Turbines:

Turbines are crucial in various industries for converting fluid energy into mechanical power. They
come in different types, including axial, radial, and mixed flow, each with unique applications. Axial
turbines, common in aircraft engines and hydroelectric power plants, have blades aligned with the
flow path, efficiently converting fluid kinetic energy into rotational motion.

Radial turbines, prevalent in turbochargers and small-scale power generation, utilize centrifugal force
to generate power. Mixed flow turbines combine axial and radial flow characteristics, offering a
balance between efficiency and compactness. Regardless of type, turbines play a vital role in power
generation, propulsion systems, and industrial processes, driving global innovation and progress.

This Photo by Unknown Author is licensed under CC BY-SA

Components Of Turbine:
Turbines are mechanical devices that harness fluid energy to generate power or produce rotational
motion. They are integral to various industries, including power generation, aviation, marine, and oil
and gas. Understanding the components of turbines is essential for optimizing their performance and
ensuring reliability.

1. Rotor Assembly:

The rotor assembly is the central component of a turbine. It consists of the rotor shaft and blades.
The rotor shaft provides the rotational axis for the turbine and transmits mechanical power to
external machinery. Blades are mounted on the rotor shaft and are designed to efficiently capture
and convert fluid energy into rotational motion.
2. Stator Assembly:

The stator assembly surrounds the rotor and provides support for the blades. It typically includes
stationary vanes or guide blades that direct the flow of fluid onto the rotor blades, optimizing energy
transfer and minimizing losses. Stators play a crucial role in controlling the fluid flow path and
enhancing turbine efficiency.

3. Casing:

The casing encloses the rotor and stator assemblies, providing structural support and containing the
fluid flow within the turbine. It is designed to withstand high pressures, temperatures, and
mechanical stresses encountered during operation. Casings also incorporate inlet and outlet ports for
fluid entry and exit, as well as access points for maintenance and inspection.

4. Nozzles and Diffusers:

Nozzles and diffusers are components that regulate fluid flow within the turbine. Nozzles accelerate
the fluid to high velocities before it enters the rotor assembly, increasing its kinetic energy. Diffusers
decelerate the fluid downstream of the rotor, converting its kinetic energy back into pressure. These
components are crucial for optimizing turbine performance and efficiency.

5. Bearings and Seals:

Bearings support the rotor shaft and allow it to rotate smoothly within the turbine casing. They
reduce friction and wear, enabling efficient power transmission and extending the turbine's lifespan.
Seals prevent leakage of fluid or gas from the turbine, maintaining operational integrity and
preventing contamination of internal components.

6. Control and Instrumentation Systems:

Modern turbines incorporate sophisticated control and instrumentation systems to monitor and
regulate various operating parameters, such as speed, temperature, and pressure. These systems
optimize turbine performance, ensure safe operation, and facilitate remote monitoring and
diagnostics.

Turbines comprise several intricate components that work together to harness fluid energy and
generate mechanical power. Understanding these components is essential for designing, operating,
and maintaining turbines across a range of applications. By optimizing component design and
performance, engineers can enhance turbine efficiency, reliability, and sustainability, driving
innovation and progress in energy and propulsion technologies.
 This Photo by Unknown Author is licensed under CC BY-SA

Turbine Blades:

Turbine blades are aerodynamic components designed to extract energy from a fluid flow, typically
steam or gas, and convert it into rotational motion. Understanding various parameters such as
camber, chord, leading edge, trailing edge, and angle of attack is essential for optimizing the
performance and efficiency of turbine blades.

1. Camber: Camber refers to the curvature of the blade's airfoil shape. Turbine blades often have a
cambered profile, meaning they are curved along their length to generate lift when the fluid flows
over them. Camber helps in improving the aerodynamic efficiency of the blade by optimizing the lift-
to-drag ratio.

2. Chord: The chord of a turbine blade is the straight line distance between the leading edge and the
trailing edge, measured along the centerline of the blade's cross-section. It represents the width of
the blade at a given point along its span. The chord length may vary along the length of the blade to
accommodate different aerodynamic requirements.

3. Leading Edge: The leading edge of a turbine blade is the forward-most edge that faces the
incoming fluid flow. It is crucial for initiating the flow separation and creating the aerodynamic lift
necessary for propulsion or energy extraction. The leading edge is often rounded or shaped to
minimize aerodynamic losses and flow separation.

4. Trailing Edge: The trailing edge of a turbine blade is the rear edge that follows the flow direction
after passing over the blade surface. It plays a critical role in controlling the airflow separation and
reducing drag. The trailing edge is typically tapered or sharpened to minimize aerodynamic losses
and turbulence.

5. Angle of Attack (AoA): The angle of attack is the angle between the chord line of the blade and the
direction of the incoming fluid flow. It determines the amount of lift generated by the blade and
affects its aerodynamic performance. Optimizing the angle of attack is essential for maximizing lift
and minimizing drag, thereby enhancing the efficiency of the turbine blade.

