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Thesis (MScEng)--Stellenbosch University, 2014. / ENGLISH ABSTRACT: The main components of a micro gas turbine engine are a centrifugal or mixed-flow compressor, a combustion chamber and a single stage axial-flow or radial-flow turbine. The goal of this thesis is to formulate a design methodology for small axial-flow turbines. This goal is pursued by developing five design-related capabilities and applying them to develop a turbine for an existing micro gas turbine engine. Firstly, a reverse engineering procedure for producing digital three-dimensional models of existing turbines is developed. Secondly, a procedure for generating candidate turbine designs from performance requirement information is presented. The third capability is to use independent analysis procedures to analyse the performance of a turbine design. The fourth capability is to perform structural analysis to investigate the behavior of a turbine design under static and dynamic loading. Lastly, a manufacturing process for prototypes of a feasible turbine design is developed. The reverse engineering procedure employs point cloud data from a coordinate measuring machine and a CT-scanner to generate a three-dimensional model of the turbine in an existing micro gas turbine engine. The design generation capability is used to design three new turbines to match the performance of the turbine in the existing micro gas turbine engine. Independent empirical and numerical turbine performance analysis procedures are developed. They are applied to the four turbine designs and, for the new turbine designs, the predicted efficiency values differ by less than 5% between the two procedures. A finite element analysis is used to show that the stresses in the roots of the turbine rotor blades are sufficiently low and that the dominant excitation frequencies do not approach any of the blade natural frequencies. Finally prototypes of the three new turbine designs are manufactured through an investment casting process. Patterns made of an organic wax-like material and a polystyrene material are used, with the former yielding superior results. / AFRIKAANSE OPSOMMING: Mikro-gasturbiene-enjins bestaan uit 'n sentrifugaal- of ‘n gemende-vloeikompressor, 'n verbrandingsruim en 'n enkel-stadium-aksiaalvloei- of ‘n radiaalvloei-turbine. Die doel van hierdie tesis is om 'n ontwerpsmetodologie vir klein aksiaalvloei-turbines saam te stel. Hierdie doel word deur die ontwikkeling en toepassing van vyf ontwerpsverwante vermoëns nagestreef. Eerstens word 'n tru-waartse-ingenieursproses ontwikkel om drie-dimensionele rekenaarmodelle van die bestaande turbines te skep. Tweedens word 'n metode om kandidaatturbineontwerpe vanaf werkverrigtingsvereistes te verkry, voorgestel. Die derde ontwerpsvermoë is om die werksverrigting van 'n turbineontwerp met onafhanklike analises te evalueer. Die vierde ontwerpsvermoë is om die struktuur van 'n turbinelem te analiseer sodat die effek van statiese en dinamiese belastings ondersoek kan word. Laastens word 'n vervaardigingsproses vir prototipes van geskikte turbineontwerpe ontwikkel. Die tru-waartse-ingenieursproses maak gebruik van 'n koördinaat-meet-masjien en 'n CT-skandeerder om puntewolkdata vanaf die turbine in 'n bestaande mikro-gasturbiene-enjin te verkry. Die data word dan gebruik om 'n drie-dimensionele model van die turbine te skep. Die ontwerpskeppingsvermoë word dan gebruik om drie kandidaatturbineontwerpe vir die bestaande mikro-gasturbiene-enjin te skep. Onafhanklike empiriese en numeriese prosedures om die werkverrigting van 'n turbineontwerp te analiseer word ontwikkel. Beide prosedures word op die vier turbineontwerpe toegepas. Daar word gevind dat die voorspelde benuttingsgraadwaardes van die nuwe ontwerpe met minder as 5% verskil vir die twee prosedures. 'n Eindige-element-analise word dan gebruik om te wys dat die spannings in die wortels van die turbinelemme laag genoeg is, asook dat die dominante opwekkingsfrekwensies nie die lem se natuurlike frekwensies nader nie. Laastens word prototipes van die drie nuwe turbineontwerpe deur 'n beleggingsgietproses vervaardig. In die vervaardigingproses word die effektiwiteit van twee materiale vir die gietpatrone getoets, naamlik 'n organiese wasagtige materiaal en 'n polistireen-materiaal. Daar word bevind dat die gebruik van die wasagtige gietpatrone tot beter resultate lei.

