An Effect of Surface Finish and Spacing between Discs

on the Performance of Disc Turbine

 
Borate H .P & Misal N.D
Department of Mechanical Engineering, SVERIS College of Engineering, Pandharpur, Solapur, India
E-mail : boratehp@gmail.com, Ndm_2001@reddifmail.com

 
Abstract – the turbine, invented by Nikola Tesla (1856-1943), is a bladeless turbine. Tesla disc turbine and a flexible test rig have
been designed and manufactured, and experimental results are presented. An analysis of the performance and efficiency of the disc
turbine is carried out. The design philosophy of the flexible test rig has been explained.
Notice that there are no blades whatsoever – parallel, closely spaced discs used. Resistance to fluid flow between the plates results in
energy transfer to the shaft. High velocity water enters the disk pack through inlet nozzle path tangent to the outer edge of the discs.
Convergent nozzle imparts high velocity water jet tangentially on disc thickness. Lower-energy water spirals toward the central exit
port, adhesion, drag and centrifugal forces continue to convert kinetic energy to shaft rotational power.
The results of the study represent the step towards development boundary layer turbine. It has been determined that surface
roughness and spacing affects the performance of the multiple disc turbines significantly. Efficiency may be improved at least up to
45%, which has been deemed achievable by Professor Warren Rice [2].
Keywords - boundary layer Turbine, disc Turbine, bladeless, Tesla.Turbine.

 
I. INTRODUCTION flexible allowing parameters to be varied in order that
their effect on the performance of the turbine can be
When an airplane flies through the air, at very high
measured. It is possible to change the number of discs,
speed, there is a thin layer of air that sticks to the wing.
disc spacing.
This layer of air goes the same speed as the airplane.
There is then shear action or shear plane between that
II. LITERATURE REVIEW
boundary layer and the surrounding quiescent air around
the aircraft. At that shear plane is where the drag is H.S.Couto, J.B.Duarte and D.Bastos-Netto
formed that holds the aircraft back. Aerodynamic tells [1].reviews the physical principles behind the Tesla
us that if we could, wave a magic wand over an air craft Bladeless Turbine, using basic fluid mechanics only,
and, eliminate or minimize boundary layer drag the Considered the relative motion of rotating surfaces, it
aircraft could fly 40% faster or further with same sets up the transport equations describing the flow
amount of horse power. In aerodynamics, boundary drag between parallel rotating disks, estimated the boundary
layer is totally unwanted precept. But, Tesla was able to layer thickness under laminar and turbulent regimes,
turn that precept around 180degrees. Tesla perceived leading to expressions yielding the width between
that boundary layer drag used to do something useful. consecutive disks. H.S.Couto explained how to calculate
the total number of disks required to attain the desired
High velocity water enters tangentially to outer
performance. Finally also described the device behavior
periphery of the disk pack through inlet nozzle; it forms
acting as an air compressor or water pump and noticed
boundary layer on either side of discs. The pressure ratio
that the as a unit source of rotating motion, these Tesla
is pushing it towards the center of the turbine. It forms a
machines can run under a very wide spectrum of not
helical path down into the center of the device, and exit
only fuels but also fluids in general
in the center, after it has transmitted all of its energy to
the discs through the boundary layer drag. Nikola Tesla [2] has filed a patent for a Disk
Turbine which uses smooth rotating disks inside a
In this present work, A Tesla disc turbine and a
volute casing. In his patent, Tesla described the motive
flexible test rig designed and manufactured by simple
forces of his machinery as being dependant on the fluid
stock material. Experimental results carried out by using
properties of viscosity and adhesion. Several successful
water medium. The overall design of the turbine is very
 