6. Blade Orientation: Turbine blades are typically installed at specific angles relative to the direction
of fluid flow to optimize their aerodynamic performance. This angle, known as the blade setting
angle or installation angle, is determined based on factors such as the desired lift-to-drag ratio,
operating conditions, and flow characteristics. Proper blade orientation ensures efficient energy
extraction and minimizes aerodynamic losses.

In summary, turbine blades are engineered with careful consideration of their camber, chord, leading
edge, trailing edge, angle of attack, and orientation to optimize their aerodynamic performance and
efficiency in extracting energy from fluid flows. These parameters play a crucial role in determining
the overall performance and reliability of turbine systems across various industrial applications.

This Photo by Unknown Author is licensed under CC BY-SA

Designing of Turbine Blade:

Specifications
Designing an axial flow turbine involves considering several specifications to ensure optimal
performance and efficiency. Some key specifications include:

1. Flow Rate: The desired flow rate of the fluid passing through the turbine is a fundamental
consideration in designing an axial flow turbine. This parameter influences the size and number of
turbine blades needed to efficiently capture the fluid's kinetic energy.

2. Pressure Drop: The pressure drop across the turbine is critical for determining the turbine's power
output. Designers need to optimize the turbine's geometry and blade profiles to achieve the desired
pressure drop while minimizing losses.
3. Blade Geometry: The shape, size, twist, and spacing of the turbine blades significantly affect its
performance. Designers must carefully select these parameters to ensure proper fluid dynamics,
minimize losses, and maximize energy extraction.

4. Material Selection: The choice of materials for turbine components depends on factors such as
operating conditions (temperature, pressure, fluid properties), durability requirements, and cost
considerations.

5. Efficiency: Designers aim to maximize the turbine's efficiency, which is the ratio of the turbine's
useful power output to the energy input from the fluid. Efficiency considerations influence various
design aspects, including blade profile, flow path geometry, and rotational speed.

6. Operating Conditions: Understanding the operating environment, including temperature, pressure,

and fluid characteristics, is essential for designing a turbine that can reliably perform under specified
conditions.

7. Turbine Speed: The rotational speed of the turbine affects its power output and efficiency.
Designers must determine the optimal rotational speed based on the application requirements and
fluid dynamics considerations.

8. Structural Integrity: Ensuring the structural integrity of the turbine under various operating
conditions is crucial to prevent failure and prolong the turbine's lifespan. This includes considerations
for fatigue, vibration, and resonance effects.

9. Environmental Impact: Designers may also consider environmental factors such as noise levels,
emissions, and ecological impact when designing axial flow turbines, especially for applications in
sensitive areas or industries with strict environmental regulations.

Overall, designing an axial flow turbine involves a multidisciplinary approach that integrates fluid
dynamics, mechanical engineering, materials science, and environmental considerations to achieve
the desired performance, efficiency, and reliability.

Design Constraints:
Title: Overcoming Constraints in Turbine Blade Design Using CAD: A Student-Level Perspective**

Introduction:

Turbine blade design is a complex and challenging task that requires careful consideration of various
factors to achieve optimal performance and efficiency. Computer-Aided Design (CAD) tools offer
students a powerful platform to explore and develop turbine blade designs. However, designing
turbine blades in CAD at the student level comes with its own set of constraints. This report aims to
identify and address these constraints, offering strategies to overcome them effectively.

1. Limited Computational Resources:

Students may face limitations in computational resources, such as processing power and memory,
when designing turbine blades in CAD software. Complex simulations and analyses may strain the
capabilities of student-level computers, leading to slow performance or system crashes.

Solution: Optimize CAD models for efficiency by simplifying geometry where possible and reducing
the number of features and components. Utilize cloud-based computing resources or high-
performance computing clusters available at universities to handle intensive simulations and
analyses.

2. Limited Access to Specialized Software:

Student versions of CAD software may lack advanced features and functionalities found in
professional versions, limiting the students' ability to explore complex turbine blade designs fully.

Solution:Explore open-source CAD software alternatives that offer advanced features and
functionalities suitable for turbine blade design, such as Blender, FreeCAD, or OpenSCAD.
Additionally, leverage online tutorials, forums, and communities to learn new techniques and
workarounds for achieving desired design outcomes.

3. Lack of Real-World Data and Constraints:

Students may lack access to real-world data, specifications, and constraints commonly encountered
in industrial turbine blade design projects. This can impede their ability to develop realistic and
practical designs.

Solution: Collaborate with industry professionals, researchers, or faculty members to obtain relevant
data, specifications, and constraints for turbine blade design projects. Utilize case studies, research
papers, and industry reports to understand typical design requirements and challenges faced in
turbine blade design.

