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Table 1: ORC unit modelling conditions Table 2: Preliminary design parameters for the air and ORC turbines O = Lmin Dmax Tmax = if τmax ≤ 25 O Iman = 4 +Tmax +Tav (2) if τav ≤ 20 (3) {τmax 25 1 ◦ if τmax > 25◦ {τav Tav = 20 1 ◦ if τav > 20◦ The parameter O is the overhang indicator, expressing the minimum tool overhang required to machine the blades. This parameter covers the flexion problem caused by the use of thin, long tools. The parameter Tmax is the indicator of the maximum blade twist τmax, and Tav is the indicator of the average blade twist τav. The twist is defined as the difference in the angles of the hub and shroud normals along the same rule. Both τmax and τav are related to the geometrical interferences arising in flank-milling ruled, twisted surfaces. A value of Iman in the order of magnitude of 3 indicates a high machining effort due to tool/workpiece flexion and geometrical errors while a low value, in the order of magnitude of 1, indicates that the aforementioned sources of machining difficulty do not affect the actual machining process. 2.3 Case studies This work employed two case studies, which were used to assess the change in efficiency and manufac- turability of the turbine geometry. The first case study is a high-pressure ratio turbine operating with air and described by Jones (1996) and Sauret (2012). The second test case is an ORC turbine, whose boundary conditions come from the ORC system opti- mization using the model by Andreasen et al. (2014), which was validated for pure fluids within 3.27 % by comparison with similar results in the literature. Table 1 lists the conditions considered for the design of the ORC system. A heat source, represented by a thermal oil loop, is cooled from 260 ◦C to 220 ◦C and powers the ORC systems. A maximum limit of 4.5 in the turbine pressure ratio was imposed to avoid 5th International Seminar on ORC Power Systems, September 9-11, 2019, Athens, Greece Zs ηts W ̇ kW 121 6.55 Paper ID: 57, Page 3 Parameter Hot fluid Hot fluid Tin Hot fluid Tout Hot fluid m ̇ Boiler pinch point Condenser fluid Condenser Tin Condenser ∆T Condenser pinch point Turbine P Rmax Turbine ηmec Pump ηis Pump ηmec Value thermal oil 260 ◦C 220 ◦C 0.7548 kg/s 10 ◦C water 40 ◦C 5 ◦C 5 ◦C 4.5 0.97 0.7 0.97 Parameter m ̇ T01 p01 p6 U/C0 N r6s /r4 r6h /r6s Ris Zr Units Air kg/s 0.33 Novec 649 0.5640 388.4 - rpm - - - - - - A turbine impeller is nowadays manufactured using five-axis machining, where flank milling is the pre- ferred process to cut the production costs. Chaves-Jacob et al. (2011) explained that the two main manu- facturing difficulties in flow passage roughing and flank milling are the flexion of the tool and workpiece, and the geometric tool path error. The former difficulty is due to to the blade forces generated between the tool and workpiece while the latter is produced by the interference between the tool and the surface and is related to the twist of the intrados and extrados of the blades. This work employs the manufacturability indicator proposed by Chaves-Jacob et al. (2011), which aims to relate the impeller manufacturability to the two aforementioned problems via key geometrical indicators. The manufacturability indicator is defined as follows: K 1056.5 kPa 580.4 450 kPa 94.7 100 0.692 0.7 106588 31302 0.632 0.665 0.413 0.444 0.56 0.58 16 14 19 17 0.851 0.845 2.2 Estimation of the turbine manufacturabilityPDF Image | RADIAL-INFLOW TURBINES FOR ORGANIC RANKINE CYCLE POWER
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