A PROJECT REPORT ON

THERMAL ANALYSIS OF A STEAM TURBINE BLADE

A Project report submitted in partial fulfillment of the requirements for the award of degree of

MASTER OF TECHNOLOGY
IN
CAD/CAM
BY
B.NARASIMHA RAO (149H1D0401)
Under the esteemed guidance of
Asso.Prof. V.M LAKSHMAIAH

DEPARTMENT OF MECHANICAL ENGINEERING

NEWTONS INSTITUTE OF SCIENCE & TECHNOLOGY

AFFLIATED TO JNTUK UNIVERSITY

MACHERLA-522426
2014-2016
ANDHRA PRADESH
 NEWTONS INSTITUTE OF SCIENCE AND TECHNOLOGY

AFFLIATED TO JNTUK UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the Project Report entitled THERMAL ANALYSIS OF A

STEAM TURBINE BLADE is a bonafide work of the student B.NARASIMHA RAO

bearing Roll No.(149H1D0401) submitted in partial fulfillment of the

requirements for the award of the degree of MASTER OF TECHNOLOGY in
CAD/CAM . The matter embodied in this report has not been submitted for the
award of any other degree.

INTERNAL GUIDE HEAD OF THE DEPARTMENT

V.M LAKSHMAIAH M.tech V.M LAKSHMAIAH M.tech

Asso. Professor Asso. Professor
Mechanical Engineering Mechanical Engineering

PRINCIPAL
Dr. V. Kirankumar Ph.D
Newtons institute of science & technology EXTERNAL EXAMINER
 DECLARATION

I hereby declare that the entire work embodied in this project entitled THERMAL
ANALYSIS OF A STEAM TURBINE BLADE has been carried out by me and no part of it has been

submitted for the award of any degree or diploma at any other university or institutions.

B.NARASIMHA RAO
(149H1D0401)
 ACKNOWLEDGMENT

I am extremely grateful to Dr.V.Kiran Kumar, Principal

and. Asso.Prof. V.M Lakshmaiah, HOD, Department of Mechanical Engineering,
Newtons institute of science & technology, Macherla, for giving us an opportunity
to take up the project.

I am extremely thankful to Asso.Prof. V.M Lakshmaiah, Project Coordinator

and Internal Guide, Department of Mechanical Engineeringfor his constant guidance,
encouragement and moral support throughout the project.

I am thankful to Prof. Syed MoazzamAli,Taiba Engineering Consultants (TEC)

International for their support in using the software available with them and continued
guidance in executing the project.

I will be failing in duty if I do not acknowledge with grateful thanks to the authors
of the references and other literatures referred in this Project.

I express my thanks to all staff members and friends for all the help and co-
ordination extended in bringing out this Project successfully in time.
 INDEX

Page no

Abstract

Chapter1INTRODUCTION 1-6

Chapter2 INTRODUCTION TO CATIA 7-11

Chapter3 INTRODUCTION TO ANSYS 12-50

Chapter4 - ANALYSIS WITH CARBON CARBON

COMPOSITE MATERIALS 51-59

Chapter5 - ANALYSIS WITH HIGH MODULUS

CARBON FIBER REINFORCED
POLYMER COMPOSITE MATERIALS 60-72

Chapter6 CONCLUSION 73-73

 THERMAL
ANALYSIS OF
A
STEAM TURBINE
BLADE
THERMAL ANALYSIS OF A STEAM
TURBINE PROPELLER BLADE
 ABSTRACT

Steam turbine is an excellent prime mover to convert heat energy of

steam to mechanical energy. Of all heat engines and prime movers the
steam turbine is nearest to the best and it is widely used in power plants
and in all industries where power is needed for process.

In power generation mostly steam turbine is used because of its greater thermal
efficiency and higher power-to-weight ratio. Because the turbine generates rotary
motion, it is particularly suited to be used to drive an electrical generatorabout
80% of all electricity generation in the world is by use of steam turbines.

In this project we are going to design a propeller blade assembly in Catia

V5 R21 and thermal analysis is done in Ansys. In order to evaluate the
effectiveness of composites and metal propeller using FEA packaged
(ANSYS). Thermal analysis is performed on both Aluminum and composite
propeller to find out the heat flux and thermal error.
 INTRODUCTION

A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it

into useful work. A turbine is a turbo machine with at least one moving part called a rotor

assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that

they move and impart rotational energy to the rotor. Early turbine examples

are windmills and waterwheels.

The first turbines to be used were the steam turbines but now on the basis of the fluid from

which energy is extracted there are four major types of turbines:

Steam turbines

Water turbines

Wind turbines

Steam turbines

Steam Turbine

Steam turbines use up high pressure steam to produce energy. These turbines are not used for

producing electricity but they are used to propel jet engines. Steam turbines are the latest

types of turbines. Their structure is advanced but the principle is same.

