Finite Element Model of Aero Turbine Blades Investment Casting Process Based on Hypermesh

2010 ◽  
Author(s):  
Dou Yangqing ◽  
Bu Kun ◽  
Dou Yangliu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Investment Casting ◽  
Turbine Blades ◽  
Casting Process ◽  
Element Model ◽  
Investment Casting Process

scholarly journals Finite Element Model Correlation of an Investment Casting Process

2014 ◽  
Vol 797 ◽  
pp. 105-110 ◽  
Author(s):  
Eva Anglada ◽  
Antton Meléndez ◽  
Laura Maestro ◽  
Ignacio Domínguez
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Investment Casting ◽  
Material Properties ◽  
Casting Process ◽  
Element Model ◽  
Experimental Measurements ◽  
Manual Adjustment ◽  
Investment Casting Process ◽  
Model Correlation

The achievement of reliable simulations, in the case of complex processes as is the investment casting, is not a trivial task. Their accuracy is significantly related with the knowledge of the material properties and boundary conditions involved, but the estimation of these values usually is highly complex. One helpful option to try to avoid these difficulties is the use of inverse modelling techniques, where experimental temperature measurements are used as base to correlate the simulation models. The research presented hereafter corresponds to the correlation of a finite element model of the investment casting process of two nickel base superalloys, Hastelloy X and Inconel 718. The simulation model has been developed in a commercial software focused specifically on metal casting simulation. The experimental measurements used as base for the adjustment, have been performed at industrial facilities. The methodology employed combines the use of an automatic tool for model correlation with the manual adjustment guided by the researchers. Results obtained present a good agreement between simulation and experimental measurements, according to the industrial necessities. The model obtained is valid for the two studied cases with the only difference of the alloy material properties. The values obtained for the adjusted parameters in both cases are reasonable compared with bibliographic values. These two circumstances suggest that the obtained correlation is appropriate and no overfitting problems exist on it.

Fundamental Frequencies of Turbine Blades With Geometry Mismatch in Fir-Tree Attachments

2006 ◽  
Vol 128 (3) ◽  
pp. 512-516 ◽  
Author(s):  
Fei Qin ◽  
Liming Chen ◽  
Ying Li ◽  
Xiaofeng Zhang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Significant Influence ◽  
Turbine Blades ◽  
Three Dimensional ◽  
Element Model ◽  
Gap Size ◽  
Fundamental Frequencies ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

Geometry mismatch in a turbine blade root, which arose in manufacturing process or caused by wearing out during service, leads to contact conditions changed in fir-tree attachments. As a result, shifting of the fundamental frequencies and redistribution of stress in the blade base possibly cause failure of the blade. A three-dimensional finite element model of a blade and its fir-tree attachments have been constructed and analyzed by taking into account contact nonlinearity in the attachments and large deformation effect of the blade. The geometry mismatch was introduced into the finite element model by defining gaps between two contact surfaces in the attachments. The influence of gap configuration and gap size on contact and fundamental frequencies was investigated. Results showed that gap configuration has significant influence on fundamental frequencies of the blade, especially on its bending modes. Gap size has little influence on the frequencies but significant influence on the contact status and thus changes stress distribution in the attachments. The results also suggest that modeling contact behavior in fir-tree attachments is necessary to obtain more accurate fundamental frequencies.

A finite element model of the squeeze casting process

2006 ◽  
Vol 16 (5) ◽  
pp. 539-572 ◽  
Author(s):  
Roland W. Lewis ◽  
Eligiusz W. Postek ◽  
Zhiqiang Han ◽  
David T. Gethin
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Squeeze Casting ◽  
Casting Process ◽  
Element Model ◽  
Squeeze Casting Process

Quick Aeromechanical Assessment of Turbine Blades Based on Shell Element Based Models

