Thermo-Mechanical Analysis of Various Film Cooling Hole Geometries

Tripod hole film cooling designs can provide improved cooling with reduced coolant usage. It is essential to determine the impact of strong cooling near hole locations due to increased thermal gradients around the hole region. In this paper, efforts have been made to predict the same using a numerical analysis. Local temperature distribution on the blade surface causes different rates of expansion, resulting in a differential strain, furthering the impact of the numerical study and creating a need to understand the thermo-mechanical behavior of blade design. The thermal stresses that are generated near the film cooling holes are compared for different cooling hole shapes and eventually weigh the thermal advantage of a tripod hole over the cylindrical standard design. Standard k-ε was used to validate the CFD results, ensuring by a fine mesh of 5 million tetrahedrons. Validation includes comparison of the experimental results, with a numerical one where similar blade material and working temperatures are used. Upon validation, CFD was run again at engine temperature conditions with Haynes230 alloy as the blade material. Surface temperature contour enabled structural analysis using a finite element approach. Equivalent stresses (Von-Mises stresses) on the blade emerging from the analysis provided more information about stress dependency on blowing ratio.