Integrated Turbopump Thermo-Mechanical Design and Analysis Tools - - PowerPoint PPT Presentation

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Integrated Turbopump Thermo-Mechanical Design and Analysis Tools - - PowerPoint PPT Presentation

May 21, 2023 579 likes •798 views

Integrated Turbopump Thermo-Mechanical Design and Analysis Tools September 12, 2001 Mike Platt Concepts NREC Summary Steady and transient thermo-mechanical effects drive life, reliability, and cost Design cycle needs upfront

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SLIDE 1

Concepts NREC

Integrated Turbopump Thermo-Mechanical Design and Analysis Tools

September 12, 2001 Mike Platt

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Summary

  • Steady and transient thermo-mechanical

effects drive life, reliability, and cost

  • Design cycle needs upfront consideration of:

– fits, clearance, preload – cooling requirements – stress levels, LCF limits, HCF margin

  • Data synthesis is needed from component

design tools

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SLIDE 3

TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Current Design System

Testing for Component

Reverse Engineer

Test Engineers Turbomachinery

and Solid Modeling (SM) System Issues

Arbitrary Surface Strip Milling SDRC I-DEAS Catia, and Others Generators Cooling Gears Motors

Computer Aided

AutoCAD Mechanical Desktop

Drafting (CAD)

Pro-Engineer Solid Edge

9

Development Rapid Prototyping

Sintered Casting Cores Stereo Lithography

Numerical Machining

11a

Ruled Surfaces

Development

Hot Film Dependent Thermal Structural Time Laser Pneumatic

System Product

Physical Lab

11b 10

Supporting the

Laboratory": "Virtual

CFD Studies

12 7b Pushbuttton CFD FINE/TURBO

FEA

Design Optimization Dynamics (CFD) Computational Fluid

FINE/TURBO

Preprocessing CFD

Pushbuttton CFD

Life Evaluation

Postprocessing

Campbell Diagram Interference Diagram

RotorLab

Forced Response Unbalance Response Critical Speeds Seals Bearings

Rotor Dynamics

8 5 Pushbuttton CFD FINE/TURBO

Postprocessing CFD

Designers and

Existing Designs

2

NASTRAN

4 7a

ANSYSTM

TM

AXISTRESS

Preprocessor Analysis (FEA) Finite Element

STRESSPREP

Stress and 3D FEA for

TM

Vibration Analysis

3

COSMOS

6

  • f Design Intent to Tested Design

Compressor, Pump, and Turbine Laboratory

Semi-Automated Comparison

"Synthesis": and Throughflow Analysis 3D Geometry Generation

Rapid Loading Calculations Quasi 3D Flow Calculations

Design Optimization:

COMPAL, PUMPAL, RITAL,

Meanline (Quasi-2D)

Design Analysis - Full Data Reduction and Comparison Performance Curves 1 AXIAL

  • f Rotors and Stators

2D and 3D Description

AXCAD CCAD

3242R6 Simplified CETI

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

SBIR Tool Development

  • Use LNG turbopump design

during feasibility study

– 630 gpm at 29.6 krpm – 37 lbm/s

  • Utilize existing component analysis tools to

drive assembly models

  • Integration into collaborative environment, not

just interfacing separate tools

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Current Design System

Meanline 3D Blading & CFD Stress & Vibration

  • Captures blade and disk stress,

vibration, thermals

  • Misses radial and axial preload effects,

thermal conduction through bore

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SLIDE 6

TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Current Design System

Meanline 3D Blading & CFD Stress & Vibration

  • Captures blade and disk stress,

vibration, thermals

  • Misses radial and axial preload effects,

seal interaction, bore conduction

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Current Design System

  • Captures nominal bearing, seal, and

shaft design

  • Misses radial and axial preload effects
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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Thermo-Mechanical Design Tools

  • Utilize data from

component design tools

– Rotor, shaft, housing geometry – Primary flow from pump and turbine – Internal cooling flow – Bearing, seal, and shaft design

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SLIDE 9

TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Thermo-Mechanical Design Tools

  • Temperature, stress, deflection
  • Blade clearance, seal clearance,

bearing race interference

  • Thrust load, bearing preload
  • Rotor clamp loads, shaft torque
  • Stress results feed probabilistic models
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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Typical Thermal Results

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Typical Deflection Results

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Typical Stress Results

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Life & Confidence Goals

Fixed Confidence Level Fixed Number of Cycles

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Typical Transient Results

20 40 60 80 100 120 140 20 40 60 80 100 120 140 160 Time (sec) Stress (ksi)

  • 150
  • 50

50 150 250 350 450 Temperature (°F) Elem/Node - 10020/10114 Elem/Node - 10020/10118 Elem/Node - 10015/10118 Elem/Node - 10015/10117 Elem/Node - 10010/10117 Elem/Node - 10010/10113 Elem/Node - 10020/10114 Elem/Node - 10020/10118 Elem/Node - 10015/10118 Elem/Node - 10015/10117 Elem/Node - 10010/10117 Elem/Node - 10010/10113

N10114 N10118 N10113 N10117

;

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SLIDE 15

TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Goals for Design Tool Integration

  • Collaborative working environment
  • Integrate with existing component

design and analysis tools

  • Direct data sharing, including CAD files
  • Extensible to other solvers and

applications

  • Preserve intellectual property
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SLIDE 16

TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Integration with CAD Kernel

  • Consistent and
  • pen data format
  • Combine geometry

and analytical results

  • Direct support for

native CAD files

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Design Tool Integration

Meanline Blading & throughflow CFD Assembly thermo-mechanics Application X

OLE

Parasolid Database

  • Flow Options
  • Fluid Type
  • Geometry
  • Blades
  • Disks
  • Shaft
  • Bearings
  • Materials
  • Cost Options
  • Life Options
  • Machining

Agile Framework Coordination between analysis codes Assembly & System Optimization

OLE OLE

Stress & vibration

OLE OLE

DLL

OLE

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Integration with Parasolid Data

Parasolid Database

DLL

CNREC Parasolid geometry and attributes Shared data structure

  • r POD

3rd Party routines to work with application

access geometry directly

3rd Party Application

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Integration with Design Framework

OLE

·File open ·File save ·Refresh from file ·Manufacturability metrics ·Cost metrics ·Weight Application X Agile Framework

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TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC

Conclusions

  • Thermo-mechanical analysis tool

provides upfront design capability

  • Existing component design tools are

effectively leveraged

  • Dual-use capability will give a broad

user base

  • Parasolid kernel allows collaboration

with a wide applications base