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Design study for performance improvement of a hybrid pico pelton turbine and its additive manufacturing using a laser powder bed fusion method

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Abstract

The adoption of additive manufacturing (AM) to complement conventional manufacturing to produce industrial components has been widely accepted. This is critical to the fabrication of designs with high complexity, which traditional manufacturing cannot match. In this regard, a commercial Pelton turbine with a traditional design was improved using both reverse engineering and hydro-dynamic finite element method simulations to produce a new design. Then, the performance of our new design is experimentally evaluated in terms of its rotational speed. In our new design, using the Design for AM (DfAM), several drawbacks of the traditional Pelton turbine design (e.g., improper welding and alignment and blunt splitters that lead to a heeling effect) were overcome by the following steps: (i) employing computational fluid dynamics analysis, (ii) consequently, extracting key geometrical characteristics from the original design, such as the number of buckets, runner wheel diameter, and bucket width, and length (iii) finally, referencing other design parameters using generally known empirical data. DfAM techniques were applied to reduce the post-processing requirements of additively manufactured turbine buckets, considering minimum feature size and avoidance of support structures on water-contacted surfaces, as well as simple and manual support removal. The new design in this study exhibits high rotational speeds ranging from 8.2 to 32.73% at an inlet pressure of 5 MPa and different nozzle angles.

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Acknowledgements

This work was funded by the Technology Development Fund of Innovation of Smart Manufacturing (Proj. # SE220026, # SE220028) from the Korea Ministry of SMEs.

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Author notes

  1. Ulanbek Auyeskhan and Tack Lee have contributed equally to this work.

Authors and Affiliations

  1. 3D Printing Manufacturing Process Center, Korea Institute of Industrial Technology, Ulsan, South Korea

    Ulanbek Auyeskhan, Tack Lee, Yujin Park, Donghyun Kim, Chung-Soo Kim & Dong-Hyun Kim

  2. Department of Mechanical Engineering, Ulsan National Institute of Science and Technology, Ulsan, South Korea

    Ulanbek Auyeskhan & Namhun Kim

  3. Department of Mechanical Engineering, University of Ulsan, Ulsan, South Korea

    Donghyun Kim

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  1. Ulanbek Auyeskhan
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Contributions

UA: Conceptualization, Methodology, Software, Investigation, Validation, Writing – original draft. TL: Conceptualization, Methodology, Investigation, Validation, Writing – review & editing. YP: Investigation, Validation. DK: Investigation, Validation. NK: Conceptualization, Methodology, Writing—review & editing. C-SK: Conceptualization, Methodology, Writing—review & editing. D-HK: Conceptualization, Methodology, Funding Acquisition, Writing—review & editing.

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Correspondence to Dong-Hyun Kim.

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Auyeskhan, U., Lee, T., Park, Y. et al. Design study for performance improvement of a hybrid pico pelton turbine and its additive manufacturing using a laser powder bed fusion method. Int J Interact Des Manuf 18, 107–117 (2024). https://doi.org/10.1007/s12008-023-01396-4

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