4 - Discs - Chapter 4 - Rotating Discs v. 2014.11 - Lecture Notes

Muzio M.
Gola
Costruzione di macchine - Machine Design
Discs and thick walled tubes - Chapter 4
a
ol
Chapters
.g
1 Plane elastic fields
2 Elastic stresses in discs and thick-
walled tubes
m
3 Plastic stresses in thick-walled tubes
4 Rotating discs
io
uz
m
Version Muzio M. Gola - DIMEAS 1

May 2014 Politecnico di Torino - Italia
These slides are a support to the Machine Design, and related, classes held by prof. M.M. Gola at POLITO, Technical University of Torino – For educational purposes and classroom use only
Chapter 4 - Rotating discs
m.gola
2008
Index of contents
1. Constant thickness 10. Summary of disc life and
2. Variable thickness disc failure criteria
a
3. Uniform strength disc
ol
4. Stepwise profile Appendices: increasing disc
.g
approximation speed up to burst
5. Temperature and its gradient 11. Appendix 1 (movie frames)
m
6. Case study of stresses Disc only, without slots and
in a turbine disc io blades
7. Comparison between 12. Appendix 2 (movie frames)
Grammel and FEM Rotating disc with slots and
uz
8. The shape of a turbine blades
m
disc - elastic stresses 13. Appendix 3: the Hallinan

burst criterion
9. Burst design of a turbine
disc
How would you feel if this happened to you?
m.gola
2013
American Airlines
Boeing 767-200
uncontained CF6-80A
engine failure that led
to aircraft fire.
a
ol
12.30 PM, Friday,
June 2, 2006 at LAX.
.g
The aircraft was
undergoing a ground
m
run-up of the (left)
No.1 engine when the
problem occurred. The io
CF6-80A was being
tested after the crew
uz
bringing the aircraft in
from the New York
reported abnormal
m
power response
the engine duringfrom
the flight. The turbine disk exited the engine and sliced through
the aircraft belly and lodged in the outboard side of the #2 engine.
http://www.skybrary.aero/bookshelf/books/1374.pdf
1. Constant thickness (1/6)
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2008
The force per unit volume due to r

rotation is: r
 v r d  b  dr
 v   2 r radius
a
angular speed c
ol
density
which for a constant thickness disc c
.g
produces the equilibrium equation:
a
m
dr
r  r   c   2r 2  0
dr io
Now the same scheme will be
uz
applied as in Ch. 2 / Sect. 5 b
d
m

m.gola
2008
d c
r   c   r   0
dr
d c 1 d
 c  r 
a

dr E dr
ol
1 dr
 c  r   1    c   r   r   c   2r 2  0
.g
r
E dr
m
 d c dr  dr
r    1   r  (1  )2r 2  0
 dr dr  dr
io
 d d 
uz
r  c  r    (1  )2r 2
 dr dr 
2
2r
m
r   c   (1  )  A'
2

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2008
1d
r r r   A' (3  ) 2r 2
r dr 2
r  
3    2r 2  A  B
and by integration
a
8 r2
ol
d 1  3  2r 2  A  B
.g
r  r  r   c   2r 2  0 c  
dr 8 r2
h
m
Had we a (very) thin shell
io
rotating at outer, or external,
radius re , the circumferential d b
uz
stress 0 , calculated through  0bh
the radial equilibrium equation: 
m
0bh d  2re  bhre d  0  2re2

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 r   0
3    r 2  A  B 0 plays the role of a
reference stress,
8 re2 r2 incorporating tha disc
dimension and its
1  3  r 2  A  B
a
rotational speed
 c   0
ol
8 re2 r2
A  0
3    1  ri2 
.g
The integration constants are 8  re2 
found through the boundary
B   0
3    r 2
m
conditions: i
8
Di
r  r  0
2
io Which substituted in the
uz
formulas at the upper–left
De
r   r  0 corner, give expressions for
2 stresses due to the centrifugal
m
effect alone:

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2008
 r  0
3    1  Di2  Di2  D2  1
 2 2 2
8  De D De  0,8
c /0  /
c 0
3     Di2 Di2 1  3  D2 
0,6
a

c  0 1  2  2  2
3    De 
0,4
ol
8  De D r /0
0,2
r /0
.g
0
r,max at D  Di De or: D  Di 0,5 0,6 0,7 0,8 0,9 1
D / De
m
De De
Finally, radial displacement is:io
D1
 c  r  
uz
u 
2E
3    Di2 1   2 D2   
m
 Di2 
 0 D 1   1  2   1    2  
16 E   De  D 3    De 
2

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2008
In the special case of a solid disc: 0,6
c /0
A  0
3    ; B=0
0,4
a
8
r /0
ol
0,2
Then:
.g
0
 r   0
3    1  D2  0 0,25 0,5 0,75
D / De
1
m
 
8  D2e 
3     1  3  D2 

c  0
io
1 
8  3    D2e 
uz
 3   
 1   2 D2   
m
1D 
1    
 
u   c  r   0 D
2E 16 E  3    D2e 
2. Variable thickness disc (1/2)
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2008
Turbine discs seldom are made flat. They are made thicker towards
the centre, and are tapered to a smaller thickness toward the
periphery. This is to avoid the pronounced stress concentrations in
the central part.
a
ol
When a disc has a variable thickness b=b(r), the radial equilibrium
equation is:
.g
d
r r b   c b   2 r 2 b
m
dr
io
This is exactly integrable, together with
uz
compatibility and material equations, in
very few cases: the hyperbolic disc, the
m
constant stress disc. The hyperbolic disc solution is due to A.

Stodola Dampf- und Gas-Turbinen, Springer, Berlin 1924, several
editions in english as “Steam and gas turbines”, Mc Graw-Hill, NY
2. Variable thickness disc (2/2)
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2008
For all these early (pre-numerical) solutions, a large amount of

sources is available; however, the reader is urged to refer to
some of the main classical textbooks such as, for instance, the
a
one from Stodola or the one from J. P. den Hartog, Advanced
ol
Strength of Materials, Mc Graw-Hill, 1952
.g
For the case called “constant stress” or “uniform strength” solution,
let us quote from J.P. den Hartog, page 65:
m
In view of the considerable complications in the design of flat or
hyperbolic rotating disks, it is remarkable that a simple solution has
io
been found to the question of designing the thickness variation t(r)
of a disk so as to make its stresses equal over the entire area. The
uz
solution was found, about 1900, by engineers of the De Laval
Company in Sweden and was first published in Stodola famous book
m
“Steam and Gas Turbines”.

