Outline - 2017 - Draft - RevD
Outline - 2017 - Draft - RevD
Outline - 2017 - Draft - RevD
FACULTY OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Gas Turbine Design AERO465/MECH6161
Raja Ramamurthy
Senior Aerodynamicist, Installation Aerodynamics
Pratt & Whitney Canada
Tsukasa Yoshinaka
Aerodynamics Consultant to
Pratt & Whitney Canada Inc.
COURSE OUTLINE:
Gas Turbine Cycles: Review of Ideal and real cycles Effect of pressure ratio and turbine inlet temperature.
Propulsion: Thrust and propulsive efficiency Factors affecting thrust Turbojet, turbofan and turboprop Propelling
nozzle and thrust augmentation.
Aircraft Design: Factors affecting aircraft and propulsion system requirements and design.
Energy Transfer and Flow in Turbomachines: Euler equation Velocity triangles Reaction Blading terminology
Lift and drag Three-dimensional flow.
Aerodynamic Losses: Types Mechanisms Loss coefficients Stage and overall efficiencies Profile, annulus,
secondary and leakage losses Loss reduction.
Turbines: Characteristics and applications Axial and radial Stage and overall blade loading coefficient Specific
speed Compressor and power turbines Cooled schemes.
Compressors: Components and equations Axial and centrifugal Inlet guide vanes Slip factor Diffuser Stall and
choke margin.
Combustion: Combustion efficiency, smoke, emissions, temperature distribution
Air/Oil Systems: Cooling, anti-icing, ventilation, bearing compartments, cabin bleed
Engine Durability: Factors affecting critical component durability and design considerations.
Performance Characteristics: Dimensionless groups Stage characteristics Performance maps Limiting factors
Surge Component matching.
Design Process: Meanline, through-flow and airfoil design Selection of parameters Two and three dimensional
design.
Technology and Industry Trends: Recent technology evolution and where the industry is likely to go in the near term
COURSE GRADING:
Design Report Part A 5% (Due: February 2, 2017)
Presentation of material + Final Exam Q&A 25% (Due: April 6 & 13, 2017)
Final Design Report with detailed calculations: 60% (Due: April 13, 2017)
Peer Review 10% (Due: April 20, 2017)
Additional Information:
1) Late Design Reports cannot be accepted.
2) Office Hours: Thursdays 5:15 -5:45pm in class (or in hallway just outside).
3) There will be an FAQ section set up online where you will find answers to frequently asked questions.
4) You can also e-mail your questions directly to [email protected], and if necessary arrange for a meeting in person.
Lecture 11: Durability & Airworthiness & Technology Trends March 30, 2017
(Textbook Chapter 8)
- Failure mechanisms
- Structural analysis design process & requirements
- Creep & Oxidation
- Low Cycle Fatigue (LCF)
- High Cycle Fatigue (HCF)
- Material capabilities
- Installation considerations
- Airworthiness & industry regulations
- Technology developments and future trends
Lecture 13: Engine Design Review Meeting Part II April 13, 2017
- Group presentation for design review with a Panel of experts.
TEXTBOOKS
1. Course Handbooks with lecture material (will be made available for download)
2. Cohen H., Rogers G.F.C. & Saravanamuttoo H.H.I., Gas Turbine Theory, Longman.
REQUIRED
3. Moustapha, H, Zelesky M, Baines N, Japikse D, Axial and Radial Turbines, Concepts NREC
STRONGLY RECOMMENDED
Pratt & Whitney Canada is currently seeking risk sharing partners for the design, development and
eventual production of a new family of Gas Turbine Engines. The new family of engines will be based
upon a 2 shaft Turbofan arrangement with a bypass ratio of 3. This engine will be used mainly at 35K
feet altitude and will fly at a 0.75 Mn. The engine configuration will be a Fan driven by a one stage
shrouded axial Fan Turbine, 1 axial LPC stage plus 1 centrifugal HPC stage driven by a one stage
axial unshrouded high pressure axial turbine (HPT). Your contribution to the partnership will be the
design and development of the rotating components on the low spool of the engine (Fan Blade and
stator & LPT stage) that will potentially be used as a common core on 2 other derivatives of this
engine. The preliminary design review will be held on April 6 & 13 2017, and as a potential partner,
you will be expected to present your proposed design and trade studies to a panel of technical
experts who will be considering whether or not to consider you as a partner for this potential new and
lucrative engine program.
