Turbine Disc Design:
Every new gas turbine design is required by the marketplace to be more efficient than previous models. As a result, the design process uses more and more advanced analysis.
Working for a gas turbine original equipment manufacturer, we designed the turbine disc and blades of a new engine. We performed the stress and vibration analyses using finite element analysis, ensuring that the disc conformed to project requirements even as the boundary conditions changed as design aspects of other parts of the engine became firmer. As part of the project team based on the manufacturer's site, we were also able to add value to complementary aspects of the overall design and development process.
Since the development of a new product is a considerable peak in engineering workload, the gas turbine manufacturer managed this demand, and simultaneously imported key expertise, with the strategic use of consultants.
Root Cause Failure Analysis of Engine Rubbing:
Some gas turbine operators were experiencing unexpected casing rubs. The turbine manufacturer did not have an explanation for the events and started an investigation.
As part of the investigation, we performed multiple simulations of how the moving and static parts of the engine might behave under different initiating scenarios. This was accomplished by creating several versions of finite element models of the engine components and assemblies. By comparing the results of the simulation with test data and quantitative observations of actual damage, we were able to discount several possible failure sequences and narrow down the search for the root cause.
Advanced simulation was used as a tool to understand actual engine performance. Our analysis was a key part in the investigation and was used to understand the causes of the damage observed. By outsourcing the analysis component, the manufacturer was able to import expertise for the in-service issue and at the same time avoid delaying other project plans.