HIDRAULICA Nr.

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decembrie 2006

A NEW METHOD TO OBTAIN THE BLADE SURFACE INTERSECTIONS

WITH HORIZONTAL CUTTING PLANES
OF THE FRANCIS TURBINE RUNNER
Teodor MILOS, PhD, Assoc. Prof.*

*Department of Hydraulic Machinery, “Politehnica” University of Timişoara, Bv Mihai Viteazul 1,

300222-Timişoara, România, Tel.: (+40) 256 403683, Email: teodor.milos@gmail.com

1. Introduction

Technical and technological progress registered in the last period in hydraulics machinery domain,
impose a new tackling in a few design phases. In a first time the actual calculus technique is net superior
comparative with the 20…30 years ego, and then grace of that the optimize methods was developed, giving
possibility to the designer to analyze in short time more possible variants, to make the corrections depending
of results obtained by numerical simulation of flow, results of experimental measurements, findings from
exploitation, etc. To that on add a new requirements of exploitation by extension of the functioning regimes
domain in nearness of optimum regimes.
The experience accumulated up to now in the design domain of Francis turbine runner offer a great
volume of information referring to options and solutions which can be adopted in diverse phases of rotor
blades sizing. Getting over of these phases through classical methods, grapho-analytical, it is heavily, is
necessary long time and cannot put in evidence the majority positive or negative aspect of an option taken
on path. Accordingly, it is impose necessary, that all Francis turbine runner design to be realized
computationally and using appropriately computer graphics.
The implementation on the computer of classical method for blade intersection with horizontal cutting
planes opens out new perspectives for to solve this problem. Such as heaving the 3D coordinates of the
points which represent the profiles contour from stream surfaces, defines lines segment which joint two
homologous points from the contour of two consecutive profiles. Intersecting these line segments analytical
defined in 3D with equidistant horizontal cutting planes will result much more points for to define the resulted
curves then classical method even through that was transposed on the computer.
For case study was taken a Francis runner integral designed on the computer, heaving nsHP=238
and specific speed ν=0,413.

2. Transposition in calculus algorithm of the grapho-analytical method for determination of the

intersection curves of the runner blade with horizontal cutting planes

The blade images (projections) in meridian plane and in horizontal cutting plane (perpendicular on
the rotating axes) are not enough for runner execution. The suction side and pressure side surfaces of the
blade are curved and twisted in space and accordingly any views or sections would make after classical
rules of technical design, do not obtains a contour enough clear of the blade allow for execution. Therefore it
is usual to make successive intersections of the blade with parallel planes, perpendicular on the rotating
axes. Cutting out in these planes the intersection contours of the blade and replace it’s at the initial level,
assembling of all contour planes from all horizontal cutting planes obtain a 3D interpolation of the blade
surfaces. Beside technological role, the intersection with horizontal cutting planes has designation to verify
the uniformity of the blade surfaces. In case that the resulted curves from the blade intersection present
undulations, inflexions, etc. signify that on road was produced errors or the options in certain job step of
design was not well correlation.
Starting from these considerations, the intersection with horizontal cutting planes is made after
certain strategy through the obtained results to permit a reconstruction 3D of the blade at all exactly in
technological processes. Thus the ranges which the horizontal cutting planes intersect the both edges
(leading and trailing edge) and much sufficient streamlines, and the blade is a little curved, will be intersected
by one rare fascicle of horizontal cutting planes. Another zones, heaving less stream lines or the blade been
curved to outlet will be intersected with a great number of horizontal cutting planes.
For the case of analyzed runner the projection in meridian plan was divided in three zones according
with fig. 1, two zones are more thicken and one is more rare. In the rare area distance between two
consecutive planes is of 50 mm, and in the thicken area distance is half.

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Fig. 1. The definition of intersection zones with horizontal cutting planes and
the identification modality of the points resulted in projection (case suction side)

It was choused like reference plane, the plane which pass through intersection point of leading edge
with shroud (to diameter D1e). This plane gives the order name zero (0). Numerating order follow-up was
increasing (z – grown) and was continued after down from the reference plane. The position of these planes,
their numbering and zones delimitations are according to figure 2.

Fig. 2. Position of the horizontal cutting planes and their numbering

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Heaving defined the fascicle of horizontal cutting planes start effectively to found the intersections
points. Taking for example certain horizontal cutting plane, a line in meridian plane of runner blade, this will
intersect the streamlines and eventual leading edge and trailing edge. The obtained points will heave the
coordinate z=const., the same for all and the corresponding radius different. The operation is made
programming in a code procedure; the results are saved in a matrix heaving the number of lines equal with
the number of points. The radiuses obtained are identically for pressure side, suction side and camber line
which in a cylindrical projection from meridian plane are overlapped. The only zone where appear differences
is at the intersection with trailing edge where in meridian plane too the leading edge and trailing edge is
modified referring to camber surface. The number of matrix columns is equal with the number of the
streamlines plus the two edges, leading edge and trailing edge. In the table of this matrix zero value will
signify intersection inexistence, and all is different of zero will indicate the value and the existence of an
intersection point, table 1.

