Fluid Flow Simulation Study of Tesla Turbine Power

Performance

A Project Study Presented to the Faculty of the Department of Mechanical

Engineering Xavier University – Ateneo de Cagayan

In Partial Fulfillment of the Requirements for the Degree of Bachelor

of Science in Mechanical Engineering

Jesse Jose Cruz

Pete Lemuel Nasol
Johpit Vincent Opalla
Vince Rae Raguro
Robin Nicolo Tagle

May 2022
 APPROVAL SHEET

This project study entitled Fluid Flow Simulation Study of Tesla Turbine Power
Performance, prepared and submitted by Jesse Jose Cruz, Pete Lemuel Nasol, Johpit
Vincent Opalla, Vince Rae Raguro, Robin Nicolo Tagle in partial fulfillment of the
requirements for the degree of Bachelor of Science in Mechanical Engineering has
been examined, accepted and passed for oral examination.

DR. ELMER B. DOLLERA, PME

Chairperson. ME Department

PANEL OF EXAMINERS

Approved by the Committee on Oral Examination with the grade of .

ENGR. YURI G. MELLIZA ENGR. NESTOR G. IPANAG, PME

Member Member

ENGR. CARLO DELA CRUZ DR. ROGELIO GOLEZ JR., PME

Member Member

DR. ELMER B. DOLLERA, PME

Chairperson | ME Department

Accepted and approved in partial Fulfillment of the Requirements for the Degree of
Bachelor of Science in Mechanical Engineering.

DR. ELMER B. DOLLERA, PME DR. HERCULES R. CASCON

Chairman Dean
Mechanical Engineering Department College of Engineering
 Acknowledgement

The completion of this undertaking could not have been possible without the
participation and assistance of the following individuals:

To our esteemed research adviser, Dr. Rogelio Golez Jr.,PME for guiding us and
providing us the necessary assets to finish this whole venture. The researchers were
able to design and simulate this innovation all thanks to him sharing his vast knowledge
and ideas on the field of mechanical engineering, especially on renewable energy
resources.

Special thanks to the Nasol family for giving us warm accommodation by

providing us refuge at their residence throughout this study process.

Thanks are also due to our family for supporting and providing us the essential
necessities for completing this study as well as to our colleagues for being with us,
whose contributions are sincerely appreciated and acknowledged.

All of this would not be possible without the guidance, enlightenment, and
blessing of the ever Almighty Being above, this research’s achievement and completion
was served to him, all for glorifying his name.
 TABLE OF CONTENTS

ABSTRACT…………………………………………………………………………………….1
CHAPTER 1 - INTRODUCTION
1.1 BACKGROUND……………………………………………………………………2
1.2 STATEMENT OF THE PROBLEM……………………………………………….3
1.3 SCOPE AND LIMITATIONS OF THE STUDY………………………………….4
1.4 AIM…………………………………………………………………………………..4
1.5 OBJECTIVES………………………………………………………………………5
1.6 SIGNIFICANCE OF THE STUDY………………………………………………..6
1.7 THEORETICAL FRAMEWORK……………………………………………….....6
1.8 CONCEPTUAL FRAMEWORK…………………………………………………..9
CHAPTER 2 - REVIEW OF RELATED LITERATURE
2.1 RENEWABLE ENERGY………………………………………………………....10
2.2 ENGINES AND TURBINES……………………………………………………..10
2.3 FISH FIN VS WITHOUT FISH FIN……………………………………………..12
2.4 TESLA TURBINE…………………………………………………………………20
2.5 EFFICIENCY………………………………………………………………………21
2.6 ADVANTAGES AND DEVELOPMENTS……………………………………….22
CHAPTER 3 - METHODOLOGY
3.1 RESEARCH DESIGN…………………………………………………………….26
3.2 RESEARCH INSTRUMENTS……………………………………………………26
3.3 DATA GATHERING PROCEDURE……………………………………………..27
3.4 TURBINE DESIGN MODEL………………………………………….………….28
3.5 SIMULATION PARAMETERS…………………………………………………...32
CHAPTER 4 - OBJECTIVE’S SOLUTIONS
4.1 GENERAL OBJECTIVE………………………………………………………….33
4.2 SPECIFIC OBJECTIVES………………………………………………………...34
4.3 DATA AND RESULTS…………………………………………………………….35
4.4 POWER AND EFFICIENCY CALCULATIONS………………………………...36
 4.5 STRESS SIMULATION…………………………………………………………..38
4.6 FLUID SIMULATION ANALYSIS………………………………………………..41
4.7 ANALYSIS AND DISCUSSION………………………………………………....48
CHAPTER 5 - CONCLUSION
5.1 CONCLUSION…………………………………………………………………….49
5.2 RECOMMENDATION…………………………………………………………….50
BIBLIOGRAPHY………………………………………………………………………………51

APPENDIX A…………….…………………………………………………………………….55
APPENDIX B…………….…………………………………………………………………….57
APPENDIX C…………….…………………………………………………………………….60
APPENDIX D…………….…………………………………………………………………….62
 ABSTRACT

Modifications and improvements are gradually being made towards tesla turbines,

machines that harness energy from flowing fluid into electrical energy in order to further

meet this end. However, this design causes weak friction that does not create very high

torque, making the Tesla turbine relatively inefficient for high torque applications such as

power generation. The addition of fish fins on the turbine blade may help the Tesla

turbine by allowing increased friction and torque, generating more energy overall. The

focal point of this paper is on tesla turbine performance and efficiency through a

simulation and design software, with the presence of fish fins. The turbine model was

designed using Fusion360 and AutoCAD software and simulated for Fluid Flow

performance using Autodesk CFD and ANSYS simulation software. The turbine’s stress

analysis, namely its deformation and shear stress, was also obtained using ANSYS

software. The stress analysis shows that the region of stress occurs primarily on the

outer edges of the turbine. Stress generated on the edges of the disc increases with the

increase in disc RPM. Also, force acting parallel to the area of the turbine would induce

shear stress and lead to deformation which is likely to increase due to proportionality.