1
A steam turbine, also called a combustion turbine, is a type of internal combustion engine. It

has an upstream rotating compressor coupled to a downstream turbine, and a combustion

chamber in-between.

The basic operation of the steam turbine is similar to that of the steam power plant except that

air is used instead of water. Fresh atmospheric air flows through a compressor that brings it to

higher pressure. Energy is then added by spraying fuel into the air and igniting it so the

combustion generates a high-temperature flow. This high-temperature high-pressure steam

enters a turbine, where it expands down to the exhaust pressure, producing a shaft work

output in the process. The turbine shaft work is used to drive the compressor and other devices

such as an electric generator that may be coupled to the shaft. The energy that is not used for

shaft work comes out in the exhaust steames, so these have either a high temperature or a high

velocity. The purpose of the steam turbine determines the design so that the most desirable

energy form is maximized. Steam turbines are used to power aircraft, trains, ships, electrical

generators, or even tanks.

2
Advantages of steam turbine engines:

Very high power-to-weight ratio, compared to reciprocating engines.

3
 Smaller than most reciprocating engines of the same power rating.

Moves in one direction only, with far less vibration than a reciprocating engine.

Fewer moving parts than reciprocating engines.

Greater reliability, particularly in applications where sustained high power output is

required

Waste heat is dissipated almost entirely in the exhaust. This results in a high temperature

exhaust stream that is very usable for boiling water in a combined cycle, or for

cogeneration.

Low operating pressures.

High operation speeds.

Low lubricating oil cost and consumption.

Can run on a wide variety of fuels.

Very low toxic emissions of CO and HC due to excess air, complete combustion and no

"quench" of the flame on cold surfaces

Disadvantages of steam turbine engines:

Cost is very high

Less efficient than reciprocating engines at idle speed

Longer startup than reciprocating engines

4
 Less responsive to changes in power demand compared with reciprocating engines

Characteristic whine can be hard to suppress

Applications of Steam Turbine

Land Applications: Central power stations.

Space Applications: Turbo jet and Turbo prop.

Marine application.

How Do Steam Turbine Work?

Steam turbines are comprised of three primary sections mounted on the same shaft: the

compressor, the combustion chamber (or combustor) and the turbine. The compressor can be

either axial flow or centrifugal flow. Axial flow compressors are more common in power

generation because they have higher flow rates and efficiencies. Axial flow compressors are

comprised of multiple stages of rotating and stationary blades (or stators) through which air is

drawn in parallel to the axis of rotation and incrementally compressed as it passes through each

stage. The acceleration of the air through the rotating blades and diffusion by the stators

increases the pressure and reduces the volume of the air. Although no heat is added, the

compression of the air also causes the temperature to increase.

5
The compressed air is mixed with fuel injected through nozzles. The fuel and compressed air

can be pre-mixed or the compressed air can be introduced directly into the combustor. The

fuel-air mixture ignites under constant pressure conditions and the hot combustion products

(steames) are directed through the turbine where it expands rapidly and imparts rotation to the

shaft. The turbine is also comprised of stages, each with a row of stationary blades (or nozzles)

to direct the expanding steames followed by a row of moving blades. The rotation of the shaft

drives the compressor to draw in and compress more air to sustain continuous combustion. The

remaining shaft power is used to drive a generator which produces electricity. Approximately

55 to 65 percent of the power produced by the turbine is used to drive the compressor. To

optimize the transfer of kinetic energy from the combustion steames to shaft rotation, steam

turbines can have multiple compressor and turbine stages.

6
Because the compressor must reach a certain speed before the combustion process is

continuous or self-sustaining initial momentum is imparted to the turbine rotor from an

external motor, static frequency converter, or the generator itself. The compressor must be

smoothly accelerated and reach firing speed before fuel can be introduced and ignition can

occur. Turbine speeds vary widely by manufacturer and design, ranging from 2,000 revolutions

per minute (rpm) to 10,000 rpm. Initial ignition occurs from one or more spark plugs

(depending on combustor design). Once the turbine reaches self-sustaining speed above 50%

of full speed the power output is enough to drive the compressor, combustion is continuous,

and the starter system can be disengaged.

CAD/CAE

7
Introduction to CATIA

CATIA also known as Computer Aided Three-dimensional Interactive Application and it is

software suit that developed by the French company call Dassult Systems.

