1. Turbine Vane SealTurbine Vane Seal
SupportSupport
Finite Element ModelFinite Element Model
and Analysisand Analysis
Sponsored by Standard Aero San Antonio, Inc.Sponsored by Standard Aero San Antonio, Inc.
Team Members:Team Members:
Yuval Doron, Christopher Holsonback (TL),Yuval Doron, Christopher Holsonback (TL),
Sang Kyu Lee, and Kris TatschSang Kyu Lee, and Kris Tatsch

2. Presentation RoadmapPresentation Roadmap
 BackgroundBackground
 Project MotivationProject Motivation
 Problem StatementProblem Statement
 Requirements andRequirements and
ConstraintsConstraints
 DeliverablesDeliverables
 Boundary ConditionsBoundary Conditions
 CFD ModelingCFD Modeling
 Force CalculationsForce Calculations
 ANSYS ModelingANSYS Modeling
 Completed GoalsCompleted Goals
 Remaining WorkRemaining Work
 RecommendationsRecommendations

3. Methodology RoadmapMethodology Roadmap
Boundary Conditions
Solid ModelingCFD Modeling
Force Calculations ANSYS Modeling
Inlet Flow Conditions
Forces on Stators
2-D and 3-D
TVSS Models
2-D Gas
Path
Models
Forces on
TVSS
Results

4. BackgroundBackground
 Standard AeroStandard Aero
– Global companyGlobal company
 Repair, RemanufactureRepair, Remanufacture
– Major ContractsMajor Contracts
 US Navy, Air ForceUS Navy, Air Force
– ““Repair-Rather-Than-Repair-Rather-Than-
Replace”Replace”
– Design of RepairsDesign of Repairs
www.standardaero.com/

5. BackgroundBackground
 Gas Turbine EnginesGas Turbine Engines
– Aircraft Propulsion: TurbopropAircraft Propulsion: Turboprop
Turboprop Engine Schematic
Moran and Shapiro, Fundamentals of Engineering Thermodynamics
www.allstar.fiu.edu/

6.  Rolls-Royce T56 TurbopropRolls-Royce T56 Turboprop
– Commercial industry and U.S. militaryCommercial industry and U.S. military
– 18,000 T56 engines used worldwide18,000 T56 engines used worldwide
T56 Image
BackgroundBackground
www.rolls-royce.com
www.aircraftenginedesign.com

7. Project MotivationProject Motivation
 Turbine Vane Seal Support (TVSS)Turbine Vane Seal Support (TVSS)
– Major component of T56Major component of T56
 Retains first stage stator vanesRetains first stage stator vanes
 Separates between combustor and turbine sectionsSeparates between combustor and turbine sections
Personal Communication with Mr. Mike Zoch

8. Project MotivationProject Motivation
 TVSS Interfaces with StatorsTVSS Interfaces with Stators
TVSS Flange Area
First Stage Stator Module

9. Project MotivationProject Motivation
 Problem with TVSSProblem with TVSS
– Material wearMaterial wear
 Increases vaneIncreases vane
movementmovement
 Damages vanesDamages vanes
 Reduces T56 efficiencyReduces T56 efficiency
Image of TVSS Flange Area
Location of Material Wear
Crowley, D., Turbine Vane Seal Support Finite Element Model, Project Description

10. Project MotivationProject Motivation
 Standard Aero’s SolutionStandard Aero’s Solution
– Machine damaged materialMachine damaged material
– Restore surface to like-new conditionRestore surface to like-new condition

11. Problem StatementProblem Statement
 Determine:Determine:
– Stress Concentration on TVSS UnderStress Concentration on TVSS Under
Normal LoadsNormal Loads
– MaximumMaximum Material Removed BeforeMaterial Removed Before
TVSS Fails Under Normal LoadsTVSS Fails Under Normal Loads

12. Requirements andRequirements and
ConstraintsConstraints
 RequirementsRequirements
– Finite Element Model (FEM) of TVSSFinite Element Model (FEM) of TVSS
Using ANSYS softwareUsing ANSYS software
– Easily Changeable Boundary ConditionsEasily Changeable Boundary Conditions
 ConstraintsConstraints
– Only model effects of material removal—Only model effects of material removal—
ignore replacement material.ignore replacement material.