After further calculations based on the fluid flow simulation findings, the results show an

output power of 6.598 kW and an efficiency of 43.58%. Through the use of Fish fins, the

turbine produces more output power and an efficiency increase of about 4%.

Keywords: Tesla turbine; Fish Fin Tesla Turbine; Disc; Simulation; Renewable energy;

CFD (Computational Fluid Dynamics).

1
 CHAPTER 1

INTRODUCTION

1.1 BACKGROUND

Many in our world today have adapted and innovated to the use of renewable

energy. Since the source of energy became less and less reliant on non-renewables

such as fossil fuels, which in the future may and will run out, we’ve seen drastic

improvements have been made in the field of natural and renewable energy sources.

Solar power, nuclear energy, hydropower, wind power and to an extent, wind and hydro

power, a lot has been said and done and as the world’s technology advances so does

its advancements in our renewable energy sources.

Renewable Energy is better, safer, cleaner and can never run out. The less use

of nonrenewable resources and more of renewable resources has also proved to be

better for the environment, the climate and for the people.

The Tesla turbine was invented by Nikola Tesla in 1904 and patented in 1913. A

bladeless turbine is another name for this type of turbine. Because it uses the boundary

layer effect rather than a fluid impinging on the blades, the Tesla Turbine is also known

as the boundary layer turbine, cohesion-type turbine, and Prandtl layer turbine, named

after Ludwig Prandtl.

Tesla-style drag turbines with many disks rely on an energy transfer mechanism.

Each disk's exhaust holes are positioned as close to the central shaft as practicable. A

turbine casing surrounds the disks, with a flow pressure port at each disk's exhaust

2
holes and a high-pressure nozzle positioned at the outside edges and targeted at the

gaps between each disk.The turbine rotor is made up of a series of flat, parallel disks

mounted on a shaft with a short gap between them, which serve as cylindrical micro

channels via which fluid velocity is delivered to the rotor.[1]

The Fish Fin Tesla Turbine works on the principle of boundary layer flow of the

Tesla turbine and the impulse force generated through its blade. Its major purpose is to

reduce mechanical losses and improve performance. High efficiency in a Tesla turbine

is difficult to achieve because there exist problems such as high head and insufficient

torque. In contrast, a hybrid Tesla turbine generates more torque and can operate under

more realistic conditions. Both simulation and analysis yield comparable results.

Fish Fin Tesla Turbine

This research focuses on a Tesla turbine in the shape of a disc turbine with Fish

fins assimilated between discs to increase fluid flow. The fluid's rotational motion is

turned into mechanical energy, which, thanks to the fish fin design, improves fluid flow

inside the turbine, providing more torque and hence more power and rpm.

1.2 STATEMENT OF THE PROBLEM

Despite the interesting concept of the development and application of a bladeless

turbine, the design itself has not been widely used or further developed due to the

disadvantage of having to rely on friction interaction between a smooth surface and a

3
fluid. This design causes weak friction that does not create very high torque, making the

Tesla turbine relatively inefficient for high torque applications such as power generation.

The Hybrid Tesla Turbines have proven to be more efficient and have lower mechanical

losses than a conventional tesla turbine. It is also more stable and more efficient with

higher heads and torque. However, the incorporation of the Fish fin design on the discs

can further enable the turbine to perform at higher efficiency by allowing more friction

and torque, thus generating more energy overall.

1.3 SCOPE AND LIMITATIONS OF THE STUDY

The scope of the study is limited to the Fish Fin turbine’s fluid mechanics or fluid

flow, specifically flow rates, pressure, fluid velocity, theoretical flow, shear stress and

deformation. The study is also limited to the available tools and instruments in the form

of accessible software and generators applicable to test the proposed project.

Composed mainly of Ansys and Computational Fluid Design (CFD) software as the

simulation standard and platforms such as google meet for video meetings and

sessions. The Programmed Rig Measuring Electronic Device would also be excluded in

the study.

1.4 AIM

This project aims to simulate, and explain the advantageous modification on the

efficiency of a Fish Fin Tesla Turbine over the conventional Tesla Turbine focusing

4
mainly on Fluid Flow. The design’s sustainability and cost-efficiency are also to be

considered when applied for power generation. The possible stress region resulting

from deformation would also be looked upon.

1.5 OBJECTIVES

General Objective:

● To Determine Tesla Turbine output performance and efficiency through a

simulation and design software, with fish fin additions.

Specific Objectives:

● To design and simulate the Fish Fin Tesla Turbine focusing on fluid flow through

a simulation and design software.

● To simulate the Fish Fin Tesla Turbine for stress analysis in order to determine

the possible regions of stress and deformation.

