ๅฐŠๆ•ฌ็š„ ๅพฎไฟกๆฑ‡็Ž‡๏ผš1ๅ†† โ‰ˆ 0.046078 ๅ…ƒ ๆ”ฏไป˜ๅฎๆฑ‡็Ž‡๏ผš1ๅ†† โ‰ˆ 0.046168ๅ…ƒ [้€€ๅ‡บ็™ปๅฝ•]
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Gas Turbine Design
Project Presentation
ACME Aerospace Inc.
โ€œHistory will be kind to me, for I intend to write it.โ€
- Winston Churchill
Project Plan- Milestones
๏ƒผ Overall Cycle Analysis for gas turbine configuration.
๏ƒผ High Pressure Turbine.
๏‚ง Mean line Analysis
๏‚ง Loss Calculations
๏‚ง Smithโ€™s Chart- The Sanity Check !
๏‚ง Rotor Geometry โ€“ Hub/ Tip Analysis
๏ƒผ Design Selection - Engineering Analysis
๏ƒผ Economic feasibility study โ€“ Tradeoffs !
๏ƒผ OFF- Design Analysis
๏ƒผ Business Case !
Aero + Stress
Costingโ€ฆ
ACME Aerospace Inc - Bringing Technologies of Change
Cycle Analysis
1
4
5
6
7
s
T
3
2
โˆ† ๐‘ท ๐’ƒ
(8 % + 1 %) Bleed + ACC
(3.3 % + 1.65 %) Vane + Disk
(2.1%) Disk
Cooling DetailsMass Flow Rates
๐‘š ๐‘ก = 46.94 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘ = 41.73 ๐‘˜๐‘” ๐‘ 
๐‘šโ„Ž = 5.216 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ = 0.4698 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘“๐‘ข๐‘’๐‘™ = 0.095 ๐‘˜๐‘” ๐‘ 
FAN
BOOST
STAGE
HPC
HPT
LPT
C/C
1 2 3 6 7
4 5 8
๐‘š ๐‘ก
๐‘š ๐‘
๐‘šโ„Ž
๐‘š ๐‘“
๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘
ACME Aerospace Inc - Bringing Technologies of Change
FAN
BOOST
STAGE
HPC
HPT
LPT
C/C
1 2 3 6 7
4 5 8
๐‘š ๐‘ก
๐‘š ๐‘
๐‘šโ„Ž
๐‘š ๐‘“
๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘
Cycle Analysis
Mass Flow Rates
๐‘š ๐‘ก = 46.94 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘ = 41.73 ๐‘˜๐‘” ๐‘ 
๐‘šโ„Ž = 5.216 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ = 0.4698 ๐‘˜๐‘” ๐‘ 
๐‘š ๐‘“๐‘ข๐‘’๐‘™ = 0.095 ๐‘˜๐‘” ๐‘ 
(8 % + 1 %) Bleed + ACC
(3.3 % + 1.65 %) Vane + Disk
(2.1%) Disk
Cooling Details
Stage Component Pressure
(bar)
Temperature
(K)
0-1 Diffuser 0.268 244.43
1-2 Fan 0.3819 273
2-3 Boost Comp. 1.072 382.51
3-4 HPC 3.216 549.42
4-5 C/C 3.158 1148.04
5-6 HPT 1.610 971
6-7 LPT 0.241 645.2
7-8 Hot Nozzle 0.175 593.21
2-8 Cold Nozzle 0.165 207.2
ACME Aerospace Inc - Bringing Technologies of Change
High Pressure Turbine- Mean Line
Analysis Parameters State 1 State 2 State 3
Temp (K) 1149.347 1038.2178 939.6054
P (bar) 3.15603268 2.359808269 1.434861637
C (m/s) 82.7328 446.5382 269.7755
Cw (m/s) 17.0223 485.6564 58.2745
Ca (m/s) 81.4523 180.1132 265.2863
Area (m2
) 0.0606 0.0364 0.0364
Vw(m/s) - 150.3764 393.5545
ฮฒ (ยฐ) - 39.8559 56.0173
V (m/s) - 234.6355 474.6177
MR - 0.3779 0.7928
TOR (k) - 1031.5134 1037.1271
POR (bar) - 2.22138546 2.09704923
M 0.1257 0.7093 0.45
ฮฑ (ยฐ) -10 66.2609 10.5
R (%) 0.48
Y 0.0596 0.0446
ฮถ 0.1142 0.0761
ฮท% 92.5%
Design Presumptions
Mach No Swirl Angle
Inlet 0.125 -10
Exit 0.45 10.5
Vane Blade
Aspect Ratio 0.7 1.45
Zwiefel Coeff 0.8 0.95
TE Thickness
(inches)
0.045 0.025
Reaction- 0.48
Efficiency โ€“ 0.87
๐ด๐‘2
= 4.5 x 1010
Work- 182.369 KJ/kg
๐‘š1= 4.84174 ๐‘˜๐‘” ๐‘ 
๐‘š2= 5.015 ๐‘˜๐‘” ๐‘ 
๐‘š3= 5.1298 ๐‘˜๐‘” ๐‘ 
1
2
3
Inlet to nozzle vanes
Inlet to rotor
Exit of rotor
1
2
3
ACME Aerospace Inc - Bringing Technologies of Change
Loss Calculations/ Smith Chart
92.5
Smith ChartLosses Calculation
Nozzle Section Aerodynamic Loss
Distribution
Kp Ks Kte
Blade Section Aerodynamic Loss
Distribution
Kp Ks Kte
58
65
24
11
27
15
Note: Tip Leakage losses are assumed 1 %.