CATIA is a process-centric computer-aided design/computer-assisted manufacturing/computer-

aided engineering (CAD/CAM/CAE) system that fully uses next generation object technologies

and leading edge industry standards. CATIA is integrated with Dassult Systems Product

Lifecycle Management (PLM) solutions. It allows the users to simulate their industrial design

processes from initial concept to product design, analysis, assembly and also maintenance. In this

software, it includes mechanical, and shape design, styling, product synthesis, equipment and

systems engineering, NC manufacturing, analysis and simulation, and industrial plant design. It

is very user friendly software because CATIA Knowledge ware allows broad communities of

user to easily capture and share know-how, rules, and other intellectual property assets.

Engineering Design

Catia V5 offers a range of tools to enable the generation of a complete digital representation of

the product being designed. In addition to the general geometry tools there is also the ability to

generate geometry of other integrated design disciplines such as industrial and standard pipe

work and complete wiring definitions. Tools are also available to support collaborative

development.

A number of concept design tools that provide up-front Industrial Design concepts can then be

used in the downstream process of engineering the product. These range from conceptual8
8
Industrial design sketches, reverse engineering with point cloud data and comprehensive

freeform surface tools.

Different Modules in Catia 5

Sketcher

Part Modeling

Surfacing

Sheet Metal

Drafting

Manufacturing

Shape designs

DESIGN

9
10
11
ASSEMBLY MODEL

12
INTRODUCTION TO ANSYS

ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element

Analysis is a numerical method of deconstructing a complex system into very small pieces (of

user-designated size) called elements. The software implements equations that govern the

behaviour of these elements and solves them all; creating a comprehensive explanation of how

the system acts as a whole. These results then can be presented in tabulated, or graphical

forms. This type of analysis is typically used for the design and optimization of a system far too

complex to analyze by hand. Systems that may fit into this category are too complex due to their

geometry, scale, or governing equations.

ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at

many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics

and Chemistry departments.

ANSYS provides a cost-effective way to explore the performance of products or processes in a

virtual environment. This type of product development is termed virtual prototyping.

With virtual prototyping techniques, users can iterate various scenarios to optimize the product

long before the manufacturing is started. This enables a reduction in the level of risk, and in the

cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to ensure

that users are able to see the effect of a design on the whole behavior of the product, be it

electromagnetic, thermal, mechanical etc.

13
Generic Steps to Solving any Problem in ANSYS

Like solving any problem analytically, you need to define (1) your solution domain, (2) the

physical model, (3) boundary conditions and (4) the physical properties. You then solve the

problem and present the results. In numerical methods, the main difference is an extra step called

mesh generation. This is the step that divides the complex model into small elements that

become solvable in an otherwise too complex situation. Below describes the processes in

terminology slightly more attune to the software.

1) Build Geometry

Construct a two or three dimensional representation of the object to be modeled

and tested using the work plane coordinate system within ANSYS.

2) Define Material Properties

Now that the part exists, define a library of the necessary materials that compose

the object (or project) being modeled. This includes thermal and mechanical

properties.

3) Generate Mesh

At this point ANSYS understands the makeup of the part. Now define how the

modeled system should be broken down into finite pieces.

4) Apply Loads

Once the system is fully designed, the last task is to burden the system with

constraints, such as physical loadings or boundary conditions.

14
5) Obtain Solution

This is actually a step, because ANSYS needs to understand within what state

(steady state, transient etc.) the problem must be solved.

6) Present the Results

After the solution has been obtained, there are many ways to present ANSYS

results, choose from many options such as tables, graphs, and contour plots.

15
Al 2024

TABLE 37
al 2024 > Constants
Density 2780 kg m^-3
Thermal Conductivity 151 W m^-1 C^-1

TABLE 38
al 2024 > Isotropic Elasticity
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
7.24e+010 0.33 7.098e+010 2.7218e+010

hm cfrp 10%
TABLE 37
hm cfrp 10% > Constants
Density 1240 kg m^-3
Thermal Conductivity 4.3 W m^-1 C^-1

TABLE 38
hm cfrp 10% > Isotropic Elasticity
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
7.58e+009 0.3 6.3167e+009 2.9154e+009

c-c-composites
TABLE 37
c-c-composites > Constants
Density 1800 kg m^-3

Thermal Conductivity 40 W m^-1 C^-1

TABLE 38
c-c-composites > Isotropic Elasticity
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa

9.5e+010 0.31 8.3333e+010 3.626e+010

16
Units

TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (A4, B4)

Geometry

TABLE 2
Model (A4, B4) > Geometry
Object Name Geometry
State Fully Defined
Definition
D:\Users\surya\AppData\Local\Temp\WB_SURYA-
Source
PC_3736_2\unsaved_project_files\dp0\SYS\DM\SYS.agdb