3. Uniform strength disc (1/9)
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2008
So, let us now start from the equilibrium equation:

d
r r b   c b   2 r 2 b
dr
a
The desired stress field will have
ol
1) a=0 and 2) r=constant 3) c=constant .
.g
Condition 2) implies that the disc is solid: otherwise, stress r
m
would be zero at the inner rim of a hole and should be zero over
the whole disc. io
Which proves contradictory, as shown by the equilibrium
uz
equation: a zero r would imply a non-constant c.
m

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2008
Conditions 2) 3) imply that at r

the centre, i.e., r=0, c
c c
4) r=c r
a
due to the fact that radial and c
ol
circumferential directions at the
centre are not distinguishable.
.g
m
io
uz
m

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2008
Equilibrium equation, with r=c=  (constant), produces now:

dr db
r b  r b  r r   c b   2 r 2 b
dr dr
a
=0 because r constant
ol
because r   c
.g
db 2 2 1 db  2
r    r b   r
m
dr b dr 
d  2  2 2
ln b    r  ln b   r A
dr 
io 2
uz
 2 2
 r
for r=0 b=b0 , then b  b0 e 2 
m

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2008
A disc of this type has a number of drawbacks:

1) it extends to infinity (but there is a remedy to this)
2) it does not have a central bore, and requires a special
a
coupling to the shaft, as shown on below; this is possible
ol
only with single disc turbines.
.g
m
io
uz
m

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2008
3) for the same stress there is an infinity of solutions
60
0,06
thickness
a
0,04
30
half
ol
0,02
0
0,00
0 100 200 300 radius 400 mm

0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45
.g
disc profiles with different central thickness, fixed stress:
b0= 20, 40, 60, 80 100, 120 mm, n= 104 rpm, r=7800 kg/m3
m
= 500 MPa
60
0,060
io
thickness
0,040
30
half
uz
0,020
0
0,000
00 0,05
100
0,1 0,15
200
0,2 0,25
300
0,3
radius
0,35
400 mm
0,4 0,45
m
disc profiles with different stress, fixed central thickness:

b0= 120 mm, n= 104 rpm, r=7800 kg/m3, = 500, 250, 125 MPa
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2008
The presence of blades

produces a certain stress
for a certain thickness.
a
The solution for thickness
ol
then becomes unique.
.g
Mb: mass of all blades*
re: outer rim radius
m
rb: blade mass centroid
radius io
be: outer rim thickness
rb
uz
*included “slot” attachment
on disc without circumferential
m
continuity
re
be
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2008
The centrifugal force of the blade mass

contained within angle d is:
be  d  2
 Mb   rb
a
 2 
ol
.g
m
re
io
uz
d
m

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2008
… then radial stress at the outer rim is:

d 2 1
bre  Mb  rb
2 be re d
a
area of the rim arc
ol
centrifugal acceleration
blade mass over the arc
.g
Mb 2 rb
bre    i.e. the constant stress
m
2 be re
 2 2
 r
which into: b  b0 e 2 
io However, b0 must be such that:
  b e re 2   b e re3
uz
 r 
Mb rb Mb rb
finally gives: b  b0 e r  re  be  b0 e
m

  b ere re2 r 2 
Mb rb
then : b  be e
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2008
Let us quote again from den Hartog.

The constant stress disc is the best design, if it can be applied.
(it is clear from the following that he means: it can be applied only in “single
a
disc cases”, and is subject to severe practical restrictions)
ol
For multidisk designs the constructional complications are so
.g
severe that disks with a central hole are usually applied. Then a
hyperbolic disk is better than a flat one. Flat discs are used for
m
simplicity only in cases of low rpm or low stress.
With these three general types almost all design problems can
io
be answered.
uz
… the shape can be broken up by intermediate radii into two or
more annular disks. Each of these is approximated as well as
m
possible by a hyperbola or by a flat disk, and all these disks then

are joined together by a proper boundary condition.
4. Stepwise profile approximation (1/11)
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2008
a
ol
.g
m
io
uz
m

m.gola
2008
In the detail design of high speed rotating disks, such as those

found in the compressor and turbine sections of gas turbine engines
for aircraft, today finite element models are employed to analyze
the complex shape of the disks.
a
ol
However, simplified calculation of mechanical stresses in the elastic
field is important for preliminary sizing and for cross-checking the
.g
validity of a finite element model.
To this purpose, two main methods are available, both of them easy
m
to implement with self-made software:
- the stepwise method due to Grammel*, which will be explored
io
in detail in this section
uz
- the finite-difference method proposed by Manson** in 1947
m
* GRAMMEL R., En neues Verfahren zur Berechung rotierender Scheiben. Dinglers J., 1923
** Manson, S. S. , Determination of elastic stresses in gas-turbine disks, NACA-report-871, 1947
m.gola
2008
We shall here explore only the case of disc with a central bore.
The purpose is to describe a simple numerical method, attributed to
the german scholar Grammel, which can be easily implemented on
a
an electronic sheet, and which was originally devised for manual
ol
calculations. We start with the displacements due to inner and outer
pressures, to rotation, to temperature.
.g
m
 Di2 Di2 D 2 
 2
1     2 1    1     2 1   
i
1D D De
io D 
u= 
 ri 2
  re 2 
2E D D 
1  i2 1  i2
uz