๐พ๐‘ก๐‘’ - Trailing Edge
๐พ๐‘  - Secondary
๐พ ๐‘ƒ - Profile
Efficiency After
Losses- 88.59 %
ACME Aerospace Inc - Bringing Technologies of Change
Stage Geometry- Hub Tip Analysis
-0.98
Metal Angles
-3
-4.3
64.04
67.26
70.65
48
50
57
Stagger Angles
Variation: 9
HUB
TIP
HUB
TIP
Vane Geometry- Hub Mean Tip
SI Units Hub Mean Tip
Stagger ษฃ(ยฐ) 57 50 48
Height h 0.0540
Chord C 0.0772
๐‘ก ๐‘š๐‘Ž๐‘ฅ 0.0143 0.0137 0.0132
Axial chord
๐ถ ๐‘Ž
0.0420 0.0496 0.0516
N 18 18 18
Pitch (S) 0.0400 0.0471 0 .0589
Zwiefel (ฮจ) - 0.8 -
Throat Ov 0.01347 0.0228 0.0258
ยฐ
ACME Aerospace Inc - Bringing Technologies of Change
Rotor Geometry- Hub Tip Analysis
Blade Geometry- Hub Mean Tip
-4.3
-19.44
8.7
39
63.16
60.29
57.07
Metal Angles
Stagger Angles
Variation: 32.5
52.5
38.0
20.0
HUB
TIP
TIP
HUB
SI Units Hub Mean Tip
Stagger ษฃ(ยฐ) 20 38 52.5
Height h 0.0427
Chord C 0.0294
๐‘ก ๐‘š๐‘Ž๐‘ฅ 0.00575 0.0055 0.0048
Axial chord
๐ถ ๐‘Ž
0.0276 0.0232 0.0179
N 35 35 35
Pitch (S) 0.0206 0.0244 0 .0282
Zwiefel (ฮจ) - 0.95 -
Throat Ov 0.0104 0.0121 0.0127
ยฐ
ACME Aerospace Inc - Bringing Technologies of Change
Assembled Rotor Geometry
Parameters Qty/ Measurements
No of Vanes 18
No of Blades 35
Pitch- ๐‘† ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0244
Axial ๐ถโ„Ž๐‘œ๐‘Ÿ๐‘‘ ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0232
Throat ๐‘‚๐‘๐‘’๐‘›๐‘–๐‘›๐‘” ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0121
Blade height 0.0427
Vane height 0.0540
Mean radius ( Vane) 0.1418
Mean radius (Blade) 0.1361
๐ด๐‘2
4.5 x 1010
Blade
Vane
Design Nozzle Vanes Rotor Blades
Design 1 (88.59%) 18 35
Design 2 (87.99%) 28 53
Design 3 (88.36%) 21 41
Design 4 (88.04%) 28 58
Design 5 (88.55%) 21 38
Lowest number of vanes and
blade
Blade geometry details calculated
for Design 1 ( ฮท = 88.59 %)
View- A
View- B
ACME Aerospace Inc - Bringing Technologies of Change
Aerodynamic vs Stress Analysis
๏ƒผ Aerodynamic Analysis
๏‚ง High AN^2 leads to greater value of โ€œblade speedโ€ which results in
higher pitch and less number of blades
๏‚ง Lesser number of blades reduce Profile , TE and tip leakage losses.
On contrary Secondary losses increase.
๏‚ง Efficiency increases.
