The document discusses the modeling and analysis of stresses in a steam turbine casing under transient operating conditions. It presents the finite element modeling process for the casing, including assumptions made and software used. The modeling considers thermal loading during startup and shutdown cycles. Heat transfer and thermal analyses are conducted to determine temperature distributions and thermal stresses within the casing. High stresses are found at locations like corners, welds and nozzle fits, which can lead to damage like cracking over the turbine's lifetime. The analysis aims to better understand casing behavior under transient conditions and improve design for increased reliability and life.
Piston in the internal combustion (IC) engine is robust, dynamically loaded tribo-pair that
reciprocates continuously at varying temperature. Study has been made by various researchers on piston
design, dynamics, fatigue and wear at the interface with other element in contact along with their effects on
IC engines. It was found that the friction coefficient increases with increasing surface roughness of liner
surface and thermal performance of the piston increases with increased coating thickness. The free material
liberated due to deep scoring between the piston and liner snowballs, leads to seizure failure.
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
fatigue failure analysis of steam turbine shaft using fem techniqueIjripublishers Ijri
The aim of the project is to locate best constrain location by evaluating steam turbine shaft with different materials.
Initially data collection will be done to understand rectification methodology and approach.
A 3D model of shaft will be prepared and exported into IGES (inertial graphical exchanging specifications) format to
conduct further work in ANSYS.
Structural analysis will be carried out on assembly to evaluate structural characteristics.
Model analysis will be carried out on same to find natural frequency’s (for comparison with other results)
Thermal analysis will be carried out on to find thermal characteristic.
Comparison tables will be prepared according to the obtained results from Ansys; Conclusion will be made according
to the obtained results.
Key words: steam turbine, shaft, hollow shaft,fatigue failure analysis.
STRUCTURAL AND VIBRATIONAL RESPONSE ANALYSIS OF H.P. BLADED DISC ASSEMBLYIAEME Publication
In this article, an effort has been made to deal with structural behavior of the Steam turbine HP blade and disc assembly rotating at 100% (6000 rpm) optimum speed and 120% (7200rpm) over speed conditions which in turn create large amount of centrifugal force. This is the dominating force in steam turbine blade assembly which is the cause for all its behavior. Vibrational analysis of this HP blade and disc assembly is also carried out using FEA methods to determine and predict the fatigue life of the blade and disc. The Structural analysis is carried out on the HP blade and disc to understand the Structural behaviors which comes on them in order to find out the factor of safety of the HP blade and disc assembly due to high angular velocity.
Piston in the internal combustion (IC) engine is robust, dynamically loaded tribo-pair that
reciprocates continuously at varying temperature. Study has been made by various researchers on piston
design, dynamics, fatigue and wear at the interface with other element in contact along with their effects on
IC engines. It was found that the friction coefficient increases with increasing surface roughness of liner
surface and thermal performance of the piston increases with increased coating thickness. The free material
liberated due to deep scoring between the piston and liner snowballs, leads to seizure failure.
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
fatigue failure analysis of steam turbine shaft using fem techniqueIjripublishers Ijri
The aim of the project is to locate best constrain location by evaluating steam turbine shaft with different materials.
Initially data collection will be done to understand rectification methodology and approach.
A 3D model of shaft will be prepared and exported into IGES (inertial graphical exchanging specifications) format to
conduct further work in ANSYS.
Structural analysis will be carried out on assembly to evaluate structural characteristics.
Model analysis will be carried out on same to find natural frequency’s (for comparison with other results)
Thermal analysis will be carried out on to find thermal characteristic.
Comparison tables will be prepared according to the obtained results from Ansys; Conclusion will be made according
to the obtained results.
Key words: steam turbine, shaft, hollow shaft,fatigue failure analysis.
STRUCTURAL AND VIBRATIONAL RESPONSE ANALYSIS OF H.P. BLADED DISC ASSEMBLYIAEME Publication
In this article, an effort has been made to deal with structural behavior of the Steam turbine HP blade and disc assembly rotating at 100% (6000 rpm) optimum speed and 120% (7200rpm) over speed conditions which in turn create large amount of centrifugal force. This is the dominating force in steam turbine blade assembly which is the cause for all its behavior. Vibrational analysis of this HP blade and disc assembly is also carried out using FEA methods to determine and predict the fatigue life of the blade and disc. The Structural analysis is carried out on the HP blade and disc to understand the Structural behaviors which comes on them in order to find out the factor of safety of the HP blade and disc assembly due to high angular velocity.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Thermo coupled stress analysis of exhaust manifold assemblage using abaqusINFOGAIN PUBLICATION
Comprehension of the basic conduct in the beginning period of outline can help to lessen the quantity of virtual models and the time taken for their assessment. For an engine development program, the engine exhaust manifold system is a mind boggling framework subjected to thermo mechanical burdens. The investigation of such a framework is discriminating because of the many-sided quality of meeting the basic and stream prerequisites. In this paper the Thermal Stress Index (TSI) is created for down to earth reason. Especially the TSI is appeared to be extremely powerful in discovering an ideal shape with imperatives in outline of the exhaust manifold system. Therefore, the objective for discovering an ideal state of the exhaust manifold system is to minimize the TSI, and philosophy received to address a failure of an Exhaust complex amid physical testing on an engine test bed. A non-linear thermo-auxiliary quality investigation of the exhaust manifold system gathering of the four cylinder four stroke engine is done. The FE model comprises of the exhaust manifold system get together, head and mounting bolts. The contact interaction between the parts is likewise modeled. The assembly is subjected to bolt preloads, for reproducing the mechanical assembly. The thermal loads utilized as a part of the reenactment are computed through CFD (Input). The model considers a temperature reliance of a heat exchange coefficient on wall temperature in cooling sections. For the structural analysis temperature subordinate non-linear material properties and contact non-linearity is considered.
