Research Journal of Applied Sciences, Engineering and Technology 7(15): 3114-3125, 2014

DOI:10.19026/rjaset.7.650
ISSN: 2040-7459; e-ISSN: 2040-7467
2014 Maxwell Scientific Publication Corp.
Submitted: October 09, 2013 Accepted: October 24, 2013 Published: April 19, 2014

Research Article
Stress Analysis of Nonhomogeneous Rotating Disc with Arbitrarily Variable
Thickness Using Finite Element Method

Abdur Rosyid, Mahir Es-Saheb and Faycal Ben Yahia

Mechanical Engineering Department, College of Engineering, King Saud University,
P.O. Box 800, Riyadh 11421, Saudi Arabia

Abstract: Rotating discs with variable thickness and nonhomogeneous material properties are frequently used in
industrial applications. The nonhomogenity of material properties is often caused by temperature change throughout
the disc. The governing differential equation presenting this problem contains many variable coefficients so that no
possible analytical closed form solution for this problem. Many numerical approaches have been proposed to obtain
the solution. However, in this study the Finite Element Method (FEM), which presents a powerful tool for solving
such a problem, is used. Thus, a turbine disc modeled by using ax symmetric finite elements was analyzed. But, in
order to avoid inaccuracy of the stress calculation quite fine meshing is implemented. The analysis showed that
maximum displacement occurs at the boundary of the disc, either at the outer or inner boundary, depending on the
loadings. The maximum radial stress occurs at an area in the middle of the disc which has the smallest thickness. In
this study, rotational blade load was shown to give the largest contribution to the total displacement and stress. Also,
the radial displacement and stress in a disc with variable thickness are found to be affected by the contour of the
thickness variation. In general, the results obtained show excellent agreement with the published works.

Keywords: Finite element method, nonhomogeneous material properties, rotating disc, variable thickness

INTRODUCTION properties throughout the disc and therotating disc

becomes nonhomogeneous in the radial direction.
Rotating discs have many practical engineering Generally, there are two approaches for the
applications such as in steam and gas turbine discs, solution of rotating discs, namely, theoretical and
turbo generators, internal combustion engines, casting numerical methods. For homogeneous rotating disc
ship propellers, turbojet engines, reciprocating and with constant thickness, closed-form analytical solution
centrifugal compressors just to mention a few. Brake is available. However, for nonhomogeneous rotating
disk can be an example of solid rotating disk where disc with variable thickness, analytical solution is not
only body force is involved. possible to obtain. Hence, many numerical attempts has
In reality, the thickness of the disc is frequently not been presented to solve such a problem.
constant, such as turbine discs, due to economic Timoshenko and Goodier (1970) was the first to
considerations and in order to improve mechanical obtain a closed form solution for homogeneous
performance. Turbine discs are usually thick near their constant-thickness rotating discs without any
hub and taper down to a smaller thickness toward the temperature gradient. Stodola (1927) obtained an
periphery, since a constant thickness pronounces stress analytical solution of the problem of homogeneous
concentration near the center, even for solid disc. rotating discs with hyperbolic profile thickness. Den
Furthermore, it has been shown that the stresses in Hartog (1987) reported the closed form formula for
variable thickness rotating annular and solid discs are homogeneous rotating discs with constant and
much lower than those in constant thickness discs at the hyperbolic thickness under several mechanical
same angular velocity. loadings. Boresi and Richard (2003) included thermal
In many applications, the disc is working under stress in the closed form formula. Gamer (1985)
high temperature which presents thermal loading. achieved a good adaptive numerical solution for the
Beside the fact that, the temperature throughout the disc constant thickness solid discs with a linear hardening
is usually not constant, i.e., there is temperature material. Recently, Sharma et al. (2011) conducted
gradient present throughout the disc. This temperature analysis of stresses and strains in a rotating
gradientusually resulted in changes in material homogeneous thermoplastic circular disk using FEM.

