3D Finite Element Stress Analysis of Two-Pole

Turbogenerator Rotor
Alexey I. Borovkov
Eugeny V. Pereyaslavets
Denis V. Shevchenko
Igor A. Artamonov
Computational Mechanics Laboratory,
St.Petersburg State Polytechnical University, Russia
Abstract
In the current paper the rotor (inductor) of two-pole turbogenerator is analyzed. This is the most loaded
joint by mechanical and thermal loading. One of the urgent problems during design and manufacturing
processes is the problem of rotor vibrations and balancing. Vibration of the two-pole rotor can be caused by
several reasons. Special attention should be paid to the vibration with double rotational frequency that can
be observed in general in rotors with significant l/D relation (relation of the rotor body length to its
diameter). This vibration is caused by different rotor body stiffness in two main axes directions: axis of
poles (axis of "big tooth") and neutral normal to the axis of poles. In order to compensate rotor body
stiffness anisotropy in the current job the system of regular cross-slots in the zone of "big tooth" (Laffoon's
slots or slits) is used. An integral characteristic is considered to evaluate rotor body stiffness dissymmetry:
magnitude proportional to the difference of maximum static sags (located in the middle of rotor body) in
the directions of principle moments of inertia. One of the most topical problems after application of such
cross-slots is stress concentration at the bottom of slots. In the present paper the results of 3D multi-variant
finite element (FE) structural analysis of stress concentration zones at the bottom of cross-slots under
gravity and centrifugal loading are presented. Together with the results of finite element analysis analytical
estimations after Neuber are quoted for stress concentration coefficients in U-like notches with arbitrary
depth. Various statements of the contact problems for rotor under gravity and centrifugal loading were
considered in order to analyze the effect of contact interaction consideration between various rotor parts on
stressed state.
Introduction
Double rotational frequency vibration cannot be eliminated by any balancing, and the only method of its
reduction is maximum equalization of rotor stiffness in two directions. To equalize two-pole rotor stiffness
in main axes directions two methods are known and widely used: regular cross-slots (Laffoons slots) on
the rotor body poles (big teeth) or longitudinal slots on poles filled with ferromagnetic [1-7]. Both
methods have their own advantages and weak points. In the current paper turbogenerator rotor with
stiffness equalization system in the form of Laffoons slots is considered (see Figure 1).

Figure 1. Fragment of the turbogenerator rotor body with cross-slots on big teeth
System of rotor body cross-section anisotropy elimination by cross-slots suggested by US engineer more
then 60 years ago and having been used till present days is extremely easy. On the rotor body poles a
number of cross-slots is created by milling cutter of radius R (Figure 1). Bottom of the slot is made round
to lower stress concentration. Fillet radius r is commonly equal to half slot width b, i.e. slot bottom profile
is semi-circle. In some cases milling cutter can be specially cloistered to get fillet radius more then b/2.
Rarely due to lower efficiency cross-slots are created as circle segment with rectilinear bottom.
Slots depth t and distance between them (spacing) s are defined first of all from the condition of
equalization system efficiency (extent of rotor body cross-section anisotropy decrease), secondly by safety
factor in the cross-section with stress concentrator and thirdly by limitations imposed on conditions of
electromagnetic parameters invariance. Slots width is usually equal to 1020 mm, but their influence is
obviously spread on much wider zone.
One of the most urgent problems at Laffoons slots usage for stiffness equalization is stress concentration
on the slots bottom. In the current paper the results of 3D multi-variant FE structural analysis of stress
concentration zones at the bottom of cross-slots under gravity and centrifugal loading are presented.
Together with the results of finite element analysis analytical estimations after Neuber are quoted for stress
concentration coefficients in U-like notches with arbitrary depth [8]. Comparison of stress concentration
coefficients obtained with use of FE software ANSYS [9] and Neubers formulae will help to make
conclusions about analytical estimations applicability for this important class if industrial problems.
Finite element modeling and stress analysis of turbo-generator
rotor with stiffness equalization system in the form of Laffoons
slots
Statement of problem
During FE analysis two-pole turbogenerator rotor construction will be considered. 3D solid model and rotor
body cross-section are shown in Figures 2 and 3.

Figure 2. 3D solid model of the two-pole turbogenerator rotor


Figure 3. Cross section of the two-pole turbogenerator rotor body

Gravity is acting on the rotor as loading. In the zones of bearings rigid hinges constraint condition is
applied. System of loads and boundary conditions is presented in Figure 4. By virtue of homogeneity of
materials and symmetry of geometry, loadings and boundary conditions only half of the construction is
considered. To eliminate rotor rigid body displacements along longitudinal axis Oz outer point of the rotor
body was fully constrained (marked with in Figure 4).

