This paper presents a study on a small centrifugal impeller for microturbine application from a manufacturing perspective. The aim is to analyze the impact of geometric deviations on part performance using adequate performance modeling tools and statistical methods. A one-dimensional (ID) performance analysis tool was developed in-house derived from the meanline and two-zone modeling methods. The ID model proved to be a simple and computationally inexpensive tool for having a quick performance analysis of the impeller using basic geometric information extracted from part drawings. For the sensitivity analysis, a total of eight input geometric parameters, including radii, tip-clearance, and blade angles, were varied individually within specific limits in the ID tool for classifying their influence on the output performance. Since the ID model is a simplifled version of a much more complex three-dimensional (3D) model, a commercial computational fluid dynamics (CFD) tool was used to provide a comparison with the ID model and scrutinize the effects of such deviations on the fluid behavior inside the impeller passage at a detailed level. For uncertainty quantiflcation, Monte Carlo simulation was performed using the ID model to assess the variability of overall impeller output performance to simultaneous random deviations in the input geometric parameters. The study is useful to evaluate the possibility of designing gas turbine parts for manufacturability and superior production cost-effectiveness.Ohjective. Small-scale turbomachinery experience low Reynolds number effects resulting in increased viscous losses, manufacturing difficulties, and large heat transfer between the hot and cold components. Performance is influenced by all the three factors mentioned above. Furthermore, these factors are themselves subjective to design of the components comprising the turbomachine module. Thus, it can be rightfully stated that component designs influence the aerothermodynamics and manufacturing tolerances of a turbomachine, consequently impacting the performance as illustrated in Fig. 1.Performance is primarily associated to the impeller in a centrifugal compressor [5]. Therefore, focus was given to the impeller only. Study carried out in this paper follows a special route where the performance sensitivity of an on hand centrifugal compressor impeller is scrutinized by employing selective deviations to the design using various analysis tools in order to understand the relationship between component geometry, module performance, and manufacturing tolerances. The main objectives of the study are, thus, to develop design expertise for small-scale centrifugal compressors and to study the impact of manufacturing noise on component and module performances.
MethodologyA simple methodology was devised to carry out this complicated task because of the level of uncertainty owing to the
Journal of Engineering for Gas Turbines and Power