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fatigue failure analysis of steam turbine shaft using fem technique
- 1. 194 International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) International Journal of Research and Innovation in Mechanical Engineering (IJRIME) FATIGUE FAILURE ANALYSIS OF STEAM TURBINE SHAFT USING FEM TECHNIQUE D.Jojappa1 , K.Naresh babu2 , K.krishnaveni3 . 1 Research Scholar, Department of Mechanical Engineering, Chebrolu engineering college, Guntur, AP, India. 2 Assistant professor, Department of Mechanical Engineering, Chebrolu engineering college, Guntur, AP, India. 3 Associate professor, Department of Mechanical Engineering, Chebrolu engineering college, Guntur, AP, India. *Corresponding Author: D.Jojappa, Research Scholar, Department of Mechanical Engineering, Chebrolu engineering collage, Guntur, AP, India. Email: darajojappa@gmail.com Year of publication: 2016 Review Type: peer reviewed Volume: III, Issue : I Citation: D.Jojappa, Research Scholar, "Fatigue Failure Analy- sis of Steam Turbine Shaft Using Fem Technique" International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) (2016) 194-198 INTRODUCTION OF STEAM TURBINE SHAFT Turbine shaft is one of the main machine element where high, intermediate and low pressure blades will be ar- ranged with the support of journal bearing. It has to bear not only self, blades weight and also steam pressure, tem- perature and torque. Due to high fatigue lodes (continues cyclic load) caused by above conditions shaft becomes weaker; mainly self- weight is one of the big obstacle. If self-weight can be reduced fatigue life can be improved and also mechani- cal efficiency will be increased. Previous researcher’s has done the research on materials only, in this thesis work along with materials hollow shaft will be analysed. STEAM TURBINE: A steam turbine is a mechanical device that extracts ther- mal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost completely replaced the reciprocating pis- ton steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator – about 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic ef- ficiency through the use of multiple stages in the expan- sion of the steam, which results in a closer approach to the ideal reversible process. MODELS OF STEAM TURBINE SHAFT The above image shows turbine shaft and bearings assembly Abstract 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.
- 2. 195 International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) The above image shows hallow shaft and bearings assembly MATERIALS AND BOUNDARY CONDITIONS: Weight= volume X density Low pressure blade set= 4695903 X 0.00000785 Kg/mm3 = 36.86 Intermediate pressure blade set= 2390470 X 0.00000785 Kg/ mm3 = 18.76 High pressure blade set= 2163510 X 0.00000785 Kg/mm3 = 16.98 Weight X newton’s = load Low pressure blade set = 36.86 X 9.81=361.228 Intermediate pressure blade set = 18.76 X 9.81=184.142 High pressure blade set = 16.98 X 9.81=166.404 Load /area = pressure Shaft Area of each blade set = 268535mm Low pressure blade set = 0.0013 Intermediate pressure blade set = 0.000685 High pressure blade set = 0.000619 Material 1 AISI 4130 Steel (super alloy steel) Material 1 Material 2 Haynes Hastelloy C-276 alloy STRUCTURAL ANALYSIS FOR SOLID MODEL-MATE- RIAL 1 Total deformation Equivalent stress value, it is also called as vonmisses stress which provides the average value of directional and principle stress using vonmisses theory of failure. THERMAL ANALYSIS FOR SOLID MODEL-MATERIAL1 Total heat flux FATIGUE ANALYSIS FOR SOLID MODEL-MATERIAL 1 Safety factor range on object STRUCTURAL ANALYSIS FOR HALLOW MODEL-MA- TERIAL 1 Equivalent stress
- 3. 196 International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) THERMAL ANALYSIS FOR HALLOW MODEL MATE- RIAL 1 Total heat flux FATIGUE ANALYSIS FOR HALLOW MODEL- MATERI- AL 1 Maximum life STRUCTURAL ANALYSIS FOR HALLOW MODEL-MA- TERIAL 2 Total deformation Equivalent stress The above image shows hallow shaft, bearings and center sup- port bearing STRUCTURAL ANALYSIS FOR HALLOW MODEL WITH CENTER BEARING-MATERIAL 2 Equivalent stress value, it is also called as vonmisses stress which provides the average value of directional and principle stress using vonmisses theory of failure. FATIGUE ANALYSIS FOR HALLOW MODEL WITH CENTER BEARING-MATERIAL 2 Safety factor range on object. RESULT TABLES STRUCTURAL ANALYSIS Solid shaft Hallow shaft Materials AISI 4130 Steel C-276 alloy AISI 4130 Steel C-276 alloy Total de- formation 0.021188 0.02233 0.027235 0.026332 Stress 44.67 42.056 73.184 69.301 Strain 0.000221 0.000213 0.000437 0.000426