TABLE 1. The matrix of radiuses obtained by streamlines intersection (SL=0, 1, 2,.. 10), leading edge (LE)
intersection and trailing edge (TE) intersection with horizontal cutting planes (HCP).

HCP LE 0 1 2 3 4 5 6 7 8 9 10 TE
0 0.712 0.000 0.000 0.000 0.827 0.923 1.002 1.070 1.128 1.180 1.225 0.000 1.269
1 0.691 0.000 0.000 0.736 0.857 0.955 1.037 1.108 1.172 0.000 0.000 0.000 1.201
2 0.670 0.000 0.000 0.768 0.893 0.994 1.081 1.160 0.000 0.000 0.000 0.000 1.163
3 0.650 0.000 0.000 0.807 0.936 1.043 0.000 0.000 0.000 0.000 0.000 0.000 1.133
4 0.632 0.000 0.677 0.853 0.989 1.107 0.000 0.000 0.000 0.000 0.000 0.000 1.107
5 0.613 0.000 0.727 0.909 1.057 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.085
6 0.596 0.000 0.786 0.981 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.065
7 0.579 0.000 0.861 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.046
8 0.574 0.000 0.886 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.041
9 0.000 0.642 0.960 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.029
10 0.000 0.623 0.935 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.032
11 0.000 0.668 0.996 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.024
12 0.000 0.720 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.016
13 0.000 0.779 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.008
14 0.000 0.851 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.000
15 0.000 0.947 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.992
16 0.723 0.000 0.000 0.000 0.814 0.909 0.987 1.054 1.112 1.161 1.205 1.243 0.000
17 0.734 0.000 0.000 0.000 0.802 0.896 0.974 1.040 1.097 1.146 1.189 1.226 0.000
18 0.746 0.000 0.000 0.000 0.791 0.885 0.962 1.028 1.085 1.133 1.176 1.213 0.000
19 0.758 0.000 0.000 0.000 0.781 0.874 0.952 1.017 1.074 1.123 1.165 1.202 0.000
20 0.771 0.000 0.000 0.000 0.000 0.865 0.942 1.008 1.064 1.113 1.157 1.194 0.000
21 0.784 0.000 0.000 0.000 0.000 0.856 0.933 0.999 1.056 1.105 1.149 1.187 0.00
22 0.797 0.000 0.000 0.000 0.000 0.848 0.926 0.992 1.049 1.099 1.143 1.182 0.00
23 0.811 0.000 0.000 0.000 0.000 0.841 0.919 0.985 1.042 1.093 1.138 1.178 0.00
24 0.825 0.000 0.000 0.000 0.000 0.835 0.912 0.979 1.037 1.088 1.134 1.175 0.00
25 0.840 0.000 0.000 0.000 0.000 0.000 0.907 0.974 1.032 1.084 1.131 1.173 0.00
26 0.856 0.000 0.000 0.000 0.000 0.000 0.902 0.969 1.029 1.081 1.129 1.172 0.00
27 0.873 0.000 0.000 0.000 0.000 0.000 0.898 0.966 1.025 1.079 1.127 1.171 0.00
28 0.891 0.000 0.000 0.000 0.000 0.000 0.000 0.962 1.023 1.077 1.126 1.171 0.00
29 0.910 0.000 0.000 0.000 0.000 0.000 0.000 0.960 1.021 1.076 1.126 1.171 0.00

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30 0.931 0.000 0.000 0.000 0.000 0.000 0.000 0.957 1.019 1.075 1.126 1.173 0.00
31 0.954 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.018 1.075 1.126 1.174 0.00
32 0.981 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.017 1.075 1.127 1.176 0.00
33 1.012 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.075 1.129 1.178 0.00
34 1.053 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.076 1.131 1.181 0.00

After intersection radiuses getting it come to found corresponding polar angles for to can then
calculate the coordinate x-y. According with fig. 1 for a radius obtained it trace an arc with the same
dimension which will intersect the curve in projection at a point because follow to be found polar angle. In this
case will be a little difference between the polar angles of pressure side and suction side. The obtained
results will be written in another two matrixes where the inactive elements were replaced with values “1”,
table 2.

TABLE 2. The matrix of polar angles [deg] obtained by streamlines intersection (SL=0, 1, 2,.. 10), leading
edge (LE) intersection and trailing edge (TE) intersection with horizontal cutting planes (HCP).

