Axial Turbine Blade Root Fillet and Thickness Optimization
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Solution Overview
Problem
The design of turbomachinery blades faces challenges in minimizing stress induced by flutter, forced response, and synchronous vibration, particularly in the first stage of axial turbines or compressors, where aeromechanical assessments are complex and require advanced optimization methods.
Innovation Solution
A method for manufacturing turbine blades that involves receiving initial geometrical and aerodynamic information, performing stress analysis to determine areas of maximum stress, and adjusting blade design parameters such as thickness, twist angles, and fillet radii to achieve a safety factor of at least 1.5, thereby reducing the risk of flutter and vibration-related failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blade thickness is increased to reduce stress and improve safety factor, then strength and reliability improve, but weight and device complexity increase
Solution Approach 1:
The patent applies local quality by varying blade thickness non-uniformly along the span. The thickness distribution is optimized such that thicker sections are placed where stress concentrations occur (near the root and at specific intermediate locations) while thinner sections are used where stress is lower, thereby achieving adequate strength with minimized overall weight.
Solution Approach 2:
The patent employs dynamic optimization by using iterative computational methods that adjust thickness parameters based on stress analysis results. The design process dynamically adapts the thickness distribution through multiple cycles of analysis and modification until the safety factor requirements are met, rather than using static uniform thickness.
2Reliability
If aeromechanical assessments and optimization methods are applied to reduce flutter and vibration stress, then reliability improves, but device complexity and difficulty of detection increase
Solution Approach 1:
The patent applies preliminary action by performing comprehensive aeromechanical assessments and flutter analysis during the design phase rather than waiting for operational problems. The thickness distribution is pre-optimized to prevent flutter and vibration issues before the blade enters service, incorporating safety factors and margin analyses in advance.
Solution Approach 2:
The patent uses feedback mechanisms through iterative stress analysis and optimization cycles. The design process incorporates feedback from stress analysis results to adjust thickness parameters, with multiple cycles of analysis and modification until reliability requirements are satisfied, creating a closed-loop design system.
Data Source
AI summary
A method for manufacturing a turbine blade comprising designing a turbine blade includes receiving initial geometrical and aerodynamic information of the turbine blade, obtaining the maximum amount of stress within a determined area of maximum stress, and obtaining a safety factor by dividing material yield stress of the turbine blade by the maximum amount of stress. The method further includes performing a first plurality of operations responsive to the safety factor being less than 1.5 and the determined area of maximum stress occurring at the junction of the blade airfoil and the blade root. The first plurality of operations includes creating a fillet at the junction of the blade airfoil and the blade root and increasing respective thickness of each airfoil slice of the plurality of airfoil slices with a distance from the junction of the blade airfoil and the blade root of no more than 15% of the blade airfoil length.