● To analyze the fluid flow behavior of the Fish Fin Tesla turbine using the fluid flow

simulation results.

● To calculate output power and efficiency based on the simulation results.

● To conduct an evaluation on Theoretical Fluid flow on the fish fin turbine

performance and its efficiency.

5
1.6 SIGNIFICANCE OF THE STUDY

The significance of this study is that it will offer alternative electricity and will help

address electrical shortages and blackouts. If fundamental electrical needs such as

lighting are met, it will benefit everyone, especially consumers who require light at night

to complete their outputs. This technology also promotes clean energy. A varied supply

of clean energy also decreases reliance on foreign fuels and the reduction of pollution.

The findings of this study will also serve as a research foundation for the ongoing

search for green renewable energy, as well as a useful reference for individuals

interested in studying or innovating the Tesla turbine in the future.

1.7 THEORETICAL FRAMEWORK

A moving fluid, such as water, steam, combustion gasses, or air, propels a

series of blades mounted on a rotor shaft in a turbine generator. The fluid's force on the

blade spins/rotates the rotor shaft of a generator. The generator converts the

mechanical (kinetic) energy of the rotor into electrical energy.

Tesla is a type of turbine that is included in this category. Adhesion is defined

as the tendency of different liquid molecules to adhere together as a result of attraction

forces. The viscosity of a liquid is defined as the substance's resistance to flow. These

two quantities combine to send mechanical energy from the fluid to the rotor or in the

other way in the Tesla turbine.

6
 Water, by its very nature, possesses an energy potential. As it flows, its

energy is converted to kinetic energy, also known as moving energy. Kinetic energy of

water is harnessed by installing equipment such as turbines in bodies of water such as

river ponds, lakes, or runoffs. As the liquid passes through each disc, adhesive forces

cause the molecules of the liquid immediately above the metal surface to slow down

and stick. When molecules close above the surface hit with those on the surface, they

slow down. These molecules will then act as a brake on the flow directly above them.

As one advances away from the slowed surface, the number of collisions caused by the

object surface decreases. Simultaneously, viscous forces lead the fluid's molecules to

resist separation. This produces a pulling force on the disc, which causes it to move in

the direction of the fluid.

The spinning of the turbine, which is connected to a shaft, can be used to

generate mechanical energy. After that, an alternator will be connected to this shaft.

Due to the connection of the turbine's shaft to the alternator, the alternator will rotate in

the same direction as the turbine. This rotation generates magnetic flux inside the

wound magnet of the alternator, and the resulting cutting of fluxes generates electrical

energy. The generator's electrical energy can subsequently be used to power

household items such as light bulbs and fans, benefiting consumers.

7
Flowchart of Electricity Generation and Energy Conversion

Figure 1.1 Energy Conversion Flowchart

8
1.8 CONCEPTUAL FRAMEWORK

Figure 1.2. Conceptual Framework of the Study

Figure 1 shows the conceptual framework of this study. A 3d model shall be

designed which will be subjected to fluid boundary conditions and simulated under

fluent analysis. Results from fluid simulation shall be used for the power and efficiency

calculations as well as visual representation of fluid behavior. Design material will be

added for the stress and deformation simulation under a different simulation software

showing stress regions.

9
 CHAPTER 2

REVIEW OF RELATED LITERATURE

2.1. Renewable Energy

Renewable energy is energy that is gathered from renewable resources like

sunlight, wind, waves, rain, geothermal heat and tides. Renewable because these

natural resources replenish itself on a human timeline. [2]

The supply of renewable energy is steadily expanding. In recent years, significant

investment has been done, and technological advancements have enabled countries to

create renewable energy at a lower cost. [3] Integrating renewable energy sources into

electricity generation can help to alleviate global energy concerns.[4]

Hydropower, often known as hydroelectric power, is a renewable energy source

that creates electricity by altering the natural flow of a river or other body of water using

a dam or diversion construction. To generate power, water energy uses the water

cycle's limitless, constantly renewing system. Hydropower is fueled by water, making it

a clean source of energy. Hydroelectric power won't pollute the air like power plants

that burn fossil fuels, such as coal or natural gas. [5]

2.2 Engines and Turbines

Any engine's job is to transform mechanical energy into energy from a fuel

source. The input energy is a fluid, whether it comes from air, moving water, coal, or

10
petroleum. And by fluid we mean something very specific -- it's any substance that

flows under an applied stress. Both gases and liquids, therefore, are fluids, which can

be exemplified by water. Liquid water and gaseous water, or steam, are both fluids in

the eyes of an engineer. [6]

Gas turbine engines are extensively used in aviation and power generation. The

engines are designed to offer cost-effective features, such as high efficiency, reliability

and availability. The energy demand for power generation is showing a continuous

increase, while there is also an increasing concern about the environmental

consequences of engine operation. [7]

The changing energy market focuses on decreasing power plant environmental

impacts, which improves competitiveness through financial and technological benefits.