International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Volume-2, Issue-1, 2012
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 An Effect of
o Surface Finishh and Spacing bbetween Discs on
n the Performancce of Disc Turbinne

turbines were designed and built

b by Tesla but they were Distancee between the discs, Numberr of the discs, Discs
considered not commercially y feasible at th
he time. Lack surface roughness,
r Nummber of nozzlees.
of adequate innstruments, diffficulties in han
ndling inherent
Thee following assumptions are considered foor the
speeds, and heeat dissipationn problems werre the reasons
experim
mental work.
for multiple diisk devices nott being further developed.
i) Stteady flow ii) IIncompressiblee fluid iii) neglligible
Piotr Lam
mpart [3] presented results of the design
body forrces iv) Full admission
a of working
w fluid at the
analysis of a Tesla
T bladeless turbine intennded for a co-
outer perriphery of the discs.
d
generating micro-power plaant of heat cappacity 20 kW,
which was op perated in an organic Rankiin cycle on a
low-boiling medium.
m Resullts of investigations exhibit III. THE
EROTICAL A
ANALYSIS
interesting feeatures in the t distributio
on of flow Inleet Nozzle consttruction fabricaated as shown in fig
parameters within
w the turbbine inter diskk space. The 1 for Teest Rig. Water incompressiblle fluid selecteed for
calculated flo
ow efficiency of the invesstigated Tesla performaance measuremment with assu uming flow is steady
s
turbine modelss show that thee best obtainedd solutions can flow.
be competitivee as compared d with classicall small bladed
turbines. Constant Parameters:

Warren Rice [4] esstablished moost important Spacing between Discss: 2mm Medium: Water
parameters thaat affect the peerformance andd efficiency off Disc thkk: 2mm Outlet Nozzle
N Size: 322mm2
disc turbine. However, Rice R constructed six disks Materiall of Discs: SS304 Disk Dia: 152mm m
turbine and reports
r some aspects of thhem, with the
purpose of deetermining thee feasibility off this kind off Inlet Sizze: 21mm2 No of discs: 6
turbo machineery. Starting from
f the descrription of the Surface Finish: smoothh Meedium: Water
Tesla´s paten nt, the turbbine was opperated with
compressed aira exhausting to the atmoosphere, some Flow ratte: 0.22lit/s linee Pressure: 18llb/in2
changes as th he angle of thhe nozzle and the use of a
supersonic nozzle weree made. Later, L some
improvementss were made as reducing the t gap. The
comparison between analyttical data andd results from
these experimment revealed thhat the geometry, flow rate,
and speed com mbination useed in the turbiine where not
near to those indicated by the analyses for optimum
turbine efficienncy. Rice obseerved 24% maxx efficiency.
a Warren Rice [5] have studied laminar
K.Boyd and
flow of an inccompressible fluid
f between rotating disk.
K.Boyd has proposed compplete solution of o inlet region Fig. 1 : Nozzle
N Arranggement - line diagram
d for Tesst Rig
for various inlet conditio ons. A compplete problem By applying Bernoullli’s equation,, at point1 annd at
ormulated from
statement is fo m the Naiver sttokes equation point2
with three parrameters tangenntial velocity, flow rate and
Reynolds num mber. Both the laminar and turbulent
t flow P 1 / ρ g + V 1 2 /2g + Z 1 = P 2 / ρ g + V 2 2 /2g + Z 2
considered and d suggested toorque, Power, efficiency
e and
Pressure dropp are the funcction of velocity, flow and (1)
Reynolds num mber. Where,

Most of thhe literature haas considered the

t fluid to be P1 = Pressure at point 1 V1 = velocity at pooint1
laminar and incompressiblee. In general,, it has been Z1 = Z2 Pressure headd (at same elevaation)
found that the efficiency of the
t rotor can bee very high, at P2 = Pressure at point 2 V2 = velocity at pooint 2
least equal too that achieveed by convenntional bladed
rotors. Neverthheless the Tesla turbine acceept all kind off ρ = watter density =10000kg/m g = 9.81m/s2
3

fluids, most off the literature assumed a Neewtonian fluid We know w the flow ratte i.e. Q = 0.222 lit/s=0.00021m3/s
for simplificaations except experimental test or those and P1 = 18 lb/ in2 = 1.15 bar
studies with two
t phases fluuid From the literature, we
establish the parameters
p thosse affects the performance off But, by continuity equuation.
turbine.
Q = A 1V 1 = A 2V 2 (2)