Figure 4. Scheme of loadings and boundary conditions: a horizontal big tooth axis; b
vertical big tooth axis

It should be noted that turbogenerator rotor body is made of medium-carbon steel alloy with yield stress
2 . 0
900 MPa.
At this point and further FE models are created with use of 3D 20-node solid brick structural elements
SOLID95.
Rotor FE model (with vertical big tooth axis) and its fragment are presented in Figure 5, where NE =
71268 total number of finite elements, NDF = 741255 total number of degrees of freedom. FE model is
the case of horizontal big tooth axis is similar.

Figure 5. 3D FE model of the two-pole turbogenerator rotor (taking into account symmetry
plane Oyz)
Influence of rotor components consideration during FE analysis on
stressed and deformed state:
In order to analyze influence of various rotor components on its deformed state the hierarchical sequence of
rotor models was created: starting from the simplest and ending with maximum complete that includes all
structural elements of the rotor. Four main models of this sequence are the following: 1) model A shaft
machining, rotor body; 2) model B shaft machining, rotor body, windings, wedges; 3) model C shaft
machining, rotor body, windings, wedges, retaining and centering rings; 4) model D shaft machining,
rotor body, windings, wedges, retaining and centering rings, cross slots.
In this part of the analysis 3D contact interaction between rotor body and windings, rotor body and wedges,
wedges and windings are simulated using overall ideal conjunction (Figure 6).

Figure 6. Modeling of 3D contact interaction using overall ideal conjunction
As a result of structural analyses deflections caused by gravity in the direction of axes Ox and Oy were
obtained for each of four models. Based on the results obtained it is possible to make a conclusion that
retaining and centering rings practically do not influence the deflections value. Thus, to simplify the FE
models it is suggested not to take into account the mentioned above parts of the rotor design (retaining and
centering rings).
Contact problem
Influence of contact interaction between various parts of the rotor body under gravity and centrifugal
loadings on rotor stressed and deformed state is analyzed with use of the following problems.
3D friction contact test problem with cyclic symmetry and centrifugal
loading:
As a test problem simplified rotor construction is considered under action of centrifugal loading. Numerical
model is selected so that cyclical symmetry condition can be used. 3D FE model with cyclic symmetry and
contact surfaces are shown in Figures 7 and 8, where
4 1
friction coefficients. Characteristics of 3D
FE model are presented in Table 1.

Figure 7. 3D contact FE model with cyclic symmetry


Figure 8. Contact surfaces and friction coefficients

Table 1
Name Description
Solid element type SOLID95
3D 20-Node Structural
Solid
Contact elements type
CONTA174 &
TARGE170
3D 8-Node Surface-to-
Surface Contact, 3-D Target
Segment
Number of solid elements NE 19000
Number of contact elements NCE 17500
Number of nodes NN 112000
Number of equations NEQ 337000
Number of contact pairs NCP 5

The result of calculation, distribution of radial displacements Ur, is presented in Figure 9. One can see that
value of the solution time for this problem is too big. With the purpose of solution time reducing it was
offered to simulate 3D friction contact interaction windings and rotor body, rotor body and wedges,
windings and wedges by means of combination of free surfaces (gaps) and ideal conjunction (Figure 10).

Figure 9. Radial displacements Ur (with friction contact)


Figure 10. Modeling of 3D friction contact interaction using free surfaces (gaps) & ideal
conjunction
The performed researches proved (see Figure 11) that the suggested approach of using free surfaces (gaps)
and ideal conjunction enables to reduce solution time from 50 hours to 15 minutes. It is also possible to
conclude that in the suggested approach error in calculation of rotor body surface deflections is less than 1
% in comparison with initial model:
U
= (Ur
contact
Ur) / Ur
contact
100 % 0.5 %.

Figure 11. Radial displacements Ur (without friction contact)
3D friction contact problem. Gravitational and centrifugal loads:
In this part we carry out the comparative analysis of results obtained from the solution of the following
problems:
1) Rotor (Figure 12) under the action of gravitation and centrifugal loads taking into account 3D contact
interaction between rotor body and windings, rotor body and windings (Figure 13);

Figure 12. Solid model of the turbogenerator rotor


Figure 13. Modeling of 3D friction contact interaction (
1
,
2
friction coefficients)

2) Modeling contact by means of free surfaces (gaps) and ideal conjunction (see Figure 10) for real rotor
under gravitational and centrifugal loads.
Results (Uy displacements) of the solution of these two problems (with and without 3D friction contact
interaction) are presented in Figure 14. Difference between two solutions is:
U
= (Uy
contact
Uy) / Uy
contact
100 % 3.0 %.

