “Design and Analysis of Wind504
Int. J. Mech. Eng. & Rob. Res. 2014Ajin Elias Alex and Nadeera M, 2014Turbine Blade Design System”,International Journal of EngineeringResearch and Applications, Vol. 2,No. 6, pp. 1038-1046, ISSN: 2248-9622.11. Vyas P B and Basia P R (2013), “CFDAnalysis of the Multistage Axial FlowCompressor”, Global ResearchAnalysis. Vol. 2, March, ISSN: 22778160.9. Rao J S (2011), “Weight Optimization ofTurbine Blades”, May, Altair Engineering,Inc.12. Wanshan Wang and Kai Zhang (2012),“Vibration Analysis of an Aero-EngineCompressor Blade”, InternationalConference on Mechanical Engineeringand Material Science (MEMS).10. Ujjawal A Jaiswal (2009), “Design andAnalysis of Stator, Rotor and Blades of theAxial Flow Compressor”, InternationalJournal of Sports Science andEngineering, Vol. 03.505
size. The micro turbine is actually the scale-down of the large ordinary gas turbine system. This is what gave birth to this project since the advantages of gas turbines are already known compared to other. This project deals with designing of micro turbine compressor and the corresponding overall integrity analysis of the designated compressor.
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