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This paper outlines a methodology incorporating cooling performance and manufacturing process capabilities to evaluate turbine blade film cooling cost. The manufacturing process considered is the electro discharge machining of cooling holes on turbine blades. The proposed methodology allows estimating the impact of geometry, cooling and capability variables on the unit cost of the turbine blade. A procedure based in CFD simulation is proposed to quantify the effects of geometry parameters and their variability due to manufacturing, on cooling performance. Similarly, the influence of hole design on process capabilities is addressed propounding a method to evaluate it. The methodology has been applied to two case studies namely: cooling analysis for heat transfer coefficient and assessment of non-conformance in different regions of an aerofoil.
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