13. DeliverablesDeliverables
 Set of boundary conditionsSet of boundary conditions
 FEM mesh of TVSSFEM mesh of TVSS
 Maximum machining depthMaximum machining depth
*

14. Boundary ConditionsBoundary Conditions
 DefinitionDefinition
– An imposed set of conditions that are set with inAn imposed set of conditions that are set with in
a known boundary systema known boundary system
 ExampleExample
If the room = system boundaryIf the room = system boundary
Then all objects in the room experience theThen all objects in the room experience the
set conditionsset conditions
i.e. Pressure and temperaturei.e. Pressure and temperature

15. Boundary ConditionsBoundary Conditions
 Initial RequirementsInitial Requirements
– Conditions on TVSSConditions on TVSS
– Solve for forcesSolve for forces
 Evolved RequirementsEvolved Requirements
– Conditions required by ComputationalConditions required by Computational
Fluid Dynamics (CFD) softwareFluid Dynamics (CFD) software
– CFD Software solves for ForcesCFD Software solves for Forces

16. Boundary ConditionsBoundary Conditions
 Two main categoriesTwo main categories
– Known ConditionsKnown Conditions
 Conditions that are set by designConditions that are set by design
 Conditions that are measuredConditions that are measured
– Unknown ConditionsUnknown Conditions
 Conditions that result from the designConditions that result from the design
 Conditions that are found through calculationConditions that are found through calculation
– Requires assumptionsRequires assumptions

17. Boundary ConditionsBoundary Conditions
 Known ConditionsKnown Conditions
– Given:Given:
 Max Turbine Inlet Temperature (TIT)Max Turbine Inlet Temperature (TIT)
 Compressor Exit TempCompressor Exit Temp
 Compressor Pressure RatioCompressor Pressure Ratio
 Air and Fuel Mass Flow RatesAir and Fuel Mass Flow Rates
Personal Communication with Mr. Mike Zoch

18.  Calculated ConditionsCalculated Conditions
– CFD Model Required Inputs:CFD Model Required Inputs:
 Flow Inlet Static PressureFlow Inlet Static Pressure
 Inlet Total TemperatureInlet Total Temperature
– Two Distinct Calculation MethodsTwo Distinct Calculation Methods
Boundary ConditionsBoundary Conditions

19. Boundary ConditionsBoundary Conditions
 First Method AssumptionsFirst Method Assumptions
– Steady-State, Steady FlowSteady-State, Steady Flow
– Fluid Acts as AirFluid Acts as Air
– Ideal GasIdeal Gas
Fox and McDonald, Introduction to Fluid Mechanics

20. Boundary ConditionsBoundary Conditions
 First MethodFirst Method
– Conservation of massConservation of mass
 Mass flow rate:Mass flow rate:
 Static pressure:Static pressure:
 Total temperature:Total temperature:
p
s
C
V
TT ⋅
+=
2
2
0
2
2
1
Vpp os
ρ−=
VAm ρ=
•
Fox and McDonald, Introduction to Fluid Mechanics

21. Boundary ConditionsBoundary Conditions
 Second Method AssumptionsSecond Method Assumptions
– Choked FlowChoked Flow
– 1-Dimensional, Isentropic Flow1-Dimensional, Isentropic Flow
– Ideal GasIdeal Gas
Fox and McDonald, Introduction to Fluid Mechanics

22. Boundary ConditionsBoundary Conditions
 Second MethodSecond Method
– 1-D Choked Flow employing Mach number1-D Choked Flow employing Mach number
A inlet

