Fatigue Analysis of the Microturbine Rotor Disc Made of 7075 Aluminium Alloy Using a New Hybrid Calculation Method

Abstract

Today, where the production of any kind of device may have a negative impact on the environment, it is crucial to produce machines that are as efficient as possible but that can also be strong enough to withstand harsh operating conditions for a long time. That is why this paper raises the issue of the fatigue analysis of high-speed axial-flow microturbines whose components are made of commonly used 7075 aluminium alloy. The paper presents different methods that can be used to estimate and increase the fatigue life of a turbine disc. The object of study is a 10-kilowatt vapour microturbine. The various mechanical, flow and thermal loads that can occur during the operation of the microturbine have been analysed so that the most important ones can be taken into account in the final considerations. Stress calculations were performed using analytical equations, and the finite element method (FEM) was also used. Using the stresses obtained and material characteristics, fatigue analysis was conducted. Then, new hybrid calculation methods were proposed, taking into account both analytical and numerical approaches that do not require the use of ready-made programs dedicated to fatigue analysis. To verify these methods, calculations were performed for two rotor discs with different geometries. These methods can be used by both engineers and scientists in the design process of various microturbines when fatigue calculations are performed.