Key engine characteristics at its design point (35Kft Cruise) are as follows:
Engine inlet
Scoop Factor (Vinlet/V) = 0.9
Fan + Core Compressor:
Core Mass flow = 4.5 lb/sec
Fan PR = 1.63 (constant from hub to tip)
Fan Bypass Stage (Fan Rotor + bypass stator) PR = 1.6 (target)
Fan rotor adiabatic efficiency = 91.7% (constant hub to tip)
Fan bypass stage (Fan rotor + bypass stator) adiabatic efficiency = 88% (target)
Fan core stator PR = 0.98
Core massflow = 4.5 lbs/sec
LPC PR = 2.5
LPC efficiency = 85%
HPC PR = 4 and target efficiency of 81%
Bleed air taken at HPC exit (cabin bleed + turbine cooling) = 10% of core inlet flow
Additional HPC exit Bleed air when Active Clearance Control *** is turned on = 11% of core inlet flow
Combustor:
Fuel to air ratio = .02
Heating value = 21200 BTU/lb
Efficiency & pressure loss = 0.99 & 2% respectively
Radial Temperature Distribution factor (RTDF) = 5% (peaking at 50% of span)
Turbine:
HPT target efficiency of 85%-87% with ATCC ON (assume a value for your calculations)
HPT vane cooling air = 3.3%
HPT disk cooling air (ejected just downstream of the blade) = 3.0%
HPT Shroud Cooling air with ATCC OFF = 0.6%
HPT shroud Cooling air with ATCC ON = 1.6%
ITD loss = 1.5%
LPT target efficiency of 86%-88%
LPT disk cooling air (ejected just downstream of the blade) = 3.1%
Exhaust loss = 1.4%
Engine Exit
Bypass & core Nozzle efficiencies = 93%
PART A ENGINE DESIGN (at 35K Altitude Cruise)
From the parameters given, you will need to determine all of the relevant parameters of the cycle,
including temperature, pressure, component work, engine net thrust and SFC. You will need this
information in order to have a grasp of the boundary conditions which will exist for the components
you will be designing, and also to have a feel for how much your design may cost to produce.
Specify rotor blade geometry at hub, mean and tip, in the meridional plane
Make sure that Df : between 0.35 and 0.5, at mean and tip
and that Df : less than 0.55 at hub
Note:
Make sure that Df: between 0.35 and 0.5, at hub, mean and tip
Stator Vane Geometry:
Assume stator geometry is DCA (Double Circular Arc) at hub, mean and tip, and specify vane
Vane AR (aspect ratio): 1.5 2.5, where blade height is average between LE and TE, and chord
length is at mean radius
Specify geometry details, such as RLE, t1TE, (tmax/C), C (chord length), (camber angle) and
(stagger angle),
Specify vane count, Nv
Specify incidence angle and calculate deviation angles (Use the Carters rule) for the vanes at hub,
mean and tip
Calculate Df and blade solidity, in an iterative manner with the loss and deviation angle calculations
Stage:
Inlet Mn = 0.4
Inlet swirl = 20 deg (relative to axial)
Exit Mn= 0.3 0.6
Exit swirl= -5 to +20 deg (relative to axial)
Target field life = 10000 hours
Vane:
Aspect ratio = 0.7
Zweifel coefficient at mean = 0.70 0.80
Trailing edge thickness (minimum) = 0.025 inches
Blade:
Aspect ratio = 2
Zweifel coefficient at mean = 0.8 0.95
Trailing edge thickness (minimum) = .025 inches
Tip clearance = 0.03 (Shrouded)
- All meanline design parameters including rotation speed, gaspath, velocity triangles at
inlet and exit of each component.
- Hub and tip velocity triangles including radial temperature distributions, pressures, angles,
velocity and reaction assuming a free vortex design.
- Vane and blade geometric parameters such as stagger angle, axial chord, airfoil count.
- Nozzle and rotor loss coefficients (using the modified AMDC loss system) as well as tip
clearance.
- Based upon your calculations, what is/are the weaknesses of the loss correlations you
have used? What would you propose as improvements that could be made?
- Based upon a CATIA V5 based parametric model which you will use to generate a 3D
blade shape, estimate the blade cross sectional area distribution, total blade pull and fan
turbine blade static weight.
- Based upon additional data you will be provided, estimate the expected Fan Turbine blade
field life and whether or not you can meet the target field life the customer is demanding.
- The engine is expected to run off-design at times (such as during taxi, take-off, climb, and
flight idle), where RPM will be reduced by 20%. Calculate the incidence that will result on
your design, as well as the impact this will have on stage efficiency (again, using the
AMDC and Moustapha correlations).