Answers & Homework 1b Due Thursday February 2nd 2017

40 Points
 Professor Bharat Bagepalli
Homework: Thermally Induced Elastic Deformation: Gas Turbine Shaft-Casing
You need to assess Thermally-induced stress in the design of an Aircraft Gas Turbine similar
to class example. Details are below
The Casing is 1.9 m long between Bearings, is of Cast Aluminum alloy, given:
Casing
Via Finite Element Method (FEM) modeling, it is found that pushing apart the Shaft
Bearings results in
an Axial Stiffness KC = 5.5*108 Newtons/m Axial Deflection
a Maximum Stress C-max in the Casing of 9MPa/mm Axial Deflection
Axial Coeff. Of Thermal Expansion C = 9x10-6 m/m-K meters/(meters-Kelvin)
Tensile Yield Strength SY-C = 230 MPa.

The Nickle-based steel alloy Shaft diameter is 15.5cm

The Shaft length L = 1.9 m, between bearings
Most of the material properties are
Coeff. Of Thermal Expansion (CTE) S = 11.5x10-6 m/m-K meters/(meters-Kelvin) Bearing
Youngs Modulus ES = 210GPa
Compressive Yield Strength SY-S = 240MPa. Bearing
Casing Temp Rise
Simple Model Casin TC
The Combustion Zone generates a temperature raise T of: g
TS =1100o C or K in the Shaft
Bearing L Bearing
TC = 750o C or K in the Casing
Assuming that the Shaft and Casing are stress-free at room temperature Shaft
(20o C), what are the respective Factors of Safety in Thermally-induced
Stress in the upgraded Shaft and in the Casing w.r.t yield? Show details of
how you got the numbers Shaft Temp Rise 2
TS
Answers: Thermally Induced Elastic Deformation: Gas Turbine Shaft-Casing Professor Bharat Bagepalli

Casing FBD
Thermal
Stress-free
Simple Model
L
Casing Temp Rise TC LC-T = C * TC * L
Casing
= (9x10-6 )(750)(1.9)
L
Initial @ room temp.
Bearing Bearing
= 1.28*10-2 m

Shaft

Under axial load bearings pushed apart by the Shaft

Stretched due to F
Shaft Temp Rise TS

Force
LC-F =
Stiffness
F F F F
= = m
Loads at Bearings KC 5.5108

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Answers: Thermally Induced Elastic Deformation: Gas Turbine Shaft-Casing Professor Bharat Bagepalli

Shaft FBD
Thermal

Simple Model
L
LS-T = S * TS * L
Casing Temp Rise TC
Casing = (11.5x10-6 )(1,100)(1.9)
Stress-free
= 2.4*10-2 m
L Bearing
Bearing

Under axial load bearings pushed in by the Casing

Shaft

LS-F

Shaft Temp Rise TS

F F
Compressed due to F

L FL F1.9 F
LS-F = = = = m
E E ( d2 /4) 210109{ (0.155)2/4} 2.09109

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 Professor Bharat Bagepalli
Answers: Thermally Induced Elastic Deformation: Gas Turbine Shaft-Casing
System Equilibrium

Net change in length:

Thermally expanded
Casing alone Casing Shaft
( LC-T + LC-F ) = ( LS-T - LS-F )
Note: Shaft is compressed,
Thermally expanded hence (-) sign
Shaft alone
F -2 - F
{1.28*10-2 + }= {2.4*10
2.09109
}
5.5108
Initial Final Shaft + Casing Gives F = 4.88*106 N
Casing
Shaft F 4.88106
Deflection due to F =
5.5108 5.5108
F 4.88106 LC-F = 8.87*10-3 m = 8.87mm
S-Max = 2 = 2 = 258.56*106 Pa = 258.56 MPa
( d /4) { (0.155) /4}
Max. stress (from FEM) = 9MPa/mm deflection
S 240 C-Max = 9*8.87 = 79.8MPa
Factor Of Safety Shaft = YS = = 0.928
SMax 258.56
(Fails!) SYC 230
Factor Of Safety Casing = = = 2.88
CMax 79.8
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 Alpha-s, m/m-K 1.15E-05
Professor Bharat Bagepalli
Thermal Stresses in Turbine Shaft Temp Change, Del-T-s, K 1100
HW Spring
Shaft Yield Stress, MPa 240
2017 Stress-driven Del-Ls, m 2.34E-03
Stifness Ks, N/m 2.09E+09
N/mm 2.09E+06
ds, m 0.155 Change in length (thermal) - stressFree
2.40E-02
Es, GPa 210 DelL-s, m
Ls, m 1.9 Shaft Stress Sigma-s in Assembly @
Alpha-s, m/m-K 1.15E-05 258.56
Temp, MPa
Temp Change, Del-T-s, K 1100 FOSs 0.93
Shaft Yield Stress, MPa 240 Area
Stress-driven Del-Ls, m 2.34E-03 MOI
Stifness Ks, N/m 2.09E+09 Rad of Gyration = Sqrt(I/a), k meters
N/mm 2.09E+06
Stiffness, Kc, From FEM N/m 5.50E+08
Change in length (thermal) - stressFree
2.40E-02 Stress/mm, Sigma-c From FEM,
DelL-s, m 9
MPa/mm,
Shaft Stress Sigma-s in Assembly @ Alpha-c, m/m-K 9.00E-06
258.56
Temp, MPa
Temp Change, Del-T-c, K 750
FOSs 0.93
Yield Stress, MPa 230
Area
Change in length (thermal) - stressFree
MOI 1.28E-02
Rad of Gyration = Sqrt(I/a), k meters
Casing DelL-C, m
Change in Length due to Shaft Force,
8.87E-03
Stiffness, Kc, From FEM N/m 5.50E+08 DelL-c, m
Stress/mm, Sigma-c From FEM, Casing Net Deflection, m 2.17E-02
9
MPa/mm, Casing Max Stress, MPa 7.98E+01
Alpha-c, m/m-K 9.00E-06
FOSc 2.88E+00
Temp Change, Del-T-c, K 750
Shell Stress, Sigma-c, MPa 7.98E+01
Yield Stress, MPa 230
Shaft-Shell Constraining Force, F, N 4.88E+06