 
Internationall Journal of Appplied Research inn Mechanical Enngineering (IJAR
RME) ISSN: 22331 –5950, Volum
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 An Effect of
o Surface Finishh and Spacing bbetween Discs on
n the Performancce of Disc Turbinne

Where A2 = area
a of cross seection at pt 2 = 21 mm2 and For 6 disscs
2 2
∴ A1 = Π / 4 Χ D = 3.14 / 4 Χ 0.0152 = 0.000225m ∴ I DISCSS = 0.032 X 6 = 0.192Nmm
0 2
V 1 = Q/A1 = 0.00022 /0.0000225 = 0.98 m/s m
Now froom (6)
V 2 = Q/A 2 = 0.00022/ (22 X 10 - 6 ) = 10.448 m/s 2
I = 0.032 + 0.192 = 0..195N/mm
Now put this value of V1 an
nd V2 in equattion (1) to get
now, froom (4) & (5) L = Iω
P2. But Z1 = Z2, both the pt
p at same levvel. Now (1)
becomes. ∴ ω = mrU
m / I = (2.73 X 0.076 X 1.811 )/ 0.195

P 1 / ρ g + V 1 2 /2g = P 2 / ρ g + V 2 2 /2g ∴ ω = 199.20 rad /s Forr 6 discs

But,
P2 = [(1.15X 1005 /9810 + 0.982 /19.62)
/ - (10.482 / 19.62)]9810
ω = 2Π N / 60 (99)
= 0.47 Bar
N = 19.220 X 3.75 X 60 / 6.28 = 1883.44 rpm.
Now P = F/A
A.
We know thee value of P2 2; Put this vaalue in above Now Toorque T = F Χ R (110)
equation to gett Force acting on discs thicknness. From eqquation (3) & (110)
-6
F = P2 X A2 = 69622.74 X 20
2 X 10 = 1.532
1 N (force T = 1.5532 X 0.076 = 0.116Nmm. Now,
acting on 12m
mm area only)
P = 2 Π NT
N / 60 (
(11)
But, we know the jet force foormula from peelton turbine
By puttinng the values oof N and T, wee get
U 2 COS Ø
F = ρ A(V - U) (3) ∴ P = (66.28 X 183.44 X0.116)/60
X
2
Where, A = jeet area = A2 = 21 mm , V = velocity of jet ∴ P = 2..22 watt.
= V2, U = Rellative velocity of discs. & Ø = 10º angle off
jet.
j IV. EXP
PERIMENTA
AL SET UP
Now put the values
v in above equation to geet U Thee overall designn of the turbin
ne is very flexibble as
2 -6 shown inn fig.2, which allows varying g the parameteers, in
∴ (V - U ) = 1.532
1 /(1000 X 21 X 10 X 0.98) = 12.47
order to measure theirr effect on the performance of o the
∴ (V - U) = 8.66
8 turbine. The overall ffeatures of thiis turbine Tesst Rig
∴ U = 1.81 m//s designedd and manufacctured accordinng to the experrience
noted in the reviews.
We know the angular
a momen
ntum for rotatiing part
Thee disc diameterr is 152mm (6iin), the thickneess of
L = mrU (4) each dissc is 2mm, andd the rotor-to-housing diameetrical
clearancce is 1mm. An overall view ofo the turbine can
c be
Where L = anggular momentuum, r= radius of
o disk.
seen in Fig.
F 1(a). The discs have a 2 central outlett port,
But, L = Iω (5) since thiis configuratioon was found to
t be more effficient
by Rice [4].
ment of inertiaa & ω = Angulaar velocity
Where I = mom
In this case,
I = I SHAFT + I DISCS
D (6)

ISHAFT = MR2 Where M=

M mass of thee
shaft=1.08kg, R= Radius of shaft = 15mm. (7)
I SHAFT = 1.082 X (15/100)2 X 9.81=
9 0.0238N//mm2

IDISCS = 1/2 X Md (a2 + b2 ) (8)

Where, Md = Mass
M of disk= 0.275
0 kg, a = inner
i radius off
disc = 30mm, b= outer radiu
us of disc = 76mmm.
∴ I DISC = 1/2 X 0.275(0.0152 + 0.0762 ) = 0.0332Nm2 Fig. 2 : Parts of Multiple dissc Turbine.