17
 Type DesignModeler
Length Unit Millimeters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 0.18278 m
Length Y 0.15809 m
Length Z 0.18774 m
Properties
Volume 3.4017e-004 m
Mass 0.94567 kg
Scale Factor Value 1.
Statistics
Bodies 25
Active Bodies 25
Nodes 142714
Elements 80871
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update No
Attach File Via
Yes
Temp File
Temporary
D:\Users\surya\AppData\Local\Temp
Directory
Analysis Type 3-D
Decompose
Yes
Disjoint Geometry
Enclosure and
Symmetry Yes
Processing

18
 TABLE 3
Model (A4, B4) > Geometry > Parts
Object Name Solid Solid Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment al 2024
Nonlinear Effects Yes
Thermal Strain
Yes
Effects
Bounding Box
5.4221e-002 5.2216e-002 4.7726e-002 4.0689e-002
Length X 3.152e-002 m
m m m m
2.5368e-002 1.8505e-002 1.9002e-002
Length Y 3.332e-002 m 2.77e-002 m
m m m
3.4587e-002 4.3789e-002 5.4256e-002 5.5442e-002
Length Z 5.046e-002 m
m m m m
Properties
6.2288e-006 6.2289e-006
Volume 6.2287e-006 m
m m
Mass 1.7316e-002 kg
9.0702e-002 8.6755e-002 7.8835e-002 6.7479e-002 5.3458e-002
Centroid X
m m m m m
-2.9433e-002 -1.6934e-002 -3.4463e-003 1.0113e-002
Centroid Y 2.282e-002 m
m m m m
3.2911e-003 1.7343e-002 2.8505e-002 3.6015e-002 3.9358e-002
Centroid Z
m m m m m
Moment of Inertia 5.4882e-007 5.4872e-007 5.4873e-007 3.7179e-006 3.7178e-006
Ip1 kgm kgm kgm kgm kgm
Moment of Inertia 3.8396e-006 3.8383e-006 3.8385e-006 3.8393e-006 3.8392e-006
Ip2 kgm kgm kgm kgm kgm
Moment of Inertia 3.7182e-006 3.717e-006 3.7172e-006 5.4875e-007 5.4881e-007
Ip3 kgm kgm kgm kgm kgm
Statistics
Nodes 5820 5542 5499 5471 5531

19
 Elements 3356 3147 3127 3097 3139
Mesh Metric None

TABLE 4
Model (A4, B4) > Geometry > Parts
Object Name Solid Solid Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment al 2024
Nonlinear Effects Yes
Thermal Strain
Yes
Effects
Bounding Box
2.2559e-002 4.0692e-002 4.7999e-002
Length X 2.152e-002 m 3.109e-002 m
m m m
3.5934e-002 4.2405e-002 4.6757e-002 4.8323e-002
Length Y 4.878e-002 m
m m m m
5.4847e-002 5.2196e-002 4.6963e-002 3.9076e-002 2.8875e-002
Length Z
m m m m m
Properties
6.2288e-006 6.2287e-006 6.2289e-006
Volume 6.2289e-006 m
m m m
Mass 1.7316e-002 kg
3.7729e-002 2.1365e-002 5.4817e-003 -8.842e-003 -2.0626e-002
Centroid X
m m m m m
3.3809e-002 4.7803e-002 4.9856e-002 4.8347e-002
Centroid Y 4.233e-002 m
m m m m
2.3613e-002 -4.1321e-003
Centroid Z 3.831e-002 m 3.294e-002 m 1.097e-002 m
m m
Moment of Inertia 3.718e-006 3.7176e-006 3.7167e-006 3.7172e-006 3.7169e-006
Ip1 kgm kgm kgm kgm kgm
Moment of Inertia 3.8394e-006 3.8389e-006 3.838e-006
5.4875e-007 kgm
Ip2 kgm kgm kgm
Moment of Inertia 5.4871e-007 5.4868e-007 5.4867e-007 3.8385e-006 3.8382e-006

