Rotor Disk Shape Adjustment for Turbine Material Changes
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Solution Overview
Problem
The existing methods for changing materials in turbine rotors require extensive time and labor due to variations in thermal expansion, necessitating re-design and re-grasping of thermal extension using nonsteady finite element method analysis, which is time-consuming and labor-intensive.
Innovation Solution
A method to determine a temperature rise time ratio and adjust the inter-surface distance of the rotor disk based on this ratio, allowing for the design of a new shape that reflects the changed material properties, thereby reducing the time required for designing and manufacturing a turbine after material change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If nonsteady FEM analysis is used to grasp thermal extension after material change, then measurement precision of thermal extension is improved, but loss of time increases significantly
Solution Approach 1:
The patent pre-calculates thermal extension characteristics for multiple materials during the design phase and stores them in a database. When material change occurs, the pre-calculated data is directly retrieved and used for design adjustments, eliminating the need for time-consuming nonsteady FEM analysis while maintaining measurement precision.
Solution Approach 2:
The patent creates a simplified mathematical model that copies the essential thermal extension characteristics from complex FEM analysis results. This model can quickly calculate thermal extension for material changes without repeating the full FEM analysis process, significantly reducing computation time while preserving accuracy.
2Strength
If material change is made to enhance high-temperature strength, then strength is improved, but thermal extension varies requiring re-design
Solution Approach 1:
The patent systematically varies material parameters (thermal expansion coefficient, density, specific heat) in the database to account for different material properties. When material change occurs, the system automatically adjusts design parameters based on the new material's characteristics, maintaining strength requirements while simplifying the re-design process.
Solution Approach 2:
The patent creates a universal design methodology that can handle any material change by using a standardized database and calculation model. The same procedure works for different materials with different properties, making the design process universally applicable rather than requiring material-specific analysis methods.
3Productivity
If number of repetitions of nonsteady FEM analysis is reduced, then productivity is improved, but measurement precision of thermal extension may deteriorate
Solution Approach 1:
The patent creates a simplified mathematical model that replicates the essential thermal extension behavior observed in FEM analysis. This model provides sufficiently precise results for design purposes without requiring multiple repeated FEM analyses, thus maintaining productivity while ensuring adequate measurement precision.
Solution Approach 2:
The patent performs comprehensive thermal extension analysis in advance and stores the results in a database. This preliminary action ensures high measurement precision is achieved upfront, allowing subsequent design iterations to use the stored data without repeated analysis, thereby maintaining both precision and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach shortens the time and labor needed for designing and manufacturing turbines by ensuring the rotor disk's temperature rise time and shape are optimized post-material change, reducing the number of repetitions in nonsteady FEM analysis and maintaining thermal resistance.
Implementation Method 1
thermal extension of the turbine rotor may be varied attendant on variations of physical property values of the material
Data Source
AI summary
In a turbine designing and manufacturing method attendant on a material change of a rotor disk of a turbine rotor, a temperature rise time ratio is determined which is a desired ratio of a temperature rise time of the temperature of the rotor disk from a first temperature to a second temperature after the material change to the temperature rise time before the material change. An inter-surface distance between surfaces on upstream and downstream sides of the rotor disk after the material change is determined, and a shape of the rotor disk after the material change is determined based on the inter-surface distance. The turbine is designed based on the determined shape of the rotor disk. After the material change in the shape determined in the designing process, the rotor disk and the turbine are manufactured based on the result of the designing process.