87.9
88
88.1
88.2
88.3
88.4
88.5
88.6
88.7
0 20 40 60 80
Efficiency
Number of Blades
Number of Blades vs Efficiency %
87.9
88
88.1
88.2
88.3
88.4
88.5
88.6
88.7
0.00E+00 2.00E+10 4.00E+10 6.00E+10
Efficiency
AN ^2
AN^2 VS EFFICIENCY %
0
10
20
30
40
50
60
70
0 2E+10 4E+10 6E+10
NoofBlades
AN ^2
AN ^2 vs # of Blades
Decrease in # of blades
with increasing ๐ด๐‘2
Design 1: ๐ด๐‘2
= 4.5 x 1010
Increase in efficiency
with ๐ด๐‘2
Decrease in efficiency
with increasing # of
blades
ACME Aerospace Inc - Bringing Technologies of Change
๏ƒผ Stress Analysis
๏‚ง High AN^2 leads to greater value of โ€œblade speedโ€ which
results in higher โ€œCentrifugal Tensile Stressโ€
๏‚ง More stretched blade , results in lesser effect of
โ€œGas Bending Stressโ€.
๏‚ง High efficiency corresponds to low gas bending but high
centrifugal stresses.
Aerodynamic vs Stress Analysis
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0.00E+00 2.00E+10 4.00E+10 6.00E+10
GasBendingStress(MPa)
AN ^2
Gas Bending Stress vs AN^2
Reduction in Gas bending
stress with increasing ๐ด๐‘^2
0
50
100
150
200
250
300
350
400
450
0.00E+00 2.00E+10 4.00E+10 6.00E+10
CentrifugalStress(MPa)
AN ^2
Centrifugal Tensile Stress vs AN ^2
Linear relationship b/w
Centrifugal stress & ๐ด๐‘^2
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0
50
100
150
200
250
300
350
400
450
87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7
GasBending(MPa)
CentrifugalTensile(MPa)
Efficiency
Centrifugal / Gas Bending Stress
vs
Efficiency
Centrifugal Tensile Stress (Mpa) Gas Bending Stress (Mpa)
Increasing Centrifugal stress
Decreasing Bending Stress
ACME Aerospace Inc - Bringing Technologies of Change
Cost Analysis
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
500000
Design-1
(88.59%)
Design-2
(87.9918 %)
Design-3
(88.36 %)
Design-4
(88.045 %)
Design-5
(88.554 %)
TotalRelativeCosts$
Material With Efficiency
Comparision of Engine Design for Total Relative
Cost vs Efficiency
5000 Hrs 4000 Hrs 7000 Hrs
Analysis
FORMULA
Total Cost = Fuel Cost + Total Blade Cost +
Overall Maint. Cost
๏‚ง Material Z is coming with lowest total cost
with different number of blade
configurations (or designs)
Analysis
FORMULA
Total Relative Cost = Overall Maint. Cost + Total
Blades Cost + Relative Fuel Cost
๏‚ง Considering Design 1 as our baseline Relative
Fuel Cost = 0 $
๏‚ง For Design 1, Total Relative Cost for 7000 hrs. is
minimum.
X = 5000 hrs.
Y = 4000 hrs.
Z = 7000 hrs.
10750
10800
10850
10900
10950
11000
11050
11100
11150
X Y z X Y z X Y z X Y z X Y z
35 38 41 53 58
TotalCostx1000$
Number of blades with material
Overall Cost v/s Blade Count
ACME Aerospace Inc - Bringing Technologies of Change
10880
10890
10900
10910
10920
10930
10940
10950
10960
10970
10980
0
10
20
30
40
50
60
70
87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7
TotalCostx1000$
NumberofBlades
Efficiency %
Number of Blades/Total Cost vs Efficiency
Eff % vs Total Cost
Eff % vs Number of Blades
533
534
535
536
537
538
539
106.6
106.8
107
107.2
107.4
107.6
107.8
88.59 %
(35)
88.55 %
(38)
88.36 %
(41)
88.04 %
(58)
87.99 %
(53)
FuelConsumptioncost($/Hr)
FuelConsumption(Gallons/Hr)
Efficiency (Number of blades)
Efficiency v/s Fuel Consumption/ Fuel Cost
Analysis
๏‚ง With decreasing efficiency fuel consumption and cost
increases.
๏‚ง Lesser efficiency corresponds to more number of
blades hence more losses and greater quantity of fuel
is required to fly an aircraft.
