Tolerance-based Optimization of Sinking Edm for Industrial Seal Slot Manufacture

Seal plates for turbine vanes significantly reduce gap losses and thus play a major role in increasing the efficiency of turbines. The industrial production of seal slots, which position the seal plates in the turbine vanes, is driven by the need for high productivity in combination with a reliable processing of necessary geometrical and surface integrity features. A machining technology that is able to machine hard-to-cut materials such as nickel-based alloys is electrical discharge machining. Due to its electro-thermal working principle it is able to machine materials independently from their mechanical properties even at high aspect ratios. Achievable removal and wear rates as well as the resulting surface properties strongly depend on the discharge energy. Furthermore, the discharge energy affects the working gap sizes and therefore flushing efficiencies when machining high aspect ratio cavities. This relationship is investigated taking into account various contemporary generator technologies and graphite grades from both published literature and own experimental investigations. Their effect on machining performance focusing on productivity, recast layer thickness and crack formation is quantified. Based on this data a novel empirical model for tolerance-based optimization is developed. The model is used to perform an optimization on an existing serial production and implementation has been proven successful.

Tolerance-Based Optimization of Sinking EDM for Industrial Seal Slot Manufacture

Seal plates for turbine vanes significantly reduce gap losses and thus play a major role in increasing the efficiency of turbines. The industrial production of seal slots, which position the seal plates in the turbine vanes, is driven by the need for high productivity in combination with a reliable processing of necessary geometrical and surface integrity features. A machining technology that is able to machine hard-to-cut materials such as nickel-based alloys is electrical discharge machining. Due to its electro-thermal working principle it is able to machine materials independently from their mechanical properties even at high aspect ratios. Achievable removal and wear rates as well as the resulting surface properties strongly depend on the discharge energy. Furthermore, the discharge energy affects the working gap sizes and therefore flushing efficiencies when machining high aspect ratio cavities. This relationship is investigated taking into account various contemporary generator technologies and graphite grades from both published literature and own experimental investigations. Their effect on machining performance focusing on productivity, recast layer thickness and crack formation is quantified. Based on this data a novel empirical model for tolerance-based optimization is developed. The model is used to perform an optimization on an existing serial production and implementation has been proven successful.

A Numerical Study of the Effect of Particle Size on Particle Deposition on Turbine Vanes and Blades

Particle deposition could decrease the aerodynamic performance and cooling efficiency of turbine vanes and blades. The particle motion in the flow and its temperature are two important factors affecting its deposition. The size of the particle influences both its motion and temperature. In this study, the motion of particles with the sizes from 1 to 20 μm in the first stage of a turbine are firstly numerically simulated with the steady method, then the particle deposition on the vanes and blades are numerically simulated with the unsteady method based on the critical viscosity model. It is discovered that the particle deposition on vanes mainly formed near the leading and trailing edge on the pressure surface, and the deposition area expands slowly to the whole pressure surface with the particle size increasing. For the particle deposition on blades, the deposition area moves from the entire pressure surface toward the tip with the particle size increasing due to the effect of rotation. For vanes, the particle capture efficiency increases with the particle size increasing since Stokes number and temperature of the particle both increase with its size. For blades, the particle capture efficiency increases firstly and then decreases with the particle size increasing.

Variations of cooling performance on turbine vanes due to incipient particle deposition

In this paper, to demonstrate the deposition effects on cooling performance, the changing patterns of film cooling due to particle deposition are numerically investigated on a turbine vane that is cooled by an array of film-holes. The uniqueness of this work is addressing the cooling performance at an early deposition stage, in which deposits are relatively slight. The build-ups of the deposits are simulated by moving grid nodes on the wall boundaries. Results show that in addition to particle velocity, the blowing conditions and wall temperatures are two important factors to determine the deposition patterns. Increasing coolant-to-mainstream mass flow ratios and lowering wall temperatures can help inhibit the growth of deposits. In addition, the modifications of the vane profile due to incipient deposition are completely different from those with excessive deposition. Although flow fields are less sensitive to the early-stage deposits in the subsonic vane passage, cooling effectiveness is significantly changed and the changes are linked to the mass flow ratios. Compared to the cooling performance from a non-deposition case, reduced cooling performance due to incipient deposition is found at a low mass flow ratio of 1.09%, while cooling performance is improved at moderate and high mass flow ratios of 1.64% and 2.06%.

STUDI KERUSAKAN HIGH PRESSURE TURBINE VANE PESAWAT ATR72-500 WINGS AIR DI BANDARA SULTAN SYARIF KASIIM II PEKANBARU

The aircraft can fly as there is a thrust from the engine that causes the aircraft to have speed. The components of the aircraft engines are compressor, combustion chamber, turbine and propeller. High pressure turbine vanes is a component in the Hot section or turbine section that serves to direct the hot gas flow from the combustion chamber to the turbine. The purpose to be achieved in this research is to analyze and find out the cause of high pressure turbine vane damage and know the gas engine efficiency PW127. Cause of damage due to treatment not done according to the schedule until the phenomenon of overtemperature after combustion chamber and the content of impurities in the water laundering results. After the Brayton cycle calculation is obtained the temperature value of the turbine entry 1563oC (1836 K). These results exceed the turbine inlet temperature according to manual maintenance engine. Based on laboratory test, the content of 250 mg/m2 sulfur and 1800 mg/m2 chloride is obtained. This content causes damage by erosion or corrosion of high pressure turbine vane components. The value of gas efficiency is 42% according to the outside Air tempetarure. The thermal efficiency of gases will increase with increasing temperature conditions.

Hybrid RANS/LES Simulation of Combustor/Turbine Interactions

Accurate prediction of thermal field in high pressure turbines is a critical aspect of aerodynamic and durability design. This is particularly true when the flow at turbine inlet exhibits large gradients in temperature, both radially and circumferentially. In other words, in the presence of hot streaks from the combustor. In the numerical study presented in this paper, coupled high-fidelity eddy-resolving simulations of a combustor and a turbine are used to study the differences in the temperature profile at the exit of the first vane and the heat flux on the first blade, resulting from different positioning, or clocking, between the combustor fuel nozzles and turbine vanes. The resolved unsteadiness and turbulence from the combustor impacts mixing and secondary flow in the high pressure turbine. Temperature profiles from both actual combustor CFD simulations, as well as and modulated profiles with more pronounced variation, or pattern factor, are used at the turbine inlet. A threshold of the pattern factor that brings the benefit of clocking is identified. Clocking positioning between the combustor and vanes was studied for the most benefit.