 De De 

m
u   0 D
3      D 2
D 2
1   1  i2   1    i2 

1   2
 D 2
 ; u T
 ...
16 E   De  D 3    D2e 
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2008
These are calculated at r=ri and r=re ; a matrix notation is

convenient: this term will be described later
u e   P Q   re  u e  u eT 
a
         T
 ui  R S    ri  ui  ui 
ol
calculate it with the formula of
.g
previous slide
D i2 D i2
1     2 1    2 2
m
1 De De 1 De De
P Q
2 E D i2 2 E D i2
1 2 io 1 2
De De
uz
D i2
1     2 1   
1 Di 2 1 Di De
m
R  S
2 E D i2 2 E D i2
1 2 1 2
De De
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2008
re,4
disc 4
re,3 = ri,4
a
ol
disc 3
re,2 = ri,3
.g
disc 2
m
re,1 = ri,2
io disc 1
ri,1
uz
rotation
m
axis 0
profiled disc step-wise
approximation Case with N=4 discs
m.gola
2014
The analytical model we use for the flat disc section considers
radial stress r distributed uniformly over the width b …
bk+1
a
ol
k+1
.g
r i,k 1 re,k = ri,k+1
 r e ,k
m
k … therefore the force:
io re,k bk re,k d = ri,k+1 bk+1 ri,k+1 d
is transmitted through the
uz
bk boundary surface at radius:
d re,k = ri,k+1
m
which means ne,k d = ni,k+1 d

section view side view

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2008
Two disc elements k and k+1 will then exchange, through

their contact surfaces, a total force: ni,k 1 ri,k 1d  ne ,k re ,k d
where ne,k = ni,k+1 is
bk+1
a
a “force per unit arc length”.
ol
k+1
.g
ni,k 1 ri,k 1d
re,k = ri,k+1
m
ne ,k re ,k d
k io
uz
bk
d
m
section view side view

In general k=1,2,…,N
m.gola
2008
It is then convenient to rewrite the matrix form of displacement

equations for each disc element k so that the boundary “unit
arc-length” forces appear, remember that ni,e=i,eb :
a
ue   P / bk Q / bk  ne  ue  ueT 
          T 
ol

 ui k R / bk S / bk k  ni k ui k ui k
.g
which in condensed form:
Q' ne  ~
m
ue  P' ue 
       ~ 
 ui k R ' S'  k  ni k  u i k
io
This will now be transformed into the so called “transfer form”:
uz
ue     ui      T  ui   V

m
n     n    k  k where:
 e k    
 k  i k  k ni k

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2008
P'  P'  P' ~

    Q' S'  ~
ue  ui
R'  R'  R'
1 S' 1
   ~ ui
a
R' R' R'
ol
At this point calculations are easily implemented on an electronic
.g
sheet. Starting from the innermost disc, k=1, where ni,1=0 and
ui,1= ûi,1 unknown, we can implement a numerical feed-forward
scheme:
m
u = ui,2
ûi  ue  e,1
T 1    V1   
io
 0 1 ne 1
ue,2= ui,3
uz
u u
T  2  i   V2   e 
ni 2 ne 2
m
ne,1= ni,2
ne,2= ni,3 ui  ue  … etc.
T  3    V3   
n
 i 3 ne 3
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2008
At the end, when k=N:

ui  ue  ne ,N
T N    VN     re ,N 
ni N ne N bN
a
ol
It is understood that re,N is a linear function of ûi,1 ; one
possibility, calculate it for ûi,1  0 and for ûi,1  Di,1 / 1000 .
.g
 re,N u*i,1 However we know that that
m
the blade system produces a
radial stress:
bre
io
Mb 2 rb
uz
bre 
2 bNe re
m
ûi,1 hence the displacement ui*,1

Di,1 at the inner radius.
0
ui*,1
1000
m.gola
2008
Once the displacement ui,1= ui*,1 at the inner radius is known, all:
ui  ue 
  and   can be calculated - for k=1, … ,N - as in slide 9 .
ni k ne k
a
ol
Then :
.g
ni,k ne ,k
ri,k  re ,k 
bk bk
m
and, from material constitutive equation for plane stress plus
io
circumferential strain definition, c is calculated at any radius:
uz
1
 c   c  r   T   c  E c  r  ET
E
m
u
 c  E  r  ET
r
5. Temperature and its gradient (1/7)
m.gola
2011
See Ch. 2, Sect. 5, Sl. 3. Thermal expansion adds to linear strain

(in the case of isotropic material) an equal term in all directions
i=1,2,3 :
iT    T
a
ol
.g
linear thermal
expansion temperature
coefficient increase from initial
m
or reference T0
Then the plane stress Hooke law:
io
1
 r   r  c   T
uz
E
1
 c   c  r    T
m

m.gola
2011
d c
r   c   r   0
dr
d c 1 d  dT 
 c  r   
a

dr E dr dr
ol
1 d r
.g
 c  r   1    c   r  r   r   c   0
E dr
m
 d c d r  d r  dT 
r    1   r  rE 0
 dr dr  dr dr
io
d
 c   r   E dT 
uz
dr dr (Develop as in
 dT 
d 1 d 2 
  Ch. 2 Sect. 5)
m
 r  r   E
dr  r dr  dr

m.gola
2011
This can be integrated only if the function T(r) is known.

A simple approach interpolates temperature with a polynomial:
n k
r
a
T   ak  
ol
k 0  re 
.g
In the case of tubes, where heat is transmitted by conduction
through the wall, the well known solution is:
m
r  re 
Te ln   Ti ln 
 ri  r dT  a
T 
io  a ln r  b 
 re  dr r
uz
ln 
 ri 
Te  Ti  Te ln ri  Ti ln re
m
a b
 re   re 
ln  ln 
 ri   ri 
m.gola
2011
In a numerical approach it is convenient to split the disc in smaller

elements, and interpolate linearly the temperature inside each of
them. The linear temperature interpolation produces:
a
Te  Ti
T  Ti  r  ri  ; T  T  T0 ( T0 reference temperatur e)
ol
re  ri
.g
d Te  Ti
T  
dr re  ri
m
Then the final differential equation is:
 dT 
d 1 d 2 
   Te  Ti
r  r   E
io  E

dr  r dr  dr re  ri
uz
... ...
m
2 Te  Ti r 3

r  r  E  Ar 2  B
re  ri 3

m.gola
2011
Te  Ti r B
… which gives the radial stress:  r  E A 2
re  ri 3 r
d
Applying the equilibrium r r    c  0
a
equation, stress c is obtained: dr
ol
d  Te  Ti r 2 B
 c    E  Ar  
.g
dr  re  ri 3 r
m
Te  Ti 2r B
 c  E A 2
io re  ri 3 r
uz
Boundary conditions: r  ri   r  0 r  re   r  0
m
then ….

