MSU-Iligan Institute of Technology

College of Engineering and Technology

Department of Mechanical Engineering and Technology
ME-165 Fluid Machinery

Design and Fabrication of a Single Stage Axial

Flow Gas Turbine for a Turbocharger

Cabahug, Diether V.
Gorres, Paul Jacob
Jason, Hannie Mae M.
Laxina, Jashper N.

BSME IV

Engr. Peter A. Panorel

August 1, 2019
 I. Introduction

Gas turbines provide a means of transferring energy from a pressurized fluid to

mechanical energy in the form of a rotating shaft. The gas turbine compresses ambient air in
a compressor and then channels the compressed air into the combustion chamber. The
movement of the products of combustion through the turbine rotates the turbine shaft. [1]

Gas turbines take place in category of turbo machines. And it has very different fields
of application. Beside jet motors and helicopter motors used on flying, it is used in marine gas
turbine composed of basic and auxiliary driver mechanisms, gas turbines used for truck, high-
speed trains, tanks, gas turbines used for electrical generation and pump rotation. [2]

Gas turbines are comprised of a compressor, combustor, and turbine. These

components work together to produce power or thrust, depending on the application. To
begin the cycle, the compressor rotates and draws in ambient air. As it is taken in by the
compressor, the air is pressurized, in some cases to 40 times atmospheric pressure [3]. The
pressurized air then moves into the combustion chamber where a fuel mixture is ignited,
heating the pressurized air and causing it to expand into the turbine. As the heated air
expands through the turbine it pushes against the turbine blades which then rotate the
turbine shaft. The rotational energy is used to spin a generator and create electricity. Because
they are attached to the same shaft, the rotation of the turbine also rotates the compressor,
keeping the system operating. Of the power generated by the turbine, 55%-65% is used to
drive the compressor and the remainder is used to drive a generator [4].

Basically, axial flow turbines is employed in large turbochargers e.g. ship propulsion
and electrical generation, typically 1 MW and above of power output. The essential design
philosophy of larger turbochargers is that they have high efficiencies over a limited flow range
unlike the automotive turbochargers, which usually have a rather lower efficiency over a wide
flow range. All turbochargers need to be compact, durable, and have low unit cost. Typically,
for these large units, low unit cost is maintained by using single stage turbines even for
pressure ratios greater than 4.5 to 1. [5]

In this study, axial flow gas turbine is considered, specifically, for a turbocharger.
Turbochargers are used to increase the power output of internal combustion engines by
compressing the air prior to it being admitted into the engine. This is achieved by employing
a centrifugal compressor driven by a turbine that is powered by the engine exhaust gases. An
air or water cooler is often used to reduce the temperature of the air entering the engine,
enabling greater power to be achieved by the engine. Yet, the latter is not within the scope
and limitations of this study.
 Now, the main objective of this study is to design and fabricate a single stage gas
turbine for a turbocharger. The design will be implemented in Solidworks flow simulation for
its performance test which will then the data acquired will be compared to the manual
calculations using Microsoft Excel. The data will then be discussed further. The data on the
performance of the gas turbine will be correlated between the Computational Fluid Dynamics
(CFD) results and Calculations using Microsoft Excel on their power output using the torque
and speed (RPM).

II. Methodology

1. DESIGN REQUIREMENTS

Total pressure at the turbine inlet, p01 3.08 bar

Static pressure at turbine exit, p3 1.53 bar
Entry temperature of products of 1119K
combustion to turbine, T01
Mass flow rate, ṁ 8 kg/s
Reaction ratio, R 0.5
Flow coefficient, ϕ 0.67
Target efficiency, ηtt 95%
Cp 1.178kJ/kg-K
γ 1.32
Table 2.1. Preliminary design requirements

The table above shows the preliminary requirements for the design of the axial flow
turbine. These values will be used for further calculations

2. VELOCITY DIAGRAMS OF THE AXIAL-TURBINE STAGE

Fig. 2.1. Velocity diagram for an axial turbine stage

Source: Hall., S. L. (2010). Fluid Mechanics and Thermodynamics of Turbomachinery Sixth Edition. Elsevier Inc .
 The axial turbine stage comprises a row of fixed guide vanes or nozzles and a row of
moving blades or buckets, which is called the stator and rotor, respectively. Fluid enters the
stator with absolute velocity c1 at angle α1 and accelerates to an absolute velocity c2 at angle
α2 as shown in the velocity diagram (Fig. 2.1). These angles are measured from the axial
direction.

