This disclosure relates generally to turbines, and, more specifically, to systems and methods for stress relief in dovetails for axial-mounted turbine rotor blades.
Blades (also sometimes referred to as “buckets”) for gas turbine engines, particularly blades that are coupled to engine hubs using axial dovetails, are subjected to substantial stresses caused by radially-outwardly directed forces imposed on the blades by the rotation of the turbine rotor. Specifically, axial dovetails include one or more axially-extending tangs that are subjected to substantial, unevenly-applied radial loading during turbine operation. Accordingly, loads imposed on axial dovetails, and stresses resulting from the loads, are concentrated in specific areas along the lengths of the tangs due to a non-uniform load path defined by the loads. As such, a useful service life (also referred to as a “low cycle fatigue life”) of a blade, as a whole, is influenced by the useful service life of the dovetails, specifically in areas of load concentration along fillets between dovetail tangs. An increase in service life of a turbine component yields lower costs, as that facilitates replacement of the turbine component at greater time intervals.
Accordingly, it is desirable to provide an axial dovetail construction that facilitates a reduction in loading in areas of load concentration.
In an aspect, a method for relieving stress on a dovetail of a turbine rotor blade in a gas turbine is provided. The method includes coupling at least one turbine rotor blade to a turbine disk for rotation about an axis, the at least one turbine rotor blade including a dovetail axially insertable into a correspondingly-shaped slot defined in the turbine disk, wherein the correspondingly-shaped slot includes an inner surface. The method also includes defining at least one tang on the dovetail that extends axially along at least a portion of the dovetail, the at least one tang including a tang length. The method also includes defining at least one stress relief surface in the at least one tang, the at least one stress relief surface extending along a central portion of the tang length, such that contact between the at least one tang and the inner surface is precluded, along at least the central portion of the tang length.
In another aspect, a system for relieving stress on a dovetail of a turbine rotor blade in a gas turbine is provided, wherein the turbine rotor blade is coupled to a turbine disk for rotation about an axis. The system includes at least one turbine rotor blade coupleable to the turbine disk. The at least one turbine rotor blade includes a dovetail axially insertable into a correspondingly-shaped slot defined in the turbine disk, wherein the correspondingly-shaped slot includes an inner surface. The system also includes at least one tang defined on the dovetail that extends axially along at least a portion of the dovetail, such that the at least one tang includes a tang length. The system also includes at least one stress relief surface defined in the at least one tang, that extends along a central portion of the tang length, such that contact between the at least one tang and the inner surface is precluded, along at least the central portion of the tang length.
In a further aspect, a turbine rotor blade for use in a gas turbine is provided. The turbine rotor blade includes a dovetail insertable parallel to an axis of the gas turbine into a correspondingly-shaped slot defined in a turbine disk, wherein the correspondingly-shaped slot includes an inner surface. The turbine rotor blade also includes at least one tang defined on the dovetail and extending axially along at least a portion of the dovetail, the at least one tang including a tang length. The turbine rotor blade also includes at least one stress relief surface defined in the at least one tang, the at least one stress relief surface extending along a central portion of the tang length, such that contact between the at least one tang and the inner surface is precluded, along at least the central portion of the tang length.
As used herein, the terms “axial” and “axially” refer to directions and orientations extending substantially parallel to a longitudinal axis of a gas turbine engine. Moreover, the terms “radial” and “radially” refer to directions and orientations extending substantially perpendicular to the longitudinal axis of the gas turbine engine.
In operation, air flows through compressor assembly 102 such that compressed air is supplied to combustor assembly 104. Fuel is channeled to a combustion region and/or zone (not shown) that is defined within combustor assembly 104 wherein the fuel is mixed with the air and ignited. Combustion gases generated are channeled to turbine section 108 wherein gas stream thermal energy is converted to mechanical rotational energy. Turbine section 108 is coupled to rotor 110, for rotation about an axis 106.
Each rotor blade 126 is coupled to rotor disk 112 using any suitable coupling method that enables gas turbine engine 100 to function as described herein. Specifically, in the exemplary embodiment, each rotor blade 126 includes a dovetail 134 coupled to shank 132. Dovetail 134 is insertably received axially (i.e., in a direction parallel to axis of rotation 106 illustrated in
In at least some known gas turbine engines that include at least one rotor blade 126 coupled to an axial dovetail 134, rotation of rotor 110 imposes substantially radially-directed stress forces on at least one of axial dovetail 134 and areas of rotor disk 112 adjacent slot 136. In at least some known gas turbine engines, peak numerical values of the imposed substantially radially-directed stress forces are encountered within a generally central region 123 along a length L of axial dovetail 134, with a maximum stress force value encountered at or within a general vicinity of a midpoint 125 along length L. Accordingly, the loads imposed on dovetail 134 and adjacent areas of disk 112 is not uniformly distributed, or is said to be “unbalanced,” along length L.
Dovetail 134 of rotor blade 126 includes a plurality of axially-extending tangs 142, 143, 144 and 145 (shown in
The radially-directed stress forces described above result in compressive loads imposed on pressure faces of dovetail tangs 142-145, for example. The compressive loads are sometimes referred to as “crush loads.” The radially-directed stress forces described above also result in tensile loads on fillet radii, such as radius 174, between tangs. Inasmuch as fillets, such as fillets 172, 173, or 175 are located in areas where dovetail 134 is relatively thin, e.g., in comparison to tangs 142-145, tensile loads in fillets, such as fillets 172, 173, and/or 175 are the loads which typically limit a low-cycle fatigue life of a dovetail.