๏‚ง Reduction in Power to Weight Ratio with more # of
blades
Cost Analysis
ACME Aerospace Inc - Bringing Technologies of Change
Design Selection โ€“ Aero + Stress +Cost
0
0.2
0.4
0.6
0.8
1
1.2
1.4
10880
10890
10900
10910
10920
10930
10940
10950
10960
10970
10980
87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7
GasBendingStress(MPa)
TotalCostx1000($)
Efficiency %
Aerodynamics/Stress Analysis vs Cost
(Material Z )
Total Cost (Z-Material) x 1000 Gas Bending Stress (Mpa)
๐‘จ๐‘ต^๐Ÿ=4.5 x ๐Ÿ๐ŸŽ^๐Ÿ๐ŸŽ
0.00
10000.00
20000.00
30000.00
40000.00
50000.00
60000.00
70000.00
87.9
88
88.1
88.2
88.3
88.4
88.5
88.6
88.7
0 10 20 30 40 50 60 70
FuelCostDifference/Annum
Efficiency%
Number of Blades
Fuel Cost Difference/ Number of Blades
vs
Efficiency
# ๐ต๐‘™๐‘Ž๐‘‘๐‘’๐‘  ๐‘ฃ๐‘  ๐ธ๐‘“๐‘“ %
# ๐ต๐‘™๐‘Ž๐‘‘๐‘’๐‘  ๐‘ฃ๐‘  ๐น๐‘ข๐‘’๐‘™ ๐ถ๐‘œ๐‘ ๐‘ก ๐ท๐‘–๐‘“๐‘“
๐‘จ๐‘ต^๐Ÿ= 4.5 x ๐Ÿ๐ŸŽ^๐Ÿ๐ŸŽ
(Design 1)
Analysis
๏‚ง With increasing efficiency, total cost as well as gas bending stress has
minimum value.
๏‚ง For ๐ด๐‘2
4.5 x 1010
Efficiency = 88.59 % Design 1
Analysis
๏‚ง Increasing number of blades lead to reduced efficiency and
more Aerodynamic losses.
๏‚ง Further relative fuel cost increases with more number of blades
pointing to the fact that greater quantity of fuel will be required
to travel longer distances.
Chosen Design
Cost of Engine โ€“ 10.88 M ($)
ACME Aerospace Inc - Bringing Technologies of Change
OFF- Design Analysis
0
10
20
30
40
50
60
70
80
90
100
200.00
250.00
300.00
350.00
400.00
450.00
500.00
550.00
600.00
800 1000 1200 1400 1600 1800
Efficiency(%)
FuelConsumption(Kg/Hr)
Peak cycle temperature (K)
Performance Analysis of Peak Cycle Temperature
Design
(88.59 %)
Increasing Fuel
Consumption
Efficiency
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
88 88.5 89 89.5 90 90.5
TipControlClearance(%)
Efficiency (%)
Tip Control Clearance vs Efficiency
Analysis
๏‚ง With increasing peak cycle temperature, fuel consumption
increases since more fuel needs to be burned.
๏‚ง A sharp increase in efficiency to a maximum value and then it dips
and remains constant.
๏‚ง With increasing ACC supply, tip clearance reduces and hence
reduction in tip leakage losses
Decrease in efficiency with an
increase in tip clearance
ACME Aerospace Inc - Bringing Technologies of Change
Other Design Options :
๏ƒผ For lower than chosen ๐ด๐‘2
value โ€“
Design 2
โ€ข # of Blades = 38 More Weight
โ€ข Increase in Cost = $ 6627
โ€ข Decrease in Centrifugal Tensile Stress = 44.73
MPa.
Design 3
โ€ข # of Blades = 41 More Weight
โ€ข Increase in Cost = $ 30256
โ€ข Decrease in Centrifugal Tensile Stress = 89.46
MPa.
๏ƒผ Efficiency Front
๏‚ง Decrease in efficiency can be countered by
increasing peak cycle temperature slightly
which will not affect our blade metallurgy as
well.
Parameter Design-1 Design-2 Design-3
Efficiency 88.59 88.55 88.36
AN^2 4.5*10^10 4*10^10 3.5*10^10
No Of Blades 35 38 41
Centrifugal Tensile
Stress (MPa)
402.573 357.84 313.11
Gas Bending Stress
(MPa)
0.71212106 0.806799171 0.98
Total Cost ($) 10888097.35 10894725.07 10918354.12
Difference in Cost ($) - 6627.72 30256.76
Difference in Centrifugal
Stress (MPa)
- 44.73 89.46
Chosen Design
0
0.04
0.08
0.12
0
10
20
30
40
50
60
70
80
90
100
900 1000 1100 1200 1300 1400 1500 1600 1700
SFC(kg/hr.N)
Efficiency%
Peak Cycle Temperature - K
Peak Cycle Temp vs SFC & Eff. %
Efficiency %
SFC
Design 2/3
Slight increase in T
ACME Aerospace Inc - Bringing Technologies of Change
Business Caseโ€ฆ
Why ACME Aerospace โ€ฆ
๏‚ง Team Synergy
๏‚ง Customer consciousness
๏‚ง Two pronged expertise
Aerodynamics + Stress
Inevitable Choice !
High efficiency Lesser Cost High โ€œPower to Weightโ€ Ratio
Less fuel consumption Better Specific Aircraft Range (SAR) miles/lbm of fuel
Less fuel requirement More space for passengers โ€ฆ
Low Maintenance Downtime More Operational Time โ€ฆ
MORE REVENUES !