2014 ◽  
Author(s):  
Suryarghya Chakrabarti ◽  
Letian Wang ◽  
K. M. K. Genghis Khan
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Natural Frequencies ◽  
Turbine Blades ◽  
Computation Time ◽  
Shell Element ◽  
Element Model ◽  
Shell Elements ◽  
Barrier Coating ◽  
Order Of Magnitude

A fast finite element model based tool has been developed to calculate the natural frequencies of fundamental modes of cooled gas turbine bladed disk assemblies during conceptual design. The tool uses shell elements to model the airfoil, shank, and disk, and achieves order of magnitude reduction in computation time allowing exploration of a wide design space at the preliminary design stages. The analysis includes prestress effects due to centrifugal loading and approximate temperature loading on the parts. Sensitivity studies are performed to understand the relative impact of design features such as airfoil internal geometry, bond coat, and thermal barrier coating on the system natural frequencies. Critical features are selected which need to be modeled to get an accurate natural frequency estimate. The results obtained are shown to be within 5% of the frequencies obtained from a full-fidelity finite element model. A case study performed on seven blade designs illustrates the use of this tool for quick aeromechanical assessment of a large number of designs.

scholarly journals CERAMIC CORES FOR TURBINE BLADES : A TOOLING PERSPECTIVE

2013 ◽  
pp. 93-99
Author(s):  
PRADYUMNA R ◽  
BAIG M A H
Keyword(s):  
Investment Casting ◽  
Turbine Blades ◽  
Casting Process ◽  
Ceramic Core ◽  
Pin Fin ◽  
Investment Cast ◽  
Investment Casting Process ◽  
Forced Cooling ◽  
Super Alloy ◽  
Ceramic Mix

Blade/vane components used in aerospace turbines are of twisted aerofoil shape, made by the process of investment casting, using Ni based super-alloy materials. These castings operate at turbine inlet temperatures (TET) close to the melting point of the alloy, in order to maximize thermal efficiency and thrust of the engine. The castings are made hollow, with intricate features such as turbulator, pin-fin, etc built-in to maximize the effect of heat transfer during forced cooling through internal passages. The hollow geometry in the castings is produced during the investment casting process by using a suitable ceramic core made from Silica or Alumina based mixes. These ceramic cores are high pressure injected by forcing the ceramic mix into dedicated molds or dies. Development of such dies is an involved process by itself, addressing issues right from ceramic mix behavior to manufacturability of the injection mould. The present paper attempts to highlight issues related to tooling development for ceramic cores used in investment cast turbine blade/vane components.

Quick Method for Aeroelastic and Finite Element Modeling of Wind Turbine Blades

2014 ◽  
Author(s):  
Jeffrey Bennett ◽  
Robert Bitsche ◽  
Kim Branner ◽  
Taeseong Kim
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Wind Turbine ◽  
Natural Frequencies ◽  
Turbine Blades ◽  
Element Model ◽  
Wind Turbine Blades ◽  
Quick Method ◽  
Cross Sectional ◽  
Aeroelastic Simulations

In this paper a quick method for modeling composite wind turbine blades is developed for aeroelastic simulations and finite element analyses. The method reduces the time to model a wind turbine blade by automating the creation of a shell finite element model and running it through a cross-sectional analysis tool in order to obtain cross-sectional properties for the aeroelastic simulations. The method utilizes detailed user inputs of the structural layup and aerodynamic profile including ply thickness, orientation, material properties and airfoils to create the models. After the process is complete the user has two models of the same blade, one for performing a structural finite element model analysis and one for aeroelastic simulations. Here, the method is implemented and applied to reverse engineer a structural layup for the NREL 5MW reference blade. The model is verified by comparing natural frequencies to the reference blade. Further, the application to aeroelastic and structural evaluations is demonstrated. Aeroelastic analyses are performed, and predicted fatigue loads are presented. Extreme loads from the aeroelastic simulations are extracted and applied onto the blade for a structural evaluation of the blade strength. Results show that the structural properties and natural frequencies of the developed 5MW blade match well with the reference blade, however the structural analysis found excessive strain at 16% span in the spare caps that would cause the blade to fail.

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