In the rotor inlet, taking the relative velocity ω2 at an angle β2

3. MEAN RADIUS DESIGN

According to Hall., S. L. (2010), the steps in a preliminary design of an axial flow turbine
is essentially a process of trial and error and several different approaches are possible
depending on the data available, any additional assumptions that may have to be made.

Solving for the mean radius design, determining first the isentropic enthalpy across the stage
is necessary,
∆ℎ𝑖𝑠 = ℎ01 − ℎ3𝑠𝑠

And the isentropic temperature ratio is,

𝛾−1)
𝑇3𝑠𝑠 𝑝3 ( 𝛾
=( )
𝑇01 𝑝01

Therefore,
𝑇3𝑠𝑠
∆ℎ𝑖𝑠 = 𝐶𝑝 𝑇01 (1 −
𝑇01 )

Fig. 2.2. General Mollier Diagram for a Turbine Stage

Source: Hall., S. L. (2010). Fluid Mechanics and Thermodynamics of Turbomachinery Sixth Edition. Elsevier Inc.
Using the figure above,
∆𝑊 = ℎ01 − ℎ03

Thus, the total efficiency is

∆𝑊
𝜂𝑡𝑡 =
ℎ01 − ℎ03𝑠𝑠

For axial entry flow with α1=0,

𝑐𝑥 𝑡𝑎𝑛𝛼2
𝑅 =1−
2𝑈
Thus,
1 2
∆𝑊 = 𝑈𝑐𝑥 𝑡𝑎𝑛𝛼2 = 2(1 − 𝑅)𝑈 2 = 𝜂𝑡𝑡 (𝛥ℎ𝑖𝑠 − 𝑐 )
2 𝑥
Since,
𝑐𝑥
𝜙=
𝑈
𝜂𝑡𝑡 𝛥ℎ𝑖𝑠
𝑈2 =
1
2(1 − 𝑅) + 2 𝜂𝑡𝑡 𝜙 2

4. MEAN RADIUS VELOCITY TRIANGLES AND EFFICIENCY

For calculating the total-to-total efficiency with α3=0°,

𝑈
𝑡𝑎𝑛𝛽3 =
𝑐𝑥
2𝑅
𝑡𝑎𝑛𝛽2 = 𝑡𝑎𝑛𝛽3 −
𝜙

And,
𝑐𝑥
𝑤3 =
𝑐𝑜𝑠𝛽3
𝑐𝑥
𝑐2 =
𝑐𝑜𝑠𝛼2

The calculations for total-to-total efficiency is approximated as,

−1
𝜁𝑅 𝑤 2 3 + 𝜁𝑁 𝑐 2 2
𝜂𝑡𝑡 = [1 + ]
2𝛥𝑊

Where, 𝜁 = 𝑆𝑜𝑑𝑒𝑟𝑏𝑒𝑟𝑔 𝑙𝑜𝑠𝑠 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡𝑠,

𝜀 2
𝜁 = 0.04 [1 + 1.5 ( ) ]
100
𝜀𝑟𝑜𝑡𝑜𝑟 = 𝛽2 + 𝛽3

𝜀𝑛𝑜𝑧𝑧𝑙𝑒 = 𝛼2
And the total-to-static efficiency,
−1
𝜁𝑅 𝑤 2 3 + 𝜁𝑁 𝑐 2 2 + 𝑐 2 𝑥
𝜂𝑡𝑡 = [1 + ]
2𝛥𝑊
𝛥𝑊
The stage loading coefficient is, 𝜓 = and the nozzle exit,
𝑈2
𝑐2
Mach number 𝑀2 =
√𝛾𝑅𝑇 2
𝑐22
𝑇2 = 𝑇01 −
(2𝐶𝑝 )

𝛾𝑅 = (𝛾 − 1)𝐶𝑝

5. TIP AND ROOT RADII CALCULATIONS

The axial flow area for area at nozzle exit is 𝐴2 = 𝑚̇/(𝜌2 𝑐𝑥 ) where 𝜌2 = 𝑝2 /(𝑅𝑇2 ). To
determine the static pressure 𝑝2 taking into account the nozzle losses,

for the nozzle,

At this point in the design we have no information on the magnitude of nozzle

efficiency. However, in a nozzle the losses will be low and a value 𝜂𝑁 = 0.97 is selected. Using
𝑇
this value and earlier data, determine𝑇2𝑠 = 0.0997. Hence,
01

