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The pursuit of more efficient and durable gas turbines has resulted in smaller, lighter designs capable of withstanding heavy loads and extreme operating temperatures. These conditions present a major challenge to designers tasked with meeting demanding durability targets. Higher turbine flow temperatures lead to higher efficiency, but can cause design problems for the turbine blades, so cooling techniques are used to keep blade temperatures under control.
Simulations of flow over film-cooled flat plates were performed, a three-dimensional Reynolds-averaged unsteady Navier-Stokes solver has been used to simulate the blade, using the conjugate heat transfer method. An unstructured mesh approach was chosen for the initial calculations due to the difficulty of generating a structured mesh for such a complicated geometry. T-Rex technique was used to create layers of prismatic cells in the boundary layer to increase accuracy while maintaining a reasonable mesh zise. The mesh was created for both the fluid and solid domains based on the mesh size parameters determined by the mesh sensitivity studies performed earlier for the base cooling configuration. The height of the first point from the wall in the liquid was chosen so that y+ ≈ 9. The meshes had a point-to-point match at the interface between the liquid and solid domains to eliminate the error due to interpolation. The meshes contained an average of twelve million elements for the fluid and solid domains combined.
Initial results showed that the mini-trench holes (MTS) performed differently than all other optimized configurations, so further mesh study was performed to see if the original mesh parameters were still valid for the optimized geometries. The mid-span surface temperature distribution for the baseline configuration on both the initial mesh based on previously determined mesh parameters and the refined mesh. The results show some minor differences near the board edges, but very little change in the film-cooled region. Similar results were observed for the other film cooling configurations except for the MTS case. The refined meshes averaged 18 million elements for fluid and solid combined.
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