Structural topology optimization for generative design of personalized aneurysm implants: Design, additive manufacturing, and experimental validation

2017 ◽  
Author(s):  
Long Jiang ◽  
Shikui Chen ◽  
Chander Sadasivan ◽  
Xiangmin Jiao
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Experimental Validation ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Generative Design

Innovative Design, Structural Optimization and Additive Manufacturing of New-Generation Turbine Blades

2021 ◽  
pp. 1-31
Author(s):  
Lorenzo Pinelli ◽  
Andrea Amedei ◽  
Enrico Meli ◽  
Federico Vanti ◽  
Benedetta Romani ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Topological Optimization ◽  
Mode Shapes ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
New Generation

Abstract The need for high performances is pushing the complexity of mechanical design at very high levels, especially for turbomachinery components. Structural topology optimization methods together with additive manufacturing techniques for high resistant alloys are considered very promising tools, but their potentialities have not been deeply investigated yet for critical rotating components like new-generation turbine blades. This research work proposes a methodology for the design, the optimization and the additive manufacturing of extremely stressed turbomachinery components like turbine blade-rows. The presented procedure pays particular attention to important aspects of the problems as fluid-structure interactions and fatigue of materials, going beyond the standard structural optimization approaches found in the literature. The numerical procedure shows robustness and efficiency, making the proposed methodology a good tool for rapid design and prototyping, and for reducing the design costs and the time-to-market typical of these mechanical elements. The procedure has been applied to a low-pressure turbine rotor to improve the aeromechanical behavior while keeping the aerodynamic performance. From the original geometry, mode-shapes, forcing functions and aerodynamic damping have been numerically evaluated and are used as input data for the following topological optimization. Finally, the optimized geometry has been verified in order to confirm the improved aeromechanical design. After the structural topology optimization, the final geometries provided by the procedure have been then properly rendered to make them suitable for additive manufacturing. Some prototypes of the new optimized turbine blade have been manufactured to be tested in terms of fatigue.

Innovative Design, Structural Optimization and Additive Manufacturing of New-Generation Turbine Blades

2020 ◽  
Author(s):  
Andrea Amedei ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Benedetta Romani ◽  
Lorenzo Pinelli ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Forced Response ◽  
Mode Shapes ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
New Generation

Abstract The need for high performances is pushing the complexity of mechanical design at very high levels, especially for turbomachinery components. In this field, structural topology optimization methods together with additive manufacturing techniques for high resistant alloys are considered very promising tools, but their potentialities have not been deeply investigated yet for critical rotating components like new-generation turbine blades. In this framework, this research work proposes a methodology for the design, the optimization and the additive manufacturing of extremely stressed turbomachinery components like turbine blade-rows. The presented procedure pays particular attention to important aspects of the problems as fluid-structure interactions (forced response and flutter phenomena) and fatigue of materials, going beyond the standard structural optimization approaches found in the literature. The new design strategy enables a substantial reduction of the component mass, limiting the maximum stress and improving the vibrational behaviour of the system in terms of eigenfrequencies, modal shapes and fatigue life. Furthermore, the numerical procedure shows robustness and efficiency, making the proposed methodology a good tool for rapid design and prototyping, and for reducing the design costs and the time-to-market typical of this kind of mechanical elements. The procedure has been applied to a low-pressure turbine rotor to improve the aeromechanical behavior while keeping the aerodynamic performance. From the original geometry, mode-shapes, forcing functions (due to rotor/stator interactions) and aerodynamic damping have been numerically evaluated and are used as input data for the following topological optimization. Finally, the optimized geometry has been verified in order to confirm the improved aeromechanical design. After the structural topology optimization, the final geometries provided by the procedure have been then properly rendered to make them suitable for additive manufacturing. Some prototypes of the new optimized turbine blade have been manufactured from aluminum to be tested mechanically and in terms of fatigue.

scholarly journals Generative Design by Using Exploration Approaches of Reinforcement Learning in Density-Based Structural Topology Optimization

Designs ◽  
2020 ◽  
Vol 4 (2) ◽  
pp. 10 ◽  
Author(s):  
Hongbo Sun ◽  
Ling Ma
Keyword(s):  
Topology Optimization ◽  
Reinforcement Learning ◽  
Gaussian Distribution ◽  
Beta Distribution ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Generative Design ◽  
Vast Number ◽  
Two Parameters ◽  
Upper Confidence Bound

A central challenge in generative design is the exploration of vast number of solutions. In this work, we extend two major density-based structural topology optimization (STO) methods based on four classes of exploration algorithms of reinforcement learning (RL) to STO problems, which approaches generative design in a new way. The four methods are: first, using ε -greedy policy to disturb the search direction; second, using upper confidence bound (UCB) to add a bonus on sensitivity; last, using Thompson sampling (TS) as well as information-directed sampling (IDS) to direct the search, where the posterior function of reward is fitted by Beta distribution or Gaussian distribution. Those combined methods are evaluated on some structure compliance minimization tasks from 2D to 3D, including the variable thickness design problem of an atmospheric diving suit (ADS). We show that all methods can generate various acceptable design options by varying one or two parameters simply, except that IDS fails to reach the convergence for complex structures due to the limitation of computation ability. We also show that both Beta distribution and Gaussian distribution work well to describe the posterior probability.

Towards Structural Topology Optimization of Rotor Blisks

2018 ◽  
Author(s):  
Enrico Boccini ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Lorenzo Pinelli ◽  
Lorenzo Peruzzi ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Current Trend ◽  
Three Dimensional ◽  
Optimization Techniques ◽  
Structural Topology Optimization ◽  
Concept Design ◽  
Structural Topology ◽  
Disk Model ◽  
Manufacturing Techniques

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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