20
 Ip3 kgm kgm kgm kgm kgm
Statistics
Nodes 5587 5501 5470 5424 5498
Elements 3183 3134 3123 3082 3139
Mesh Metric None

TABLE 5
Model (A4, B4) > Geometry > Parts
Object Name Solid Solid Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment al 2024
Nonlinear Effects Yes
Thermal Strain
Yes
Effects
Bounding Box
5.2604e-002 5.4511e-002 5.4447e-002 5.2428e-002 4.8025e-002
Length X
m m m m m
4.5289e-002 4.0098e-002 2.5368e-002
Length Y 3.304e-002 m 1.951e-002 m
m m m
1.9031e-002 2.7456e-002 3.7845e-002 4.6097e-002
Length Z 1.995e-002 m
m m m m
Properties
6.2289e-006
Volume 6.2288e-006 m 6.2289e-006 m
m
Mass 1.7316e-002 kg
-2.907e-002 -3.3598e-002 -3.3901e-002 -2.9956e-002 -2.2036e-002
Centroid X
m m m m m
4.3381e-002 3.5296e-002 2.4641e-002 1.2144e-002 -1.3442e-003
Centroid Y
m m m m m
-2.0663e-002 -3.7495e-002 -5.3484e-002 -6.7537e-002 -7.8699e-002
Centroid Z
m m m m m
Moment of Inertia 5.4873e-007 5.487e-007 5.4872e-007
5.4875e-007 kgm
Ip1 kgm kgm kgm
21
Moment of Inertia 3.7171e-006 3.7178e-006 3.718e-006 3.7174e-006 3.7176e-006
Ip2 kgm kgm kgm kgm kgm
Moment of Inertia 3.8383e-006 3.8391e-006 3.8394e-006 3.8387e-006 3.8389e-006
Ip3 kgm kgm kgm kgm kgm
Statistics
Nodes 5511 5532 5566 5363 5181
Elements 3130 3138 3168 3027 2912
Mesh Metric None

TABLE 6
Model (A4, B4) > Geometry > Parts
Object Name Solid Solid Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment al 2024
Nonlinear Effects Yes
Thermal Strain
Yes
Effects
Bounding Box
4.1059e-002 3.1748e-002 2.2559e-002 1.8348e-002
Length X 2.389e-002 m
m m m m
2.5193e-002 3.3409e-002 4.0618e-002 4.8692e-002
Length Y 4.576e-002 m
m m m m
5.1763e-002 5.4672e-002 5.4704e-002 5.1955e-002 4.6637e-002
Length Z
m m m m m
Properties
6.2288e-006 6.2288e-006
Volume 6.2287e-006 m
m m
Mass 1.7316e-002 kg
-1.068e-002 3.5435e-002 5.1319e-002
Centroid X 3.342e-003 m 1.907e-002 m
m m m
-1.4904e-002 -2.7611e-002 -4.712e-002 -5.2593e-002
Centroid Y -3.86e-002 m
m m m m
Centroid Z -8.6209e-002 -8.9551e-002 -8.8503e-002 -8.3132e-002 -7.3809e-002
22
 m m m m m
Moment of Inertia 3.8396e-006 3.8389e-006 3.8391e-006 3.8386e-006 3.8388e-006
Ip1 kgm kgm kgm kgm kgm
Moment of Inertia 3.7183e-006 3.7176e-006 3.7179e-006 3.7173e-006 5.4866e-007
Ip2 kgm kgm kgm kgm kgm
Moment of Inertia 5.4879e-007 5.4877e-007 5.4878e-007 5.4864e-007 3.7175e-006
Ip3 kgm kgm kgm kgm kgm
Statistics
Nodes 5434 5601 5575 5606 5386
Elements 3068 3188 3161 3193 3068
Mesh Metric None

TABLE 7
Model (A4, B4) > Geometry > Parts
Object Name Solid Solid Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment al 2024
Nonlinear Effects Yes
Thermal Strain
Yes
Effects
Bounding Box
3.4506e-002 4.9586e-002 5.3277e-002
Length X 4.324e-002 m 0.11269 m
m m m
4.9613e-002 4.8579e-002 4.5532e-002 9.9285e-002
Length Y 4.041e-002 m
m m m m
3.8743e-002 2.8693e-002 2.4001e-002
Length Z 1.995e-002 m 0.11491 m
m m m
Properties
6.2288e-006 6.2288e-006 1.9068e-004
Volume 6.2289e-006 m
m m m
Mass 1.7316e-002 kg 0.53009 kg
6.5642e-002 7.7425e-002 8.5869e-002 9.0398e-002 2.8943e-002
Centroid X
m m m m m
23
 -5.4647e-002 -5.3136e-002 -4.8171e-002 -4.0086e-002 -1.6655e-003
Centroid Y
m m m m m
-6.1164e-002 -4.6061e-002 -2.953e-002 -1.2698e-002 -2.5593e-002
Centroid Z
m m m m m
Moment of Inertia 3.8389e-006 3.8377e-006 3.8382e-006 5.4874e-007 4.8538e-004
Ip1 kgm kgm kgm kgm kgm
Moment of Inertia 5.4867e-007 5.4863e-007 5.4868e-007 3.8389e-006 9.3123e-004
Ip2 kgm kgm kgm kgm kgm
Moment of Inertia 3.7175e-006 3.7165e-006 3.717e-006 3.7176e-006 4.8538e-004
Ip3 kgm kgm kgm kgm kgm
Statistics
Nodes 5357 5309 5472 5557 10921
Elements 3048 3007 3105 3157 5974
Mesh Metric None