Corresponding Author: Mahir Es-Saheb, Mechanical Engineering Department, College of Engineering, King Saud University,
P.O. Box 800, Riyadh 11421, Saudi Arabia
This work is licensed under a Creative Commons Attribution 4.0 International License (URL: http://creativecommons.org/licenses/by/4.0/).
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Guven (1997, 1998) obtained an analytical solution

of the problem of rotating variable thickness discs with
rigid inclusion for the elastic-plastic (Guven, 1997) and
fully plastic state (Guven, 1997). Leopold (1984)
calculated elastic stress distributions in rotating discs
withvariable thickness by using a semi-graphical
method. Later, semi-analytical analysis of Functionally
Graded Materials (FGM) rotating discs with variable
thickness was proposed by Bayat et al. (2008). Hojjati
and Jaffari (2007) proposed Variation Iteration Method
(VIM) to obtain the elastic analysis of non-uniform
thickness and density rotating discs subjected to only
centrifugal loadings. However, You et al. (2000) Fig. 1: Infinitesimal element of the disc
proposed numerical analysis using Runge-Kutta method
compared to FEM for elastic-plastic rotating discs with
arbitrary variable thickness and density. Likewise,
Hojjati and Hassani (2008) proposed Variablematerial
Properties (VMP) method and numerical analysis using
Runge Kuttas method compared to FEMfor rotating
discs of non-uniform thickness and density. Recently,
they also proposed semi-exact solution for thermo-
mechanical analysis of FGM elastic-strain hardening
rotating discs (Hassani et al., 2012). Furthermore, to
solve nonhomogeneous rotating disc with variable
thickness, Jahed et al. (2005) proposed discretization of
the disc into a finite number of rings, where each ring Fig. 2: Displacements in infinitesimal element of the disc
has constant thickness and material properties, but
different rings may have different thickness and 1 dh d t 2 (2)
r + r + r + r =0
material properties. h dr dr r g
In this study, therefore, the problem of
nonhomogeneous rotating disc with arbitrarily variable Because the problem is axisymmetric, stress
thicknessis addressed and other related issues are components in tangential direction vanish:
discussed and presented. It is demonstrated that the
analytical solution for such a problem is not possible to
d d (3)
be obtained. Consequently, to solve this problem the FE t cos drdh t cos drdh = 0
technique is used. The complete details of the FE 2 2
formulation and analysis of the problemalong with
numerical examples to verify the solution are presented By simplification and taking sin (d/2) = d/2 due to
in the next sections. small angle , we obtained:

METHODOLOGY Compatibility: Displacaments occurs in the disc is

shown in Fig. 2. The compatibility ends up with strain-
Analytical solution for elastic nonhomogeneous disc displacement relation as follows:
with variable thickness under mechanical and
thermal loading: The problem can be considered as du
plane stress with variable thickness. Hence, z = 0, as u + dr dr u du
this is a static problem, the solution has to satisfy r = = (4)
dr dr
equilibrium, compatibility and constituve law of the
material properties.
t =
( r + u ) d rd =
u (5)
Equilibrium: Assuming that the weight of the disc is rd r
neglected, equilibrium of infinitesimal element of the
disc, as shown in Fig. 1, in the radial direction is: Properties of material, which are expressed by
constitutive law of material: Because the problem is
elastic, Hookes law is used to get the stress-strain
+ 2
relation.

