This final year project presents the design, fabrication and testing of Tesla Bladeless Turbine for a 500 W hydropower system. One of the important components of Tesla turbine is the disc; its dimensions are determined from previously conducted research from Warren Rice, who mathematically modeled the flow between two co-rotating discs. Other scientists validated his results and published turbine performance plot, which can be used for further research. Using these results of the discs, the dimensions of the shaft were determined by considering a shaft under cyclic loading. Bearings were selected using analytical techniques and then the dimensions of the stator that is the outer cylinder were determined considering it as a thin walled cylinder. The nozzle slot in the outer cylinder was considered as an initial crack and stress analysis were performed to ensure safe operation. The design parameters and the processes adopted to calculate these parameters are shown in the report. Using these dimensions, a three dimensional CAD model of the turbine is generated using Solid works 2016, and modified to eliminate any problems in the shape and dimensions of individual parts. The parts were then manufactured and assembled in the innovation lab at FME GIKI. Once the assembly is completed, the turbine was tested under different working conditions, at the fluid mechanics lab of FME GIKI. In the end, the performance of the turbine was compared with that of conventional hydro-powered turbines, to see how much it can compete with the already accomplished turbines, used in the industry.

1. Design and Fabrication of
Tesla turbine
FIRASAT NOOR
SYED JALAL FARID
SYED MAAZ BIN RAZI
SYED SAAD REHMAN

2. Aim
 To implement Tesla Turbine for small scale commercial purposes by improving
the design of previous Tesla Turbine
Objectives
 Design a 500 Watt Tesla Turbine
 Fabrication of Turbine
 Testing of Turbine
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3. Working Principle
 Works on boundary layer effect
 The motion of fluid on a discs creates friction
that tends to rotate the discs
 Fluid enter radially at the outer boundary of the disc
 And exits axially at the center of the disc
 The discs coupled with shaft transmits the power to outside
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4. CAD Model
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5. Design Methodology
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6. Design Parameters
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7. Fabrication
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Complete turbine assembly

8. Testing
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Complete testing setup
• Pump was used for input
• Flow rate and pressure were measured
• Input Power = Flow rate x Pressure
• For output, pulley was used
• Torque and RPM were measured
• Output Power = Torque x Angular velocity

9. Results
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10. Results (Contd.)
 Maximum Efficiency is 51%.
 Maximum Power is 119 W for an input of 542 W
 Maximum Torque is 3.50 Nm.
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11. Future work
 CFD Analysis of the turbine can be performed
 Nozzle Design can be improved
 Effect of disc roughness on the performance of the turbine can
be analyzed
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