This leads to an increased share of renewable power generation and also a focus on

highly efficient, flexible and cleaner conventional power plants. [7]

A recent study conducted in 2018 focused on the development of the Tesla

Turbine by adding the existence of Fish Fins which serve as blades. The purpose of

these fins is to provide minimal resistance to the water's adhesion to the disks, hence

increasing the water's adhesion to the disks and thus show an increase in power and

rpm. Below are the data from their research comparing the Tesla Turbine with and

without the addition of Fish fins. [17]

11
2.3 Fish Fin VS Without Fish Fin

A study conducted in 2018 by Abuzo et al. [17] worked on fabricating a Tesla

turbine disk with “fish fins” based on the given size and thickness of the disk as well as

to measure and compare the Tesla turbine with and without “fish fins” using different

flow rates in order to evaluate the economic viability of the Tesla turbine with “fish fins”

as a new type of turbine disk. The following graphs and tables are the data and results

taken from physical experimentation of a Tesla turbine with and without fish fins.

Table 2.3.1 Physical Data Without the use of Fish Fins – Flow Rate and Resulting

Power

Flow Rate (m^3/s) Average Power (W)

0.073 15.460849

0.084 16.622558

0.1 18.496029

0.12 19.481931

Flow Rate – Average Power relation table representation [Abuzo et al.]

12
Graph 2.3.1 Physical Data Without the use of Fish Fins – Flow Rate and

Resulting Power

Figure 2.3.1 Flow Rate – Average Power relation graph representation [17]

The data reveals that when water flow rate increases, electricity increases. The

initial flow rate is 15 watts and increases by more than 1 watt but less than 2 watts.

Power increases practically in perfect agreement with flow rate, therefore there is no

immediate power increase.

Table 2.3.2. Physical Data Without the use of Fish Fins – Flow Rate and RPM

Flow Rate (m^3/s) Rpm

0.073 61

0.084 149

13
 0.1 241

0.12 330

Flow Rate – RPM relation table representation [Abuzo et al.]

Graph 2.3.2. Physical Data Without the use of Fish Fins – Flow Rate and RPM

Figure 2.3.2. Flow Rate – RPM relation graph representation [17]

The data reveals a modest rise in rpm as the water flow rate increases. Starting

at 61 rpm, the flow rate gradually increased to 100-150 rpm. There is no rapid addition

of rpm, and a large rise in rpm relies on a large increase in flow rate.

14
Table 2.3.3. Physical Data with the use of Fish Fins – Flow Rate and Resulting

Power

Flow Rate (m^3/s) Average Power (W)

0.073 17.76102521

0.084 19.86616529

0.1 21.05432773

0.12 23.78305

Flow Rate – Resulting Power relation table representation [Abuzo et al.]

Graph 2.3.3. Physical Data with the use of Fish Fins – Flow Rate and Resulting

Power

Figure 2.3.3. Flow Rate – Resulting Power relation graph representation [17]

15
 The data reveals a considerable increase in power as water flow rate is raised.

That's 17 watts (far higher than the initial power of the turbine without fish fins), and it

keeps rising. Power increases by almost 2 watts in an instant, and the rise is uniform.

Table 2.3.4. Physical Data with the use of Fish Fins – Flow Rate and Resulting

RPM

Flow Rate (m^3/s) Rpm

0.073 120

0.084 210

0.1 360

0.12 570

Flow Rate – RPM relation table representation [Abuzo et al.]

Graph 2.3.4. Physical Data with the use of Fish Fins – Flow Rate and RPM

Figure 2.3.4. Flow Rate – RPM relation graph representation [17]

16
 The data reveals that as flow rate increases, rpm increases significantly. The

initial flow rate is 120 rpm (almost double the rpm of the turbine without fish fins). Also,

the rpm rise is instantaneous from the first to the second flow rate up to the next flow

rate. For example, the first to second flow rate differs by 90 rpm, the second to third by

150 rpm, and the third to fourth by 210 rpm.

Table 2.3.5. Comparison of Physical Data Flow Rate and Power

POWER COMPARISON

WITH FISH FIN NO FISH FIN

17.76102521 15.460849

19.86616529 16.622558

21.05432773 18.496029

23.78305 19.481931

Power Comparison table representation [Abuzo et al.]

17
Graph 2.3.5. Comparison of Physical Data Flow Rate and Power

Figure 2.3.5. Power Comparison graph representation [17]

Table 2.3.6. Comparison of Physical Data Flow Rate and RPM

RPM COMPARISON

WITH FISH FIN NO FISH FIN

120 61

210 149

360 241

570 330

RPM Comparison table representation [Abuzo et al.]

18
Graph 2.3.6. Comparison of Physical Data Flow Rate and RPM

Figure 2.3.6. RPM Comparison graph representation [17]

Using the same controlled variable, flow rate, the turbine with fish fins produces

more power and rpm than the turbine without fish fins. This growth could be due to

several things. One is that a finned configuration gives some more frictional resistance

on the blade as the water passes, making the water cling more to the disk's surface as

it turns before escaping at the turbine's outlet. A finned design also recycles water as it

turns, increasing the turbine's rpm instantly. So, the turbine with fins is efficient in terms

of output.

19
2.4 Tesla Turbine

In 1913 Nikola Tesla, best known for his work with alternating current (AC)

electricity, patented a turbine without blades, that uses a series of rotating discs to

convert energy of fluid flow to mechanical rotation, which can be used to perform useful

work.