Structural and Thermal Analysis of Metal - Ceramic Disk BrakeIJSRD
Disk brakes are using from so many years in automotive and still researches are going on in this field for decreasing the temperature effect so that by this we can operate easily. Many new materials are introduced for the disk brake rotor to withstand high temperature produced during braking action. Apart from the high temperature property, the disc rotor materials must also have high thermal conductivity property, as this property decides the amount of heat dissipation to the air stream from the disk rotor. A brake material with good temperature and high thermal conductivity property gives maximum efficiency by overcoming the problem of thermo-mechanical instability [TEI] in the rotor which is more common in low thermal conductivity brake rotor material. In the present work, a Grey cast iron material and metal-ceramic has been chosen for the disk brake rotor. Number of methods before already introduced to know the history of the different materials related to disk brakes, analysis will be done in 2d and 3d in analytical and numerical methods. With different types of assumptions these numerical methods ranges from finite differences to finite elements. To conclude the temperature history for the Grey cast iron material, and metal-ceramic, a numerical simulation technique called finite element method is used. Transient analysis is carried out in ANSYS to predict temperature distribution as a function of time in the disk brake rotor. The results from the transient analysis are compared. As the brake rotor can be treated as the coupled field problem, it is mandatory to do structural analysis after performing thermal analysis in ANSYS to study the stability and rigidity behavior of the rotor material. The results from the transient analysis are given as the input to the structural analysis in order to conclude the stress distribution and displacement in disk brake rotor under thermal loading. The stability behavior of different brake rotor material is compared to facilitate the conceptual design of the disk brake system.
Design & Analysis of a Disc Brake using Feaijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
In this paper three different cut patterns of brake disc are studied for heat transfer rate. Heat transfer rate increases with number of cuts in the disc. This is because large area is exposed to air which makes more heat transfer through conduction and convection. But increase in number and size of cuts decreases the strength of disc. And analysed thermally in ANSYS for different material and design created in CREO 3.0.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...ijsrd.com
Automobile braking system is one of the most important mechanical devices among the others. The disc brake is a device that slows or stops the rotation of a wheel by converting the friction to heat. But if the brakes get too hot, they will cease to work as they cannot dissipate enough heat. This condition of failure is known as brake fade. Disc brakes are exposed to large thermal stresses during routine braking and extraordinary thermal stresses during hard braking. Ventilation applications on disc brake can significantly improve the brake system performance by reducing the heating of the discs. In this study, the thermal behavior as well as the performance of ventilated brake discs using different pattern of holes will be investigated at continuous brake conditions with finite element analysis and the results will be compared with a solid disc.
Modeling and Thermal Analysis of Disc BrakeIJERA Editor
The disc brake is a device used for slowing or stopping the rotation of the vehicle. Number of times using the brake for vehicle leads to heat generation during braking event, such that disc brake undergoes breakage due to high Temperature. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the Thermal analysis of the Materials for the Aluminum, Grey Cast Iron, HSS M42, and HSS M2. A comparison between the four materials for the Thermal values and material properties obtained from the Thermal analysis low thermal gradient material is preferred. Hence best suitable design, low thermal gradient material Grey cast iron is preferred for the Disc Brakes for better performance.
Simulation of gas turbine blade for enhancement of efficiency of gas turbine...IJMER
As day by day population of the world is increasing and our resources are frequently reducing
hence to meet this demand of the world of energy we have to move to a device which have a maximum
efficiency for the condition turbo-machinery are better suited machines having a good efficiency, in
which a Gas turbine is best example of turbo- machinery Turbine is the part of gas turbine which provide
the power to compressor to run or provide power to external source from where energy can be extracted
by attaching alternator in the shaft of Gas turbine. As in earlier a lot of work have been done by the
researcher to increase the efficiency and standard of Gas turbine by the method of film cooling, coating,
and curvature of blade to protect the blade from high temperature of 1200 C° inside the Gas turbine to
increase the life of blade without considering about the efficiency of the engine As in this work is to
enhancement of efficiency of Gas turbine. Gas turbine blade is very important component of engine as
they are attached to both turbine or compressor and turbine provide energy to compressor hence the
turbine blade are more important component to enhance the efficiency which will be analyzed on the
basis of blade height area of fluid flow , area of blade thickness and angles . This simulation is based on
the define value of temperature pressure density of fluid and solid used in blade construction will be
meshed in ANSYS and calculation on the basis of FEM and the result from this calculation over the
temperature and fluid flow inside the gas turbine of different number of blade is studied will be compare
to reach high efficiency point. By determent these value output is formulated on graph chart and will be
studied and result obtain
THERMAL AND STRUCTURAL ANALYSIS OF AN EXHAUST MANIFOLD OF A MULTI CYLINDER EN...IAEME Publication
The paper deals with the thermal and structural analysis of a multi cylinder engine exhaust manifold, for the given dimensions. The dimensions of the exhaust manifold are taken from the drawing. The 3D model is prepared using NX-CAD software. Thermal and Coupled Field analysis are performed. Critical frequencies in the operating range are obtained by performing Modal analysis. Harmonic analysis is performed and the deflections and stresses at the nearest natural
frequencies are plotted. The exhaust manifold design’s acceptance is done from the results obtained in different analysis. It is an effort to automate design optimization which would reduce technical,schedule, and cost risks for new engine developments.