More options in design available
ACME Aerospace Inc - Bringing Technologies of Change
MERCIโ€ฆ !
ACME Aerospace Inc
Bringing Technologies of Change

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Presentation Acme engineering- Two Stage Turbo Shaft Engine- Pratt and Whittney

  • 1. Gas Turbine Design Project Presentation ACME Aerospace Inc. โ€œHistory will be kind to me, for I intend to write it.โ€ - Winston Churchill
  • 2. Project Plan- Milestones ๏ƒผ Overall Cycle Analysis for gas turbine configuration. ๏ƒผ High Pressure Turbine. ๏‚ง Mean line Analysis ๏‚ง Loss Calculations ๏‚ง Smithโ€™s Chart- The Sanity Check ! ๏‚ง Rotor Geometry โ€“ Hub/ Tip Analysis ๏ƒผ Design Selection - Engineering Analysis ๏ƒผ Economic feasibility study โ€“ Tradeoffs ! ๏ƒผ OFF- Design Analysis ๏ƒผ Business Case ! Aero + Stress Costingโ€ฆ ACME Aerospace Inc - Bringing Technologies of Change
  • 3. Cycle Analysis 1 4 5 6 7 s T 3 2 โˆ† ๐‘ท ๐’ƒ (8 % + 1 %) Bleed + ACC (3.3 % + 1.65 %) Vane + Disk (2.1%) Disk Cooling DetailsMass Flow Rates ๐‘š ๐‘ก = 46.94 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘ = 41.73 ๐‘˜๐‘” ๐‘  ๐‘šโ„Ž = 5.216 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ = 0.4698 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘“๐‘ข๐‘’๐‘™ = 0.095 ๐‘˜๐‘” ๐‘  FAN BOOST STAGE HPC HPT LPT C/C 1 2 3 6 7 4 5 8 ๐‘š ๐‘ก ๐‘š ๐‘ ๐‘šโ„Ž ๐‘š ๐‘“ ๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ ACME Aerospace Inc - Bringing Technologies of Change
  • 4. FAN BOOST STAGE HPC HPT LPT C/C 1 2 3 6 7 4 5 8 ๐‘š ๐‘ก ๐‘š ๐‘ ๐‘šโ„Ž ๐‘š ๐‘“ ๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ Cycle Analysis Mass Flow Rates ๐‘š ๐‘ก = 46.94 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘ = 41.73 ๐‘˜๐‘” ๐‘  ๐‘šโ„Ž = 5.216 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘๐‘™๐‘’๐‘’๐‘‘ = 0.4698 ๐‘˜๐‘” ๐‘  ๐‘š ๐‘“๐‘ข๐‘’๐‘™ = 0.095 ๐‘˜๐‘” ๐‘  (8 % + 1 %) Bleed + ACC (3.3 % + 1.65 %) Vane + Disk (2.1%) Disk Cooling Details Stage Component Pressure (bar) Temperature (K) 0-1 Diffuser 0.268 244.43 1-2 Fan 0.3819 273 2-3 Boost Comp. 1.072 382.51 3-4 HPC 3.216 549.42 4-5 C/C 3.158 1148.04 5-6 HPT 1.610 971 6-7 LPT 0.241 645.2 7-8 Hot Nozzle 0.175 593.21 2-8 Cold Nozzle 0.165 207.2 ACME Aerospace Inc - Bringing Technologies of Change
  • 5. High Pressure Turbine- Mean Line Analysis Parameters State 1 State 2 State 3 Temp (K) 1149.347 1038.2178 939.6054 P (bar) 3.15603268 2.359808269 1.434861637 C (m/s) 82.7328 446.5382 269.7755 Cw (m/s) 17.0223 485.6564 58.2745 Ca (m/s) 81.4523 180.1132 265.2863 Area (m2 ) 0.0606 0.0364 0.0364 Vw(m/s) - 150.3764 393.5545 ฮฒ (ยฐ) - 39.8559 56.0173 V (m/s) - 234.6355 474.6177 MR - 0.3779 0.7928 TOR (k) - 1031.5134 1037.1271 POR (bar) - 2.22138546 2.09704923 M 0.1257 0.7093 0.45 ฮฑ (ยฐ) -10 66.2609 10.5 R (%) 0.48 Y 0.0596 0.0446 ฮถ 0.1142 0.0761 ฮท% 92.5% Design Presumptions Mach No Swirl Angle Inlet 0.125 -10 Exit 0.45 10.5 Vane Blade Aspect Ratio 0.7 1.45 Zwiefel Coeff 0.8 0.95 TE Thickness (inches) 0.045 0.025 Reaction- 0.48 Efficiency โ€“ 0.87 ๐ด๐‘2 = 4.5 x 1010 Work- 182.369 KJ/kg ๐‘š1= 4.84174 ๐‘˜๐‘” ๐‘  ๐‘š2= 5.015 ๐‘˜๐‘” ๐‘  ๐‘š3= 5.1298 ๐‘˜๐‘” ๐‘  1 2 3 Inlet to nozzle vanes Inlet to rotor Exit of rotor 1 2 3 ACME Aerospace Inc - Bringing Technologies of Change