A bladeless turbine is what Tesla Turbine is called. Because it uses the

boundary layer effect rather than a fluid impinging onto the blades like a typical turbine,

the Tesla turbine is also known as the boundary layer turbine, cohesion-type turbine,

and Prandtl layer turbine.The following parts of the Tesla turbine are: stator, shaft, inlet,

exhaust outlet and smooth discs. Nikola Tesla patented this turbine in 1913.[8]

It consists of a sealed chamber with a series of densely packed parallel disks

attached to a shaft. When a fluid enters the chamber and passes between the disks,

the disks rotate, which causes the shaft to rotate. This rotating motion can be utilized to

power everything from pumps to blowers to compressors to cars and airplanes. [6]

According to Nikola Tesla's 1913 patent, the working fluid enters the chamber in

a tangential direction through the inlet and flows along the surface of the disk through

the disk spacing. The flow swirls towards the middle before exiting the outlet axially. It

adheres to the disks due to fluid viscosity and adhesion, creating a no-slip state

immediately adjacent to the disk surface and a boundary layer velocity gradient in the

working medium away from the surface. Due to friction and velocity, fluid spirals to the

middle, where exhaust is, as it slows down and adds energy to the disks. Because of

20
the increased centrifugal force as disks begin to rotate and their speed increases, fluid

now moves in longer spiral routes.[9]

The energy transfer of the Tesla turbine is unique compared to the traditional

bladed turbine, a boundary layer velocity gradient forms throughout the working

medium away from the surface. The fluid properties of viscosity and adhesion makes

the turbine rotate as the fluid adheres to the disks and flows adjacent to the disk

surface. As the disks continue to rotate, the speed increases and the fluid travels in

longer spiral paths due to large centrifugal force.[9]

There are cases of the revolutionary turbine being used in a new generation of

cleaner, more fuel-efficient automobiles Phoenix Navigation and Guidance Inc.

(PNGinc), based near Munising, Michigan, is one company that is making significant

progress. PNGinc has merged disk turbine technology with a pulse detonation

combustor to create an engine that, according to the company, achieves remarkable

efficiencies. [6]

2.4 Efficiency

Typically, turbines are around 80-90% efficient. Nikola Tesla claimed that his

turbine design efficiency can go up to 95%. Due to factors related to technological

growth and the features of the innovation market at the time, the Tesla turbine was

unable to be effectively commercialized Coupled with the fact that large power firms

had already made significant investments in blade turbines, barring important investors

21
from participating. Despite Tesla's claims of up to 95% efficiency for his machine,

reported efficiencies were often around 30-40%. [6].

One recent study conducted in 2017 in India entitled “Study and Design of

Bladeless Tesla Turbine” calculated that the Tesla turbine has only 34.69% efficiency.

Their Tesla turbine design is similar to the conventional Tesla turbine design and the

researchers of that study used steam to run the turbine.[10] Tesla's objective of 95

percent efficiency was never attained. Despite over a century of effort, there are few

applications for this style of design, which is hindered by a lack of genuine data. [11].

Tesla's novel design was restricted by the limitation of technology and research

available at the time. Because there are no blades, frictional and viscous forces are

used to drive a set of stacked discs; these forces are what cause losses in traditional

turbines. Researchers aimed to establish the turbine, but have never been able to meet

the efficiency levels anticipated by Nikola Tesla. Tesla's original design was intended to

replace inefficient full-scale turbines at the time.Under compiled works, various scaled

designs of the Tesla turbine have shown that it is still most effective under microscale

power generation.[12]

2.5 Advantages and developments

Tesla turbines compared to traditional bladed turbines have several advantages.

This includes how easy it is to manufacture because of its simple disk design

compared to those huge and specially designed bladed turbines, simple disk design

22
equates to low cost production, it has high power to weight ratio, there is a significant

reduction of emission and noise level, and its simple configuration means inexpensive

motor.[13] Fluids used can be steam or water. It is unaffected by sediment erosion due

to lack of vanes. Only one notable challenge related to the Tesla turbine is its low

efficiency.[14]

Disks have cheaper production costs than blades, and their overall design is

simpler and easier to construct. The turbine may also be operated with a variety of

fluids without causing significant harm to the disks. Examples include Newtonian and

non-Newtonian fluids, mixtures of solids, liquids, and gases, as well as viscous and

non-viscous fluids, Newtonian and non-Newtonian fluids. The turbine's fluid flow can

also be turned into a pump, and the disks don't suffer from the cavitation problems that

bladed turbines do.[15]

The Tesla turbine has an advantage over the rest of the turbines used in

practice today because of the simplicity of its constructive solution. Second, it only has

one rotating piece. Third, the Tesla turbine can be used in two ways (fluid acting on the

discs in the turbine regime or the runner acting on the fluid in the pumping regime)

which makes the Tesla turbine interesting in terms of application. [11]

Though the good qualities of the Tesla Turbine, there has been no viable and

mass commercial applications due to its disadvantages mainly, compared to machines,

is that it generates low torque even at high speeds, making it inefficient as a power

source for vehicles, power generators, etc. With this in mind, one way to increase the

torque is to use discs that supply more torque than the original discs. The discs will be

23
making use of a new design and improving the adhesive effect of the boundary layer

[16].