With 𝜌2 = 𝑝2 /(𝑅𝑇2 ) and 𝑅 = 285.6 𝑘𝐽/𝑘𝑔°𝐶 the flow area is then

It is assumed that the blades are untampered and made of steel (𝜌𝑚 =
7850 𝑘𝑔/𝑚3. The blade tip radius is determined by,

And the blade temperature is determined by

6. VARIATION OF REACTION AT THE HUB

For all radii,

 When referring to be the mean radius the subscript m will be added to the variables
R and r

Combining the two expressions the radial variation of reaction is

7. CHOOSING A SUITABLE STAGE GEOMETRY

Deciding on a suitable configuration for the turbine is not as easy as several factors need
to be considered in making a decision. The size of the unit can be of importance and usually
the turbocharger needs to be made as small as possible. By making 𝑟𝑡 smaller, the speed of
rotation must increase. As a result both the blade length and the root stress are increased. It
is also necessary to check that the blade pitch s is not so small that the blades cannot be safely
attached to the rim of the turbine disc. In small turbines such as this design it may be
practicable to consider either machining the blades and disc from a single forging or welding
the blades onto the disc.
The blade aspect ratio H/s is another factor that can affect the efficient working of the
turbine. This ratio needs to be sufficiently large that the end wall losses and secondary flow
losses do not become excessive. A just acceptable value of H/s is 2.0, the values of 𝑍 =
2𝜋𝑟𝑚 /𝑠 resulting from this choice are shown.

8. ESTIMATING THE PITCH/CHORD RATIO

A simplified form of Zweifel’s criterion is applied to the rotor’s mean radius.

An approximate geometric relationship between the axial chord, b, and the true
chord, l, can be found based upon the assumption of a single circular arc to represent the
camber line of a turbine blade in a cascade, as shown in the figure below.

Fig. 2.3. Construction Details to Determine Stagger Angle

Source: Hall., S. L. (2010). Fluid Mechanics and Thermodynamics of Turbomachinery Sixth Edition. Elsevier Inc.
 From the construction details shown in the figure above the stagger angle ξ can be
obtained from

With the stagger angle established, hence, s/l = (s/b)(b/l).

III. Findings

1. CALCULATIONS

In this section, calculations implemented in the Microsoft excel using the equations
formulated are shown below, and will be compared to the data accumulated in Solidworks
flow simulation.

The preferred design parameters and the boundary conditions are shown below in Fig.
3.1 and 3.2, respectively and the results of the calculations via Microsoft Excel using the
formulas from the methodology are also shown in Fig. 3.3 to 3.7.

Fig. 3.1. Design Parameters

Fig. 3.2. Boundary Conditions

The figures above shows the initial conditions and parameters set for the design of the
model that will be used both in Solidworks flow simulations and in the manual calculations,
which will be shown to the next figures.
 Fig. 3.3. Mean Radius Design and Velocity Triangles and Efficiency Calculations

The figure above tells the calculation for the creation of the velocity triangles that can
be seen from Fig. 2.1.

Fig. 3.4. Root and Tip Radii Calculations

The figure above tells the calculation for the determination of the root and tip radius
of the blades, which will be implemented in the Solidworks design as well.
 Fig. 3.5. Varying r/rt Calculations

The figure above tells the calculation for varying the ratio of radius of the blades to its
tip for determination of the different angles and speeds.

Fig. 3.6. Suitable Geometry with Pitch/Chord Ratio Estimations

Fig. 3.7. Confirmation for the design

From the figure above, the power output for the manual calculation yields 154,518.61
kW with a rotational speed of approximately 4798 rpm and the following rotor dimensions:
tip radius of 0.08m, blade chord of 0.05m and a blade temperature of 1113.42K.
 2. SOLIDWORKS DESIGN

2.1 Rotor and Stator

The design of the model of the gas turbine was made using an airfoil tool maker, a site
that can compare, create and plot airfoils. The resulting graph is then integrated into the
Solidworks application using the curve through xyz feature. The curve is then attached to the
created cylinder with a specific measurement which is then elongated with the use of the
extruded boss/base feature in the application. Then, using the circular pattern feature in
solidworks, the extruded part is then circulated with a specific number of instances indicating
the number of blades of the model.