Figure 14. Uy displacements: a with 3D friction contact interaction; b without 3D
friction contact interaction, using free surfaces and ideal conjunction
Graphs of Uy and Ur displacements under gravitational and centrifugal loadings are shown in Figures 15
and 16.

Figure 15. Uy displacements along lines AB, BC

Figure 16. Uy displacements along line A1B1
From the obtained results it is possible to conclude that the suggested way of contact interaction modeling
with the help of free surfaces (gaps) and ideal conjunction with a good degree of accuracy describes real
behavior of object. As the advantages of this approach one can concern simplicity of realization and, what
is most important, decrease of calculation time of problems in dozens of times.
Algorithm of rotor body bending stiffness dissymmetry
compensation:
Results of rotor structural analysis under action of gravity without Laffoons slots (i.e. before stiffness
equalization procedure) are presented in Figure 17. Deformed state of the rotor without windings is shown
for better visualization of the results. The analysis was performed for 2 directions of big tooth axis
horizontal and vertical.

Figure 17. Plot of Ux and Uy displacements in the rotor body without Laffoons slots for
horizontal (a) and vertical (b) big tooth axis
When choosing optimal criterion that characterizes rotor body stiffness anisotropy it should be noted that in
the equation of rotor transverse vibrations components exist that correspond to the difference between static
sags of the rotor in the directions of cross-section principal moments of inertia. In some papers where
discrete (1D) models of massless rotor with the disk are considered these values are called static stiffness
of the rotor in principal moments of inertia directions. In virtue of this fact it seems natural to choose
value connected with difference between static sags of the rotor (under gravity loading) to characterize
stiffness anisotropy.
As a value that characterizes non-equality of rotor body cross-section principal moments of inertia the so-
called anisotropy coefficient is generally used expressed in term of percents [1-7]:
% 100
+

=
Iy Ix
Iy Ix
. (1)
Analogous to (1), as integral characteristic of stiffness anisotropy we introduce the value proportional to the
difference of maximum (in the middle of the rotor body) static sags in the directions of cross-section
principal moments of inertia and call this value rotor stiffness anisotropy coefficient
U
:
% 100
) , inf(
max max
max max

=
Uy Ux
Uy Ux
U

. (2)
For many generators supports flexibility is such that maximum static sag in the middle of the rotor body
and support deformations are values of the same order. Thats why value of
U
coefficient for the rotor on
flexible supports can be much greater then on rigid supports. Thus to determine stiffness anisotropy
coefficient the condition of rigid (zero flexibility) supports should be added.
Consider main stages of the bending stiffness dissymmetry compensation algorithm:
Step 1. The rotor model at the first stage is analyzed without cross slots, i.e. two problems for two
directions of gravity are solved. As a result of the solution of these problems by comparison of Ux and Uy
deflections one can receive an initial dissymmetry value.
Step 2. On the second stage of research initial parameters of cross slots are chosen. Depth of saw cuts h and
step s are determined, firstly, by efficiency conditions of a compensation system (i.e. decreasing of the
dissymmetry degree). Secondly by strength conditions for the rotor body in the section with the
concentrator, and thirdly by restrictions, caused by the necessity to keep electromagnetic parameters of
generator.
The width of saw cuts b is usually equal to 020 mm; the depth of saw cuts h should be at least several
times less than diameter of the rotor body. The choice of optimum number of cross slots is characterized by
the relation of saw cuts depth h to their step s: n = h / s. For a choice of optimum number of cross slots this
relation should be less or approximately equal to 1.
Step 3. On the further steps of compensation for rotor body stiffness dissymmetry finer adjustment of cross
slots parameters is required.
During the analysis of rotor design described in the current paper the following parameters of Laffoons
slots were taken as initial (fillet radius r on the bottom of the cuts was not considered):
n = 10-16 number of slots;
s = 150-300 mm spacing (distance between slots);
t = 90-120 mm slot depth;
b = 10-20 mm slot width;
R = 250-350 mm milling cut radius.
Deformed states of the rotor under gravity loading for two positions of big tooth axis are shown in Figure
18. The analysis was performed for the following parameters of cross slots: n = 12; s = 220 mm; t = 110
mm; b = 10 mm; R = 300 mm.