Coordinate Systems

TABLE 8
Model (A4, B4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Connections

TABLE 9
Model (A4, B4) > Connections
Object Name Connections
State Fully Defined
Auto Detection
Generate Automatic Connection On Refresh Yes
Transparency
Enabled Yes

24
 TABLE 10
Model (A4, B4) > Connections > Contacts
Object Name Contacts
State Fully Defined
Definition
Connection Type Contact
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Auto Detection
Tolerance Type Slider
Tolerance Slider 0.
Tolerance Value 7.6505e-004 m
Use Range No
Face/Face Yes
Face/Edge No
Edge/Edge No
Priority Include All
Group By Bodies
Search Across Bodies

TABLE 11
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region Region 2 Region 3 Region 4 Region 5
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 39 Faces 1 Face 38 Faces
Target 1 Face 4 Faces 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled

25
 Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 12
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 6 Region 7 Region 8 Region 9 Region 10
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 39 Faces 1 Face 40 Faces 1 Face
Target 1 Face 4 Faces 1 Face 4 Faces 1 Face
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 13
Model (A4, B4) > Connections > Contacts > Contact Regions
26
 Contact Contact Contact Contact Contact
Object Name
Region 11 Region 12 Region 13 Region 14 Region 15
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 40 Faces 1 Face 38 Faces 1 Face 38 Faces
Target 4 Faces 1 Face 4 Faces 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 14
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 16 Region 17 Region 18 Region 19 Region 20
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 40 Faces 1 Face 40 Faces 1 Face
Target 1 Face 4 Faces 1 Face 4 Faces 1 Face
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded

27
 Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 15
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 21 Region 22 Region 23 Region 24 Region 25
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 40 Faces 1 Face 40 Faces 1 Face 40 Faces
Target 4 Faces 1 Face 4 Faces 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip Program Controlled

28
 Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 16
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 26 Region 27 Region 28 Region 29 Region 30
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 38 Faces 1 Face 38 Faces 1 Face
Target 1 Face 4 Faces 1 Face 4 Faces 1 Face
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 17
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 31 Region 32 Region 33 Region 34 Region 35

29
 State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 40 Faces 1 Face 40 Faces 1 Face 40 Faces
Target 4 Faces 1 Face 4 Faces 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 18
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 36 Region 37 Region 38 Region 39 Region 40
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 38 Faces 1 Face 39 Faces 1 Face
Target 1 Face 4 Faces 1 Face 4 Faces 1 Face
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled

30
 Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 19
Model (A4, B4) > Connections > Contacts > Contact Regions
Contact Contact Contact Contact Contact
Object Name
Region 41 Region 42 Region 43 Region 44 Region 45
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 39 Faces 1 Face 39 Faces 1 Face 40 Faces
Target 4 Faces 1 Face 4 Faces 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration
Program Controlled
Tolerance
Elastic Slip
Program Controlled
Tolerance
Normal Stiffness Program Controlled

31
Update Stiffness Program Controlled
Thermal
Program Controlled
Conductance
Pinball Region Program Controlled

TABLE 20
Model (A4, B4) > Connections > Contacts > Contact Regions
Object Name Contact Region 46 Contact Region 47 Contact Region 48
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face 40 Faces
Target 1 Face 4 Faces
Contact Bodies Solid
Target Bodies Solid
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 7.6505e-004 m
Suppressed No
Advanced
Formulation Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Thermal Conductance Program Controlled
Pinball Region Program Controlled

32
Mesh

TABLE 21
Model (A4, B4) > Mesh
Object Name Mesh
State Solved
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Fine
Element Size Default
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 3.3195e-006 m

33
 Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Advanced
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 142714
Elements 80871
Mesh Metric None

Steady-State Thermal (A5)

TABLE 22
Model (A4, B4) > Analysis
Object Name Steady-State Thermal (A5)
State Solved
Definition
Physics Type Thermal
Analysis Type Steady-State
Solver Target Mechanical APDL
Options
Generate Input Only No

34
 TABLE 23
Model (A4, B4) > Steady-State Thermal (A5) > Initial Condition
Object Name Initial Temperature
State Fully Defined
Definition
Initial Temperature Uniform Temperature
Initial Temperature Value 22. C

TABLE 24
Model (A4, B4) > Steady-State Thermal (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls

35
 Solver Type Program Controlled
Radiosity Controls
Flux Convergence 1.e-004
Maximum Iteration 1000.
Solver Tolerance 0.1
Over Relaxation 0.1
Hemicube Resolution 10.
Nonlinear Controls
Heat Convergence Program Controlled
Temperature Convergence Program Controlled
Line Search Program Controlled
Output Controls
Calculate Thermal Flux Yes
General Miscellaneous No
Store Results At All Time Points
Max Number of Result Sets Program Controlled
Analysis Data Management
Solver Files Directory D:\Users\surya\Desktop\turbine\tubine_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files Directory
Save MAPDL db No
Delete Unneeded Files Yes
Nonlinear Solution Yes
Solver Units Active System
Solver Unit System mks

TABLE 25
Model (A4, B4) > Steady-State Thermal (A5) > Loads
Object Name Temperature Convection Radiation
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 24 Faces 141 Faces 1456 Faces
Definition
Type Temperature Convection Radiation
Magnitude 600. C (ramped)
Suppressed No
Film Coefficient 1.e-003 W/mC (ramped)
Ambient Temperature 80. C (ramped) 50. C (ramped)
Correlation To Ambient
Emissivity 1. (step applied)

36
 FIGURE 1
Model (A4, B4) > Steady-State Thermal (A5) > Temperature

37
 FIGURE 2
Model (A4, B4) > Steady-State Thermal (A5) > Convection

38
 TABLE 26
Model (A4, B4) > Steady-State Thermal (A5) > Convection
Steps Time [s] Convection Coefficient [W/mC] Temperature [C]
0. 0. 22.
1
1. 1.e-003 80.

FIGURE 3
Model (A4, B4) > Steady-State Thermal (A5) > Radiation

39
Solution (A6)

TABLE 27
Model (A4, B4) > Steady-State Thermal (A5) > Solution
Object Name Solution (A6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done

TABLE 28
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 29
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Results
Thermal
Object Name Temperature Total Heat Flux Directional Heat Flux
Error
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Thermal
Type Temperature Total Heat Flux Directional Heat Flux
Error
By Time
Display Time Last

40
 Calculate Time
Yes
History
Identifier
Suppressed No
Orientation X Axis
Global Coordinate
Coordinate System
System
Results
Minimum 516.37 C 1341.5 W/m -1.3968e+006 W/m 4.3002e-007
1.9023e+006
Maximum 600. C 1.7645e+006 W/m 83.246
W/m
Minimum Occurs On Solid
Maximum Occurs On Solid
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 2
Integration Point Results
Display Option Averaged

41
TEMPERATURE

42
TOTAL HEAT FLUX

DIRECTIONA L H EAT FLUX

43
DIRECTIONAL HEAT FLUX

44
THERMAL ERROR

Static Structural (B5)

TABLE 30
Model (A4, B4) > Analysis
Object Name Static Structural (B5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 22. C
Generate Input Only No

TABLE 31
Model (A4, B4) > Static Structural (B5) > Analysis Settings
Object Name Analysis Settings

45
 State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Program Controlled
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Nonlinear Controls
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Store Results At All Time Points
Max Number of Result Sets Program Controlled
Analysis Data Management
Solver Files Directory D:\Users\surya\Desktop\turbine\tubine_files\dp0\SYS-1\MECH\
Future Analysis None
Scratch Solver Files Directory
Save MAPDL db No
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks

TABLE 32
Model (A4, B4) > Static Structural (B5) > Imported Load (Solution)

46
 Object Name Imported Load (Solution)
State Fully Defined
Definition
Type Imported Data
Interpolation Type Mechanical Results Transfer
Suppressed No

TABLE 33
Model (A4, B4) > Static Structural (B5) > Imported Load (Solution) > Imported Body
Temperature
Object Name Imported Body Temperature
State Solved
Scope
Scoping Method Geometry Selection
Geometry 25 Bodies
Definition
Type Imported Body Temperature
Suppressed No
Source Environment Steady-State Thermal (A5)

FIGURE 4
Model (A4, B4) > Static Structural (B5) > Imported Load (Solution) > Imported Body
Temperature

47
 Model (A4, B4) > Static Structural (B5) > Imported Load (Solution) > Imported Body
Temperature
Source Time (s) Analysis Time (s)
1 End Time 1
*

Solution (B6)

TABLE 34
Model (A4, B4) > Static Structural (B5) > Solution
Object Name Solution (B6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done

TABLE 35
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE 36
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Results
Object Name Equivalent Stress Total Deformation
State Solved
Scope
Scoping Method Geometry Selection

48
 Geometry All Bodies
Definition
Type Equivalent (von-Mises) Stress Total Deformation
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged
Results
Minimum 6.7001e-011 Pa 1.1656e-015 m
Maximum 0.53364 Pa 1.7879e-014 m
Minimum Occurs On Solid
Maximum Occurs On Solid
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1