HCP LE 0 1 2 3 4 5 6 7 8 9 10 TE
0 44.73 1.00 1.00 1.00 24.75 15.02 9.32 5.61 3.09 1.38 0.36 1.00 0.00
1 44.72 1.00 1.00 35.13 18.61 10.57 5.73 2.52 0.42 1.00 1.00 1.00 0.00
2 44.72 1.00 1.00 26.24 13.22 6.55 2.39 0.02 1.00 1.00 1.00 1.00 0.00
3 44.71 1.00 1.00 18.76 8.46 2.85 1.00 1.00 1.00 1.00 1.00 1.00 0.00
4 44.71 1.00 34.08 12.47 4.20 0.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
5 44.71 1.00 22.72 7.08 0.48 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
6 44.70 1.00 13.91 2.44 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
7 44.70 1.00 7.01 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
8 44.70 1.00 5.33 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
9 1.00 26.25 1.54 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
10 1.00 30.56 2.62 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
11 1.00 21.27 0.28 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
12 1.00 14.03 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
13 1.00 8.35 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
14 1.00 3.90 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
15 1.00 0.45 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00
16 44.73 1.00 1.00 1.00 28.15 17.42 11.23 7.25 4.53 2.68 1.48 0.83 1.00
17 44.73 1.00 1.00 1.00 31.81 19.97 13.24 8.94 6.05 4.06 2.74 2.03 1.00
18 44.74 1.00 1.00 1.00 35.75 22.67 15.33 10.71 7.63 5.52 4.11 3.39 1.00
19 44.74 1.00 1.00 1.00 39.99 25.54 17.54 12.57 9.28 7.04 5.58 4.85 1.00
20 44.74 1.00 1.00 1.00 1.00 28.58 19.86 14.50 11.02 8.66 7.15 6.46 1.00
21 44.75 1.00 1.00 1.00 1.00 31.83 22.33 16.54 12.83 10.37 8.84 8.20 1.00
22 44.75 1.00 1.00 1.00 1.00 35.28 24.93 18.69 14.74 12.17 10.62 10.06 1.00
23 44.76 1.00 1.00 1.00 1.00 38.97 27.69 20.96 16.76 14.07 12.52 12.04 1.00
24 44.76 1.00 1.00 1.00 1.00 42.91 30.61 23.36 18.89 16.09 14.54 14.17 1.00

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25 44.77 1.00 1.00 1.00 1.00 1.00 33.71 25.89 21.12 18.22 16.68 16.43 1.00
26 44.78 1.00 1.00 1.00 1.00 1.00 37.01 28.56 23.48 20.44 18.94 18.85 1.00
27 44.78 1.00 1.00 1.00 1.00 1.00 40.52 31.39 25.97 22.80 21.31 21.31 1.00
28 44.79 1.00 1.00 1.00 1.00 1.00 1.00 34.40 28.61 25.30 23.83 23.95 1.00
29 44.80 1.00 1.00 1.00 1.00 1.00 1.00 37.59 31.40 27.94 26.59 26.65 1.00
30 44.81 1.00 1.00 1.00 1.00 1.00 1.00 40.99 34.36 30.74 29.20 29.54 1.00
31 44.81 1.00 1.00 1.00 1.00 1.00 1.00 1.00 37.45 33.37 32.10 32.52 1.00
32 44.82 1.00 1.00 1.00 1.00 1.00 1.00 1.00 40.72 36.66 35.13 35.61 1.00
33 44.83 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 39.89 38.29 38.78 1.00

Connecting the resulting points from the same horizontal cutting plane obtains the intersection curves
(kind of cholinar diagram) separate for pressure side and suction side. The resulted curves are interpolated
with SPLINE function and are presented in fig. 3.

Fig. 3. The curves resulted by horizontal cutting planes intersection of the suction side

These two figures put in evidence the shape correctness of the blade resulted and are not practical
importance in a blade execution.
Grouping double curves of the same horizontal cutting plane from pressure side and suction side it
obtains the image effective intersection of the plane with blade surfaces. These are presented in coordinate
system xOy where point abscissas and ordinates calculate with relations:

 x = r ⋅ cos ϕ
 (1)
 y = r ⋅ sin ϕ
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According with matrix tables it observes that are available a little numbers of points for tracing these curves.
In view of smoothing these curves is used interpolation with SPLINE functions. In case of technological
execution these curves dimension appropriately so that theirs trace on the auxiliary technological material to
be at all exactly. In figures 5 and 6 are exemplified two significant contours.

Fig. 5. The intersection of blade with plane no. 3.

Fig. 6. The intersection of blade with plane no. 20.