m.gola
2011
T  Ti ri B Multiplying the first times ri2

 E e A 2 0
re  ri 3 ri
Te  Ti re B
 E A 2 0 and the second times re2 :
a
re  ri 3 re
ol
By subtraction: By subtraction:
.g
E  re2ri2 E  re2  re ri  ri2
B Te  Ti  2 2 A Te  Ti  2 2
3 3
m
re  ri re  ri
io
 E  Te  Ti  re2  reri  ri2 re2ri2 1 
 r    r  
 
uz
3 r  r r  r r  r 2
 e i  e i e i r 
 E  Te  Ti  re2  reri  ri2 re2ri2 1 
m
 c     2r  
 re  ri r 
2
 3 re  ri  re  ri

m.gola
2011
From:
1
uT  r c  r  c  r 
E
a
the displacement at diameter D, where the temperature is T :
ol
.g
 Di2 Di
 1 2 
m
*
D  Te  Ti  De De D
T
u 

1  
 2   ...
2 3 D D De
1 i  1 i
De 
io De
uz
Di2 

D2e D2e  D *
...  1      ( T  T0 )
m
2
Di D 2
1 
De 
6. Case study of stresses in a turbine disc (1/10)
m.gola
2011

A rotating disc of a turbine disc is shown
 b=48
here (grey shape)
rim
r=397
Bore radius: 220 mm
a
Outer radius at blade support: 397 mm
ol
r=388 Hub: from bore dia. to 280 mm, tapered
r=375
web
.g
b=4,5 (linear approximation) from 240 mm
Web: from 280 mm to 375 mm
 m
Rim: from 375 mm to outer dia, tapered
io
(linear approximation) up to 397 mm
hub
r=280
uz
b=20
m
r=240
r=220

m.gola
2011

The disc cross-section is here shown (grey
1 b=48
shape) together with its Grammel
rim
r=397
2 b=26,4
approximation (blue lines) in five constant
thickness rings, or annular elements
a
numbered 1 to 5.
ol
r=388
3
r=375
web
Cylindrical sections are represented by
.g
b=4,5
cylindrical rings of the same thickness.
 m
Tapered sections have a trapezoidal cross-section.
They are approximated by a cylindrical ring whose
io
b=12,1 thickness is calculated so that the total ring mass –
hub
4 i.e. volume too - is preserved.

r=280
uz
5 b=20 The thickness formula to be employed is therefore:
b  be  r  r b  2be 
b i  ri  e i  i 
m
ri  re  3 bi  be 
r=240
r=220
ri = ring inner radius bi = inner thickness

re = ring outer radius be= outer thickness
m.gola
2011
Some numerical examples will now be discussed in order to

help grasp the essential in the shaping of a disc and related
stresses towards its strength optimisation.
r 1
Data is:
a
397 b=48
375 b=26,4 n = 3646 rpm rotation speed
ol
2  = 8220 kg/m3 disc density
E = 1,74 105 MPa Young modulus (average)
.g
b=4,5
3  = 1,5 105 °C-1 thermal expansion coefficient
280
Mb = 58,30 kg total mass of blades & slots
b=12,1
m
4 Md = 33,95 kg total disc mass
b=20
220 5 r,e= 36,1 MPa outer radius tensile stress
io (blade & slot pull)
T = profile °C temperature: profile with radius
(assumed linear: diagram in slide 9)
uz
Rp0,2=profile MPa yield strength: profile with T and
radius assumed linear (diag. in slide 9).
m
Disc cooling conditions are not discussed here (see Sect. 8,

0 sl. 5, 6). Material properties are representative of those of
n INCONEL 718.
m.gola
2012
thermal disc only blades & slots only total stresses , temp. elast. limit
397 400 400 400 400
375 375 375 375
r
r(mm)
350 350 350 350
a
325 325 325 325
300 300 300 300
ol
275 275 275 275
MPa
.g
250 250 250 250
225 225 225

220 225
MPa MPa MPa MPa MPa

MPa MPa
MPa MPa °C MPa MPa
200 200 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
The diagrams above show stresses (horizontal axis) vs. r (MPa)

radius r (vertical axis); the rightmost diagrams show also
io c (MPa)
T, temperature, and Rp0,2 , the elastic limit. eq(V. Mises) (MPa)
Rp0,2 (MPa)
uz
The jumps of stresses are here left in evidence. T ( °C )
The jump in this Sect. 6, are the discrete cylinder stepwise approximation of sl. 2.
m
depends on the model discretisation, i.e., from the jump of thickness b when
passing from bk of element k to bk+1 of element k+1 (see Sect. 4 sl. 11 of this
Chapter) which, in this Sect. 6, are the discrete cylinder stepwise approximation of
sl. 2.
MPa MPa
m.gola
2012
397 400 400 400 400
375 375 375 375
r
r(mm)
350 350 350 350
a
325 325 325 325
300 300 300
ol
300
275 275 275 275

MPa
.g
250 250 250 250
225 225 225

220 225
MPa MPa MPa MPa MPa MPa MPa °C MPa MPa

200 200 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
Of course, the real disc stresses will vary over the thickness r (MPa)
in a continuous way, as in the version of the diagrams
io c (MPa)
shown above. eq(V. Mises) (MPa)
They may be obtained for r radial stresses by dividing the Rp0,2 (MPa)
uz
(radial) loads per unit length n by the real local disc T ( °C )
thickness. In this example, real thicknesses are those shown in Sect. 6 sl. 1.
m
This being done, also c (see Sect. 4 sl. 11) will vary without jumps.
This representation is preferable to the previous one, and will be used throughout
the next slides.
MPa MPa
m.gola
2013
disc only blades & slots only total stresses , temp. elast. limit
397 400
thermal 400 400 400
400
375 375 375 375
r
r(mm)
350 350 350 350
375
a
325 325 325 325
300 300 300

350
ol
300
275 275 275 275

MPa
.g
325
250 250 250 250
225 225 225

220 225

300
200 200 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
r (MPa)
275
io c (MPa)
eq(V. Mises) (MPa)
250 Rp0,2 (MPa)
uz
T ( °C )
225
Proceeding from left to right we can
m
compare the magnitudes of stresses

200 of different origin: first “thermal”
-250 0 250 stresses … …

m.gola
2013
thermal blades & slots only total stresses , temp. elast. limit
disc only
397 400 400 400 400
400
375 375 375 375
r
r(mm)
350 350 350
375 350
a
325 325 325 325
300 300 300
ol
300
350
275 275 275 275
MPa
.g
250
325 250 250 250
225 225 225

220 225

200
300 200 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
r (MPa)
275 io c (MPa)
250 Rp0,2 (MPa)
uz
T ( °C )
225
… then “disc only” stresses
m
produced by the mass of the disc

