Generalization of two- and three-dimensional structural topology optimization

2005 ◽  
Vol 37 (1) ◽  
pp. 83-102 ◽  
Author(s):  
Ming-Hsiu Hsu ◽  
Yeh-Liang Hsu
Author(s):  
Enrico Boccini ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Simone Corbò ◽  
Stefano Falomi ◽  
...  

Structural topology optimization is an innovative approach in turbomachinery to satisfy the increasing demand for higher rotational speeds, light components and optimized natural frequencies, with a remarkable economic impact. Although this approach has never been extensively applied before to rotating machines, it is very promising for the mechanical optimization of rotor and stator components. This approach enables the creation of complex three-dimensional geometries, which are usually difficult or impossible to be built using traditional manufacturing methods. Thanks to innovative technologies and to the use of innovative materials, it is now possible to effectively exploit topology optimization. It allows to change the topology of the structures, significantly improving material distribution within a given design space for a given set of boundary conditions and loads. In this work, the authors have deeply investigated the applicability of topology optimization to the fields of turbomachinery and rotordynamics.


2021 ◽  
Vol 64 (4) ◽  
pp. 2627-2652 ◽  
Author(s):  
Michele Marino ◽  
Ferdinando Auricchio ◽  
Alessandro Reali ◽  
Elisabetta Rocca ◽  
Ulisse Stefanelli

AbstractWe propose a variational principle combining a phase-field functional for structural topology optimization with a mixed (three-field) Hu–Washizu functional, then including directly in the formulation equilibrium, constitutive, and compatibility equations. The resulting mixed variational functional is then specialized to derive a classical topology optimization formulation (where the amount of material to be distributed is an a priori assigned quantity acting as a global constraint for the problem) as well as a novel topology optimization formulation (where the amount of material to be distributed is minimized, hence with no pre-imposed constraint for the problem). Both formulations are numerically solved by implementing a mixed finite element scheme, with the second approach avoiding the introduction of a global constraint, hence respecting the convenient local nature of the finite element discretization. Furthermore, within the proposed approach it is possible to obtain guidelines for settings proper values of phase-field-related simulation parameters and, thanks to the combined phase-field and Hu–Washizu rationale, a monolithic algorithm solution scheme can be easily adopted. An insightful and extensive numerical investigation results in a detailed convergence study and a discussion on the obtained final designs. The numerical results clearly highlight differences between the two formulations as well as advantages related to the monolithic solution strategy; numerical investigations address both two-dimensional and three-dimensional applications.


Author(s):  
Enrico Boccini ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Lorenzo Pinelli ◽  
Lorenzo Peruzzi ◽  
...  

The current trend in turbomachinery is pushing forward more and more efficient machines, increasing speeds, reducing components mass and improving their vibrational behaviour. Structural topology optimization is a challenging and promising approach to satisfy all these demands, with a very remarkable economic impact. This approach enables the creation of structures characterized by complex three-dimensional geometries, which are usually difficult or impossible to be produced using traditional manufacturing processes. However, thanks to innovative technologies, as new additive manufacturing techniques, it is now possible to effectively exploit topology optimization to develop innovative components. The aim of this work is to demonstrate the applicability of structural topology optimization techniques in turbomachinery, to improve the dynamic performances and vibrational behaviour of critical components. A 3D mock-up blade geometry based on T106 profile has been designed to reproduce a typical rotor blade in design conditions. The blade has been mounted on a rough disk model, to obtain a rotor blisk in order to ensure a wide design space for the optimization. The optimization has been carried out by applying mean and fluctuating loads coming from a 3D unsteady computation of 1.5stage (stator-rotor-stator) together with the centrifugal stresses. The unsteady loads acting on the rotor skin are due to the wake of the upstream stator and the potential field generated by the downstream stator. A new concept design for the blisk has been developed and the optimized geometry has been compared to the original one to highlight the improvements in terms of mass reduction and improved dynamic behaviour. This paper will confirm the suitability of this approach to turbomachinery components and a prototype of optimized geometry will be ready to be manufactured through innovative additive manufacturing techniques for high resistance alloys.


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