+ + + Due to only mechanical loading and z = 0:

= 0 (1)
1
r = ( r t ) (6)
E
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1 Now subtituting Eq. (29) and (31) into (2), which is

t = (t r ) (7)
the equilibrium equation in radial direction, we
E
obtained a second order Ordinary Differential Equation
Because there is also thermal loading; then, (ODE) of the form:

total = elastic + therm al (8) d 2u

+f1
du
+ f 2u = f 3
2
dr dr
and
where,
therm al = T (9)
1 d hE
f1 = + ln 1 2
r dr
Hence, the total strains become:
1 d hE 1 d
1 f2 = + ln +
r = ( r t ) + T (10) r 2 r dr 1 2 r dr
E

d 2 2 d hE (20)
t =
1
( t r ) + T (11) f3 =
dr
( (1+ )T ) 1Eg r + (1 + ) T ln
dr 1 2
E
The coefficients of the ODE contain variable
Re-arranging Eq. (10) and (11), we get:
parameters:
r = E r + t E T (12) r , h = h (r ), E = E (r ), = (r ), = (r ), = (r ),T = T (r )

and Because the coefficients of the ODE contain many

variable parameters, there are no exact solutions for this
t = E t + r E T (13) ODE. However, as stated earlier, there have been
numerous numerical approaches to solve such a
Subtituting Eq. (13) into (12) to get r: problem. But in this study, the FE approach is utilized.
The details of the FE analysis and solution are
E E T presented below.
r = ( r + t ) (14)
1 2 1
Fem solution for elastic nonhomogeneous disc with
variable thickness under mechanical and thermal
Now subtituting Eq. (12) in to (13) to get t:
loading: FEM is one of the most successful and
dominant numerical method in the last century. It is
E E T
t = ( t + r ) (15) extensively used in modeling and simulation of
1 2 1 engineering and science due to its versatility for
complex geometries of solids and structures and its
Subtituting Eq. (4) and (5) into (14) we get: flexibility for many non-linear problems.
Most discs with variable thickness in the
E du u E T (16) applications are ax symmetric. For such a case, ax
r = +
1 2 dr r 1 symmetric element is the most economical but adequate
to use in the finite element analysis. For any other cases
E du u in which the disc is not ax symmetric and therefore not
r = + (1 + ) T (17)
adequate to be modeled by axisymmetric element,
1 2 dr r
cyclic element and 3D solid element can be used.
The axisymmetric symmetric element has 2
Similarly, substituting Eq. (4) and (5) into (15) we get:
translational degrees of freedom per node. Using
cylindrical coordinate system where z is the axis, r is
E u du E T (18)
t = + the radius and is the circumference angle, the stresses
1 2 r dr 1 in the axisymmetric problem is shown in Fig. 3.
Internal and external pressure working at the inner
E u du and outer surface of the disc are surface forces. The
t = + (1 + ) T (19)
1 2 r dr element surface force vector is given by:
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App. Sci. Eng. Technol., 7(15): 3114-3125, 2014