Radiator is a device used to cool internal combustion engine by radiating heat out via a fluid called coolant which is being circulated around the engine.
Current generation radiators consist of two header tanks placed on bottom and top interlinked by a passage of tubes, which are flattened in order to maximize the surface area. It is made up of brass or copper soldered to brass headers, but to save money aluminum tubes with plastic headers may also be used.
Experimental Analysis and Investigation for Thermal Behaviour of Ventilated D...ijsrd.com
In the present review, we discuss works that have been published in the last 15 – 20 years that are based on the computational and experimental analysis of thermal properties of disc brake rotor of various types; new applications of the theory of heat conduction, convection and radiation. As the rapid development of computer engineering have led to a considerable increase in the number of solvable problems, and the refining of mathematical methods and approaches enables one to construct analytic solutions of these problems. In the paper, we outline the main directions of investigation of the processes of interaction of bodies with regard for heat release. We describe computational methods in more detail as compared with other approaches, because, to our mind, they are very promising for deriving simple engineering relations for braking processes on the basis of the equations of the thermal dynamics of friction; also the actual braking system is much transient and a lot of variable changes at a time which becomes very difficult to calculate experimentally.
Heat Transfer Analysis and Optimization of Engine Cylinder Fins of Varying Ge...IOSR Journals
: The main aim of the project is to analyze the thermal properties by varying geometry, material and
thickness of cylinder fins. Parametric models of cylinder with fins have been developed to predict the transient
thermal behavior. The models are created by varying the geometry, rectangular, circular and curved shaped
fins and also by varying thickness of the fins. The 3D modeling software used is Pro/Engineer.The analysis is
done using ANSYS. Presently Material used for manufacturing cylinder fin body is Aluminum Alloy 204 which
has thermal conductivity of 110-150W/mk. We are analyzing the cylinder fins using this material and also using
Aluminum alloy 6061 and Magnesium alloy which have higher thermal conductivities.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Thermo coupled stress analysis of exhaust manifold assemblage using abaqusINFOGAIN PUBLICATION
Comprehension of the basic conduct in the beginning period of outline can help to lessen the quantity of virtual models and the time taken for their assessment. For an engine development program, the engine exhaust manifold system is a mind boggling framework subjected to thermo mechanical burdens. The investigation of such a framework is discriminating because of the many-sided quality of meeting the basic and stream prerequisites. In this paper the Thermal Stress Index (TSI) is created for down to earth reason. Especially the TSI is appeared to be extremely powerful in discovering an ideal shape with imperatives in outline of the exhaust manifold system. Therefore, the objective for discovering an ideal state of the exhaust manifold system is to minimize the TSI, and philosophy received to address a failure of an Exhaust complex amid physical testing on an engine test bed. A non-linear thermo-auxiliary quality investigation of the exhaust manifold system gathering of the four cylinder four stroke engine is done. The FE model comprises of the exhaust manifold system get together, head and mounting bolts. The contact interaction between the parts is likewise modeled. The assembly is subjected to bolt preloads, for reproducing the mechanical assembly. The thermal loads utilized as a part of the reenactment are computed through CFD (Input). The model considers a temperature reliance of a heat exchange coefficient on wall temperature in cooling sections. For the structural analysis temperature subordinate non-linear material properties and contact non-linearity is considered.
Structural and Thermal Analysis of Metal - Ceramic Disk BrakeIJSRD
Disk brakes are using from so many years in automotive and still researches are going on in this field for decreasing the temperature effect so that by this we can operate easily. Many new materials are introduced for the disk brake rotor to withstand high temperature produced during braking action. Apart from the high temperature property, the disc rotor materials must also have high thermal conductivity property, as this property decides the amount of heat dissipation to the air stream from the disk rotor. A brake material with good temperature and high thermal conductivity property gives maximum efficiency by overcoming the problem of thermo-mechanical instability [TEI] in the rotor which is more common in low thermal conductivity brake rotor material. In the present work, a Grey cast iron material and metal-ceramic has been chosen for the disk brake rotor. Number of methods before already introduced to know the history of the different materials related to disk brakes, analysis will be done in 2d and 3d in analytical and numerical methods. With different types of assumptions these numerical methods ranges from finite differences to finite elements. To conclude the temperature history for the Grey cast iron material, and metal-ceramic, a numerical simulation technique called finite element method is used. Transient analysis is carried out in ANSYS to predict temperature distribution as a function of time in the disk brake rotor. The results from the transient analysis are compared. As the brake rotor can be treated as the coupled field problem, it is mandatory to do structural analysis after performing thermal analysis in ANSYS to study the stability and rigidity behavior of the rotor material. The results from the transient analysis are given as the input to the structural analysis in order to conclude the stress distribution and displacement in disk brake rotor under thermal loading. The stability behavior of different brake rotor material is compared to facilitate the conceptual design of the disk brake system.