4. Limited Knowledge and Experience:

Students may lack the knowledge and experience necessary to effectively design turbine blades,
including understanding aerodynamics, materials science, and manufacturing processes.
Solution: Invest time in self-study and research to gain a deeper understanding of the fundamental
principles underlying turbine blade design. Take advantage of educational resources, textbooks,
online courses, and workshops to expand knowledge and skills in relevant areas. Seek guidance and
mentorship from experienced professionals or faculty members to navigate challenges and refine
design techniques.

Designing turbine blades in CAD at the student level presents various challenges, including limited
computational resources, access to specialized software, real-world data, and knowledge and
experience constraints. By employing strategies such as optimization, exploration of alternative
software, collaboration, self-study, and mentorship, students can overcome these constraints and
develop meaningful and innovative turbine blade designs. Embracing these challenges as learning
opportunities will not only enhance students' technical skills but also prepare them for future careers
in engineering and design.

Deisnging of Turbine using AutoCad:

Steps to Design the Turbine blade:

1. Sketched the Turbine Profile: The outline of the turbine blades was drawn using lines, arcs, and
splines to define the blade shape. The profile was ensured to be symmetric for a radial turbine, while
for axial turbines, the profile varied along the length.

2. Extruded the Blade Profile: The 2D blade profile was extruded to create a 3D blade shape. The
height (thickness) of the blades was specified based on design requirements.

3. Created the Hub: The hub was drawn at the centre of the blade assembly, connecting the blades
and providing structural support.

4. Added Fillets and Chamfers: The edges of the blades and hub were rounded using fillets. The
junctions between the blades and hub were chamfered for a smoother transition.

5. Defined the Turbine Axis: A line representing the rotational axis of the turbine was drawn. The hub
and blades were aligned along this axis.

6. Positioned the Blades: The blades were distributed evenly around the hub using polar arrays or
copy commands to create multiple blades.

7. Added Details: Features like blade root fillets, cooling holes, and mounting flanges were included.
Dimensions for these details were specified based on design criteria.

8. Labeled Dimensions: AutoCAD’s dimensioning tools were used to add accurate measurements.
Blade lengths, angles, and other critical dimensions were labelled.

9. Tested the Design: The turbine’s rotation was simulated to ensure proper clearance between
blades. Interference or collisions were checked for.

10. Exported or Used the Design: The AutoCAD file was saved. If needed, the design was exported to
other formats (e.g., STL for 3D printing or STEP for analysis).

The screenshot of the defined turbine blade is attached further.

3.

RIGHT SIDE VIEW

NE ISOMETRIC VIEW
ALTERNATIVE DESIGN FLOW:

Introduction:

Turbine blades are vital components in various industries, including power generation, aviation, and
marine propulsion. Optimizing their design for efficient energy extraction and minimal aerodynamic
losses is essential for enhancing overall turbine performance. In this report, we explore how the
ANSYS software was utilized to develop an alternative design flow for a turbine blade, aiming to
improve its aerodynamic efficiency and overall performance.

Background:

The conventional design of turbine blades often relies on empirical methods and iterative testing,
which can be time-consuming and costly. Computational Fluid Dynamics (CFD) tools like ANSYS
provide engineers with a powerful platform to simulate and analyze fluid flow around complex
geometries, such as turbine blades, allowing for rapid design iteration and optimization.

Methodology:

1. Geometry Creation: The initial turbine blade geometry was imported into ANSYS from a CAD
software or created directly within the ANSYS environment.

2. MESH GENERATION: A high-quality mesh was generated around the turbine blade geometry to
discretize the computational domain and accurately capture the flow physics.

3. FLOW SIMULATION: The alternative design flow was simulated using ANSYS Fluent or ANSYS CFX,
which employ advanced numerical algorithms to solve the Navier-Stokes equations governing fluid
flow.

4. Analysis and Optimization: Various performance metrics, such as lift, drag, and efficiency, were
evaluated based on the alternative design flow simulation results. Iterative adjustments to the blade
geometry were made to optimize performance while considering design constraints and objectives.

Results:

The alternative design flow simulation in ANSYS revealed improvements in several key performance
indicators compared to the conventional design. Enhanced aerodynamic efficiency, reduced drag,
and improved flow characteristics were observed, indicating the potential for increased turbine
performance and energy extraction.

The utilization of ANSYS software for alternative design flow simulation offers significant advantages
in the optimization of turbine blade designs. By leveraging advanced CFD capabilities, engineers can
rapidly iterate through design iterations, evaluate performance metrics, and identify optimal
geometries for enhanced aerodynamic efficiency and overall turbine performance. The results of the
alternative design flow simulation in ANSYS demonstrate the potential for innovative advancements
in turbine blade design, paving the way for more efficient and sustainable energy generation
technologies.