Progresses in conjugate heat transfer simulation method provide a new approach for turbine blade cooling design. The procedure of air-cooled blade design introduced in this paper consists of two levels, a schematic design using 1D flow network calculation method, and a detailed design based on CFX conjugate heat transfer simulation.
The program platform for the design method was developed, including an air-cooled blade design program, a 1D cooling structure flow network solver, and conjugate mesh generation tools for air-cooled blade.
The design platform contains parametric methods for blade profile, cooling channel, and various cooling structures. The key parametric algorithm named Element Design Method was invented and introduced, which brings about parametric design for complex cooling channel, and accelerates the calculation model generation during the schematic design and detailed design.
The flow network solver for schematic design consists of a pressure solving program, a temperature solving program, and a film cooling solving program. The pressure solving program uses linear method to solve the momentum equation, so higher stability of the flow network solver can be achieved. In detailed design, CFD pre-treatment using the commercial software is time-consuming. The mesh generation tools, combined with parametric design programs, can automatically create hexahedron/mixed mesh for turbine cascade and cooling structures with considerable speed and quality, which significantly reduces the difficulty of pre-treatment during detailed design.