- 4. 197 International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) THERMAL ANALYSIS Solid shaft Hallow shaft Materials AISI 4130 Steel C-276 alloy AISI 4130 Steel C-276 alloy Tempera- ture 591.63 579.95 588.53 577.73 Heat flux 0.66966 0.42049 0.60857 0.38725 Thermal error 7.4585e6 1.7605e6 4.7633e6 9.8352e5 MODEL ANALYSIS Solid shaft Hallow shaft Materials AISI 4130 Steel C-276 alloy AISI 4130 Steel C-276 alloy Total de- formation HZ 1 144.92 143.39 168.41 166.42 Total de- formation HZ 2 145.18 143.65 177.22 175.15 Total de- formation HZ 3 418.62 413.79 372.42 368.31 Total de- formation HZ 4 419.11 414.27 382.68 378.51 Total de- formation HZ 5 709.51 695.61 475.99 470.09 FATIGUE ANALYSIS Solid shaft Hallow shaft Materials AISI 4130 Steel C-276 alloy AISI 4130 Steel C-276 alloy LIFE 5e11 5e11 5e11 5e11 Damage 1.034 0.86538 3.7329 3.2395 HALLOW SHAFT WITH CENTER SUPPORT BEARING TABLE STRUCTURAL ANALYSIS Materials C-276 alloy Total deformation 0.22403 Stress 65.783 Strain 0.00041147 THERMAL ANALYSIS Materials C-276 alloy Temperature 577.73 Heat flux 0.38723 Thermal error 9.8352e5 MODEL ANALYSIS Materials C-276 alloy Total deformation HZ 1 372.95 Total deformation HZ 2 383.67 Total deformation HZ 3 953.67 Total deformation HZ 4 975.5 Total deformation HZ 5 1190.4 FATIGUE ANALYSIS Materials C-276 alloy LIFE 5e11 Damage 2.8291 CONCLUSION This thesis work deals with “FATIGUE FAILURE ANAL- YSIS OF STEAM TURBINE SHAFT USING FEM TECH- NIQUE” to compare solid and hollow shafts; to suggest best material and suitable location for the center bearing. Structural, model, thermal and fatigue analysis is done on solid and hollow shafts along with bearings by vary- ing materials; as per the analysis results hollow shaft is having little bit high stress and deformation but these are within the limit only while considering factor of safety. Bearing was installed near high pressure blades for ad- ditional support to use hollow shaft to reduce stress con- centration; then above analysis was conducted to evalu- ate results. As per the analysis work results hollow shaft with center bearing and C-276 material will be the better option; us- ing these conditionsshaft weight can be reduced up to 51kgs [^16%] which interns increases the mechanical ef- ficiency. REFERENCE 1.THERMAL STRESS ANALYSIS IN STEAM TURBINE RO- TOR - A REVIEW by Ms. Mohini R. Kolhe1, Prof. A. D. Pachchhao2, Prof. H.G.Nagpure3. 2.Calculation of Thermal Stress and Fatigue Life of 1000 MW Steam Turbine Rotor by ShuangBian, Wenyao Li. 3.DESIGN AND ANALYSIS OF STEAM TURBINE ROTOR byM. Chandra Sekhar Reddy. 4.Residual Life Assessment of 60 MW Steam Turbine Ro- tor by K. Venkatesh*, P. VeeraRaju**, T. Jayananda Ku- mar** 5.TRANSIENT THERMAL ANALYSIS OF A STEAM TUR- BINE ROTOR by Shilpa P. Bhorkar, Dr. A.V. Vanalkar. 6.ZvonimirGuzović, BranimirMatijašević, TihomirMihalić “Characteristics Of Non- Stationary Thermal Stresses In The Low-Pressure Part Of The Rotor”15th International Research/Expert Conference TMT-2011,Prague,Czech Republic 12-18 September 2011. 7.Chunlin Zhang, Niansu Hu, Jianmei Wang, Qiping,chen,FengHe,Xiaoli “ Thermal Stress Analysis for Rotor of 600MW Steam Turbine”978-1-4244-4813- 5/10/&25.00c/2010/IEEE. 8.G SukhvinderKaurBhatti, ShyamalaKumari, M L Nee- lapu, C Kedarinath, Dr. I N Niranjan Kumar” Transient State Stress Analysis On An Axial Flow Gas Turbine Blades And Disk Using Finite Element Procedure”. in Int. Conf. on HEAT TRANSFER, THERMAL ENGINEERING and ENVIRONMENT, Elounda, Greece, August 21-23, 2006 (pp323-330). 9.Deepak Dhar, A. M. Sharan.” Transient Stress Analysis and Fatigue Life Estimation of Turbine Blades” Journal of Vibration and Acoustics OCTOBER 2004, Vol. 126 Õ 495.
- 5. 198 International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) 10.Yong Li, Haoran Sun, YuhuoNie “Thermal Stress Anal- ysis of 600MW Steam Turbine Rotor in Different Govern- ing Modes” 978-1-422-4813-5 28-31-March2010 IEEE. 11.Sudheendra,V.S,SRamamurthKMurugesan”Transie nt,Thermal Analysis Of A Turbine Rotor”nal-ir.nal.res. in/8928 [7]Stuart R Holdsworth , EdoardoMazza&Arnd Jung” creep-fatigue damage developmentduring service- cycle thermo-mechanical fatigue test of 1CrMoV rotor steel”. Author D.Jojappa, Research Scholar, Department of Mechanical Engineer- ing, Chebrolu engineering college, Guntur, AP, India. K.Naresh babu, Assistant professor, Department of Mechanical Engineer- ing, Chebrolu engineering college, Guntur, AP, India. K.krishnaveni, Associate professor, Department of Mechanical Engineer- ing, Chebrolu engineering college, Guntur, AP, India.