In the development of modern rotorcraft vehicles, many unique challenges emerge due to the highly coupled nature of individual rotorcraft design disciplines therefore, the use of an integrated product and process development (IPPD) methodology is necessary to drive the design solution. Through the use of parallel design and analysis, this approach achieves the design synthesis of numerous product and process requirements that is essential in ultimately satisfying the customers demands. Over the past twenty years, Georgia Techs Center for Excellence in Rotorcraft Technology (CERT) has continuously focused on refining this IPPD approach within its rotorcraft design course by using the annual American Helicopter Society (AHS) Student Design Competition as the design requirement catalyst. Despite this extensive experience, however, the documentation of this preliminary rotorcraft design approach has become out of date or insufficient in addressing a modern IPPD methodology. In no design discipline is this need for updated documentation more prevalent than in propulsion system design, specifically in the area of gas turbine technology. From an academic perspective, the vast majority of current propulsion system design resources are focused on fixed-wing applications with very limited reference to the use of turboshaft engines. Additionally, most rotorcraft design resources are centered on aerodynamic considerations and largely overlook propulsion system integration. This research effort is aimed at bridging this information gap by developing a preliminary turboshaft engine design methodology that is applicable to a wide range of potential rotorcraft propulsion system design problems. The preliminary engine design process begins by defining the design space through analysis of the initial performance and mission requirements dictated in a given request for proposal (RFP). Engine cycle selection is then completed using tools such as GasTurb and the NASA Engine Performance Program (NEPP) to conduct thorough parametric and engine performance analysis. Basic engine component design considerations are highlighted to facilitate configuration trade studies and to generate more detailed engine performance and geometric data. Throughout this approach, a comprehensive engine design case study is incorporated based on a two-place, turbine training helicopter known as the Georgia Tech Generic Helicopter (GTGH). This example serves as a consistent propulsion system design reference highlighting the level of integration and detail required for each step of the preliminary turboshaft engine design methodology.

Gas turbine engines for aircraft applications are required to meet multiple performance and sizing requirements, subject to constraints established by the best available technology level. The performance requirements and limiting values of constraints that are considered by the cycle analyst conducting an engine cycle design occur at multiple operating conditions. The traditional approach to cycle analysis chooses a single design point with which to perform the on-design analysis. Additional requirements and constraints not transpiring at the design point must be evaluated in off-design analysis and therefore do not influence the cycle design. Such an approach makes it difficult to design the cycle to meet more than a few requirements and limits the number of different aerothermodynamic cycle designs that can reasonably be evaluated. Engine manufacturers have developed computational methods to create aerothermodynamic cycles that meet multiple requirements, but such methods are closely held secrets of their design process. This thesis presents a transparent and publicly available on-design cycle analysis method for gas turbine engines which generates aerothermodynamic cycles that simultaneously meet performance requirements and constraints at numerous design points. Such a method provides the cycle analyst the means to control all aspects of the aerothermodynamic cycle and provides the ability to parametrically create candidate engine cycles in greater numbers to comprehensively populate the cycle design space from which a "best" engine can be selected. This thesis develops the multi-design point on-design cycle analysis method labeled simultaneous MDP. The method is divided into three different phases resulting in an 11 step process to generate a cycle design space for a particular application. Through implementation of simultaneous MDP, a comprehensive cycle design space can be created quickly for the most complex of cycle design problems. Furthermore, the process documents the creation of each candidate engine providing transparency as to how each engine cycle was designed to meet all of the requirements. The simultaneous MDP method is demonstrated in this thesis on a high bypass ratio, separate flow turbofan with up to 25 requirements and constraints and 9 design points derived from a notional 300 passenger aircraft.