Fig. 3.8. Stator

The stator has a larger inner diameter compared to the rotor because this is where
the bearing is attached.

Fig. 3.9. Rotor

 For the rotor, its inner diameter is smaller than the Stator because this is where the
shaft is attached. Keyholes are also created in order to fit the key and to turn the shaft as the
rotor also turns.

2.2 Shaft
In creating the shaft, a cylinder is created with a protruding part that acts as a key to
fit it to the rotor so that as the rotor rotates, the shaft also rotates with it.

Fig. 3.10. Shaft

2.3 Casing

In creating the casing, an inner and outer circle was drawn with a specific
measurement and is then extruded. A new subassembly was also created so that the stator
and the casing will be connected.

Fig. 3.11. Casing

2.4 Bearing

In solidworks there is an add on called Toolbox that has a collection of standard

measurements of tools, it is located in the design library. The chosen bearing for this model
is the sBearings - sfk - 6204. It is then attached in the hole of the stator. The dimensions are:

Fig. 3.12. Bearing Dimensions

Fig. 3.13. Deep Groove Ball Bearing (6204-Z)

3. SOLIDWORKS FLOW SIMULATION

Solidworks Flow Simulation is an intuitive Computational Fluid Dynamics (CFD)

solution embedded within Solidworks 3D CAD that enables the user to quickly and easily
simulate liquid and gas flows through and around the axial flow gas turbine designs to
calculate product performance and capabilities. These simulation is then necessary so that
the manual calculations of performance parameters done by the researchers can be
correlated to the Solidworks flow simulation.

In preparation for the flow simulation to begin solving the axial flow gas turbine
design, few key introductory steps must be done to determine necessary standards set by the
user. These steps are the project name, unit system, analysis type where in this model is
internal and the rotation on local averaging, fluid type, and then the initial and ambient
conditions.

Input data like the computational domain is necessary so that the software can
determine the control volume desired by the researchers. Meshing or Finite Element Analysis
(FEA) is a very crucial step in design analysis since it provides a reliable numerical technique
for analyzing engineering designs. The process starts with the creation of a geometric model
then, the program subdivides the model into small pieces of simple shapes (elements)
connected at common points (nodes). Manual meshing control mode was done on the
different sizes of elements for components, faces, edges, and vertices of the gas turbine
model. See Figure (3.13)

Fig. 3.14. Computational Domain and Mesh of the single stage axial flow gas turbine model

Rotating Region is also a step done to conduct the design analysis. A cylinder that
encompasses the geometry of the rotor of the gas turbine was inserted but not merged. The
cylinder was then set as a rotating region with the calculated angular velocity.

Fig. 3.15. Rotating Region on the Rotor

 The calculated inlet and outlet performance parameters was then integrated as
boundary conditions for the design. Inlet and Outlet Lids was made where it served as opening
and closing for the design and used as faces to specify the boundary parameters and
conditions. Inlet Mass flow of 8kg/s, inlet sonic velocity of 557.46 m/s and the thermodynamic
parameters of the calculated temperature and pressure was also admissioned in the inlet Lid.
Outlet boundary conditions such as the design parameter of static pressure was admissioned
in the outlet lid.

Fig. 3.16. Inlet and Outlet Boundary Conditions

In finite element analysis used in this study, a problem is represented by a set of

algebraic equations that must be solved simultaneously. Iterative methods solve the
equations using approximate techniques where in each iteration, the solution is assumed and
the associated errors are evaluated. The iterations continue until the errors become
acceptable. The solver converged after 20 hours and 31 minutes, 156 iterations with a total
number of cells of: 1,056,210 where solid cells were 366,965 and fluid cells were 689,245.

The use of the Goal step is to use as a convergence parameter to help coordinate with
the iterative solver to know when it is going to stop or converge. Goal post is set to the Torque
produced by the rotation of the Rotor. Which the researchers can then use the Torque
parameter to get the Power Output of the turbine in the flow simulation then later on
correlate with the Power output computed by manual calculations.