23. Boundary ConditionsBoundary Conditions
 Mach Number Found Using Area ratiosMach Number Found Using Area ratios
– k from a Brayton Cycle model
– Areas from Engineering Drawings
( )
( )
( )
M
M
k
k
A
A
k
k
k
k
12
1
2
12
1
*
2
1
1
2
1
−
+
−
+−






⋅
−
+
⋅




 +
=
Fox and McDonald, Introduction to Fluid Mechanics

24. Boundary ConditionsBoundary Conditions
 Choked Flow CorrelationsChoked Flow Correlations
– Total Pressure:Total Pressure:
– Total temperature:Total temperature:
( )
k
k
s
M
k
pp
−






⋅




 −
+=
1
2
0 2
1
1






⋅




 −
+⋅= 2
0
2
1
1 M
k
TT s
* Fox and McDonald, Introduction to Fluid Mechanics

25. CFD ModelingCFD Modeling
 DetermineDetermine
ForcesForces
 2-D Cross-2-D Cross-
SectionsSections
Personal Communication with DongMei Zhou

26. CFD ModelingCFD Modeling
 Gas Path ModelGas Path Model

27. CFD ModelingCFD Modeling
 Gas Path ModelGas Path Model

28. CFD ModelingCFD Modeling
 Added Inlet SectionAdded Inlet Section
Personal Communication with Dr. David Bogard

29. CFD ModelingCFD Modeling
 Mesh ElementsMesh Elements

30. CFD ModelingCFD Modeling
 Boundary ConditionsBoundary Conditions
– Pressure Inlet (Total and Static)Pressure Inlet (Total and Static)
– Inlet Total TemperatureInlet Total Temperature
– Pressure Outlet (Static)Pressure Outlet (Static)
– Frictionless, Adiabatic Top WallsFrictionless, Adiabatic Top Walls
– No Slip, Constant Temperature Stator SurfacesNo Slip, Constant Temperature Stator Surfaces
Personal Communication with Dr. David Bogard

31. CFD ModelingCFD Modeling
 Grid Independent Study: ForcesGrid Independent Study: Forces

32. CFD ModelingCFD Modeling
 Grid Independent StudyGrid Independent Study

33. CFD ModelingCFD Modeling
 Grid Independent StudyGrid Independent Study

34. CFD ModelingCFD Modeling
 Results: Verification of Choked FlowResults: Verification of Choked Flow
Throat Region
M,max ≈ 1.0

35. CFD ModelingCFD Modeling
 Results: Verification of ConstantResults: Verification of Constant
Velocity InletVelocity Inlet
Constant Static
Pressure,
Constant
Velocity Inlet

36. CFD ModelingCFD Modeling
 Results: Forces on Stator SectionsResults: Forces on Stator Sections
Ftan, Section EE
Ftan, Section CC
Ftan, Section AA
Faxial, Section
EE
Faxial, Section
CC
Faxial, Section
AA

37. CFD ModelingCFD Modeling
 Results: Force DistributionsResults: Force Distributions

38. CFD ModelingCFD Modeling
 Results: Resultant ForcesResults: Resultant Forces
FResultant, tan
FResultant, axial
Moment, M
*

39. Force CalculationsForce Calculations
 PurposePurpose
– Map CFD Forces to TVSSMap CFD Forces to TVSS
 MethodMethod
– Static analysisStatic analysis
– DefiningDefining
sectionssections
FResultant, tan
FResultant, axial
Moment, M

40. Force CalculationsForce Calculations
 Defining SectionsDefining Sections

41. Force CalculationsForce Calculations
 Defining Sections

42. Force CalculationsForce Calculations
Buckle Condition
Twist Condition
 Static Analysis

43. Force CalculationsForce Calculations
 Point ForcesPoint Forces
 Distributed LoadsDistributed Loads
 PressuresPressures