Figure 18. Plot of Ux and Uy displacements in the rotor body with Laffoons slots for
horizontal (a) and vertical (b) big tooth axis
Rotor stiffness dissymmetry coefficients
U
for the rotor body without (
0
U
) and with (
L
U
) cross slots
are the following:
% . %
) Uy , Ux inf(
Uy Ux
max max
max max
U
8 8 100
0

=
,
% . %
) Uy , Ux inf(
Uy Ux
max max
max max
L
U
0 2 100

=
.
Deformed central axes of the rotor body with and without Laffoons slots are presented in Figure 19.

Figure 19. Deformed central axes of the rotor body at two positions of big tooth axis:
without Laffoons slots; b with Laffoons slots
The results presented enable to conclude that initial stiffness dissymmetry was equal to % 8 . 8
0
U
; after
application of Laffoons slots to equalize ending stiffness the dissymmetry was lowered to the value
% .
L
U
0 2
, where points to the overcompensation of the rotor.
Further procedure of the compensation was aimed to find optimal values of cross slots parameters and lead
to the following results:
Slots optimal parameters: n = 12, s = 220 mm, t = 96 mm, b = 10 mm; R = 300 mm
Stiffness anisotropy coefficient at these parameters is equal to
% .
opt L
U
1 0
.
Thus, algorithm of stiffness dissymmetry compensation is very simple, technological and efficient (low
cost). Moreover, Laffoons slots can be made on the assembled rotor. These advantages of the dissymmetry
compensation system with cross slots give it priority over others. Nevertheless, cross slots on the rotor
body poles cause a number of problems for design and exploitation, connected in general with deterioration
of electromagnetic parameters and operating characteristics [1-7].
During design and creation of Laffoons slots several structural restrictions must be considered that can
dramatically hinder their application. First of all it is structural restrictions determined by winding
characteristics of the rotor, i.e. its tooth zone size, body diameter, number of longitudinal slots with
winding. The specified parameters defined radial width of the pole (big tooth), i.e. free space for the
cross slot. Important technological restriction is the relation of mill radius and minimum size of mill
fastener construction.
In addition to mentioned the problems of quantitative evaluation of mechanical parameters of rotor
dissymmetry compensation system (i.e. the value of residual dissymmetry) and estimation of stress
concentration factor on the bottom of slots seem to be urgent at Laffoons slots design process.
Finite element modeling and analysis of 3D stressed state and
stress concentration in the Laffoons slots
The value of stress concentration factor on the bottom of cross slot is the defining parameter at evaluation
of workability of rotor body dissymmetry compensation by Laffoons slots. Until present days this value
was estimated by theoretical coefficients obtained by Neuber [8]. This approach is questionable because
Neuber considered 2D problems, but stress distribution on the bottom of the cross slot is a priori not plane.
Experimental determination of stress concentration (for example, with use of strain gages) is very difficult
task.
At present the most efficient way to analyze stress concentration in cross slots is the full-scale numerical
simulation with use of up-to-date FE software that enables to obtain maximum reliable results is a
reasonable time.
Multilevel Submodeling Method
To analyze local 3D stressed state on the bottom of Laffoons slot with use of ANSYS FE software [9] it is
necessary to apply multilevel submodeling method that is based on locality principle in composite
structures mechanics [10], developed in details in Computational Mechanics Laboratory of SPbSPU
(Russia) and successfully evaluated by solution of various complex problems of structural mechanics.
Analysis of stresses in Laffoons slots will be carried out for one of central slots where maximum bending
stresses arise.
In multilevel submodeling method after obtaining solution for macro model (on the macro level i = 0) at
every next step i (i >1) 3D problems for i-level submodels should be solved. These problems can be
problems for elastic, elasto-plastic media, contact problems, and composite structures or, at last, elasto-
plastic contact interaction of composite structures. It depends on the peculiarities of local stresses in the
zone where the correct FE solution is to be obtained. Deriving submodel of i level from (i-1)-level
submodel, it is necessary to apply kinematical boundary conditions on the submodel cut-boundary S
(i-1, i)
.
These boundary conditions are interpolated displacements obtained from the solution for (i-1)-level
submodel. Such boundary conditions bring about some edge-effect-like perturbation into stressed state of i-
level submodel, but this perturbation appears only close to the cut-boundary. If the cut-boundary is far
enough from stress concentration zone of interest there will be obligatory zone of results correlation for i-
level and (i-1)-level submodels U
(i)
U
(i-1)
. In this way with use of multilevel submodeling method correct
results can be obtained even for the problems with singular stresses.
First level submodel:
3D first and second level submodels of the rotor body zone containing Laffoons slot are created that
contain all geometrical features of the slot (see Figure 20). First level submodel (Figure 20a) is intended to
find out exactly local stressed state on the bottom of Laffoons slot. FE first level submodel has the
following characteristics: NE
s
(1)
= 63 082, NN
s
(1)
= 269 702, NDF
s
(1)
= 809 106.