  • 6. Loss Calculations/ Smith Chart 92.5 Smith ChartLosses Calculation Nozzle Section Aerodynamic Loss Distribution Kp Ks Kte Blade Section Aerodynamic Loss Distribution Kp Ks Kte 58 65 24 11 27 15 Note: Tip Leakage losses are assumed 1 %. ๐พ๐‘ก๐‘’ - Trailing Edge ๐พ๐‘  - Secondary ๐พ ๐‘ƒ - Profile Efficiency After Losses- 88.59 % ACME Aerospace Inc - Bringing Technologies of Change
  • 7. Stage Geometry- Hub Tip Analysis -0.98 Metal Angles -3 -4.3 64.04 67.26 70.65 48 50 57 Stagger Angles Variation: 9 HUB TIP HUB TIP Vane Geometry- Hub Mean Tip SI Units Hub Mean Tip Stagger ษฃ(ยฐ) 57 50 48 Height h 0.0540 Chord C 0.0772 ๐‘ก ๐‘š๐‘Ž๐‘ฅ 0.0143 0.0137 0.0132 Axial chord ๐ถ ๐‘Ž 0.0420 0.0496 0.0516 N 18 18 18 Pitch (S) 0.0400 0.0471 0 .0589 Zwiefel (ฮจ) - 0.8 - Throat Ov 0.01347 0.0228 0.0258 ยฐ ACME Aerospace Inc - Bringing Technologies of Change
  • 8. Rotor Geometry- Hub Tip Analysis Blade Geometry- Hub Mean Tip -4.3 -19.44 8.7 39 63.16 60.29 57.07 Metal Angles Stagger Angles Variation: 32.5 52.5 38.0 20.0 HUB TIP TIP HUB SI Units Hub Mean Tip Stagger ษฃ(ยฐ) 20 38 52.5 Height h 0.0427 Chord C 0.0294 ๐‘ก ๐‘š๐‘Ž๐‘ฅ 0.00575 0.0055 0.0048 Axial chord ๐ถ ๐‘Ž 0.0276 0.0232 0.0179 N 35 35 35 Pitch (S) 0.0206 0.0244 0 .0282 Zwiefel (ฮจ) - 0.95 - Throat Ov 0.0104 0.0121 0.0127 ยฐ ACME Aerospace Inc - Bringing Technologies of Change
  • 9. Assembled Rotor Geometry Parameters Qty/ Measurements No of Vanes 18 No of Blades 35 Pitch- ๐‘† ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0244 Axial ๐ถโ„Ž๐‘œ๐‘Ÿ๐‘‘ ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0232 Throat ๐‘‚๐‘๐‘’๐‘›๐‘–๐‘›๐‘” ๐‘๐‘™๐‘Ž๐‘‘๐‘’ 0.0121 Blade height 0.0427 Vane height 0.0540 Mean radius ( Vane) 0.1418 Mean radius (Blade) 0.1361 ๐ด๐‘2 4.5 x 1010 Blade Vane Design Nozzle Vanes Rotor Blades Design 1 (88.59%) 18 35 Design 2 (87.99%) 28 53 Design 3 (88.36%) 21 41 Design 4 (88.04%) 28 58 Design 5 (88.55%) 21 38 Lowest number of vanes and blade Blade geometry details calculated for Design 1 ( ฮท = 88.59 %) View- A View- B ACME Aerospace Inc - Bringing Technologies of Change
  • 10. Aerodynamic vs Stress Analysis ๏ƒผ Aerodynamic Analysis ๏‚ง High AN^2 leads to greater value of โ€œblade speedโ€ which results in higher pitch and less number of blades ๏‚ง Lesser number of blades reduce Profile , TE and tip leakage losses. On contrary Secondary losses increase. ๏‚ง Efficiency increases. 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 0 20 40 60 80 Efficiency Number of Blades Number of Blades vs Efficiency % 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 0.00E+00 2.00E+10 4.00E+10 6.00E+10 Efficiency AN ^2 AN^2 VS EFFICIENCY % 0 10 20 30 40 50 60 70 0 2E+10 4E+10 6E+10 NoofBlades AN ^2 AN ^2 vs # of Blades Decrease in # of blades with increasing ๐ด๐‘2 Design 1: ๐ด๐‘2 = 4.5 x 1010 Increase in efficiency with ๐ด๐‘2 Decrease in efficiency with increasing # of blades ACME Aerospace Inc - Bringing Technologies of Change