The Tesla disc turbine has not yet been used commercially due to its low

efficiency and other operational difficulties. Further research and modification of the

Tesla turbine were temporarily suppressed after the invention of the gas turbine which

was much more efficient than the Tesla turbine.[13]

A turbine with fish fins produces more power and rpm compared to the turbine

without fish fins. This is based on the overall analysis of the power and rpm, with the

same controlled variable, which is the flow rate. Several factors could be attributed to

this increase. One is that a finned setup offered some additional frictional resistance on

the blade as the water passes making the water cling more to the disk’s surface as it

rotates before exiting at the turbine’s outlet compared to the without fins setup in which

some water will eventually fall down or slip at the blade’s surface. Another factor is that

a finned setup recycles the water as it rotates and adds up back to the input water

making the turbine increase its rpm instantaneously.[17]

Turbines work by turning a fluid's kinetic energy into another form of energy. [21]

When conventional turbines are scaled down, research reveals that two primary

problems arise. The first is the rapidly increasing rotational speed, while the second is

the significantly reduced flow efficiency.[22] With regards to the casing design, a study

conducted recently in 2021 used a design wherein the inlet and outlet were

symmetrically built on the same side of the casing for the purpose of better gas flow

24
management and enhanced kinetic energy utilization. For the design, an additional

outlet which will be located on the side of the stator will be added. [20]

25
 CHAPTER 3

METHODOLOGY

3.1 Research Design

The research methodology to be used is descriptive research. Descriptive

research design aims to obtain information to systematically describe a phenomenon

or situation. The researchers seek fluid flow simulation, and stress and deformation

analysis of Fish Fin Tesla Turbine and a shred of comparison to Conventional Tesla

Turbine.

3.2 Research Instruments

The researchers will primarily rely on a simulation software due to the limitation

of conducting the research. The data being gathered during the simulation shall be

recorded from the simulation software and will be used for the calculation of the output

power and turbine efficiency.

Design and conceptualization of the Turbine and other necessary components

such as the fish fins will be done through the use of computer-aided design software

namely AutoCAD and Fusion360.

To gather various data depending on the flowrate and pressure of the water

being pumped into the system, the researchers shall utilize the fluid flow analysis of the

simulation software CFD 2021.

26
 Ansys simulation software will be used to account for the deformational stress

portion of the simulation for visual representation of the possible material changes

under stress caused by the given flow rates.

From the results, the researchers can investigate displacement, stresses, and

common failure criteria, and efficiency on fluid flow as well as its effect. The results are

calculated based on assumption of linear response to the stress, and fluid flow.

3.3 Data Gathering Procedure

The researchers shall expose the projects and be tested on different

experimental set-ups via simulation which depend on the controlled water pressure

output and flow rate of water for the fluid flow which will also be subjected to stress to

investigate its point of deformation, displacement and failure with the use of a software

simulation tool. Then, the researchers shall record the results of different experimental

set-ups in Microsoft Excel Spreadsheet and examine the data gathered.

The data gathering procedure will follow these steps:

Step 1: Create a Conventional Tesla Turbine and Fish Fin Tesla Turbine through

AutoCAD and Fusion 360.

Step 2: Export the model subjected to testing for fluid flow and stress analysis

simulation through CFD 2021 and Ansys.

27
 Step 3: Calculate results using CFD 2021 software for fluid flow and Ansys for

stress analysis.

Step 4: Examine the results gathered from simulation and calculations for the Fish

Fin Tesla Turbine.

Step 5: Draw conclusions based on acquired data and test results.

3.4 Turbine Design model

Conventional Turbine Blades Isometric Views

Figure 3.4.1 Conventional Turbine Blades isometric views

28
 Fish Fin Isometric Views

Figure 3.4.2. Fish Fin Turbine Blades isometric views

29
 Fish Fin Other Component Isometric Views

Figure 3.4.3. Fish Fin Turbine Cascade Isometric Views

30
 Simulation Model View

● Used for Simulation proper

● Model with ten discs with eight fish fin addition with cascade water outlet

Figures 3.4.4. and 3.4.5. models from simulation view

The Fluid Simulation was performed using Autodesk CFD software while the
Stress Analysis was executed with the use of ANSYS software for analyzing the
turbine’s mechanical properties such as its deformation and shear stress.

31
 3.5 Simulation parameters

Software Autodesk CFD

Fluid Water

Mesh Type Automesh

Solver Type Velocity and Pressure based,

Transient state

Disc and Blade Type Flow driven

Disc motion Angular

Outlet boundary condition 0 Gauge pressure, unknown

boundary condition

Inlet Velocity 1 m/s (accumulating)

Outlet Pressure - inlet

Time interval (s) 0.5

Number of iterations 100

Disc Material Stainless steel 316

Table 3.5. Simulation Parameters (Inputs)

Grade 316 stainless steel was used since it has a better corrosion resistance as

well as resistance to chemicals and chlorides, such as salt, compared to grade 304

stainless steel.

32
 CHAPTER 4

OBJECTIVES’ SOLUTIONS

4.1 General Objective

● To Determine Tesla Turbine output performance and efficiency through a

simulation and design software, with fish fin additions.

Solution:

The researchers will utilize the use of AutoCAD, Fusion 360 and Autodesk CFD,

in order to visualize and come up with a design of Fish Fin Tesla Turbine. AutoCAD

stands for Computer Aided Design. Fusion 360 is a cloud-based 3D modeling design

and production software platform. This software is used for designing and drafting.

They allow the user to conceptualize ideas, product designs and drawings to the

required level of technical accuracy, perform rapid design calculations and simulations

in the field of manufacturing industries.