Design & Analysis of a Disc Brake using Feaijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
In this paper three different cut patterns of brake disc are studied for heat transfer rate. Heat transfer rate increases with number of cuts in the disc. This is because large area is exposed to air which makes more heat transfer through conduction and convection. But increase in number and size of cuts decreases the strength of disc. And analysed thermally in ANSYS for different material and design created in CREO 3.0.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...ijsrd.com
Automobile braking system is one of the most important mechanical devices among the others. The disc brake is a device that slows or stops the rotation of a wheel by converting the friction to heat. But if the brakes get too hot, they will cease to work as they cannot dissipate enough heat. This condition of failure is known as brake fade. Disc brakes are exposed to large thermal stresses during routine braking and extraordinary thermal stresses during hard braking. Ventilation applications on disc brake can significantly improve the brake system performance by reducing the heating of the discs. In this study, the thermal behavior as well as the performance of ventilated brake discs using different pattern of holes will be investigated at continuous brake conditions with finite element analysis and the results will be compared with a solid disc.
Modeling and Thermal Analysis of Disc BrakeIJERA Editor
The disc brake is a device used for slowing or stopping the rotation of the vehicle. Number of times using the brake for vehicle leads to heat generation during braking event, such that disc brake undergoes breakage due to high Temperature. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the Thermal analysis of the Materials for the Aluminum, Grey Cast Iron, HSS M42, and HSS M2. A comparison between the four materials for the Thermal values and material properties obtained from the Thermal analysis low thermal gradient material is preferred. Hence best suitable design, low thermal gradient material Grey cast iron is preferred for the Disc Brakes for better performance.
Simulation of gas turbine blade for enhancement of efficiency of gas turbine...IJMER
As day by day population of the world is increasing and our resources are frequently reducing
hence to meet this demand of the world of energy we have to move to a device which have a maximum
efficiency for the condition turbo-machinery are better suited machines having a good efficiency, in
which a Gas turbine is best example of turbo- machinery Turbine is the part of gas turbine which provide
the power to compressor to run or provide power to external source from where energy can be extracted
by attaching alternator in the shaft of Gas turbine. As in earlier a lot of work have been done by the
researcher to increase the efficiency and standard of Gas turbine by the method of film cooling, coating,
and curvature of blade to protect the blade from high temperature of 1200 C° inside the Gas turbine to
increase the life of blade without considering about the efficiency of the engine As in this work is to
enhancement of efficiency of Gas turbine. Gas turbine blade is very important component of engine as
they are attached to both turbine or compressor and turbine provide energy to compressor hence the
turbine blade are more important component to enhance the efficiency which will be analyzed on the
basis of blade height area of fluid flow , area of blade thickness and angles . This simulation is based on
the define value of temperature pressure density of fluid and solid used in blade construction will be
meshed in ANSYS and calculation on the basis of FEM and the result from this calculation over the
temperature and fluid flow inside the gas turbine of different number of blade is studied will be compare
to reach high efficiency point. By determent these value output is formulated on graph chart and will be
studied and result obtain
THERMAL AND STRUCTURAL ANALYSIS OF AN EXHAUST MANIFOLD OF A MULTI CYLINDER EN...IAEME Publication
The paper deals with the thermal and structural analysis of a multi cylinder engine exhaust manifold, for the given dimensions. The dimensions of the exhaust manifold are taken from the drawing. The 3D model is prepared using NX-CAD software. Thermal and Coupled Field analysis are performed. Critical frequencies in the operating range are obtained by performing Modal analysis. Harmonic analysis is performed and the deflections and stresses at the nearest natural
frequencies are plotted. The exhaust manifold design’s acceptance is done from the results obtained in different analysis. It is an effort to automate design optimization which would reduce technical,schedule, and cost risks for new engine developments.
Radiator is a device used to cool internal combustion engine by radiating heat out via a fluid called coolant which is being circulated around the engine.
Current generation radiators consist of two header tanks placed on bottom and top interlinked by a passage of tubes, which are flattened in order to maximize the surface area. It is made up of brass or copper soldered to brass headers, but to save money aluminum tubes with plastic headers may also be used.
Experimental Analysis and Investigation for Thermal Behaviour of Ventilated D...ijsrd.com
In the present review, we discuss works that have been published in the last 15 – 20 years that are based on the computational and experimental analysis of thermal properties of disc brake rotor of various types; new applications of the theory of heat conduction, convection and radiation. As the rapid development of computer engineering have led to a considerable increase in the number of solvable problems, and the refining of mathematical methods and approaches enables one to construct analytic solutions of these problems. In the paper, we outline the main directions of investigation of the processes of interaction of bodies with regard for heat release. We describe computational methods in more detail as compared with other approaches, because, to our mind, they are very promising for deriving simple engineering relations for braking processes on the basis of the equations of the thermal dynamics of friction; also the actual braking system is much transient and a lot of variable changes at a time which becomes very difficult to calculate experimentally.
Heat Transfer Analysis and Optimization of Engine Cylinder Fins of Varying Ge...IOSR Journals
: The main aim of the project is to analyze the thermal properties by varying geometry, material and
thickness of cylinder fins. Parametric models of cylinder with fins have been developed to predict the transient
thermal behavior. The models are created by varying the geometry, rectangular, circular and curved shaped
fins and also by varying thickness of the fins. The 3D modeling software used is Pro/Engineer.The analysis is
done using ANSYS. Presently Material used for manufacturing cylinder fin body is Aluminum Alloy 204 which
has thermal conductivity of 110-150W/mk. We are analyzing the cylinder fins using this material and also using
Aluminum alloy 6061 and Magnesium alloy which have higher thermal conductivities.