  • 11. ๏ƒผ Stress Analysis ๏‚ง High AN^2 leads to greater value of โ€œblade speedโ€ which results in higher โ€œCentrifugal Tensile Stressโ€ ๏‚ง More stretched blade , results in lesser effect of โ€œGas Bending Stressโ€. ๏‚ง High efficiency corresponds to low gas bending but high centrifugal stresses. Aerodynamic vs Stress Analysis 0 0.2 0.4 0.6 0.8 1 1.2 1.4 0.00E+00 2.00E+10 4.00E+10 6.00E+10 GasBendingStress(MPa) AN ^2 Gas Bending Stress vs AN^2 Reduction in Gas bending stress with increasing ๐ด๐‘^2 0 50 100 150 200 250 300 350 400 450 0.00E+00 2.00E+10 4.00E+10 6.00E+10 CentrifugalStress(MPa) AN ^2 Centrifugal Tensile Stress vs AN ^2 Linear relationship b/w Centrifugal stress & ๐ด๐‘^2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 0 50 100 150 200 250 300 350 400 450 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 GasBending(MPa) CentrifugalTensile(MPa) Efficiency Centrifugal / Gas Bending Stress vs Efficiency Centrifugal Tensile Stress (Mpa) Gas Bending Stress (Mpa) Increasing Centrifugal stress Decreasing Bending Stress ACME Aerospace Inc - Bringing Technologies of Change
  • 12. Cost Analysis 0 50000 100000 150000 200000 250000 300000 350000 400000 450000 500000 Design-1 (88.59%) Design-2 (87.9918 %) Design-3 (88.36 %) Design-4 (88.045 %) Design-5 (88.554 %) TotalRelativeCosts$ Material With Efficiency Comparision of Engine Design for Total Relative Cost vs Efficiency 5000 Hrs 4000 Hrs 7000 Hrs Analysis FORMULA Total Cost = Fuel Cost + Total Blade Cost + Overall Maint. Cost ๏‚ง Material Z is coming with lowest total cost with different number of blade configurations (or designs) Analysis FORMULA Total Relative Cost = Overall Maint. Cost + Total Blades Cost + Relative Fuel Cost ๏‚ง Considering Design 1 as our baseline Relative Fuel Cost = 0 $ ๏‚ง For Design 1, Total Relative Cost for 7000 hrs. is minimum. X = 5000 hrs. Y = 4000 hrs. Z = 7000 hrs. 10750 10800 10850 10900 10950 11000 11050 11100 11150 X Y z X Y z X Y z X Y z X Y z 35 38 41 53 58 TotalCostx1000$ Number of blades with material Overall Cost v/s Blade Count ACME Aerospace Inc - Bringing Technologies of Change
  • 13. 10880 10890 10900 10910 10920 10930 10940 10950 10960 10970 10980 0 10 20 30 40 50 60 70 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 TotalCostx1000$ NumberofBlades Efficiency % Number of Blades/Total Cost vs Efficiency Eff % vs Total Cost Eff % vs Number of Blades 533 534 535 536 537 538 539 106.6 106.8 107 107.2 107.4 107.6 107.8 88.59 % (35) 88.55 % (38) 88.36 % (41) 88.04 % (58) 87.99 % (53) FuelConsumptioncost($/Hr) FuelConsumption(Gallons/Hr) Efficiency (Number of blades) Efficiency v/s Fuel Consumption/ Fuel Cost Analysis ๏‚ง With decreasing efficiency fuel consumption and cost increases. ๏‚ง Lesser efficiency corresponds to more number of blades hence more losses and greater quantity of fuel is required to fly an aircraft. ๏‚ง Reduction in Power to Weight Ratio with more # of blades Cost Analysis ACME Aerospace Inc - Bringing Technologies of Change
  • 14. Design Selection โ€“ Aero + Stress +Cost 0 0.2 0.4 0.6 0.8 1 1.2 1.4 10880 10890 10900 10910 10920 10930 10940 10950 10960 10970 10980 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 GasBendingStress(MPa) TotalCostx1000($) Efficiency % Aerodynamics/Stress Analysis vs Cost (Material Z ) Total Cost (Z-Material) x 1000 Gas Bending Stress (Mpa) ๐‘จ๐‘ต^๐Ÿ=4.5 x ๐Ÿ๐ŸŽ^๐Ÿ๐ŸŽ 0.00 10000.00 20000.00 30000.00 40000.00 50000.00 60000.00 70000.00 87.9 88 88.1 88.2 88.3 88.4 88.5 88.6 88.7 0 10 20 30 40 50 60 70 FuelCostDifference/Annum Efficiency% Number of Blades Fuel Cost Difference/ Number of Blades vs Efficiency # ๐ต๐‘™๐‘Ž๐‘‘๐‘’๐‘  ๐‘ฃ๐‘  ๐ธ๐‘“๐‘“ % # ๐ต๐‘™๐‘Ž๐‘‘๐‘’๐‘  ๐‘ฃ๐‘  ๐น๐‘ข๐‘’๐‘™ ๐ถ๐‘œ๐‘ ๐‘ก ๐ท๐‘–๐‘“๐‘“ ๐‘จ๐‘ต^๐Ÿ= 4.5 x ๐Ÿ๐ŸŽ^๐Ÿ๐ŸŽ (Design 1) Analysis ๏‚ง With increasing efficiency, total cost as well as gas bending stress has minimum value. ๏‚ง For ๐ด๐‘2 4.5 x 1010 Efficiency = 88.59 % Design 1 Analysis ๏‚ง Increasing number of blades lead to reduced efficiency and more Aerodynamic losses. ๏‚ง Further relative fuel cost increases with more number of blades pointing to the fact that greater quantity of fuel will be required to travel longer distances. Chosen Design Cost of Engine โ€“ 10.88 M ($) ACME Aerospace Inc - Bringing Technologies of Change
  • 15. OFF- Design Analysis 0 10 20 30 40 50 60 70 80 90 100 200.00 250.00 300.00 350.00 400.00 450.00 500.00 550.00 600.00 800 1000 1200 1400 1600 1800 Efficiency(%) FuelConsumption(Kg/Hr) Peak cycle temperature (K) Performance Analysis of Peak Cycle Temperature Design (88.59 %) Increasing Fuel Consumption Efficiency 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 88 88.5 89 89.5 90 90.5 TipControlClearance(%) Efficiency (%) Tip Control Clearance vs Efficiency Analysis ๏‚ง With increasing peak cycle temperature, fuel consumption increases since more fuel needs to be burned. ๏‚ง A sharp increase in efficiency to a maximum value and then it dips and remains constant. ๏‚ง With increasing ACC supply, tip clearance reduces and hence reduction in tip leakage losses Decrease in efficiency with an increase in tip clearance ACME Aerospace Inc - Bringing Technologies of Change
  • 16. Other Design Options : ๏ƒผ For lower than chosen ๐ด๐‘2 value โ€“ Design 2 โ€ข # of Blades = 38 More Weight โ€ข Increase in Cost = $ 6627 โ€ข Decrease in Centrifugal Tensile Stress = 44.73 MPa. Design 3 โ€ข # of Blades = 41 More Weight โ€ข Increase in Cost = $ 30256 โ€ข Decrease in Centrifugal Tensile Stress = 89.46 MPa. ๏ƒผ Efficiency Front ๏‚ง Decrease in efficiency can be countered by increasing peak cycle temperature slightly which will not affect our blade metallurgy as well. Parameter Design-1 Design-2 Design-3 Efficiency 88.59 88.55 88.36 AN^2 4.5*10^10 4*10^10 3.5*10^10 No Of Blades 35 38 41 Centrifugal Tensile Stress (MPa) 402.573 357.84 313.11 Gas Bending Stress (MPa) 0.71212106 0.806799171 0.98 Total Cost ($) 10888097.35 10894725.07 10918354.12 Difference in Cost ($) - 6627.72 30256.76 Difference in Centrifugal Stress (MPa) - 44.73 89.46 Chosen Design 0 0.04 0.08 0.12 0 10 20 30 40 50 60 70 80 90 100 900 1000 1100 1200 1300 1400 1500 1600 1700 SFC(kg/hr.N) Efficiency% Peak Cycle Temperature - K Peak Cycle Temp vs SFC & Eff. % Efficiency % SFC Design 2/3 Slight increase in T ACME Aerospace Inc - Bringing Technologies of Change
  • 17. Business Caseโ€ฆ Why ACME Aerospace โ€ฆ ๏‚ง Team Synergy ๏‚ง Customer consciousness ๏‚ง Two pronged expertise Aerodynamics + Stress Inevitable Choice ! High efficiency Lesser Cost High โ€œPower to Weightโ€ Ratio Less fuel consumption Better Specific Aircraft Range (SAR) miles/lbm of fuel Less fuel requirement More space for passengers โ€ฆ Low Maintenance Downtime More Operational Time โ€ฆ MORE REVENUES ! More options in design available ACME Aerospace Inc - Bringing Technologies of Change
  • 18. MERCIโ€ฆ ! ACME Aerospace Inc Bringing Technologies of Change
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