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An iterative process modifying the turbine geometry was followed with the main aim to reduce Von Mises stress below 540 MPa on it. The reason is to obtain sufficient margin of error considering a safety factor of 1.4 respecting the Yield strength of the rotor material at 760°C which is over the maximum temperature (730°C) on the tip of the blades. To achieve this goal several attempts were made to obtain the stress results lower than the required stress limit. The main ways to achieve this objective are to scallop the back face of the rotor and introducing fillets on the roots of the blades and the at the shaft root at the back face of the turbine as shown in figure 18 and 19, also, material has been removed from the turbine back face as appears in figure 19 (the red line shows the back face profile before cutting material). Figure 18: Rotor geometry after scalloping and introducing the fillet to roots of the blades. Figure 19: A section of the rotor showing the material removal from its back face. The mesh used in the FEA contains 2284103 nodes and 1534875 elements. A view of the mesh is shown in figure 20. A rotational speed of 140000 rpm was used instead of 130000 rpm, which is the design point speed, as a safety practice for an off-design case. Also, a cylindrical support fixing radial, tangential and axial movements in the threaded hole 18PDF Image | Optimised Radial Turbine Design D1.8
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