To test and simulate fluid flow on the Tesla Turbine with Modified Disc Spacer,

the researchers shall use CFD 2021 to know if the design is feasible and will work.

CFD 2021 is used to develop mechatronics systems from beginning to end. At the

initial stage, the software is used for planning, visual ideation, modeling, feasibility

assessment, prototyping, and project management.

If the design and simulation is finished, the researchers will proceed to the

discussion of the results and the data received.

33
4.2 Specific Objectives:

● To design and simulate the Fish Fin Tesla Turbine focusing on fluid flow through

a simulation and design software.

● To simulate the Fish Fin Tesla Turbine for stress analysis in order to determine

the possible regions of stress and deformation.

● To analyze the fluid flow behavior of the Fish Fin Tesla turbine using the fluid

flow simulation results.

● To calculate output power and efficiency based on the simulation results.

● To conduct an evaluation on Theoretical Fluid flow on the fish fin turbine

performance and its efficiency.

Solution:

The 3d design will be done through the use of AutoCAD, or Fusion 360. The

researchers shall test the project on different experimental set-ups (fluid flow and

stress analysis). For Fluid Flow Analysis the design set-up will be simulated under

accumulating water velocity at transient state flow driven motion, the results (torque,

RPM, angular velocity, and estimated velocity change) shall be recorded. After results

and data are gathered, calculations shall be done in order to solve for the power and

efficiency and conduct evaluations based on recorded and calculated results. A stress

analysis of the turbine shall also be conducted focusing on the shear stress and

deformation using Ansys software. The stress regions would also be pointed out in this

outcome.

34
4.3 Data and Results

SIMULATION RESULT DATA

Parameters Results

Disc Diameter 51 cm

Disc Thickness with fins 6 mm

Disc Volume 0.0012 m³

Number of Discs 10

Inlet Area 0.0096 m²

Estimated Velocity Change 15.77 m/s

Volume Flow Rate 0.151392 m³/s

RPM 2297

Angular Velocity 240.54 rad/s

Mass Moment of Inertia 0.12508 kg/m²

Pressure 100000 Pa

Torque 27.43 Nm

Table 4.3. Simulation Results (Outputs)

35
4.4 Power and Efficiency Calculations

The objective of using CFD is to examine the flow pattern and analyze velocity

at various points on a disk in order to determine the torque and then solve for the

powers and efficiency. The calculations below are calculated using the resulting

variables from the conducted simulation tabulated above.

Volume flow rate (Q)

Input Power (Pin)

Output Power (Pout)

36
 Efficiency (E)

Parameters Results

Volume flow rate 0. 151392 m³/s

Input Power 15.14 kW

Output Power 6.598 kW

Efficiency 43.58 %

Table 4.4. Tabulated Calculated Results

It is observable that through the use of Fish fins the turbine produces more

output power and higher efficiency. Through simulation, 43.58% efficiency was

achieved due to the existence of the fins.

37
4.5 Stress Simulations

Stress Analysis Simulation on Fish Fin Tesla Turbine

Total Deformation:

Figure 4.5.1 Total Deformation Simulation on Fish Fin Tesla Turbine

From the above simulation, the image suggests that the region of stress occurs

primarily on the outer edges of the turbine. This would mean that this red region is

prone to deformation. The stress generated on the edges of the disks increases with

the increase in disk RPM. Stress is mainly noticeable on the edges due to the

38
centrifugal force generated by the turbine disks' high angular velocity and high RPM.

Other possible reasons aside from centrifugal force leading to stress would be of fluid

forces such as pressure, velocity or flow rate which can result in fracture, yielding and

failures. Hole radius would also sometimes experience unintended increase in size due

to the centrifugal motion of the turbine as it continues to operate.

Maximum Shear Stress:

Figure 4.5.3 Maximum Shear Stress Simulation on Fish Fin Tesla Turbine

39
 When fluid flows across a surface, shear stress is created, shear stress occurs

primarily at the center or near the shaft of the discs, this is due to the reciprocating

motion of the disc and the shaft generating rotational motion, and its value is directly

proportional to the velocity of the fluid in the surrounding area. In other words, force

acting parallel to the area of the turbine would induce shear stress and lead to

deformation in the form of stretching to an extent. From the images above it can be

assumed that the higher the velocity of the flowing fluid, shear stress would likely

increase due to proportionality.

40
4.6 Fluid Simulation Analysis

Turbine Performance and Fluid intake simulation:

Figure 4.6.1

From the Ansys simulation software, it can be observed that it is during time

step 46 to 52 where signs of the velocity magnitude start to appear indicating the

41
beginning of the increase in velocity value and turbine performance. Velocity

Magnitude refers to the instantaneous speed of an object wherein the velocity vector is

directed in the same direction that the object moves. This means for movement within

a circle, the direction is always changing.

Figure 4.6.2

42
 The next illustrations show a gradual increase in velocity magnitude and turbine

performance from time steps 56 to 61. As seen from the glowing signs in the

illustration, there is more motion and components involved as well as velocity

magnitude acting upon the blades in a circular motion. Basically, there is a steady

increase in the turbine’s operation where it is possibly approaching maximum

performance.

Figure 4.6.3

43
 The illustration and graph display the turbine reaching a balanced state where it

may indicate having reached its maximum performance. This means this point may

specify that further addition or increase in velocity will not result in additional increase

of turbine performance/ efficiency. This serves as its peak velocity performance setting

and any excess resources will not result in any more efficient output performances.