200 in the centrifugal field of
0 250 500 acceleration … …

m.gola
2013
2012
thermal disc only total stresses , temp. elast. limit

blades & slots only
397 400 400 400 400
400
375 375 375 375
r
r(mm)
350 350 350 350
375
a
325 325 325 325
300 300
350 300
ol
300
275 275 275 275

MPa
.g
250 250 325 250 250
225 225 225

220 225

200 200 300 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
r (MPa)
… then “blades 275
io c (MPa)
& slots only” eq(V. Mises) (MPa)
stresses 250 Rp0,2 (MPa)
uz
produced by the T ( °C )
mass of the 225
blades and their
m
attachments on 200
the disc 0 250 500
periphery … …
m.gola
2012
2013
397 400 total400stresses temp. elast. limit
400 400
400
375 375 375 375 … finally the total
r
stresses due to all
r(mm)
350 350 350 350
375
the single causes.
a
325 325 325 325
300 300 300

The diagram puts
into evidence shows
ol
300
350
also the
MParadial
275 275 275 275
.g
250
325 250 250 250
temperature T and
220 225 225 225 225
elastic limit Rp0,2
300
200 200 200 200 diagrams
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
r (MPa)
275
io c (MPa)
250 Rp0,2 (MPa)
uz
T ( °C )
225
m
200
0 250 500 750 1000

m.gola
2012
397 400 400 400 400
375 375 375 375
r
r(mm)
350 350 350 350
a
325 325 325 325
300 300 300
ol
300
275 275 275 275

MPa
.g
250 250 250 250
225 225 225

220 225

200 200 200 200
m
-250 0 250 0 250 500 0 250 500 0 250 500 750 1000
The stress diagrams should be analysed and commented. Some possible

questions: io
• why do the “thermal” c change sign, and why are they negative at the
uz
outer radii?
• why does r start and end zero in “thermal” and “disc only” diagrams?
• how does c compare in the “thermal”, “disc only” and “blades & slots only”
m
cases?

7. Comparison between Grammel and FEM (1/3)
m.gola
2012
Computed by D. Botto - POLITO

a
ol
.g
c [Pa] r [Pa]
m
io
uz
m
Colour maps of hoop and radial stress calculated with the finite element model
shown on the right. Next slide will show diagrams of stress values along the disc
central symmetry radius.
m.gola
2012


400 400
b=48
Grammel
rim
1 FEM
2 b=26,4
375 375
r=397
a
350 350
r=388
ol
3
r=375
web
325 325
.g
b=4,5
300 300
 m
275 275
r=280
b=12,1
hub
4
io
250 250
5 b=20
uz
225 225
r=240
r=220
200 200
m
0 250 500 750 1000 0 250 500 750 1000
Comparison of Finite Elements results (on the centre symmetry axis) and Grammel
results. Remark the differences due to modelling approximations.
m.gola
2012
a
ol
.g
r [Pa] r [Pa]

m
io
uz
Details at the rim-web transition. The rim is shown without web
Colour map of radial stress on the rim connection; the map is rescaled
area; stress gradients on the web-to- allowing to show gradients near the
m
ring connection and local shape effects. rim upper surface.

The limitation of Grammel is its being one-dimensional; FEM, on the contrary, gives
stresses in two dimensions and therefore captures all local effects due to shape.
8. The shape of a turbine disc - elastic stresses (1/8)
m.gola
2013
This Section aims at exploring which is the best shape to be given to a certain
rotating disc.
The next slide compares the disc examined so far with another one having the
same bore (inner) and rim (outer) diameter, the same total disc mass ( 33,95 kg)
a
but a different thickness distribution:
ol
• the rim is kept at the same geometry in width (constrained by blade axial width)
and in thickness
.g
• the web and the hub are given the same thickness at 7,58 mm
The stress diagrams show that it is a better idea to have a thicker hub, i.e. having
more mass at a lower radius then subjected to lower centrifugal forces and to
m
lower temperatures, reduces the maximum tensile stress, which is the
circumferential (or “hoop”) stress c at the inner radius, by the following amounts:

io
• thermal (gradient) stresses: 230 vs. 316 MPa, i.e. -86 MPa Total: 815 MPa
• disc only stresses: 173 vs. 218 MPa, i.e. -45 MPa vs. 1048 MPa, i.e.
uz
• blades & slots only stresses: 412 vs. 514 MPa, i.e. -102 MPa -233 MPa
The rationale for a thick hub is then that if more mass, and the resulting cross-
m
section area, is placed at lower radii, then it is less stressed by centrifugal forces;
it has lower circumferential stress due to its own mass and can provide an amount
of strength to take the radial pull of web, rim and blades (and connecting slots).

m.gola
2012
397 b=48 400 400 400 400
b=26,4 375 375 375 375
r
r(mm)
350 350 350 350
b=4,5
a
325 325 325 325
300 300 300
ol
300
b=12,1
275 275 275 275

MPa
.g
250 250 250 250
b=20
225 225 225
220 225

Mass 33,95 kg 200 200 200 200
m
Area 2084 mm2 -250 0 250 0 250 500 0 250 500 0 250 500 750 1000
397 b=48 400 400 400 400
b=26,4 375 375 375 375
r 350 350
io 350 350
uz
325 325 325 325
r(mm)
MPa
b=7,58
300 300 300 300
MPa
275 275 275 275
m
250 250 250 250
225 225
220 225 225
MPa MPa MPa MPa MPa MPa MPa °C MPa

Mass 33,94 kg 200 200 200 200
Area 1970 mm2 -150 0 150 300 0 250 500 0 250 500 0 250 500 750 1000

m.gola
2012
In summary, keeping the same inner radius but moving some mass toward the
centre reduces all stresses at the inner radius, “thermal”, “disc mass” and “blades &
slots mass” for three reasons:
• first - because it simply adds more area where stresses are
a
highest, i.e. at the inner radius with an important effect on
ol
maximum thermal stress, reduced from c=316 to c=230 MPa,
and on “blades & slots” stress, c=514 to c=412 MPa
.g
• second - moving mass at lower radii implies less centrifugal force
separating the “half disc” (5,182105 N in the b=20 mm hub
m
case vs. 5,404105 N with uniform thickness b=7,58 mm).
• third - at equal total volume and mass, the diametral cross-section
io
area increases when we move the mass toward lower radii (here:
2084 mm2 vs. 1970 mm2), a further advantage for c because the
uz
“half disc” sum of all centrifugal forces is spread on a larger area.
The combined effect of all these elements produces the noted c reduction from
m
1048 to 815 MPa.

