Numerical study of fracture mechanics on a

rotating shaft
Lausanne, March 2011
Felipe Antônio Carreirinha Mendes

Marcelo Henrique Barbosa

Objectives:

Study of fracture mechanics on a rotating shaft.

Problem description:

A welded was made in a high stress concentration region (near the flange of a
hydraulic turbine shaft), in which two problems were detected: some inclusions on this
welding (length of 1 mm) and the hardness is smaller than the material of the shaft (A – 668
cl. E σy = 295 MPa ; σr = 485 MPa ).

Figure 1 – Problem geometry

To study these defects on the shaft two hypotheses are proposed: 1) to model the
main inclusions as cracks and study the shaft viability; 2) to study the fatigue life considering
these inclusions.

Loads on the shaft:

1 - Synchronism

Nominal power: 217,14 MW

Speed rotation: 90 RPM
 Applied torque: 23040 kN.m

Axial force: 7697 kN

Nominal power – 30%: 152 MW

Speed rotation: 90 RPM

Applied torque: 16128 kN.m

Axial force: 7697 kN

Cycle variants: - 1 start day

- Power variation day (10cycle/day)

- Power variation in each cycle ± 2,5%

Variação de potência

2 – Load rejection
Speed rotation: 153 RPM

Applied torque: 0 kN.m

Axial force: 9767 kN

Cycle variants: - 1 ocurrence/week

3 – Runaway

Speed rotation: 183 RPM

Applied torque: 0 kN.m

Axial force: 9767 KN

 Cycle variants: - 1 occurrence/ 10 years

4 – Out of phase 120º

Speed rotation: 90 RPM

Applied torque: 11112 kN.m

Axial force: 7697 kN

Cycle variants: - 1 occurrence/1 month

5 – Short circuit

Speed rotation: 90 RPM

Applied torque: 32663 kN.m

Axial force: 7697 kN

Cycle variants: - 1 occurrence/10 years