Remaining life assessment of refinery furnace tubes using finite element methodBarhm Mohamad
Crude oil heater 9Cre-1Mo steel tubes from a refinery plant were studied, after 5 years of service at nominally 650 Cº and 3 bar, to predict their remnant lives. The investigation included dimensional, hardness and tensile measurements in addition to accelerated stress rupture tests between 650 Cº and 700 Cº and microstructural examination. Tube specimens were taken from two sections, the overheated side and the side which only saw the nominal operating temperature. The method employed involved the prediction of the increase in temperature with increasing sediment deposition during the operating life times using an FEM model. In addition the predicted temperatures are used to derive appropriate creep properties at relevant temperatures in a 3D pipe FEM creep analysis to predict the pipe deformation rate. All compare well with the actual service exposed pipe measurements and layer deposition. The overheated side revealed a small loss of creep strength in a stress rupture test. A layer of sediment (appr. 10 mm thickness) consisting basically of sintered carbon (coke) spread over the inside of the tube was acting as a thermal barrier causing the temperature to rise above 650 Cº. Analysis for the overheated side predicted an upper bound temperature of 800 Cº and a life of about 50 h suggesting that failure by creep rupture could occur rapidly in the sediment region.
Effect of Spray Quenching Rate on Distortion and Residual Stresses during Ind...Fluxtrol Inc.
http://fluxtrol.com
Computer simulation is used to predict the residual stresses and distortion of a full-float truck axle that has been
induction scan hardened. Flux2D® is used to model the electromagnetic behavior and the power distributions inside
the axle in terms of time. The power distributions are imported and mapped into DANTE® model for thermal, phase
transformation and stress analysis. The truck axle has three main geometrical regions: the flange/fillet, the shaft, and
the spline. Both induction heating and spray quenching processes have significant effect on the quenching results: distortion and residual stress distributions. In this study, the effects of spray quenching severity on residual stresses and distortion are investigated using modeling.
Fatigue Analysis of Acetylene converter reactorIJMER
The structural integrity of mechanical components during several transients should be
assured in the design stage. This requires a fatigue analysis including thermal and structural analysis. As
an example, this study performs a fatigue analysis of the acetylene converter reactor during arbitrary
transients. Using heat transfer coefficients determined based on the operating environments, a transient
thermal analysis is performed and the results are applied to a finite element model along with the
pressure to calculate the stresses. The total stress intensity range and cumulative fatigue usage factor are
investigated to determine the adequacy of the design
THERMAL INVESTIGATION ON PROPELANT TANK MATERIAL BY USING FEM APPROACHIjripublishers Ijri
Rocket propellant tanks are pressure vessels where liquid fuels are stored prior to use. They have to store the propellant;
propellant combinations are used in rocket engines where the propellants spontaneously ignite when they come into
contact with each other. The two propellant components usually consist of a fuel (Unsymmetrical dimethyl hydrazine
(UDMH)) and an oxidizer (nitrogen tetroxide (N2O4)).
Fatigue Analysis of Acetylene converter reactorIJMER
The structural integrity of mechanical components during several transients should be
assured in the design stage. This requires a fatigue analysis including thermal and structural analysis. As
an example, this study performs a fatigue analysis of the acetylene converter reactor during arbitrary
transients. Using heat transfer coefficients determined based on the operating environments, a transient
thermal analysis is performed and the results are applied to a finite element model along with the
pressure to calculate the stresses. The total stress intensity range and cumulative fatigue usage factor are
investigated to determine the adequacy of the design.
Engine Block/Cylinder Block is the structure which contains the cylinders, and other parts, of an internal combustion engine. In an early automotive engine, the engine block consisted of just the cylinder block, to which a separate crankcase was attached. Engine block is affected by pressure and the thermal conditions happen inside the engine. So we come up with static structural and transient thermal analysis on the engine block. This report provides Stress, Strain and Total Deformation of Engine due to Pressure, Temperature and Heat Flux. We come up with the fatigue life of the Engine Block due to different loading conditions.
A cylinder block is an integrated structure comprising the cylinder(s) of a reciprocating engine and often some or all of their associated surrounding structures. The term engine block is often used synonymously with "cylinder block" The analysis of the combustion chamber is done by using different materials. By conducting the above analysis on the combustion chamber combustion rate, pressure and temperature gradient conditions are found and the best material for the combustion chamber is suggested.
Thermal analysis is conducted to find heat dissipation rate in engine block with the variation of materials Structural and fatigue analysis (dynamic) is conduct on engine block at working load conditions to evaluate and compare stress, strain, deformation and fatigue life with the variation of materials.
Frequency analysis is conducted on engine block with the variation of materials to evaluate frequency, Using these values material selection will be done, the value should be nearby previous one (cast iron) maximum accepted variation value 65HZ.
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYSinventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
Design & Stress Analysis of a Cylinder with Closed ends using ANSYSIJERA Editor
The significance of the title of the project comes to front with designing structure of the pressure vessel for static loading and its assessment by ANSYS , is basically a project concerned with design of different pressure vessel elements such as shell, Dish end ,operating manhole ,support leg based on standards and codes ; and evolution of shell and dish end analysed by means of ANSYS .The key feature included in the project is to check the behaviour of pressure vessel in case of fluctuating load . The procedural step includes various aspects such as selecting the material based on American Society of Mechanical Engineers (ASME) codes ,and then designing on the standards procedures with referring standard manuals based on ASME .Further we have included the different manufacturing methods practice by the industries and different aspects of it .