m.gola
2011
b=48 b=48 b=48 The next slides explore

the effect of placing the
b=4,5 b=4,5 same mass (33,95 kg) at
b=24,60
different radii.
a
ol
b=4,5
Three geometries are
explored with increasing
.g
40
bore diameter, according

to the strategy shown on
b=22,51
m
20
b=4,5 the left: the bore radius is

io increased by 60 mm
40
steps, the web is then

b=20
shortened, and the hub
uz
20
b=20 thickness must be

(slightly) increased in
m
r=240
r=220
r=280
r=340
r=388
r=397
r=375
order to obtain the equal

total disc mass.
m.gola
2011
400 In all the diagrams that will

follow, the assumption is made
375 that the disc temperature
follows the same profile (equal
a
350
temperature at equal radius).
ol
T Rp0,2
This may be a rough
.g
325
°C MPa
assumption since cooling
300
conditions change markedly.
m
275 Here again both the real
temperature profile and yield
io
strength are approximated, for
250
uz
225
educational purposes, via a
linear interpolation.
m
200
500 600 700 800 900 1000

m.gola
2011
GE CF6-50 Of course this

High pressure turbine
cooling path assumption of
linearly varying
temperature is too
a
rough, and not
realistic, because
ol
the intentional
.g
cooling obtained
by bleeding air on
the inner part of
m
the disc cannot be
effective if the disc
io does not extend
sufficiently away
from the hottest
uz
So, in the real case, in shorter discs we should expect blade area.
temperatures higher than the ones we assume here.
m
This would bring down the values of Rp0,2 .

Please keep in mind that the subject of disc cooling needs a special expertise in
thermal numerical analysis which is not explored in these notes.
m.gola
2012
b=48 400 b=48 400 b=48 400

1
1
2
a) 1
2
b) 2
c)
375 375 375
b=24,60
3
b=4,5
3 4
3 350 350
5
350
b=4,5
b=22,51 b=13,32
a
325 325 325
4
ol
300 300 300
5
.g
275 275 275
b=12,1
4
250 250 250
b=20
m
225 225 225
200 200 200

0 250 500 750 1000 0 250 500 750 1000 0 250 500 750 1000
1:
2:
3:
b=
b=
b=
48
48
4,5
mm
mm
mm
io 1:
2:
3:
b=
b=
b=
48 mm
26,37 mm
4,5 mm
1:
2:
3:
b=
b=
b=
48,00 mm
36,37 mm
24,60 mm
4: b= 20 mm
uz
4: b= 13,32 mm 4: b= 24,60 mm
5: b= 20 mm 5: b= 22,51 mm 5: b= 24,60 mm
r (MPa) This slide shows the stepwise geometry of the three discs
illustrated in sl. 4 of this Section.
m
c (MPa)
eq(V. Mises) (MPa) Disc mass for all cases is 33,95 kg
Rp0,2 (MPa) The interplay of various thermal and centrifugal factors will
T ( °C ) become evident through careful inspection of data in next slide.
m.gola
2012
b=48 400 b=48 400 b=48 400

1
1
2
a) 1
2
b) 2
c)
375 375 375
b=24,60
3
b=4,5
3 4
3 350 350
5
350
 
b=4,5
b=22,51 b=13,32
a
325 325 325
4
ol
300 300 300
5
 
.g
275 275 275
b=12,1
4
250 250 250
b=20
m
225
  225 225
200 200 200

0 250 500 750 1000 0 250 500 750 1000 0 250 500 750 1000
max Tresca eq. stress : 815 MPa

Rp0,2 at  radius: 966 MPa
io max Tresca eq. stress : 766 MPa
max Tresca eq. stress : 702 MPa
eq. stress / Rp0,2 ratio: 0,84 eq. stress / Rp0,2 ratio: 0,82 eq. stress / Rp0,2 ratio: 0,77
uz
At point  c, due to split causes: At point  c, due to split causes: At point  c, due to split causes:
Thermal: 230 MPa Thermal: 156 MPa Thermal: 78 MPa
Disc own mass: 173 MPa Disc own mass: 182 MPa Disc own mass: 190 MPa
m
Blades & slots: 412 MPa Blades & slots: 448 MPa Blades & slots: 435 MPa
Total: 815 MPa Total: 766 MPa Total: 702 MPa
Half-disc centr. force: 5,18 105 N Half-disc centr. force: 5,49 105 N Half-disc centr. force: 5,88 105 N
Half blades & slots force: 1,38 106 N Half blades & slots force: 1,38 106 N Half blades & slots force: 1,38 106 N
Total diametral cross-section: 4169 mm2 Total diametral cross-section: 3831 mm2 Total diametral cross-section: 3532 mm2
Total mean hoop stress c: 455 MPa Total mean hoop stress c: 503 MPa Total mean hoop stress c: 556 MPa
9. Burst design of a turbine disc - plasticity (1/4)
m.gola
2012
The reason why solution a) is to be preferred to b), and b) to c) is

not evident from the elastic stress diagrams, where in fact the
maximum hoop stress c decreases slightly moving from solution a)
to c). However, remark that this is due to the lower impact of
a
thermal gradients when the disc has a lower radial extension.
ol
The semi-empirical criterion for design to burst was proposed by
.g
Robinson (1944)*, and is still used today as a rule-of-the-thumb for
design to burst. It assumes that the disk will burst when the
m
average hoop nominal stress c,m equals the tensile strength of the
material Rm. io
It is a very elementary example of plastic limit-state design.
uz
The two halves of a each kth rotating ring which composes the disc
are subjected to a separating centrifugal force Fc during rotation,
m
due to its own mass, which is easily calculated as follows:
* Robinson E., Bursting Tests of Steam-Turbine Disk Wheels., A.S.M.E. Trans., vol. 66, no. 5, July 1944,pp. 373-380;
discussion, pp. 380-38
m.gola
2012
Fc,k FFc,k
c ,k 
2 2
3