Fig. 4: A half cross sectional view of the disc with

Fig. 3: Stresses in the axisymmetric problem dimensions in mm

pr he thickness of the disc varies along the

analysis. The
{ f s } = [ N s ]
T
(21)
dS radial direction. The temperature varies along the radial
S pz
direction as well. Due to the temperature variation,
Centrifugal forces due to rotational speed of the Young modulus, Poisson ratio and thermal coefficient
disc are body forces. The element body force vector is change as function of the temperature. Because the
given by: temperature changes as function of radius, then Young
modulus, Poisson ratio and the he thermal coefficient can
Rb also be expressed as function of radius. Because
{ f b } = 2 [ N ]
T
(22)
r .dr .dz analytical solutions of such a problem is not available
A Zb as already explained, finite element analysis was carried
out to obtain the solutions.
The element thermal forces working on the disc are
given by:
Geometry and material properties: The disc is
axisymmetric. The geometry of the disc is shown in
{ fT } = 2 T
D T rdA (23)
Fig. 4. For convenience, the change of temperature,
A
Young Modulus, Poisson ratio and thermal coefficient
is assumed linear. The density of 8220 kg/m3 is
The total element forces {f} are sum of th
the element
assumed to be constant.
surface forces, the element body forces and the element
The steady state temperature at the outer boundary
thermal forces. The global force vectors {F} are
obtained by assembling all the element forces. is equal to the temperature of high temperature gas.
The element stiffness matrix is given by: Based on the data given by Barack and Domas (1976),
Liu et al. (2002), Claudio et al.. (2002), Jahed et al.
(2005), Maruthi et al.. (2012) and Elhefny and Guozhu
[ k ] = 2 [ B ] [ D ][ B ] r .dr .dz
T
(24)
(2012), this temperature has a range of 550-900C.
550 In
A
this study, a value of 800C C is used. Throughout the
Assembling all of the element stiffness matrices, disc, the temperature gradually decreases as the radius
the global stiffness matrix [K] is obtained. The global gets closer to the inner boundary. The temperature
displacement vectors are given by {F} = {K}{d}. throughout the disc never reaches the same value as a
The displacement function vectors are given by: cooling system is applied inside the disc. Based on data
published by Barack and Domas (1976) and Jahed et al.
{ } = [ N ]{d } (25) (2005) and recently by Maruthi et al. (2012), the
temperature at the inner boundary has a range of 450-
450
500C. In this study, a value of 500C 500 is used.
The global strain vectors are given by:
Following the aforementioned boundary temperatures
along with assumption that the t temperature
{} = [ B]{d} (26)
changethroughout the disc is linear, the following
relation is used to express the temperature change:
Finally, the global stress vector are given by:
T (r) = 3 r + 324; r in mm (28)
{ } = [ D ][ B ]{d } (27)
The temperature distribution is shown in Fig. 5.
5
Numerical example: In this example, an axisymmetric Due to the temperature variation, Young Modulus,
gas turbine disc was analyzed. Noncommercial ANSYS poisson ratio and thermal coefficient vary throughout
Workbench was used to conduct the finite element the disc as follows:
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Fig. 5: Temperature distribution throughout the disc

Fig. 6: Young modulus variation throughout the disc

Fig. 8: Thermal coefficient variation throughout the disc

E (r) = - 0.15 r + 188.5; r in mm, E in GPa (32)

(r) = (4.0816 x 10-4) r + 0.26245; r in mm (33)

(r) = (2.0408 x 10-8) r + (12.1224 x 10-6);

r in mm (34)

The change of Young modulus, Poisson ratio and

thermal coefficient is shown in Fig. 6 to 8.

Fig. 7: Poissons ratio variation throughout the disc Element type, loads and boundary conditions:
Axisymmetric model is used due to the axisymmetric
E ( T ) = - 0.05 T + 200; E in GPa (29) geometry of the disc. Furthermore, because the model is
symmetric in longitudinal direction, then half of the
( T ) = (1.3333x10-4) T + 0.23 (30) section area was used.
Shrink fit with the rotor shaft causes a radial force
(T) = (6.6667x10-9) T + (10.6667x10-6) (31) in outward direction on the inner surface of the disc.
This force results in 300 MPa compressive pressures on
As the temperature is a function of radius, Eq. (29) the inner surface of the disc. The rotation of the disc
to (31) can be expressed as functions of radius, such causes a centrifugal body force in outward direction.
that E, v and are given by: The rotation velocity is 15,000 rpm = 1570 rad/s. The
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Fig. 9: FEM model with the loads and boundary conditions

