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Research Papers

The Effects of Manufacturing Tolerances on Gas Turbine Cooling

[+] Author and Article Information
Ronald S. Bunker

 GE Global Research Center, Niskayuna, NY 12309

J. Turbomach 131(4), 041018 (Jul 13, 2009) (11 pages) doi:10.1115/1.3072494 History: Received August 30, 2008; Revised October 10, 2008; Published July 13, 2009

This study presents a summary of the effects of manufacturing methods and processing steps upon the resulting thermal boundary conditions for typical highly cooled turbine airfoils. Specific emphasis is placed on the conservatism that must be “designed into” the component for survival due to realistic manufacturing tolerances. Using the features of a typical blade design, the main geometric factors that can influence the blade heat transfer capability through manufacturing variability are enumerated. The tolerances on those geometric factors are provided, and the approximate quantitative impact on thermal boundary conditions is summarized. A simple example of airfoil cooling for a representative wall section is used to tabulate the variations with the resulting changes in the most affected thermal boundary conditions. Each of the main geometric factors is then evaluated in terms of its possible effect on maximum metal temperature. Paretos of the effects of manufacturing factors exhibit which factors are key and where tighter tolerances may help. Monte Carlo analysis results show the probability distributions associated with overall cooling changes tied to the tolerances.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

Typical aviation high-pressure turbine cross section with vane and blade

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Figure 2

Design cycle for highly cooled turbine airfoils

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Figure 3

Detailed design process for cooled airfoils

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Figure 4

Example of thermal boundary condition uncertainty and impact levels

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Figure 5

Sample cooling design for a high-pressure turbine blade

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Figure 6

Simplified model for estimation of blade cooling effects

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Figure 7

One-dimensional heat transfer model applied to each blade surface location

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Figure 8

Pareto of blade metal temperature changes for manufacturing factors (°C)

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Figure 9

Monte Carlo simulation frequency chart for blade metal temperature changes

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Figure 10

Cumulative distribution of effect on blade row cooling flow rate

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Figure 11

Pareto of metal temperature changes for predominantly film cooled blade (°C)

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