ABSTRACT
Obtaining a closed form analytical formulation for complex mechanical structures such
as turbine rotors with multiple blade assemblies can be very problematic. Building a
prototype without optimizing the structural stress levels may result in unnecessary
hardware costs. In this work, mathematical models for highest stress or lowest factor of
safety on critical components of a small modular cross-flow hydro turbine rotor have
been explored for various design options through a response surface analysis. The
response surface model is obtained based on finite element analysis results following
design of simulated experiments. Rotor design parameters have been investigated to
optimize factor of safety on critical components without violating the specified weight
limits. Box-Henken data tables have been used to obtain the response surface model.
The attained response model yields the maximum stress and lowest factor of safety for
critical rotor components for various combinations of design parameters. Verification
runs indicate that response model successfully predicts factor of safety levels close to
finite element calculations.