 
Internationall Journal of Appplied Research inn Mechanical Enngineering (IJAR
RME) ISSN: 22331 –5950, Volum
me-2, Issue-1, 20012
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 An Effect of
o Surface Finishh and Spacing bbetween Discs on
n the Performancce of Disc Turbinne

The goal beehind the nozzzle design is too increase the In this
t study 4 vvariations in thhe number of discs
kinetic energyy of the flowing medium at the t expense off used forr same set up.. Experiments carried out 6 discs
its pressure and
a internal en nergy and thee nozzle must and spaccing 0.5mm, 11mm, 1.5mm, 2mm, 2.5mm. And
provide similaar mass flow too each disc & space. Nozzle surface finish varies ffrom smooth to t 500ra. Desiign of
designed on the
t basis of ennergy conservaation law and Experimments carried ouut in the follow
wing manner. Spiral
S
coefficient off discharge likke venturimeteer, it imparts grooves machined onn discs surfacces by using lathe
equal jet on eaach disc and du ue to its conveergent shape it machinee and fixture.
increases kinettic energy of jeet as shown in fig.3.
TAB
BLE 1 EXPERIIMENTAL DE
ESIGN MATRIIX
The diameter of this cenntral hole is 300mm. In order
to accommod date the outlett of the fluid,, the shaft is flow Spaacing Surfacce finish
supported as a boss by mean
ns of bearings in nside it + + +
- + +
+ - +
- - +
+ - -
- - -
+ + -
- + -
Flow + = 27Llit/m andd Flow - = 10.22lit/m
Spacing + = 3mm andd Spacing - = 0.5mm
0
Surface finish + =smoooth and Surface finish - = 5000ra
Fig
g. 3 : Cross Secction of Test Rig
R A. Determination of Speed of the Rotor.
R
The experrimental test riig is designed to investigate In thhe test rig usedd in this research, the speed output
o
performance of o Turbine is shown in Fig.4.The test rig (N) can be obtained diirectly by meaans of a Taco Meter.M
used in the preesent research work consistss of 3 cylinder The metthodology for tthe use of this device is simpple. At
piston pump. Rubber O-ringgs are also proovided for air the bothh end the shaft centering operration done whhich is
ween casing annd side plate. The
tight joint betw T shaft with provision to insert a tipp of Taco Meteer. This method was
disk supportedd on two bearinngs. found too be accuratee and inexpennsive. Then anngular
In previou
us studies air medium weree used, but in velocity obtained by ussing formula.
this present work
w we usedd water mediium. And for ω = 2 Π N / 60 (122)
constant flow rate and to provide
p high-p
pressure water
we used positiive displacemeent pump as shhown in fig.4. Usinng the flexibillity for changing parameters that
A test rig devveloped in succh way that it measures the the turbrbine used inn these investigation peermits,
various parammeters that are necessary to determine the variationns in the numbber of discs to obtain Performmance
performance the Turbine. Flow rate vaary from the comparisons data. In thhis present wo ork five variatioons in
10Lit/m to 27llit/m. discs spacing and threee variations in n surface rougghness
considerred to carry out experimeent. Same connstant
parameteers as consiidered in thheoretical anaalysis.
Variablee parameters arre the flow, spacing betweenn discs
and surfface finish of thhe discs.