Figure 20. Fragments of 3D solid models of the rotor body containing Laffoons slot first
(a) and second (b) level submodels (taking into account symmetry plane Oyz)
As a basis for 3D stressed state analysis slot with the following initial parameters was chosen: t = 110 mm;
b = 10 mm; r = 5 mm. The solution was obtained for the first level submodel in Figure 21 equivalent von
Mises stress
i
field is presented originating in the rotor under gravity loading. It can be seen that
equivalent stresses
i
dont exceed 11 MPa, while yield stress of the rotor body material is
0.2
= 900
MPa.

Figure 21. Distribution of equivalent von Mises stress
i

in the first level submodel
Multilevel submodeling:
For the detailed analysis of local stressed and deformed state of the zone with Laffoons slot the 3D second
level submodel (Figure 20b) was created. FE second level submodel (Figure 22) has the following
parameters: NE
s
(2)
= 37 558, NN
s
(2)
= 163 790, NDF
s
(2)
= 491 370.

Figure 22. FE second level submodel of the rotor body containing Laffoons slot (taking
into account symmetry plane Oyz)
Result of FE modeling field of bending stresses
z
, obtained with use of the second level submodel is
presented in Figure 23. Stress distribution along slot bottom is shown in Figure 24, where arc
coordinate along slot bottom. An important fact is noticed that when both gravity and centrifugal loading
are acting on the rotor stress values increase in many times, but character of stress distribution doesnt
change. At this point and further centrifugal loading in ANSYS was simulated by specifying angular
velocity
z
= 377s
-1
.

Figure 23. Stress
z
distribution in the second level submodel

Figure 24. Distribution of
z
and equivalent von Mises stress
i
along Laffoons slot
Comparative analysis of results obtained with use of macro model and submodels (Figure 25), shows that
on the boundaries of first- and second level submodels bending stress
z
coincide with stresses in macro
model, but every next submodel defines local stresses on the bottom of the slot more exactly. The presented
results allows to conclude that the second level submodel used to analyze stresses in Laffoons slot is
chosen correctly.

Figure 25. Plot of bending stresses
z

distribution along line GH for the macro model,
first and second level submodel
Estimation of stress concentration factors in the Laffoons slots
depending on geometry of rotor body:
Computation of stress concentration factors in the Laffoons slots was carried out both with use of ANSYS
FE software [9] and theoretical estimations. At FE simulation bending stresses in the middle of rotor body
without Laffoons slots (in the cross-section in point O) were taken as nominal (see Figure 22). As it was
said above to determine theoretical stress concentration factor K
t
(analysis of stresses on the bottom of rotor
slot) estimations made by Neuber [8] were utilized.
It was found that factors that dramatically influence stress concentrator factor value are fillet radius r on the
bottom of the slot, slot width b and spacing s. Dependence of stress concentration factor K
t
and relation of
slot depth t and spacing s is presented in Table 2 and Figure 26a. Dependences of stress concentration
factor K
t
and fillet radius r on the bottom of the slot and slot width b are analogous. Other geometrical
features of the rotor body and slots (rotor body diameter D, mill radius R and slot depth t) practically
doesnt affect stress concentration factor value being varied in wide range.

Figure 26. Dependence of stress concentration factor K
t
and relation of slot depth t and
spacing s
In Table 2 and Figure 26a K
t
, values calculated after Neuber are presented in comparison with results of FE
analysis. It follows from these results that at t/s 0.40.7 (this range of t/s value is characteristic for real
turbogenerators) stress concentration factor K
t
, calculated after Neuber gives upper estimation and its
difference with FE results is 5-8%.
Analysis of stresses in the case when rotor is loaded by centrifugal loading in addition to gravity (Figure
26b), enables one to conclude that stress concentration factors increase in 1.5 times, while maximum
bending stresses increase in 15-20 times.
Table 2
t/s K
t
ANSYS
K
t