absolute value of the radial stress occurs at the inner

surface of the disc. As the radius increases, the
displacement and stress decrease until it reaches the
minimum value on the outer surface of the disc. An
(a) abrupt increase of the stress distribution occurs at the
smallest thickness of disc as stress concentration occurs
there. The rounded-off value of the minimum stress is
zero, which satisfies zero pressure boundary condition
on the outer surface of the disc.
(b) Case 2: The disc is subjected to rotational body load
only: The centrifugal body force causes radial
Fig. 10: (a) Coarse and (b) refined meshings of the model
displacement and stress in outward direction, as shown
in Fig. 12. It is shown that the displacement curve
blades attached on the outer surface of the rotating disc
follows the thickness contour of the disc. Increasing
causes a centrifugal force in the outward direction on
thickness tends to result in increasing displacement.
the outer surface of the disc. This centrifugal force
The maximum displacement occurs at the inner surface
results in 500 MPa tensile pressures on the outer of the disc whereas the minimum occurs at the outer
surface of the disc. Furthermore, high temperature of surface. The maximum radial stress occurs at the
the hot blades is transferred by conduction through the middle of the disc.
disc, causing linear temperature variation through the
disc radius. This results in linearly variable thermal Case 3: The disc is subjected to rotational blade load
load. only: Beside the rotational body load, the rotating
As boundary condition, frictionless support (i.e., attached blades cause additional centrifugal load
rollers) is put on the disc side which functions as working on the outer surface of the disc. This load
symmetry plane. Thus, no displacement perpendicular causes displacement and stress in outward direction, as
to this plane is allowed, yet displacement along the shown in Fig. 13. The maximum displacement occurs at
plane is allowed. The model is shown in Fig. 9. the outer surface of the disc, whereas the minimum
occurs near the hub of the disc. Large radial stress
Meshing: Coarse and refined meshing qualities were occurs as the radius increases. With the given geometry
applied to the model as shown in Fig. 10. For both, of the disc, the maximum stress occurs at the smallest
nodes are only at the element corners. thickness of the disc as stress concentration occurs
there.
RESULTS AND DISCUSSION
Case 4: The disc is subjected to thermal load only:
Case 1: The disc is subjected to shrink fit load only: The thermal load causes radial displacement and stress
By taking only the shrink fit load into account, the as shown in Fig. 14. The displacement has negative
radial displacement and stress are shown in Fig. 11. The values at most of the radius values. The negative values
displacement and stress have outward direction due to represent displacement in inward direction. Near the
the shrink fit load coming from the shaft. The outer surface, the displacement has positive values,
maximum displacement as well as the maximum which means that the displacement has outward
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(a)

(b)

Fig. 11: (a) Radial displacement (mm) and (b) stress (MPa) due to shrink fit only

(a)

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(b)

Fig. 12: (a) Radial displacement (mm) and (b) stress (MPa) due to rotational body load only

(a)

(b)

Fig. 13: (a) Radial displacement (mm) and (b) stress (MPa) due to rotational body load only
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(a)

(b)

Fig. 14: (a) Radial displacement (mm) and (b) stress (MPa) due to thermal load only

Fig. 15: Radial displacement due to combined loads (mm)

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(a)

(b)

Fig. 16: Radial stress distribution, (a) with coarse meshing, (b) with refined meshing

direction. Thus, due to the thermal load, the disc minimum displacement of 1.136 mm occurs at the
expands to inward and outward direction. The radial middle of the disc.
stress has outward direction. The rounded-off stress at The radial stress at the inner surface is negative,
the inner and outer surface of the disc is zero. The which means that it is compressive with outward
maximum stress occurs at the middle of the disc. direction. As the radius increase, this compressive
stress decreases until it reaches zero at some radius
Case 5: The disc is subjected to combined loads: By value, then it starts being positive, which means that it
combining all the loads, the radial displacament of the is tensile with outward direction. Near the smallest
disc with refined meshingis shown in Fig. 15. Large thickness of the disc, the maximum stress occurs. The
radial displacement occurs at the inner and outer stressat the inner and outer surface are 299.22 MPa
surface of the disc. The displacements at the inner and (compressive, outward direction) and 500 MPa (tensile,
outer surface are 1.31 and 1.33 mm, respectively. The outward direction) respectively.
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Table 1: Maximum radial displacement and stress