4. SOLIDWORKS FLOW SIMULATION RESULTS

Graphs and tables of the converged results will then be presented here. Results for
performance parameters such as Velocity, Pressure, Temperature of fluid and Torque versus
every iteration of the solver and along the geometry of the turbine will be discussed and
shown here. Solidworks cut plot and flow trajectory features are used to show the imagery of
the various changes in the performance parameters.
4.1 Velocity

Fig. 3.17 Velocity (Z) Flow Trajectory

Fig. 3.18. Velocity (Z) Cut Plot along the Right Plane

4.2 Pressure

Fig. 3.19. Pressure Flow Trajectory

 Fig. 3.20. Pressure Cut Plot along the Right Plane

4.3 Temperature

Fig. 3.21. Temperature Flow Trajectory

Fig. 3.22. Temperature Cut Plot along the Right Plane

 Torque values are given in every iteration. Average, Minimum and Maximum values
are being used as basis for correlation. Graphs and the calculated power output with the given
angular velocity will also be presented here.

Fig. 3.23. Torque vs Iteration

Fig. 3.24. Power Output vs Iteration

Fig. 3.25. Ave., Min., and Max. Torque Values and the calculated Power Output
IV. Results and Discussion

The calculated power output result using Microsoft excel is 154,518.61 kW while the
CFD results yielded a minimum value of 168,612.07 kW and a maximum value of 193,246.16
kW, therefore an average value of 182,361.31 kW. It can be seen that the values of power
output from the manual calculations and the CFD results are quite comparable using the
minimum value from the CFD. However comparing from the average value the difference is
quite high. A large contributing factor as to why this is, is due to the meshing of the CFD
analysis due to limits on the hardware of the computer, which results to having not very fine
meshing of the gas turbine in order to accommodate the specs of the computer. With fine
meshing, the results can then approach the value of that of the calculated.

V. Fabrication

The designed model from Solidworks was 3-D printed for an actual test experiment.
The prototype was printed using polylactic acid (PLA) material in a Prusa i3 mk2 3-D printer.

Fig. 5.1. Polylactic Acid (PLA) Material

Source: https://www.kisspng.com/png-3d-printing-filament-polylactic-acid-makerbot-acry-4544758/

Fig. 5.2. Prusa i3 mk2 3-D printer

Source: https://www.3dhubs.com/3d-printers/original-prusa-i3-mk2
 Before printing, file conversions are made. First, the file was sliced into three parts:
rotor, stator, and its shaft and converted into stereo lithography (STL) file ready for 3-D
printing.

(a) (b)

(c)
Fig. 5.3. Print 3-D view: (a) rotor (b) stator (c) shaft

Fig. 5.4. Final 3-D printed prototype

 Since the prototype is printed only in a model type of the design, due to material and
resources availability, the actual test experiment was not made possible. Therefore, the study
is only limited to both the manual calculations using Microsoft Excel and the results in
Solidworks flow simulation.

V. Conclusions

The design that is governed by the initial assumptions (free-vortex design, choices of
degree of reaction, and flow coefficient) as well as decisions made about the radius ratio and
blading. The CFD results of the Solidworks model yielded promising results that are almost
comparable to the results that were manually calculated. Thus, making the Solidworks model
a valid one for the set parameters and test conditions. Also, a fabricated prototype of the
created model was also made. However, actual test experiments on the fabricated model
were not possible due to several limitations on the test conditions and the material used for
fabrication. Thorough research can be made in the creation of the airfoil to increase the
efficiency of the blade.

References

[1]Gas Turbine. Minnesota State University, Mankato. :

http://cset.mnsu.edu/engagethermo/components_gasturbine.html.
[2] Soner ÇELEN, A. M. (2009). DESIGN AND ANALYSIS OF AXIAL FLOW TURBINE WITH
COMPUTER SOFTWARE. INTERNATIONAL SCIENTIFIC CONFERENCE. GABROVO:
https://www.researchgate.net/publication/260517053.
[3] The GE90 Engine, GE Aviation. http://www.geaviation.com/commercial/engines/ge90/,
Last accessed: 7/12/2015.
[4] Gas Turbine for Power Generation: Introduction, Wartsila. (2015).
http://www.wartsila.com/power-plants/learning-center/technical-comparisons/gas-
turbine-for-power-generation-introduction.
[5] Hall., S. L. (2010). Fluid Mechanics and Thermodynamics of Turbomachinery Sixth Edition.
Elsevier Inc.

Airfoil Tools. (n.d.). Retrieved from http://airfoiltools.com/

Basson, J. G. (December, 2014). Design methodology of an axial-flow turbine for a micro jet
engine. Stellenbosch University, Private Bag X1, Matieland 7602, South Africa:
Department of Mechanical and Mechatronic Engineering, Thesis: MEng. (Mechanical).