mjt 04 ppt

Structural Analysis of Aluminum alloy Diesel Genarator Cylinder using FEA

Satya Thrinadh b

Guide

P.Phani kumarAssistant professorDepartment of mechanical engineeringSasi institute of technology and engineering

April 21, 2023 Structural Analysis of Super alloy Gas Turbine Blade by Using FEA

April 21, 2023

Contents :• Abstract• Introduction • Need of the software• Geometrical Modeling of blade• Discretization of the Gas turbine blade • Structural analysis of a Gas turbine blade

analysis of blades• Conclusion

Structural Analysis of Super alloy Gas Turbine Blade by Using FEA

April 21, 2023

Abstract :

• This paper analyses a catastrophic cylinder failure of a four stroke 14v diesel engine of an electrical power plant when running to nominal speed of 600rpm.

• the rated power of the engine was 7.5MW and before failure had accumulated 80,000h in service operating mainly of full load.

• as result the piston and liner of cylinder were broken, the crank case main crank shaft bearings next to this cylinder

• were also damaged the mechanical properties of cylinder (aluminium alloy) including tensile properties and brinel hardness were evaluated no signs of fatigue failure were identify in piston .

• a finite element model of the cylinder has shown that the most heavy loaded areas match the fractured zones


April 21, 2023

Introduction :• Diesel generator cylinder are subjected to different types of loading such as

fluid or gas forces, inertia loads and centrifugal forces. Due to these forces various stresses are induced in rotor blades.

• The present project deals with the stress analysis of a typical blade made up of cast iron , which is subjected to centrifugal loading.

• The analysis results shows that stress is sever due to centrifugal forces compared that due to dynamic gas forces.


April 21, 2023

Diesel genarator cylinder working :

• Gas turbines usually operate on an open cycle .

• Air at ambient conditions is drawn into the compressor, where its temperature and pressure are raised. The high pressure air proceeds into the combustion chamber, where the fuel is burned at constant pressure.


Fig.1. Flow diagram of a Gas turbine plant

April 21, 2023

• The high-temperature gases then enter the turbine where they expand to atmospheric pressure while producing power output.

• Some of the output power is used to drive the compressor.

• The exhaust gases leaving the turbine are thrown out.

• Blades may be considered to be the heart of turbine and all other member exist for the sake of the blades.

Without blading there would be no power and the slightest fault in blading would mean a reduction in efficiency and costly repairs.

• Brass ,Copper Nickel ,Nickel Brass ,Cast iron, Manganese copper ,Phosphor Bronze ,Mild steel Nickel steel are commonly used blade materials

• Now a days Gas turbine blades are manufactured by Nickel based super alloys


April 21, 2023

• Superalloy - an alloy with high mechanical strength and resistance to surface degradation at high temperatures of 1200°F (650°C) or above.

• Able to maintain high strengths at high temperatures, Good corrosion and oxidation resistance at high temperatures (Cr, Al),Good resistance to creep and rupture at high temperatures

• 3 main classes of super alloys

Ni – Co- Base superalloy (Monels)

Ni-Cr – Base superalloy

Ni-Fe– Base superalloy • The study has been conducted with three different Nickel based super alloy

materials,

Monel-400, Inconel 625&Haste alloy X.



April 21, 2023

Need of a software:• The finite element method (FEM) has now become a very important tool of

engineering analysis• The stress analysis in the fields of civil, mechanical and aerospace engineering,

nuclear engineering is invariably complex and for many of the problems it is extremely difficult to obtain analytical solutions. In these situations engineers usually resort to numerical methods to solve the problems.

• With the advent of computers, one of the most powerful techniques that have been developed in the engineering analysis is the finite element method and the method being used for the analysis of structures/solids of complex shapes and complicated boundary conditions.


April 21, 2023

• The type of modeling that is required in order to model the aerofoil shape is surface modeling.

• In the current analysis the modeling platform selected for developing the geometrical model of cylinder is CATIA-V5R19.

• Cylinder model is surface modeling type so it is designed by using different tools like sketcher, fill, pad, multi section tool options.

Geometrical Modeling :


April 21, 2023

Steps involved in Modeling of gas turbine blade

Sketch spline profile

Multi section

Fill


April 21, 2023

Base section sketcher

Base section extrude

Final stage of gas turbine blade


April 21, 2023

Fig.2. Solid modelling of gas turbine blade by using CATIA-V5R19


April 21, 2023

• Meshing is an integral part of the computer aided engineering (CAE) analysis process. The mesh influences the accuracy, convergence and speed of the solution.