 bk re3,k  ri3,k  
● 2 2 2

  re ,k A k 1  k  k2  
a
3
ol
ri,k
re,k 2
 Mk  re ,k

4 1  k  k2 
.g
bk
3 1  k 
1_Hertz_Chapter 1_Hertz contacts 2012 XXXI
m
Fc,k: half-disc centrifugal force Ak : bk(re,k-ri,k), ring cross section area
bk : disc width M’k: half disc mass
k: ri,k/re,k , bore ratio io
uz
dr 2r (r d b dr)
centrifugal pressure :  2r dr
r d b
d
 
m
radial resul tan t : 2r dr b 2r  22r 2 b dr

r

int egral on the disc : 22 b
ri
re
r 2 dr 
2 2 3 3
3

 b re  ri 
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2012
To this, add the resultant of the tension applied by the pull of blades
and slots at the outer radius of the half rim; this tension was
evaluated for the case examined in these slides (Sect. 6 sl. 2) at:
a
r,e= 36,1 MPa
ol
Then the average hoop stress c on the two diametral cross
.g
sections is then, from simple radial equilibrium (with A  A k ): 
m
 c ,m   Fc ,k r ,e b 2re 2
   re,k Ak 1  k  k  
2 2 r ,e b re
2A 2A
io 3A A
Note that thermal stresses are eliminated by the plastic flow of the
uz
– idealised – perfectly plastic material. Then only stresses
proportional to 2 (or n2 , rpm) are into play:
m
0 ,5
 c ,m Rm  c ,m Rm  Rm 
2
 2 or 2
 2 i.e. nburst  n  

 burst n nburst   c ,m 
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2012
b=48 b=48 b=48

1
a) 1
b) 1
c)
2 2 2
b=24,60
3
n = 3646 rpm n = 3646 rpm n = 3646 rpm
b=4,5
3 4
3
2A = 4169 mm2 2A = 3831 mm2 5
2A = 3532 mm2
a
b=4,5
b=22,51 b=13,32
c,m = 455 MPa 4 c,m = 503 MPa c,m = 556 MPa
ol
Rm = 1100 MPa 5 Rm = 1100 MPa Rm = 1100 MPa
.g
nburst= 5672 rpm nburst= 5394 rpm nburst= 5127 rpm
b=12,1
4
b=20
m
5
Here the burst criterion is [Robinson 1944], as said before.

io
The comparison above is based on a representative value or
ultimate strength Rm=1100 MPa, reasonable as an average value for
uz
INCONEL 718 in the present range of temperatures. As a matter of
fact, we should take slightly lower values for cases b) and c).
m
It is clear from this simple comparison why disc a) is preferred: it

has a much larger safety margin to burst than discs b) and c).
10. Summary of disc life and failure criteria (1/6)
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Disc Life/Failure Analysis

First of all, a typical (design)
flight profile must be defined,
along with temperature
a
response calculations to
ol
determine the metal
temperatures as a function of
.g
time into the flight.
Transient and steady-state
m
temperatures are then found.
io
Disc stress analysis includes the
effects of blade loads, blade-to-
uz
disk attachments, thermal
stresses, elasticity, creep,
m
acceleration and deceleration

transients, transfer of loads
among joining elements. GE CF6-50 High pressure turbine
m.gola
2012
In detail, the following must be taken into consideration: for burst

stresses :
• the average hoop stress, checked against Rm , if the semi-
empirical criterion according to Robinson is adopted (however,
a
refinements are welcome)
ol
For thermal stresses:
.g
• in high temperature applications the transient thermal gradients
may be severe and affect the fatigue life of the component.
m
For composed rotation and thermal stresses:
• the radial stress in the web, checked against creep
io
• the total equivalent stress (composed by thermal plus rotation),
checked against yield stress in order to avoid excessive
uz
deformation which could lead to contact between blade tips and
casing elements
m
• the peak equivalent stresses - due to speed changes and

associated thermal cycles - checked against fatigue ruptures
at critical points such as fillets, disc dovetails, holes and grooves.
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2012
The critical items of an aicraft engine disc failure analysis are

connected to the particular failure mode being investigated, and to
its consequence on safety grounds.
a
Typically, the following must be considered:
ol
• Crack initiation analysis: low cycle fatigue, flight cycles to crack
initiation
.g
• Crack propagation analysis: fracture mechanics, initial defect size
and flight cycles to failure
m
• Plastic creep analysis
io
• Burst: burst speed margin
• Fragmentation patterns: number and size of fragments
uz
• Fragment energy: fragment kinetic energy available for
penetration
m

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2012
A caveat: while simplified (Grammel or

Manson) analysis is sufficient to
evaluate global stress / strain /
displacement effects (like radial creep
a
and radial elastic/plastic displacement)
ol
at a preliminary design stage, elastic
peak stress analysis can be handled,
.g
due to its highly local features, only via
a Finite Element analysis.
m
It emerges clearly the complex
interaction of factors that play a role in
io
the strength of a turbine or compressor
uz
disc; the reading proposed in the next
two slides brings some fundamental
m
aspects into the limelight. Source:

http://www.sig1.com/turbo.htm

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2012
Awareness of such a combination of problems has been growing

during the last decades, as it can be gathered by the discussion
contained in a quite obsolete however classic paper*:
Mr. B. R. Dudley, B.Sc. (Eng.) (Associate Member), and Mr. M. J. Owen
a
further wrote that while supporting the plastic design method for rotating
ol
discs there was another mode of failure which was becoming of
importance, namely, failure by fatigue due to cycles of stress associated
.g
with speed changes. The possibility of fatigue failure was obviously greater
in applications where frequent stopping and starting and variations of
m
speed occurred. Each sequence start-runstop provided one cycle of stress
with, possibly, cycles of smaller amplitude superimposed due, for example,
to speed changes from “cruise” or “idle” to maximum power.
io
In aircraft gas-turbines, particularly, high working stresses were used with
uz
high-strength alloy steels which did not have a proportionally high fatigue
limit. Consequently, a design which was safe for operation at steady speed
(whether the design be based on elastic or plastic considerations) might
m
have a fatigue life less than the probable number of cycles in its operating
life.
*Heyman J., Plastic design of rotating discs, Proceedings Institution Mechanical Engineers 1847-1996, Vol. 172 , 1958
m.gola
2012
Too little was known about fatigue, particularly under conditions of

combined stress, for it to be possible to predict the life of a complicated
component even if its elastic stress distribution were known, but designs
could frequently be greatly improved by attention to detail and avoidance
a
of unnecessary stress raisers. It was worth noting that those might be fully
operative since at running speed the stresses would normally be less than
ol
the elastic limit.
.g
It was suggested that when fatigue was worthy of consideration a wise
procedure would be to use the plastic analysis method to design the profile
of the disc and then to calculate the elastic stress distribution. The elastic
m
stress distribution should be examined in the light of fatigue data and
operating experience. Finally, the detail design should be critically
io
examined for stress raisers, particular attention being paid to changes of
section at spacing flanges, balancing rings, and similar features.
uz
m