Figure 4.6.4

44
 Beyond higher velocity, the efficiency will reach its peak and there will no longer

be a rise. Meaning higher velocity does not essentially mean higher efficiency output,

there will be a limit at a certain threshold.

Figure 4.6.5

45
 After maximum performance, the illustration shows that if the velocity were to

reach a point after the recommended or optimal setting for maximum performance, the

turbine’s velocity magnitude and efficiency will start to drop. This is the case taken from

time step 100 coming from the previous illustrations of maximum performance from

time steps 62 and 63.

VELOCITY STREAMLINE

Figure 4.6.6

As it passes over the turbine Fins, the streamline's velocity lowers a certain

degree. Because the streamline transfers its energy to the Fins, the disk or fin rotates

as well. The nozzle of the input pipe is where the maximum velocity occurs.

46
PRESSURE CONTOUR

Figure 4.6.7

This figure shows that water enters at a high rate and, due to the narrow surface

of the blades and with the addition of the fish fin, narrows the entryway. This

occurrence then causes the turbine to spin. The contact between the blades and the

water, plus the aforementioned reasons, causes the decrease in water pressure as it

exits the outlet. It can be summarized that the pressure is greater as it enters the inlet.

Due to the narrow surface area of the blade, a decrease in pressure will occur.

47
4.7 ANALYSIS AND DISCUSSION

The output power of the model with 10 discs and eight fish fin extensions and

cascade water exit was 6.598 kW with an efficiency of 43.58 percent. When fish fins

are inserted between discs, fluid flow and torque are enhanced. With the addition of

fish fins in the turbine design, there is an increase in friction interaction between the

fluid flow and the disc blades. There is more surface grip to help with the turbine

rotation resulting in more rpm. In comparison to standard Tesla turbines from previous

tests, the Fish Fin Tesla Turbine boasts a four percent increase in efficiency, creating

more power overall.

The simulation reveals that the region of stress and deformation is

predominantly located on the outside edges of the turbine, with shear stress near the

location of the shaft and the disc holes caused by the rotating motion. Determining the

regions of stress is important to ensure that a design will fulfill its intended function in a

given load environment. Knowing the regions of stress can also significantly help in

recognizing which areas of a specific design will most likely lead to deformation and

fracture first. Owing to the increase in disc RPM, this stress is generated, and the force

operating perpendicular to the area would induce shear stress and lead to a certain

degree of stretching due to proportionality.

48
 CHAPTER 5

5.1 Conclusion

The general objectives of the study is to design and simulate the Fish Fin Tesla

turbine focusing on fluid flow and determine the possible regions of stress and

deformation. Simulation was done through Ansys and CFD software. The model used

in the simulation proper was fitted with ten discs and eight fish fin additions with

cascade water outlet. From the results, it can be inferred that an output power of 6.598

kW with an efficiency of 43.58 % was achieved. In comparison to the conventional

Tesla turbine of past studies, the Fish fin Tesla Turbine has an increase in efficiency of

about 4% than the 30-40%[6] and is much greater in comparison to the recent study

conducted in 2017 in India which has only 34.69% efficiency [10], thus generating more

power output.

The simulation also shows the region of stress and deformation occurs primarily

on the outer edges of the turbine and shear stress near the shaft location and the disc

holes induced by the rotating motion. With this, the study has accomplished its task of

designing and simulating the Fish Fin Tesla turbine focused on fluid flow simulation and

the possible regions of stress and deformation. The researchers believe that using this

Fish fin innovation as base, more improvements could be made to even further raise

efficiency.

49
5.2 Recommendations

Following the simulation of the Fish Fin Tesla turbine, the researchers have

developed a number of recommendations.

1. First, to achieve a higher power output, one must consider a high velocity. A

sturdy and efficient material capable of withstanding such flow is necessary.

2. Second, future researchers may implement innovations in the area of the design

of the turbine in order to attain better results.

3. Turbine designs should focus on turbine blade modifications and keep in mind

economic feasibility.

4. Future researchers could also add the boundary conditions and parameters of

temperature value to determine factors related to blade cavitation and if it affects

turbine performance as well.

5. Future researchers could also consider the effects of stress and deformation on

the power performance of turbines.

6. Fabrication of the turbine would be in the best interest of the researchers. A

study comparing the simulated data to the raw data of the fabricated turbine

would yield more thorough and conclusive findings.

50
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54
 Appendix A

Design Layout

Disc Thickness

Disc Diameter

Cascade Inlet Dimensions

55
Fish Fin Tesla Turbine vs Conventional Tesla Turbine Disc

56
 Appendix B

Simulation Results

Total Deformation Results Simulation on Fish Fin Tesla Turbine

57
Maximum Shear Stress Results Simulation on Fish Fin Tesla Turbine

58
 Fish Fin Tesla Turbine Streamline Initial Simulation

Fish Fin Tesla Turbine with additional Outlet Initial Simulation

59
 Appendix C

Design Equation and Calculations

Torque as calculated by the software is:

Flow Rate is determined using the variable from the design model and simulation data:

Input power is calculated using the equation below:

60
Output power is determined using the data results from simulation:

Efficiency is simply solved as percentage ratio of output and input power respectively:

61
Appendix D

Gantt Chart

62