• Based on topology of meshing, it is categorized broadly into two types

1. Tetra meshing

2. Hexa meshing

Tetra meshing: • Good automated methods exist which can combine tetra mesh with

inflation layers (e.g. on wall boundaries).• Less cells are introduced when adapted, than that of hexa meshes

Discretization of the Gas turbine blade :


April 21, 2023

Hexa meshing:• In general cases, the same accuracy can be achieved with 30 to 50% less cells,

as that of the tetra mesh.(Provided that the grid quality is good.• This is especially important in the analyses of streamlined bodies with

possible separations, such as propeller blades.

Tetra mesh Hexa mesh

• Project contains stream lines only so preferred meshing ishexa meshing


April 21, 2023

• Meshing of cylinder was completed By using HYPERMESH 10.• The centrifugal forces acting on the blade is considered as one point load (static

load) and the point is located at the middle of the blade • Element type(solid 45) and load (38kN) acting on the blade mentioned in

HYPERMESH 10


April 21, 2023

Fig.3. Hexa mesh model of a Diesel genarator cylinder


April 21, 2023

Fig.4. Static load applied on Diesel genarator cylinder


April 21, 2023

• The most popular software, which is based on Finite Element Analysis, is “ANSYS” package, which is used in this work.

• By using ANSYS 14.5 structural analysis of a diesel generator cylinder was completed.

• The analysis of diesel generator cylinder mainly consists of the following two parts:

Structural

Thermal analysis. • The analysis is carried out under steady state conditions using Ansys software.

• The study has been conducted with aluminum alloy material

Aluminum alloy

Structural analysis of a Diesel generator cylinder :


April 21, 2023

propertie UnitsMonel alloy 400 Inconel- Haste

s 625 alloy X

E Pa 179 E09 150E0 144E099

ρ Kg/cu 8800 8400 8300m

K W/m-K 21.8 10 25

μ --- 0.32 0.331 0.348

α E-06/oC 13.9 15 16

CP J/KgK 427 410 450

Melting OC 1350 1380pointYield MPa 240 1030 360stress

Details of Diesel genarator cylinder D=1308.5 mm, N=3426 rpm, L=117mm, d=2mm

Table 1 Mechanical properties of Monel alloy 400, Inconel 625 & Hastealloy X


April 21, 2023

Static analysis:• The von misses stresses are obtained as shown in the figure; • It is observed that the maximum von misses stress is

79.762 N/mm2 for Monel alloy 400,

77.2914 N/mm2 for Haste alloy X and

78.8299N/mm2 for Inconel 625 alloy.

• The deformations are obtained as shown in the figure;• It is observed that the maximum deformation is

0.905 mm

0.112 mm and

0.108 mm

for Monel-400, Haste alloy X and Inconel 625 alloy respectively.

From the above results it is observed that the stress is low for Haste alloy X and deformation are low for Monel-400 alloy.


April 21, 2023

Fig.5 Maximum deformation induced in Monel alloy400 blade, mm

Fig.6 Maximum deformation induced in Inconel 625 blade, mm

Fig.7 Maximum deformation induced in Haste alloy-X blade, mm


April 21, 2023

Fig.8 Stress induced in Monel alloy400 blade, N/mm2

Fig. 9 Stress induced in Inconel 625 blade, N/mm2

Fig. 10 Stress induced in Haste alloy-x blade, N/mm2


April 21, 2023

Thermal analysis:• From the post processing, The stresses and deformations by static thermal

analysis at steady state are obtained as shown in fig. • It is observed that the maximum von misses stress is

1310.09 N/mm2 for Monel 400 alloy,

1341.79 N/mm2 for Haste alloy X and

1136.41N/mm2 for Inconel 625 alloy.• The deformations are obtained as shown in the figure;• It is observed that the maximum deformation is

0.115mm,

0.139 mm and

0.131 mm

For Monel-400, Haste alloy X and Inconel 625 alloy respectively.• From the above results it is observed that the stress is low for Inconel 625 alloy

and deformation is low for Monel 400 alloy.


April 21, 2023

Fig.11 Maximum deformation induced in




April 21, 2023

Fig.14 Stress induced in Monel alloy400 blade, N/mm2

Fig. 15 Stress induced in Inconel 625 blade, N/mm2

Fig. 16 Stress induced in Haste alloy-x blade, N/mm2


April 21, 2023

Conclusion :• The finite element analysis for structural and thermal analysis of diesel generator

cylinder is carried out using solid45 element.• The temperature has a significant effect on the overall generator cylinder. • Maximum elongations and minimum thermal stresses are observed at the cylinder

surface section and minimum elongation and maximum thermal stresses at the root of the cylinder.

• Maximum stresses and strains are observed at the diesel generator cylinder and upper surface along the generator cylinder one type of materials of construction i.e., Aluminum alloy

• It is found that the temperature has a significant effect on the overall stresses induced in the diesel generator cylinder. From the analysis of results, Aluminum alloy is best material for Diesel generator cylinder.



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