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 consideration of: – fits, clearance, preload – cooling requirements – stress levels, LCF limits, HCF margin • Data synthesis is needed from component design tools TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
3242R6 Simplified CETI Compressor, Pump, and Turbine Meanline (Quasi-2D) Design Optimization: COMPAL, PUMPAL, RITAL, Current Design System 3D Geometry Generation AXIAL and Throughflow Analysis Design Analysis - Full CCAD Performance Curves AXCAD "Synthesis": Data Reduction Semi-Automated Comparison 2D and 3D Description and Comparison of Rotors and Stators of Design Intent to Tested Design Rapid Loading Calculations 1 Laboratory Quasi 3D Flow Calculations Testing for Reverse Engineer Component Existing Designs 12 Development Finite Element 2 Pneumatic Analysis (FEA) Laser Preprocessor Product CFD Hot Film "Virtual Development Preprocessing Thermal STRESSPREP Laboratory": System Structural Turbomachinery AXISTRESS Pushbuttton CFD Time CFD Studies Dependent FINE/TURBO Supporting the Designers Physical Lab 11a 6 11b 3 and Computational Fluid Rapid Prototyping Dynamics (CFD) 3D FEA for Test Engineers Design Optimization Stereo Lithography 10 Stress and Sintered Casting Cores Pushbuttton CFD Vibration Analysis FINE/TURBO Numerical Machining TM COSMOS Ruled Surfaces Strip Milling ANSYS TM 4 Arbitrary Surface CFD TM 9 NASTRAN Postprocessing Computer Aided Pushbuttton CFD Drafting (CAD) FINE/TURBO and Solid Modeling (SM) 8 7a Solid Edge AutoCAD Mechanical Desktop Pro-Engineer 5 SDRC I-DEAS FEA Rotor Dynamics Catia, and Others Postprocessing System Issues RotorLab Campbell Diagram Gears Interference Diagram Seals Motors Life Evaluation Generators Bearings Cooling Critical Speeds Unbalance Response TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC Forced Response 7b
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 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 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 TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Current Design System • Captures nominal bearing, seal, and shaft design • Misses radial and axial preload effects 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 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 TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Typical Thermal Results TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Typical Deflection Results TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Typical Stress Results TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Life & Confidence Goals Fixed Confidence Level Fixed Number of Cycles TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Typical Transient Results 140 450 Elem/Node - 10020/10114 Elem/Node - 10020/10118 Elem/Node - 10015/10118 Elem/Node - 10015/10117 Elem/Node - 10010/10117 Elem/Node - 10010/10113 120 Elem/Node - 10020/10114 Elem/Node - 10020/10118 350 Elem/Node - 10015/10118 Elem/Node - 10015/10117 N10113 N10114 Elem/Node - 10010/10117 Elem/Node - 10010/10113 100 N10117 N10118 250 Temperature (°F) 80 Stress (ksi) ; 150 60 50 40 -50 20 0 -150 0 20 40 60 80 100 120 140 160 Time (sec) 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 TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Integration with CAD Kernel • Consistent and open data format • Combine geometry and analytical results • Direct support for native CAD files TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Design Tool Integration Meanline OLE Parasolid Agile Database Framework Blading & throughflow OLE •Flow Options Coordination •Fluid Type between analysis •Geometry codes •Blades CFD OLE •Disks Assembly & •Shaft System •Bearings Stress & vibration Optimization •Materials OLE •Cost Options •Life Options •Machining Assembly thermo-mechanics OLE DLL Application X OLE TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Integration with Parasolid Data DLL Parasolid Database CNREC 3 rd Party Shared Parasolid routines to data 3 rd Party geometry work with structure and Application application or POD attributes access geometry directly TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
Integration with Design Framework OLE · File open Application X · File save Agile · Refresh from file Framework · Manufacturability metrics · Cost metrics · Weight 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 TFAWS 01 Integrated Thermo-Mechanical Tools Concepts NREC
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