V. RES
SULT AND DISCUSSION
D
Nozzzle size desiggned in such wayw that it immparts
equal fo
orce on each diisc for minimuum spacing andd also
maximuum spacing bettween the disccs. After conduucting
the experiments as pper matrix, we noticed thaat this
turbine working efficciently for sixx discs. Due to t the
2
nozzle opening,
o for thhree discs jet imparted on 6mm
6
areas onnly and for six discs jet area imparted on 122mm2
Fig.
F 4 : Experimental Set up. area means
m 6 discc pack use more jet forces f
 
Internationall Journal of Appplied Research inn Mechanical Enngineering (IJAR
RME) ISSN: 22331 –5950, Volum
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 An Effect of Surface Finish and Spacing between Discs on the Performance of Disc Turbine
comparatively three discs. Then all the experiments
carried out for six disc and by varying spacing like 0mm
.05mm, 1mm, 1.5mm, 2mm, 2.5mm
Fig 5a & 5b shows the variation of speed with
respective flow. As flow increases speed increases. But
spacing increases speed decreases, because for
minimum spacing friction or shear force between jet and
disc increases, rotating disc form a boundary layer
around the wall and jet also form boundary around it. Jet
high velocity boundary layer drags the discs. Disc
rotating comparatively low speed hence disc trying to
oppose jet velocity. Due to this shear forces developed
between two boundary layers. And Kinetic energy of jet
utilized for disc rotation.
Fig.5a : A plot of Flow v/s Speed for 6 smooth discs and
2.5mm spacing
For 2.5 mm spacing, more amount of jet water
passing through the gap comparatively 0.5mm spacing,
boundary layer forms between discs, but jet boundary
layer and disc boundary layer apart from each other. Jet
uses the maximum kinetic energy to carry the fluid
between discs. And flow rate difference is also observed
at the outlet. For minimum spacing flow rate is
comparatively less than maximum spacing.
For 0.5 mm spacing, boundary layer forms between
discs, but jet boundary layer and disc boundary layer
overlap with each other. Jet uses the maximum kinetic
energy to drag discs.
Fig. 5b : A plot of Flow v/s Speed for 6 smooth discs and
0.5mm spacing
International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Volume-2, Issue-1, 2012
34 
Fig.6 shows the speed variation with respective
flow, Here 6 rough (spiral grooves) discs used with
2mm spacing. From these readings plot, we observed
that the experimental curve closer to the theoretical
curve, actually theoretical curve plot by considering
impulse force only but existence of friction force or drag
force due to boundary layer effect difference found for
three various conditions as shown in fig 5 & 6.
Spiral grooves on discs surfaces machined in such
way that once jet enters the groove it follows the spiral
path and exists thru central port. During rotation of discs
centripetal force also exist which act inward to outward
and that opposes to jet to come rapidly at the central port
and due to this jet passes thru long spiral path and
kinetic energy of jet utilized to drag the discs
Fig. 6 : A plot of Flow v/s speed for 6 Rough discs and
0.5mm spacing
A. Output torque, power and efficiency
Torque on the shaft measured by Prony Break
dynamometer. The methodology for the use of this
device is simple. Essentially the measurement is made
by wrapping a belt around the output shaft of the unit
and measuring the force transferred to the belt through
friction. The friction is increased by tightening the belt
until the frequency of rotation of the shaft is reduced. In
its simplest form an engine is connected to a rotating
drum by means of an output shaft. A friction band is
wrapped. Around half the drum's circumference and
each end attached to a separate spring balance. A
substantial pre-load is then applied to the ends of the
band, so that each spring balance has an initial and
identical reading. When the engine is starting the
frictional force between the drum and the band will
increase the force reading on one balance and decrease it
on the other. The difference between the two readings is
used to calculate torque, because the radius of the driven
drum is known. Once we knew the spring balance we
can determine the torque by equation.
 An Effect of Surface Finish and Spacing between Discs on the Performance of Disc Turbine

T = (D + tb) X 9.81 X S (13) Rotor speed increases with number of discs up to a

Where, D = Drum Dia., tb = Belt thickness,
S = Spring Balance
Then the Output Power calculated by P = 2∏NT / 60
First, confirm that you have the correct template for
your paper size. This template has been tailored for
output on the
certain level due to increasing area of contact of jet
water and wall and it leads to the increase in friction
force and boundary layer effect.
For wide spacing between the discs it works as
impulse turbine only.
For appropriate spacing between discs it works with
impulse force and also boundary layer effect. For
minimum spacing equipment vibration also increases for
high speed compare to maximum gap, Hence vibration
analysis became important factor.
Present experiments showed that the losses
occurring in the nozzle are large and hence this needs to
be tackled for improving the overall efficiency of the
Tesla disc turbine.
Experimental work shows that the efficiency of disc
turbine may be increased by 5 to 6% by using spiral
groove discs (Rough discs).

