Cummins: Turbine Wheel – Automated Analysis Tool Completes Analysis Work 10x Quicker



Future savings of ~£1,400/turbine design.

Future designs completed 10 x faster

Results in 60% of the expected time

SUMMARY

Cummins Turbo technologies tasked us with evaluating 66-off fixed geometry turbine wheel designs estimated to take 1,000 engineering hours. Our approach delivered results in 60% of the expected completion time and left Cummins with a tool that will save them a significant amount of time and money for future designs.

SITUATION

Our client, Cummins Turbo Technologies, is based in the UK design and manufacture medium to heavy-duty diesel engine turbo solutions. They were looking to carry out analysis on already in-service turbine wheels to evaluate the tangential and radial strain force ratios (SFR) for 66-off fixed geometry turbine wheels to develop a database of information which provides insight into the relative performance of different wheel designs in high cycle fatigue (HCF). This database would be used to identify trends between certain design features and particular performance in HCF which would drive future designs.

CHALLENGE
  • Even though the analysis would provide significant benefits to turbines in development or future designs, Cumins did not have the necessary capacity, at this time, to carry out the estimated ~1000hours of ANSYS Workbench analysis.
  • The analysis methodology involved carrying out a linear elastic modal analysis coving 40 modes within a given frequency range of interest related to the running speed. A harmonic analysis was then carried out using the mode superposition method with a maximum and minimum frequency range specified to encompass mode 1.
  • We applied the harmonic loadings as unit forces in the radial, and tangential directions and separately applied at the inducer blade tip. The phase angle of these harmonic loads was calculated using a single order of excitation for each wheel.
SOLUTION

To support the Cummins team, we were able to provide the additional suitably qualified engineering resources to carry out the 1000 hours of work. However, instead of using ANSYS Workbench we proposed to Cummins the use of ANSYS APDL to develop parametrised macros building an automation tool (Process Optimisation). The macros would automatically carry out the meshing, modal and harmonic analysis and then post process outputting mesh checks, modal eigenvalue results and various contour plots and graphs related to the harmonic analysis used in putting together the SFR result database. This approach significantly decreased the time taken to complete all 66 turbine wheels (~600 hours), and it provided the Cummins team with a robust tool for use on all future turbine wheel designs.

BENEFITS
  • We delivered results in 60% of the expected time
  • We developed a robust analysis/automation tool that can be used on future designs completing the analysis of one turbine wheel approx. 10 times quicker. 
  • Future use of our tool provides a cost saving of an engineer’s time of ~ £1,400/turbine design.


Cummins Turbo technologies tasked us with evaluating 66-off fixed geometry turbine wheel designs estimated to take 1,000 engineering hours. Our approach delivered results in 60% of the expected completion time and left Cummins with a tool that will save them a significant amount of time and money for future designs.



Our client, Cummins Turbo Technologies, is based in the UK design and manufacture medium to heavy-duty diesel engine turbo solutions. They were looking to carry out analysis on already in-service turbine wheels to evaluate the tangential and radial strain force ratios (SFR) for 66-off fixed geometry turbine wheels to develop a database of information which provides insight into the relative performance of different wheel designs in high cycle fatigue (HCF). This database would be used to identify trends between certain design features and particular performance in HCF which would drive future designs.



  • Even though the analysis would provide significant benefits to turbines in development or future designs, Cumins did not have the necessary capacity, at this time, to carry out the estimated ~1000hours of ANSYS Workbench analysis.
  • The analysis methodology involved carrying out a linear elastic modal analysis coving 40 modes within a given frequency range of interest related to the running speed. A harmonic analysis was then carried out using the mode superposition method with a maximum and minimum frequency range specified to encompass mode 1.
  • We applied the harmonic loadings as unit forces in the radial, and tangential directions and separately applied at the inducer blade tip. The phase angle of these harmonic loads was calculated using a single order of excitation for each wheel.


To support the Cummins team, we were able to provide the additional suitably qualified engineering resources to carry out the 1000 hours of work. However, instead of using ANSYS Workbench we proposed to Cummins the use of ANSYS APDL to develop parametrised macros building an automation tool (Process Optimisation). The macros would automatically carry out the meshing, modal and harmonic analysis and then post process outputting mesh checks, modal eigenvalue results and various contour plots and graphs related to the harmonic analysis used in putting together the SFR result database. This approach significantly decreased the time taken to complete all 66 turbine wheels (~600 hours), and it provided the Cummins team with a robust tool for use on all future turbine wheel designs.



  • We delivered results in 60% of the expected time
  • We developed a robust analysis/automation tool that can be used on future designs completing the analysis of one turbine wheel approx. 10 times quicker. 
  • Future use of our tool provides a cost saving of an engineer’s time of ~ £1,400/turbine design.
Maximum Principal Strain over Frequency Contour plot
Maximum Tangential Displacement over Frequency Contour Plot
Turbine Wheel Harmonic Radial and Tangential Loading
Turbine Wheel Model

SECTOR

PROJECT ATTRIBUTES

ANSYS Parametric Design Language (APDL)

Harmonic Analysis

Modal Analysis

Strain Force Ratio (SFR)


Quote Open

The analysis methodology involved carrying out a linear elastic modal analysis coving 40 modes within a given frequency range of interest related to the running speed.

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