Similar to IJCER (www.ijceronline.com) International Journal of computational Engineering research (20)
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...Jeffrey Haguewood
Sidekick Solutions uses Bonterra Impact Management (fka Social Solutions Apricot) and automation solutions to integrate data for business workflows.
We believe integration and automation are essential to user experience and the promise of efficient work through technology. Automation is the critical ingredient to realizing that full vision. We develop integration products and services for Bonterra Case Management software to support the deployment of automations for a variety of use cases.
This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
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IJCER (www.ijceronline.com) International Journal of computational Engineering research
1. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
Design and Analysis of HP steam turbine casing for Transient state
condition
1
J.Ramesh,2C.Vijaya Bhaskar Reddy, 3 Dr. B. Jayachandraiah
P.G Student1
Assistant Professor2 (Sr)
Head & Vice-principal3
Department Of Mechanical Engineering,
Sri Kalahasteeswara Institute Of Technology, Srikalahasti.
Abstract
Transient regimes arising during start-ups, shut-downs and load changes give rise to unsteady temperature distribution with
time in steam turbine casing high pressure (HP) which results in non-uniform strain and stress distribution. So that problems
such as stress corrosion, cracking and fatigue of steam turbine casing, In this work the thermo mechanical analysis of steam
turbine casing will be established by finite element method. In this work the temperature and stress distributions for turbine
inner casing were calculated by finite element analysis. The three dimensional model of the Steam Turbine Casing was created
using the CATIA software. The model was meshed using software HYPERMESH. Boundary conditions were given on the
finite element model through ANSYS.
In this paper, the transient temperatures and stresses distributions within a turbine inner casing were achieved from actual
operation data during cold start-up. The paper analyses the creap, centrifugal stress sub stained at high temperature in thermal
stresses setup during the startup and shutdown the stream turbine and most serious thread of the rotor blades near the bore,
creep cracks to initiates go to size which could results brittle fracture of the rotor blades. Due to crackness life of the steam
turbine decreases.
Keywords: Transient condition, 3-D model, Hypermesh, FE model, Thermal expansion
1.Introduction
Generally turbine casings used are split horizontally and vertically. The casing houses the blades rotor, nozzles, and
diaphragms. It also holds glands for steam sealing at each end for preventing leakage of steam from where the shaft passes
through. The steam casing of turbine is generally arranged with centre line support i.e the support points are on the same
horizontal plane as the centre line of the turbine. The steam end pedestal sits upon a flexible panting plate which provides
rigidity in the vertical and lateral planes, but allows flexibility in the axial plane for casing thermal expansion.
The combined thrust and journal bearing of the turbine rotor is housed in the steam end pedestal. The rotor, therefore, is moved
axially towards the steam end with the axil movement of the casing. The casing is that portion of the turbine that either supports
or supported by the bearing housings. The steam ring is attached to or is a part of the casing. All casing joints have metal to
metal sealing surfaces no strings or gaskets are used. All turbines manufactured by Maxwatt use multiple piece casings
consisting of two or more pieces that are split at the horizontal centerline to facilitate inspection or removal of the turbine rotor.
The casings are either cast, fabricated, or a combination of both depending on operating conditions. The casing can be of iron,
carbon steel, carbon moly steel, or chrome moly steel.
Types Of Casings
1.1 Single Stage Turbine Casing
Single stage turbine casings are two piece casings. The casing consists of the upper half and the lower half the lower half casing
houses both the inlet and exhaust connections. The bearing housings are either cast integrally with or bolted to the lower half
casing. All single stage frames except the type GA and SA turbine have the steam ring cast integrally with the casing this means
that the material required for the steam ring is also required for the casing. In those cases where the steam ring is not cast as the
part of the casing, different materials for the steam ring and casing can be utilized. The two components are bolted together.
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2. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
1.2 Multistage Turbine Casing:
Multistage turbine casing are considered to be horizontally split casing even through a vertical split may also be used. The point
of juncture of the vertical and horizontal splits is called a four way joint and is the most difficult area in the whole turbine
assembly to seal against steam pressure because of this Maxwatt employs a construction called barrel construction in normal
construction the steam ring forms the high pressure section of the casing and is bolted directly to the intermediate and exhaust
portions of the casing. This puts the four way split at the first stage which is where the highest case pressure is encountered in
the multistage turbine.
2. Literature Review
[1] Has developed modern CAE tools like Hyper mesh, ANSYS and Pro-E etc. have been utilized to model and analyze
existing LP casing and for redesigning it to suit the new efficient modern design of rotor. This paper presents the numerical
stress analysis of the turbine casing of an aero-engine. High thermal stress gradients were found at the region of casing where
fatigue cracks were detected during engine operation [2]. [3] Has analyzing the failure of a weld repaired turbine casing after 30
years of total service including 5 years after weld repair. The casing was weld repaired by a high Cr–Ni weld metal (24Cr–
32Ni–4Mn–Fe). The base metal low alloy ferritic steel (1Cr–0.5 Mo steel) with ferrite–pearlite structure did not show any
abnormality to indicate significant degradation. [4] Has studied about designing of complex steam turbine low pressure casing
the ever growing competition in capital intensive power sector is pressing turbine manufacturer’s world over to develop new
efficient steam turbine designs and to update/retrofit the old steam turbine which are in service. BHEL is also putting up major
design development efforts to meet the present market challenges. This paper depicts how the modern CAE tools like
Hypermesh, ANSYS and Pro-E etc. have been utilized to model and analyse existing LP casing and for redesigning it to suit the
new efficient modern design of rotor.