Fig.7 : A plot of flow v/s Power at various flow rates for A. Suggestion for Future Work
six discs and 05mm spacing. Some of the following topics would be interesting
To determine the efficiency, we have to determine I/P for further investigation.
power [10]. By the following formula In a future study, it will be interesting to analyze the
Input Power = PI/P = ρ g Q h (14) influence of the inlet nozzle numbers and positions .The
influence of the disc holes and the outlet nozzle size
Where, ρ = Densityof water, Q = flow of fluid m3/s , must be also analyzed.
h = Watercolumnheight.
Influence of the composite material for discs on the
and ρ g = γ turbine performance.
But, Pline = γ x h (15)
Compressible analysis of the multiple disc turbines
Where, Pline = static Pressure
PI/P = Pline X Q (16) REFERENCES
HydraulicEfficiency= Power O/P / Power I/P (17)
[1] H.S.Couto, J.B.F. Duarte and D. Bastos-
By considering one case for sample calculations of Netto,Tesla Turbine Revisit, Department of
efficiency. Mechanical Engineering, 8th Asia-Pacific
International Symposium on Combustion and
∴ Q = 0.22lit/s = 2.2 X 10 - 4 m 3 /s Energy Utilization, October 2006, Sochi, Russian
Federation
Pline = 0.47 bar = 3238.3N/mm2
[2] N Tesla, Tesla turbine, United States Patent, May
Hydraulic Efficiency = 2.2 X 10 - 4 X 3238.3 = 7.1% 1913.

VI. CONCLUSIONS [3] Piotr Lampart and Krzysztof Kosowski. Design

Study and analysis of this work come to conclusion
that Number of discs, spacing between discs and surface
finish of discs affects the performance of turbine
significantly
This work was carried out to study performance of
disc turbine operating on water medium, however
previous studies and experimentation carried out with
air and steam medium.
analysis of Tesla micro-turbine operating on a
low-boiling medium, Polish Maritime
Research, Special issue 2009S1; pp. 28-33.
[4] W.Rice, An Analytical and Experimental
Investigation of Multiple- series A, Vol. 87,
No. 1 Jan. 1965, pp. 29-36 Disk Turbines,
Journal of Engineering for Power, Trans. ASME.
[5] K.Boyd and W. Rice, Laminar inward flow of an
incompressible fluid between rotating disk, with

 
International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Volume-2, Issue-1, 2012
35 
 
 An Effect of Surface Finish and Spacing between Discs on the Performance of Disc Turbine

full Peripheral Admission, Journal of Applied

[9] P.N.Modi and S.M.Seth. Hydralics and Fluid
Mechanics, June 1968, pp. 229-237.
Mechnics including Hydralic Machines. HFM
[6] N.Huybrechts, Numerical Study of a Tesla Publication, Fifth Edition 2005, pp.221, 284-289,
Turbine, Free University of Brussels, Applied 915-973.
Mechanics Department.
[10] K. Sheshagiri Hebbar, K.Sridhara and P. A.
[7] F.William Beans, Investigation into the Paranjpe. 1970, Performance of Conical Jet
Performance characteristics of a Friction Nozzles in Terms of Discharge Coefficient,
Turbine Flow, Journal of Space Craft, Vol. 3, Journal of the Aeronautical Society of India, Vol.
No. 1, January 1966, pp. 131-134. 22, No 1, pp.3-9
[8] L.Matsch, and W.Rice. Flow at low Reynolds
number with partial admission between rotating
disk. Journal of Applied Mechanics, Vol. 35,
Trans. ASME, Vol. 90 series E, March 1968. pp. ”””
768-770.

 
International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Volume-2, Issue-1, 2012
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