UCSD Solar Turbine
Pre-Swirler
University of California, San Diego
Department of Mechanical and Aerospace Engineering
MAE 156B: Senior Design Project (Winter 2024)
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Background:
Solar Turbines is a global developer of continuous combustion turbine engines. For this project, we will be focusing on redesigning the pre-swirler component of their mid-sized turbine, specifically for additive manufacturing.
Solar Turbines is a global developer of continuous combustion turbine engines. For this project, we will be focusing on redesigning the pre-swirler component of their mid-sized turbine, specifically for additive manufacturing.
The Pre-swirler, located in the diaphragm of the turbine engine, is composed of an inner and outer ring with vanes and directs air at a specific angle and velocity to enhance turbine efficiency.
The Pre-swirler, located in the diaphragm of the turbine engine, is composed of an inner and outer ring with vanes and directs air at a specific angle and velocity to enhance turbine efficiency.
Process:
Additive manufacturing utilizes computer-aided-design (CAD) to create 3D designs through a layer-by-layer process. It can greatly reduce labor expenses and time as it allows parts that are normally made individually to be printed together and aids in the mass production of the product.
Problem Definition:
Presently comprised of three components - the inner ring, the outer ring, and 52 vanes - Pre-swirlers are designed for subtractive manufacturing where the parts are machined down to the desired form and then brazed together.
Objective:
Our goal is to develop a new design for a pre-swirler utilizing additive manufacturing that is cost-effective and time-efficient, while ensuring durability, manufacturability, and performance enhancement.
Functional Requirements:
Mechanical Requirements
Bulk Stress: Below 67% of material yield
Local Stress Concentration: Below 125% of material yield strength
Flow Requirements
Preserve throat area as per the original design of Solar Turbines
Other Requirements
Material selection based on mechanical requirements and availability
Ensure compatibility and proper interface with adjacent components
Suitable printing orientation for optimal manufacturing
Final Design:
The initial step in the Design for Additive Manufacturing (DfAM) process involved examining segmentation, vane count, and throat area. Finally, each segment of the Pre-Swirler required modification to incorporate printing orientation, crucial for ensuring printing accuracy. These modifications encompassed supporting fillets, addressing elephant's foot, adjusting printing tilt, and refining the shape of the fastener holes. Thus, resulting in a successfully 3D printed metal component showcasing our DfAM approach in action.
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