44. ANSYS ModelingANSYS Modeling
Displacement Constraints
Point Forces
Pressure
 Load Condition: Section AA

45. ANSYS ModelingANSYS Modeling
 Load Condition: Section DD
Displacement Constraints
Pressure

46.  Grid Independent Study
ANSYS ModelingANSYS Modeling
0
10000
20000
30000
40000
50000
60000
0 2 4 6 8 10 12 14 16
Mesh
Stress(psi)
keypoint 44
keypoint 43
keypoint 28

47.  Chosen Mesh: 4,697 Elements
ANSYS ModelingANSYS Modeling

48. σmax
ANSYS ModelingANSYS Modeling

49.  Problems with 2-DProblems with 2-D
– Severe YieldingSevere Yielding
– Artificial ConstraintsArtificial Constraints
 3-D Approach3-D Approach
– Pie Slice SectionPie Slice Section
– More Realistic ConstraintsMore Realistic Constraints
ANSYS ModelingANSYS Modeling

50. ANSYS ModelingANSYS Modeling
 Loaded 3D Pie Portion of TVSS

51. ANSYS ModelingANSYS Modeling
 Deformed imageDeformed image
*

52. Completed GoalsCompleted Goals
 Flow Boundary ConditionsFlow Boundary Conditions
 Forces from Stator VanesForces from Stator Vanes
 3-D Finite Element Model of TVSS3-D Finite Element Model of TVSS

53. Remaining WorkRemaining Work
 Continue working with ANSYSContinue working with ANSYS
– Determine Proper MeshDetermine Proper Mesh
– Run load cases on 3-D modelRun load cases on 3-D model
– Vary material depth in flange areaVary material depth in flange area

54. RecommendationsRecommendations
 FEM Simulating Stator/TVSSFEM Simulating Stator/TVSS
InteractionInteraction
 Determine Effects of Vibration LoadDetermine Effects of Vibration Load
 Axial and Tangential Force VerificationAxial and Tangential Force Verification
via Wind Tunnel Testingvia Wind Tunnel Testing

55. QuestionsQuestions

56. Appendix 1AAppendix 1A
 Brayton Cycle ModelBrayton Cycle Model
( ) ( )hhmhhm outinoutinnetwork −−−=
••
T
h
cp
∆
∆
=
( ) ( )( )[ ]TTTTcm pnetwork 4321
−−−=
•

57. Appendix 1bAppendix 1b
 Solving for CpSolving for Cp
( )










Μ
⋅++++=
−
RTTTTcp
432
εδχβα
c
c
v
p
K =
.
Then:








Μ
−=
−
R
cc pv

58. Appendix 1CAppendix 1C
R p = 9 Comp Turb
1 428 2 953 3 869 4
Temp (K) 300 428.8612 557.7225 953.8612 1350 869.9442 786.0271
Cp 1.016574 1.131094 1.165452
Cv 0.729687 0.844206 0.878564 k-1/k
K 1.393165 1.339831 1.326541 0.253637
V dot 5
Q in 13442.1
Work isntpc -3929.91 9859.248
Work Actual -4734.831 8577.546
W/ Delta T w/ Rp
EFF 44.1102 44.555 EFF act 28.58716
BWR 39.8601 BWR act 55.2003
M dot 15
Net Work 3842715 1watt = 0.001341 hp
HP 5153
K value

59. Appendix 2Appendix 2
 Finding Velocity Using Mass FlowFinding Velocity Using Mass Flow
A
V m
⋅
=
•
ρ
TR
P
⋅
= −
ρ
( )RR inout
A
22
−⋅Π=

60. Appendix 3Appendix 3
 Validating VelocityValidating Velocity
Using Mach NumberUsing Mach Number
au
u
M =
TRkua
−
=
ua
MV ×=

61. Appendix 4Appendix 4
 3-D SolidWorks Modeling3-D SolidWorks Modeling
Image of 3-D TVSS Solid Model