3. Modeling And Analysis
3.1 Steam Turbine Casing Model
It is very difficult to exactly model the Steam Turbine casing, in which there are still researches are going on to find out
transient thermo mechanical behavior of casing during operating under higher temperature and pressure. There is always a need
of some assumptions to model any complex geometry. These assumptions are made, keeping in mind the difficulties involved
in the theoretical calculation and the importance of the parameters that are taken and those which are ignored. In modeling we
always ignore the things that are of less importance and have little impact on the analysis. The assumptions are always made
depending upon the details and accuracy required in modeling.
The assumptions which are made while modeling the process are given below
The casing material is considered as homogeneous and isotropic.
Inertia and body force effects are negligible during the analysis.
The casing is stress free before the start up.
The analysis is based on pure thermal loading and vibration and
Thus only stress level due to the above said is done. The analysis does not determine the life of the casing.
The thermal conductivity of the material used for the analysis is uniform throughout.
Fig 3.1 CAD model of the casing
3.2 Steps Involved in Finite Element Analysis
Discretization of the continuum
Selection of the displacement model
Derivation of element stiffness matrix
Assemblage of the algebraic equations for the overall discretized Continuum.
Solution of the unknown displacements.
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3. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
3.3 Heat Transfer Analysis
Heat transfer of a casing surface is affected by convection and temperature distribution of inner part is calculated by
conduction. The boundary conditions between surface and inner area for the thermal analysis were derived from calculated heat
transfer coefficient according to time Heat transfer analysis was conducted from pre-warming to steady state condition using
heat transfer coefficients and a steam temperature of each location acquired from operating data. For HP casing are made from
castings and the life assessment portions are corner radius, pipe inner surfaces and welds. For turbine casing, especially, the
major damage occurs at the nozzle fit and disk corner of casing.
3.4 Thermal Analysis
A thermal analysis calculates the temperature distribution and related thermal quantities in steam turbine casing. Typical
thermal quantities are
The temperature distribution
The amount of heat lost or gained
Thermal fluxes
Thermal gradient
Thermal simulations play an important role in the design of many engineering applications, including internal combustion
engines, turbines, heat exchangers, piping systems, and electronic components. In many cases, engineers follow a thermal
analysis with a stress analysis to calculate thermal stresses (that is, stresses caused by thermal expansions or contractions). The
basis for thermal analysis in ANSYS is a heat balance equation obtained from the principle of conservation of energy. The finite
element solution perform via ANSYS calculates nodal temperatures, and then uses the nodal temperatures to obtain other thermal
quantities.
3.5 Transient Thermal Analysis
The ANSYS Multiphysics, ANSYS Mechanical, ANSYS Professional, and ANSYS FLOTRAN products support transient
thermal analysis. Transient thermal analysis determines temperatures and other thermal quantities that vary over time. Engineers
commonly use temperatures that a transient thermal analysis calculates as input to structural analyses for thermal stress
evaluations. Many heat transfer application heat treatment problems, nozzles, engine blocks, piping systems, pressure vessels,
etc. - involve transient thermal analyses. A transient thermal analysis follows basically the same procedures as a steady-state
thermal analysis. The main difference is that most applied loads in a transient analysis are functions of time. To specify time-de-
pendent loads, and then apply the function as a boundary condition, or you can divide the load-versus-time curve into load steps
3.5 Meshing
The goal of meshing in HYPERMESH Workbench is to provide robust, easy to use meshing tools that will simplify the mesh
generation process. These tools have the benefit of being highly automated along with having a moderate to high degree of user
control. In order to carry out a finite element analysis, the model using must be divided into a number of small pieces known as
finite elements. Since the model is divided into a number of discrete parts, FEA can be described as a discretization technique.
In simple terms, a mathematical net or mesh is required to carry out a finite element analysis. If the system under investigation
is 1D in nature, use line elements to represent our geometry and to carry out our analysis. If the problem can be described in 2
dimensions, then a 2D mesh is required. Correspondingly, if the problem is complex and a 3D representation of the continuum
is required, then we use a 3D mesh.
Fig 3.2: Steam Casing (HP) Meshed Model
Issn 2250-3005(online) September| 2012 Page 1175
4. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
The meshed assembly of a steam turbine casing is as shown in the Figure 3.1.Initially IGES file of a CATIA product has been
imported to the HYPERMESH workbench then the meshing is carried out. In the present case we did tetra type of element has
been used and detail information on meshed assembly as shown in Table 3.1
Object Name Steam Casing
Length Unit Millimeters
Bodies 13
Nodes 332917
Elements 1828152
Table 3.1 Detail Information about Steam Casing Meshing
Pre-Processing
The goals of the pre-processing are to develop an appropriate finite element mesh, assign suitable material properties and apply
boundary condition in the form restraints and loads. The finite element mesh subdivides the geometry into elements, upon
which are found nodes. The nodes which are just point location in the space are generally located at the element corner and near
each mid side node there may be two-dimensional or three-dimensional elements 2D-elements can be plane stress axis-
symmetric and plane strain condition s for a 3D solid analysis only one temperature or many temperature degrees of freedom
exists at each node. Developing a mesh, most time consuming work in FEA. The geometry is meshed with mapping algorithm
or free algorithm. The first maps a rectangular grid on to a geometric region, which must have the correct number of sides. Free
meshing automatically sub-divides meshing regions into elements easy messing, disadvantage is of distorted elements.