Stress relief system 151 includes a stress relief surface 152 defined in tang 142 and a stress relief surface 153 defined in tang 143. In addition, a stress relief surface 162 is defined in tang 144, and a stress relief surface 161 is defined in tang 145. In the exemplary embodiment, each of stress relief surfaces 152, 153, 162, and 161 is created via removal of material from the corresponding one of tangs 142-145.
In the exemplary embodiment, tang material is removed from rotor blade 126 after the fabrication of rotor blade 126 has been otherwise completed. Removal of tang material is accomplished by any suitable removal method that enables system 151 to function as described, such as machining. In one exemplary embodiment, a wedge-shaped portion of tang material is removed along a length of one or more of tangs 142-145, leaving stress relief surfaces 152, 153, 162, and/or 161. In the exemplary embodiment, the wedge-shaped portion of removed tang material is of a constant shape and thickness along stress relief surfaces 152, 153, 162 and/or 161. Alternatively, the amount of material removed from tangs 142, 143, 144, and/or 145 varies along respective lengths of stress relief surfaces 152, 153, 162, and/or 161.
In an alternative exemplary embodiment also illustrated in
In alternative embodiments, arc length M may be the same length or a greater length than arc length N. Moreover, in the exemplary embodiment, stress relief surface 152 transitions into boundary walls 170 and 171 via curved corner surfaces (not shown). By using curved transitions, reduction of localized focusing of stress forces is facilitated. Similarly, stress relief surface 162 transitions into boundary walls 180 and 182 via curved corner surfaces (not shown).
In an exemplary embodiment, stress relief surface 153 includes a length equal to M, and stress relief surface 161 includes a length equal to N. In alternative embodiments, stress relief surfaces 153 and 161 have other lengths. In general, stress relief surfaces 152, 153, 162, and 161 have any lengths suitable to enable system 151 to function as described.
In the exemplary embodiment, stress relief surfaces 152, 153, 162 and 161, extend along tangs 142-145, respectively, in areas that substantially correspond to areas of maximum stress imposed on tangs 142 and 144 during operation of engine 100. Distances M and N have any length sufficient to enable system 151 to function as desired to facilitate reduction of peak radial load stresses in rotor blade 126, by redistributing loading to other areas of tangs 142-145. Moreover, lengths of stress relief surfaces 152, 153, 162, and 161, such as lengths M and N, are determined using any suitable method that enables system 151 to function as described. A consideration in determining lengths M and N is that sufficient contact surface area on each of tangs 142-145 is maintained so that a predefined value for pressure corresponding to loads imposed on each of tangs 142-145 during operation of engine 100 is not exceeded. For example, an increase in one or both of lengths M and N may, in some embodiments, necessitate an increase in overall length L (shown in
As described herein, in an engine 100 having rotor blades 126 in which stress relief surfaces 152, 153, 162 and 161 are absent, during operation, tangs 142-145 physically contact inner surfaces 156-159, and transmit radial loads, creating stresses in tangs 142-145, and/or in areas of disk 112 adjacent grooves 146-149. Accordingly, stress relief surfaces 152, 153, 162, and 161, by precluding contact between tangs 142-145 and inner surfaces 156-159, facilitate preventing transmission of substantially radially-directed stress forces between tangs 142-145 and adjacent areas of dovetail 134. Moreover, stress relief surfaces 152, 153, 162, and 161 facilitate an improved balancing of radial loading (“crush load”) along tangs 142-145 in dovetail 134, as well as balancing tensile loads in fillets, e.g., fillets 172, 173, and/or 175, in dovetail 134.
In the exemplary embodiment of
Moreover, stress relief surfaces 152, 153, 162 and 161 facilitate introduction of cooling air into open spaces created by removal of material from tangs 142-145. In an exemplary embodiment, such cooling air is supplied via an engine inner wheelspace 121 (shown in
In the exemplary embodiment of
Aside from turbine rotor blade 226 including a straight axial dovetail 234 (as compared to curved axial dovetail 134 of turbine rotor blade 126 shown in
Exemplary embodiments of a turbine rotor blade stress relief system and method are described above in detail. The turbine rotor blade stress relief systems and methods are not limited to the specific embodiments described herein, but rather, components of the turbine rotor blade stress relief system and/or steps of the method can be utilized independently and separately from other components and/or steps described herein. For example, the turbine rotor blade stress relief systems and methods described herein can also be used in combination with other machines and methods, and are not limited to practice only with gas turbine engines as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many other motor and/or turbine applications.
In contrast to known turbine rotor blade stress relief systems, the turbine rotor blade stress relief systems and methods described herein facilitate the balancing of loading along axial dovetails via the removal of material from dovetail tangs in areas in which peak load stresses are otherwise imposed on axial dovetails. In addition, the turbine rotor blade stress relief systems and methods described herein facilitate improvement in low cycle fatigue lives for rotors and enable the use of lower cost materials. The gas turbine rotor blade constructions described herein further facilitate increased blade service life, resulting in lower costs. Moreover, the gas turbine rotor blade constructions described herein facilitate the application of a better crush load balance without increasing dovetail axial length as compared to straight axial dovetails.
Although specific features of various embodiments of the methods and systems described herein may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the methods and systems described herein, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is formed by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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