49
THERMAL STRESS

50
DEFORMATION

51
ANALYSIS WITH CARBON CARBON COMPOSITE MATERIALS

INPUT DATA

52
53
54
TEMPERATURE

55
TOTAL HEAT FLUX

56
DIRECTIONAL HEAT FLUX

57
THERMAL ERROR

58
Thermal stress

59
Deformation

60
ANALYSIS WITH HIGH MODULUS CARBON FIBER REINFORCED POLYMER
COMPOSITE MATERIALS

INPUT DATA

61
62
63
TEMPERATURE

64
TOTAL HEAT FLUX

65
DIRECTIONAL HEAT FLUX

66
THERMAL ERROR

67
Thermal stress

68
Deformation

69
TABLES

Al 2024 C-C Composites HM-CFRP 10%

TEMPERATURE MIN 516.37 425.05 226.9
MAX 600 600 600
TOTAL HEAT MIN 1341.5 1209.1 184.88
FLUX MAX 1.9023E6 1.0098E6 1.876E5
DIRECTIONAL MIN -1.39688E6 -7.3828E5 -1.5414E5
HEAT FLUX MAX 1.7645E6 9.22866E5 1.8054E5
THERMAL MIN 4.3002E-7 3.3445E-7 7.8003E-8
ERROR MAX 83.246 123.38 116.81
THERMAL MIN 6.7001E-11 1.0358E-10 8.8351E-12
STRESS MAX 0.53364 0.70428 0.056365
DEFORMATION MIN 1.1656E-15 1.1588E-15 1.1556E-15
MAX 1.7879E-14 1.7886E-14 1.7886E-14

70
GRAPHS

TEMPERATURE

TEMPERATURE COMPARISION FOR TURBINE

ASSEMBLY
700

600

500

400

300 TEMPERATURE

200

100

0
AL 2024 C-C-C HM CFRP 10%

TOTAL HEAT FLUX

TOTAL HEAT FLUX COMPARISION FOR

TURBINE ASSEMBLY
2.00E+06
1.80E+06
1.60E+06
1.40E+06
1.20E+06
TOTAL HEAT FLUX
1.00E+06
COMPARISION FOR TURBINE
8.00E+05 ASSEMBLY
6.00E+05
4.00E+05
2.00E+05
0.00E+00
AL 2024 C-C-C HM-CFRP 10%

71
DIRECTIONAL HEAT FLUX

DIRECTIONAL HEAT FLUX COMPARISION FOR

TURBINE ASSEMBLY
2.00E+06
1.80E+06
1.60E+06
1.40E+06
1.20E+06
DIRECTIONAL HEAT FLUX
1.00E+06
COMPARISION FOR TURBINE
8.00E+05 ASSEMBLY
6.00E+05
4.00E+05
2.00E+05
0.00E+00
AL 2024 C-C-C HM-CFRP 10%

THERMAL ERROR

THERMAL ERROR COMPARISION FOR

TURBINE ASSEMBLY
140

120

100

80
THERMAL ERROR
60 COMPARISION FOR TURBINE
ASSEMBLY
40

20

0
AL 2024 C-C-C HM-CFRP 10%

72
THERMAL STRESS

THERMAL STRESS COMPARISION FOR

TURBINE ASSEMBLY
0.8

0.7

0.6

0.5
THERMAL STRESS
0.4
COMPARISION FOR TURBINE
0.3 ASSEMBLY

0.2

0.1

0
AL 2024 C-C-C HM-CFRP 10%

DEFORMATION

DEFORMATION COMPARISION FOR TURBINE

ASSEMBLY
1.79E-14

DEFORMATION
1.79E-14
COMPARISION FOR TURBINE
ASSEMBLY

1.78E-14
AL 2024 C-C-C HM-CFRP 10%

73
 CONCLUSION

In this project we are going to conduct the stress and deformation of a steam turbine rotor

blade assembly. As here we are going to consider the materials AL 2024, Carbon Carbon

Composites and high modulus carbon fiber reinforced polymer of 10%. As here the designed

is done in Catia v5 and analysis is done in Ansys software, here we are going to conduct thermal

and structural of the model in Ansys software.

As here we have done the analysis here we have done in the assembly model, after the

analysis all obtained results are formed in a tubular form and graphs are tabulated, as we

compare the results obtained we can observe that the HM-CFRP 10% material has got a large

variation in results as this can be considered as a best material for the better life output of the

material.

As here we observed in the structural analysis, here also the same repeated as the HM-

CFRP 10% material has got the better output with best results in the structural analysis as the

deformations are very better than the other materials, so by all these results here we can

conclude that the HM-CFRP 10% will be the better material for the better life efficiency and

better life output for the product.

74