Appendices - Increasing disc speed up to burst
m.gola
2012
Sections 11 and 12 show the frames of movies where we can see

von Mises equivalent stresses and radius increase while the disc is
subjected to an increasing rotation speed up to burst, which is here
defined as the condition when the von Mises stress reaches Re.
a
ol

R mR e 1100 MPa
.g
Material behaviour is here
oversimplified to elastic-
-ideally plastic.
m

Section 11 deals with the case of disc-only, i.e., no blades and slots
are present.
io
uz
Burst speed is predicted at 11400 rpm.
Plastic front starts at inner radius and propagates outwards.
m
Remark that in these numerical simulations yield is governed by von

Mises criterion.
11. App. 1 - Disc only, without slots and blades (1/21)
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2012
start Computed
by C. Firrone
click - POLITO
click
click
a
……
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m
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m

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burst !
a
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m

Appendices - Increasing disc speed up to burst
m.gola
2012

R mR e 1100 MPa
a

ol
Section 12 deals with the case of a disc with blades and slots, to
.g
show that this additional mass produces, in this particular case and
sue to the small thickness of the web, two plastic fronts starting
m
both at the inner radius and at the hub-web junction.
Burst is predicted at 6020 rpm. Remark that in these numerical
io
simulations yield is governed by von Mises criterion.
uz
Compare with Sect. 9 sl. 4, where Robinson criterion together with
Tresca was applied: burst was predicted there at 5672 rpm.
m

12. App. 2 - Rotating disk with slots and blades (1/22)
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2012
start Computed
by C. Firrone
click - POLITO
click
click
a
……
ol
.g
m
io
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m

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burst !
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13. Appendix 3: the Hallinan burst criterion
m.gola
2014
An alternative approach to the Robinson criterion for burst, see.

Sect.9 sl.1, is the “Hallinan criterion”, expressed by the formula*:
  R  Rm 
a
Rm
Nb  0,95 N S m
  
ol
 
   c ,avg  c ,max   c ,max 
.g
Nb = burst speed (rpm)
N = speed at which stresses are determined
m
Rm = ultimate (circumferential) strength of disk material at room temperature
c avg = average hoop (circumferential) disk stress at N rpm
io
c max = maximum hoop (circumferential) disk stress at N rpm
uz
S = empirical constant determined for the ratio of nominal
ultimate tensile strength to the notched bar ultimate
m
tensile strength
* W.N. Barack and P.A. Domas, An Improved Turbine Disk Design To Increase Reliability Of Aircraft Jet
Engines, (General Electric Co.), NASA CR-135033, 1976

4 - Discs - Chapter 4 - Rotating Discs v. 2014.11 - Lecture Notes

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Version Muzio M. Gola - DIMEAS 1

disc - elastic stresses 13. Appendix 3: the Hallinan

The force per unit volume due to r

Version Muzio M. Gola - DIMEAS 4

Version Muzio M. Gola - DIMEAS 5

0bh d  2re  bhre d  0  2re2

Version Muzio M. Gola - DIMEAS 7

r,max at D  Di De or: D  Di 0,5 0,6 0,7 0,8 0,9 1

Version Muzio M. Gola - DIMEAS 8

In the special case of a solid disc: 0,6

constant stress disc. The hyperbolic disc solution is due to A.

For all these early (pre-numerical) solutions, a large amount of

“Steam and Gas Turbines”.

Version Muzio M. Gola - DIMEAS 11

So, let us now start from the equilibrium equation:

Version Muzio M. Gola - DIMEAS 12

Conditions 2) 3) imply that at r

Version Muzio M. Gola - DIMEAS 13

Equilibrium equation, with r=c=  (constant), produces now:

Version Muzio M. Gola - DIMEAS 14

A disc of this type has a number of drawbacks:

Version Muzio M. Gola - DIMEAS 15

3) for the same stress there is an infinity of solutions

0 100 200 300 radius 400 mm

disc profiles with different stress, fixed central thickness:

The presence of blades

The centrifugal force of the blade mass

Version Muzio M. Gola - DIMEAS 18

… then radial stress at the outer rim is:

Let us quote again from den Hartog.

possible by a hyperbola or by a flat disk, and all these disks then

Version Muzio M. Gola - DIMEAS 21

In the detail design of high speed rotating disks, such as those

These are calculated at r=ri and r=re ; a matrix notation is

which means ne,k d = ni,k+1 d

Version Muzio M. Gola - DIMEAS 26

Two disc elements k and k+1 will then exchange, through

section view side view

It is then convenient to rewrite the matrix form of displacement

ue     ui      T  ui   V

Version Muzio M. Gola - DIMEAS 28

P'  P'  P' ~

At the end, when k=N:

ûi,1 hence the displacement ui*,1

See Ch. 2, Sect. 5, Sl. 3. Thermal expansion adds to linear strain

Version Muzio M. Gola - DIMEAS 32

Version Muzio M. Gola - DIMEAS 33

This can be integrated only if the function T(r) is known.

In a numerical approach it is convenient to split the disc in smaller

Version Muzio M. Gola - DIMEAS 35

Version Muzio M. Gola - DIMEAS 36

T  Ti ri B Multiplying the first times ri2

Version Muzio M. Gola - DIMEAS 37

Version Muzio M. Gola - DIMEAS 39

Cylindrical sections are represented by

4 i.e. volume too - is preserved.

ri = ring inner radius bi = inner thickness

Some numerical examples will now be discussed in order to

Disc cooling conditions are not discussed here (see Sect. 8,

375 375 375 375

300 300 300 300

225 225 225

MPa MPa MPa MPa MPa

The diagrams above show stresses (horizontal axis) vs. r (MPa)

375 375 375 375