Maximum displacement Maximum radial stress
---------------------------------------------------------- -----------------------------------------------------------------------
Load Value (mm) Position Value (MPa) Position
Shrink fit load 0.51 Inner surface 299.80 Inner surface
Rotational body load 0.28 Inner surface 192.02 Middle, near the smallest thickness
Rotational blade load 0.71 Outer surface 1204.90 Middle, near the smallest thickness
Thermal load 0.11 Middle of the disc 190.68 Middle, near the smallest thickness
Combined loads 1.33 Outer surface 1425.90 Middle, near the smallest thickness

Figure 16 shows the radial stress distribution by all turbine discs as it depends on the values of different
using both the coarse and refined meshing. It is shown loads for any specific turbine disc.
that different plot got near the smallest thickness of the The radial displacement and stress in a disc with
disc where stress concentration occurs. variable thickness are affected by the contour of the
The maximum values of the radial displacement thickness variation. The middle area of the disc is
and stress due to each load as well as combined loads proposed to have smaller thickness, but should not be
are shown in Table 1. It is shown that the rotational too thin as stress concentration will occur there.
blade load contributes the most to the total In the stress analysis, a quite fine meshing
displacement and stress. To reduce its value, reducing particularly in area with stress concentration is required
the weight of the blades and/or the rotor speed can be to avoid inaccuracy of the stress calculation due to
proposed. The maximum displacement occurs at the concentrated stress which cannot be spread well to
outer surface, yet it is only slightly larger than that at surrounding area.
the inner surface. Reducing the rotational blade load
can be proposed to reduce the displacement at the outer NOMENCLATURE
surface, as excessive displacement at that part may
cause rubbing against the stationary parts. Assuming
: Displacement
that the shrink fit is fixed, reducing the rotor speed will
: Radial strain
reduce the displacement at the inner surface. The rotor
speed should not exceed a certain speed which causes : Tangential strain
looseness between the shaft and the disc hub. The : Radial stress
maximum total stress occurs at the middle, near the : Tangential stress
smallest thickness of the disc. Thickening this part can : Specific weight
be proposed to reduce the maximum total stress as it : Gravitational acceleration
was shown that stress concentration occurs there. : Density
: Young modulus
CONCLUSION : Poisson ratio
: Thermal coefficient
Analytical solution of rotating disc with variable : Thickness of the disc
thickness and nonhomogeneous material properties can : Radius of the disc
not be obtained because there are many variable : Inner radius of the disc
parameters in the coefficients of its governing : Outer radius of the disc
differential equation. For this reason, numerous : Shape function
numerical approaches have been proposed to obtain the : Element surface force vector
approximate solutions. One of the approaches having
: Element body force vector
been widely used recently is FEM.
: Element thermal force vector
Most rotating discs used in applications are ax
symmetric. Therefore, ax symmetric element is the : Surface force vector element in radial
most economical but adequate to use for the FE direction
analysis. A turbine disc was analyzed as an example in : Surface force vector element in axial
this study. Several loads were applied. It was shown direction
that maximum displacement occurs at the boundary of : Body force vector element in radial direction
the disc, either at the outer boundary or the inner : Body force vector element in axial direction
boundary, depending on the loadings. The maximum : B matrix
radial stress occurs at the area in the middle of the disc : Stress-strain (constitutive) matrix
which has the smallest thickness. Furthermore, the : Element stifness matrix
analysis showed that each load gives different : Nodal displacement vector
contribution to the total radial displacement and stress : Displacement function vector
of the disc. The rotational blade load was shown to give : Strain vector
the largest contribution. However, this does not apply to : Stress vector
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ACKNOWLEDGMENT Hassani, A., M.H. Hojjati, G. Farrahi and R.A. Alashti,

2012. Semi-exact solution for thermo-mechanical
The authors extend their appreciation to the analysis of functionally graded elastic-strain
Deanship of Scientific Research at King Saud hardening rotating disks. Commun. Nonlinear Sci.,
University for funding the work through the research 17: 3747-3762.
group project No RGP-VPP-036. Hojjati, M.H. and S. Jafari, 2007. Variational iteration
solution of elastic non uniform thickness and
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