Research Papers

Coupled Aerothermomechanical Simulation for a Turbine Disk Through a Full Transient Cycle

[+] Author and Article Information
Zixiang Sun

Thermo-Fluid Systems UTC, School of Engineering, University of Surrey, Guildford, Surrey, GU2 7XH, UKzixiang.sun@surrey.ac.uk

John W. Chew, Nicholas J. Hills

Thermo-Fluid Systems UTC, School of Engineering, University of Surrey, Guildford, Surrey, GU2 7XH, UK

Leo Lewis

 Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, UK

Christophe Mabilat

Department of Fluid Mechanics, Atkins, Epsom, Surrey, KT18 5BW, UK

J. Turbomach 134(1), 011014 (May 27, 2011) (11 pages) doi:10.1115/1.4003242 History: Received September 10, 2010; Revised October 20, 2010; Published May 27, 2011; Online May 27, 2011

Use of computational fluid dynamics (CFD) to model the complex, 3D disk cavity flow and heat transfer in conjunction with an industrial finite element analysis (FEA) of turbine disk thermomechanical response during a full transient cycle is demonstrated. The FEA and CFD solutions were coupled using a previously proposed efficient coupling procedure. This iterates between FEA and CFD calculations at each time step of the transient solution to ensure consistency of temperature and heat flux on the appropriate component surfaces. The FEA model is a 2D representation of high pressure and intermediate pressure (IP) turbine disks with surrounding structures. The front IP disk cavity flow is calculated using 45 deg sector CFD models with up to 2.8 million mesh cells. Three CFD models were initially defined for idle, maximum take-off, and cruise conditions, and these are updated by the automatic coupling procedure through the 13,000 s full transient cycle from stand-still to idle, maximum take-off, and cruise conditions. The obtained disk temperatures and displacements are compared with an earlier standalone FEA model that used established methods for convective heat transfer modeling. It was demonstrated that the coupling could be completed using a computer cluster with 60 cores within about 2 weeks. This turn around time is considered fast enough to meet design phase requirements, and in validation, it also compares favorably to that required to hand-match a FEA model to engine test data, which is typically several months.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

The front IPT disk cavity

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Figure 2

The axisymmetric FEA model of the HP and IP turbines

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Figure 3

The transient cycle

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Figure 4

45 deg sector CFD model of the disk cavity

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Figure 5

Boundary treatment of inlet nozzles for the CFD model

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Figure 6

Coupled and uncoupled surfaces for FEA and CFD models

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Figure 7

Swirl ratio contours at representative planes, MTO condition, and standalone CFD. (a) Periodic and midangular planes. (b) Circumferential planes at three radii.

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Figure 8

Comparison of swirl ratio contours from the inner inlet preswirl nozzles for MTO, cruise, and idle conditions, standalone CFD

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Figure 9

Comparison of swirl ratio profiles near the rotating disk wall for MTO, cruise, and idle conditions, standalone CFD

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Figure 10

Deformation and temperature at the cruise condition. (a) Whole model (deformation and displacement are enlarged in the figure). (b) IPT disk.

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Figure 11

Metal temperature histories

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Figure 12

Expanded views of temperature histories

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Figure 13

Metal temperatures on the coupled disk wall at time t=8200 s

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Figure 14

Comparison of metal temperatures between coupled and noncoupled solutions

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Figure 15

Mapping between the IPT disk and the blade

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Figure 16

IPT blade tip movement. (a) Time history of displacement. (b) Expanded view of displacement. (c) Trajectory of the blade movement. Dx versus Dr.



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