Post- Processing
Post processing begins with a thorough check for problems that may have occurred during solution. Once the solution is
verified to be free of numerical problems; the quantitative of interest may be examined.. Dynamic viewing and animation
capabilities aid greatly in obtaining an understanding of the deformation pattern. Stresses being sensor qualifies, currently lack
a single visualization technique, and thus derived stress quantifies are extracted and displayed. Principle stress vectors may be
displayed as color-coded arrows, indicating both direction and magnitudes. Von-Misses stress may be displayed on the model
as color bands. Displacements magnitudes may also be displayed by color bands, but this can lead to misinterpretation as stress
plot.
4. RESULTS:
Fig4.1: Temperature Distribution in inner casing in unsteady (Transient) state condition after 2000s
Fig4.2: Temperature Distribution in inner casing in unsteady (Transient) state condition after 6000s
Issn 2250-3005(online) September| 2012 Page 1176
5. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
Fig43: Temperature Distribution in inner casing in unsteady (Transient) state condition after 12000s
Fig4.5: Temperature Distribution in inner casing in unsteady (Transient) state condition after 36000s
5. Theoretical Calculation:
1. Thickness of Casing (t) =
Where P is the Inlet pressure in bar, d is the diameter of casing in mm S is the Maximum allowable stress in material in (PSI)
500 Psi, E is the Joint efficiency factor 0.75 and , Y is Temperature coefficient 0.4.
2. Thermal Expansion = =
3. Thermal Stresses ( )=
Here = Thermal expansion of casing in inch and is Coefficient of thermal growth is 8.3 10-6 in/in0F, is the Temperature
difference in 0F and L be the length of casing in inch.
The Theoretical calculation for the whole HP casing is calculated as shown above and the calculations for each stage are
tabulated in table
6. Comparison of Results:
Analytical Mm FEA-ANSYS
Total deformation mm 0.07 0.1
Stress ( first stage) Pa 0.235E9 0.38 E9
Stages Temperatur Pressur Diamete Length Thermal Thermal
e e(ba r (mm) Expansion Stresses
r) (mm) (mm) 109 N/m2
0 0
C F
1 260 500 8 688 68 0.042 0.1254
2 230 446 6 706.5 68 0.030 0.0941
3 185 365 4 725.5 74 0.049 0.1411
4 150 302 3.5 793 104 0.109 0.1098
5 105 221 3 851 163 0.029 0.1411
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6. International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue.5
7. Conclusion:
To maintain a high level of availability and reliability in a fossil power plant, substantial consideration of failure by repeated
thermal loading should be carried out.
In this study, the transient temperatures and stresses distributions within a turbine inner casing were achieved from actual
operation data during cold start-up.
The maximum deformations are calculate in transient state condition within inner casing.
Equivalent (von-Misses) Stress distribution in Transient condition.
Total deformation and stress values are compared with analytical results calculated for 2D geometry.
If the thermal gradient is great enough, the stress at the bottom of the threads may be high enough to cause the carking. The
result shows the casing develops higher stress levels in startup condition.
8. Scope for the Future Study:
Turbine facilities that operated repeatedly under transient start-up condition are affected by various damage mechanisms such
as creep, fatigue, and oxidation and so on. In general, it is known that low cycle fatigue is one of main damage mechanisms to
determine life time of turbine rotor or casing components.
This study can be extended further to calculate the fatigue damage by the stress analysis based procedure. This approach is
based on Neuber's rule. Neuber's rule expresses the relationship between local stress and local inelastic total strain-range. Using
this study, life consumption of steam turbine inner-casing can be obtained and a guideline for effective maintenance also can be
proposed. The analysis can be extended further considering Elasto-Plastic analysis using non linear material properties as well
as temperature dependent material properties.
References:
[1] W. S. Choi, E. Fleury, G. W. Song and J.-S. Hyun, A life assessment for steam turbine rotor subjected to thermo-
mechanical loading using inelastic analysis, Key Eng. Mat. 326−328, 601−604 (2006).
[2] Lucjan Witek, Daniel Musili Ngii, thermal fatigue problems of turbine casing Vol. 1 (2009) 205-211
[3] Maneesh Batrani, BHEL Haridwar, Hypermesh an effective 3-D CAE Tool in Designing of complex steam turbine low
pressure casing in 2006.
[4] T.Stubbs, the role of NDE in the life management of steam turbine rotors, Swindon, England
[5] K. Fujiyama, Development of risk based maintenance planning program for Power Plant steam turbine, Final report on
the Joint Project, pp. 69−82 (2007).
[6] Kiyoshi SAITO, Akira SAKUMA and Masataka FUKUDA, “Recent Life Assessment Technology for Existing Steam
Turbines”, JSME International Journal Series B, Vol. 49, No. 2 (2006), pp.192-197.
[7] Development of Life Prediction System for Thermal Power Plant Based on Viscoplastic Analysis, Final report, KERPI
(2007).
Issn 2250-3005(online) September| 2012 Page 1178