Neuber
%
K
K - K
ANSYS
t
ANSYS
t
Neuber
t
100 =

0.37 8.48 8.84 4.2
0.39 8.27 8.7 5.2
0.46 7.79 8.34 7.1
0.50 7.59 8.12 7.0
0.55 7.38 7.87 6.6
0.61 7.03 7.59 8.0
0.73 6.69 7.09 6.0
Influence of secondary stress concentration on stresses in
Laffoons slots
Analysis of stresses on the bottom of Laffoons slots has shown that large zone exists (Figure 24) that
adjoins slot bottom where bending stresses are constantly high. For any secondary concentrator
scratches, marks, boreholes, etc. the mentioned above high stresses will be nominal and due to such surface
defects on the bottom of slot stresses can be many times as high as nominal bending stresses. To verify this
idea ANSYS was used to simulate and analyze one of ever-possible concentrators spherical depression
(radius and depth of the depression are equal to 0.5 mm, see Figure 27). Analysis of stresses in the zone of
secondary concentrator (Figure 28) confirms that in this zone abrupt increase of bending stresses (in 1.5-
2 times, see Figure 29a), so that stress concentration factor value can reach 2025 and even more (Figure
29b).

Figure 27. Submodel with secondary stress concentrator on the bottom of Laffoons slot

Figure 28. Distribution of
z
stresses near Laffoons slot containing stress concentrator
spherical depression


Figure 29. Stress concentration on the bottom of Laffoons slot containing stress
concentrator spherical depression: a bending stresses
z
distribution along slot
bottom; b stress concentration factor K
t
distribution along slot bottom
It seems quite natural that cases of fatigue damage of rotors that are described in literature [11] in Laffoons
slots can be explained by appearance of secondary concentrators and stress increased concentration. It
should be noted that the considered case of spherical depression is not the most sharp concentrator and
also it is very difficult to control appearance of such surface defects. This fact is precisely the most serious
restriction on the Laffoons slots application to compensate rotor body stiffness dissymmetry for high-
power turbogenerators. With turbogenerators power growth the rotor body length and distance between
supports are increasing what leads to the increase of maximum bending moment (in the middle of the rotor
body). If the nominal stresses in the cross-section are of order of 1520 MPa, the amplitude of stresses in
small concentrators can exceed limits and lead to the rotor damage [1].
Conclusion
In the current paper the analysis is carried out for the most frequently used in the past till the present
moment system of two-pole turbogenerator rotor body stiffness dissymmetry compensation methods of
regular cross slots creation on the rotor body poles, so-called Laffoons slots. Stiffness dissymmetry is one
of the main factors defining vibration state of the rotor during exploitation. With turbogenerators power
growth and consequent increase of sizes necessity of stiffness dissymmetry is becoming urgent.
One of the most suitable ways of the minimization of stiffness dissymmetry influence on its vibration state
is elimination of rotor body cross-sections anisotropy at every anisotropic part.
In the present work the advantages and weak points of rotor body stiffness dissymmetry compensation by
Laffoons slots, potential restrictions of its applications are pointed out. With use of FE analysis of stressed
and deformed state of the two-pole turbogenerator rotor body quantitative estimations of compensation
system efficiency were obtained. Example procedure of rotor body stiffness dissymmetry compensation is
presented with determination of residual dissymmetry coefficient and optimal parameters of the Laffoons
slots.
One of he most topical problem that should be solve at rotor design development with Laffoons slots
compensation system is stress concentration on the bottom of slots. In order to analyze this problem FE
models were created in ANSYS that enabled to analyze stresses state in the Laffoons slots and obtain
dependency of stress concentration factor on geometrical characteristics of the rotor body.
Together with multi-variant FE modeling theoretical estimation of stress concentration factors with use of
Neubers formulae was carried out. Comparison of FE and theoretical results shows that analytical
estimations are applicable with high degree of accuracy for a wide range of turbogenerator rotors
geometrical parameters variation.
Influence of secondary concentrators on the bottom of Laffoons slots on strength of rotor body is
considered and evaluated quantitatively. Such concentrators (small defects like scratches, marks, boreholes,
etc. appearing due to mechanical processing of the slots surface) are seriously restricting applicability of
Laffoons slots for rotor body stiffness dissymmetry compensation in high-power turbogenerators.
Influence of contact interaction consideration between various rotor elements is also analyzed in the current
work. The research performed showed that contact between rotor body, winding and wedges can be
simulated with high degree of accuracy with use of free surfaces (gaps) and ideal conjunction combination
what can be explained by specific loadings applied to rotor.
Finally it should be noted that all obtained results are of great practical importance and can be used at
design development of two-pole turbogenerators rotors.
References
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