Film cooling is one of most developed technologies which enhance the gas turbine blades operation in today’s high-thrust-to-weight-ratio gas engines. The determination of the accurate cooling holes of turbine blades is of vital importance to improving the cooling performance. However, in all current methods for manufacturing drilled cooling holes on turbine blades, the complexity of the production processes will ineluctably cause unexpected consequences such as the deformation of the turbomachinery parts, the locating error caused by fixture layouts. These issues will cause deviations in the geometry and position of the drilled holes. In this paper, a methodology is proposed to analyze the deviation and to establish an improved geometric model of drilled cooling holes with accurate positional and geometrical parameters on turbine blades. The discontinuous deformation, including the non-uniform wall thickness and shrinkage distribution, was established by deformation characteristics decoupling analysis; the surface error generated by locating error was obtained using locating error analysis. An accurate model for film cooling holes can be established by considering the process-induced deviations in geometry and positioning. The relevance of the proposed method is verified using numerical and experimental results.

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