In order to have an ensemble image for all blades, using an AutoLISP program under AutoCAD is
presented follow-up, in figures 7 and 8, the result of runner intersection with the same horizontal cutting
planes.
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Fig. 7. The intersection of Francis turbine runner with the plane no. 3.

Fig. 8. The intersection of Francis turbine runner with the plane no. 20.

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3. New analytical method for to found intersection curves of the runner blade with horizontal cutting
planes

The new method idea is appeared from 3D representation of the rotor, respectively one blade runner.
This representation suppose join with line (line segment) the homologous points from the profile contour
placed on the stream surfaces. In figure 9 is presented a runner blade in 3D intersected with one horizontal

cutting plane, and the two resulted parts of the body blade are translated on vertical for to put in evidence the
obtained surfaces in the body blade follow-up intersection.

Fig.9. The body of the blade intersected with a horizontal cutting plane and the two parts resulted
and vertically translated.

It observe that using classical method of intersection obtain only the intersection points of horizontal
cutting plane with pressure side, respectively suction side profiles from stream surface, id est. total 7 points
for pressure side and 7 points for suction side.
By this new method it make available that every profile from stream surface is definite (it are known
the coordinates x,y,z) in N points (100 ≤ N ≤ 200) to pressure side and N points to suction side. Joining the
homologous points (with the same order number) double profiles from double stream surfaces consecutively
it obtain straight lines (line segments) of whom analytical equations can be written in 3D for the case of the
straight line that pass through two given point of coordinates ( xi , j , yi , j , z i , j ) respectively
( xi , j +1 , yi , j +1 , z i , j +1 ) . The index “i" controls the order number of the point on the profile frontier from the
stream surface, and index “j" controls the order number of the stream surface. Mathematically these
equations are the form [10].

 x − xi , j z − zi, j
 =
 xi , j +1 − xi , j z i , j +1 − z i , j
 (2)
 y − yi, j = z − zi, j
 yi , j +1 − yi , j z i , j +1 − z i , j


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The horizontal cutting plane with order number “k” has in 3D the equation:
z = zk (3)
Joining these equations with the two equations from (2) will result a system of tree linear equations with tree
unknowns.
 x − xi , j z − zi, j
 =
 xi , j +1 − xi , j z i , j +1 − z i , j
 y − yi , j z − zi, j
 = (4)
 yi , j +1 − yi , j zi , j +1 − zi , j
z = z
 k


The solution of this system is immediately. Noting with “n” the order number of the line segments
encountered by section plane in direction from leading edge to trailing edge result:

 z k − zi , j
 xn,k = xi , j + (xi , j +1 − xi , j )
 zi , j +1 − z i , j
 z − zi , j
 y n ,k = yi , j + ( yi , j +1 − yi , j ) (5)
 z i , j +1 − zi , j
z = z
 n,k k



Using this method the number of points obtained grows very much canning to arrive on some areas up
to N points. Heaving more points, the intersection curves of the blades with horizontal cutting planes will be
much more exactly defined.
In figure 10 and in figure 11 it is comparatively exemplified the intersection curves with the horizontal cutting
planes by new method and the points obtained by the classical method, jointed with line segment. In some
zones it observes evident differences between the two methods.

Fig. 10. The comparison of the intersection result between the old and the new method (pl. No. 3)
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Fig. 11. The comparison of the intersection result between the old and the new method (pl. No. 19)

4. Conclusions

The described method applies with successful at Francis turbine runners and centrifugal pumps. The
point and the curves of intersection are obtained with a programming algorithm and the numerical values are
available for data base for manufacturing process and verification at finish.
A good definition of the blade surface get on-coming between the shape of the blade desired and resulted.

References

[1]. Anton I., Turbine hidraulice, Ed. Facla Timişoara, 1979;

[2]. Bărglăzan M., Turbine hidraulice şi transmisii hidrodinamice, Ed. „Politehnica”, Timişoara, 2001;
[3]. Radha Krishna H.C. (Editor), (1997) Hydraulic Design of Hydraulic Machinery, Avebury Publishing
House.
[4]. Wislicenus V. F., Turbomachinery, Dover Publ. New York, 1965, Vol. I + II;
[5]. Raabe J., Hydraulische Maschinen und Anlagen, VDI Verlag, Düsseldorf, 1970; Teil I–IV;
[6]. Henry P., Turbomachines hydrauliques, Pres. Univ. Lausanne, 1992;
[7]. Henry P., Calcul et tracé de l’aubage de la turbine Francis, Ed. IMHEF Lausanne, 1993 ;
[8]. Miloş T., Bărglăzan M., CAD Technique Used to Optimize the Francis Runner Design;
[9]. Gheorghiu Gh.Th., Algebră lineară, geometrie analitică şi diferenţială şi programare, Editura Didactică
şi Pedagogică, Bucureşti, 1977.

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