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 Genetic Algorithms As an Approach to Configuration and Topology Design

1993 ◽  
Author(s):  
Colin D. Chapman ◽  
Kazuhiro Saitou ◽  
Mark J. Jakiela
Keyword(s):  
Genetic Algorithm ◽  
Topology Optimization ◽  
Structural Optimization ◽  
Optimization Technique ◽  
Topology Design ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Element Analysis ◽  
Structure Topology ◽  
Design Representation

Abstract The Genetic Algorithm, a search and optimization technique based on the theory of natural selection, is applied to problems of structural topology optimization. Given a structure’s boundary conditions and maximum allowable design domain, a discretized design representation is created. Populations of genetic algorithm “chromosomes” are then mapped into the design representation, creating potentially optimal structure topologies. Utilizing genetics-based operators such as crossover and mutation, generations of increasingly-desirable structure topologies are created. In this paper, the use of the genetic algorithm (GA) in structural topology optimization is presented. An overview of the genetic algorithm will describe the genetics-based representations and operators used in a typical genetic algorithm search. After defining topology optimization and its relation to the broader area of structural optimization, a review of previous research in GA-based and non-GA-based structural optimization is provided. The design representations, and methods for mapping genetic algorithm “chromosomes” into structure topology representations, are then detailed. Several examples of genetic algorithm-based structural topology optimization are provided: we address the optimization of beam cross-section topologies and cantilevered plate topologies, and we also investigate efficient techniques for using finite element analysis in a genetic algorithm-based search. Finally, a description of potential future work in genetic algorithm-based structural topology optimization is offered.

Weight Reduction Design of Gear Drive Based on Parameter and Structural Optimization

2010 ◽  
Vol 139-141 ◽  
pp. 1406-1410 ◽  
Author(s):  
Ping Wang ◽  
Zhou Lan ◽  
Xiao Yang Shen
Keyword(s):  
Topology Optimization ◽  
Structural Optimization ◽  
Weight Reduction ◽  
Moment Of Inertia ◽  
Design Parameters ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Gear Drive

. For a medium or large-sized gear drive, in order to achieve the optimum weight reduction effect, an approach of weight reduction design is proposed that multi-objective optimization of gear parameters is carried out firstly, and then structural optimization is adopted to design the gear former. The rational design parameters of a gear drive are determined by the multi-objective optimization with minimizing the sum of gear volumes and the equivalent moment of inertia of input shaft (EMI) synchronously. Conceptual design of the former is given by structural topology optimization of the gear, and the reasonability of topology optimization can be demonstrated by static and dynamic analysis. The results indicate that for a double-reduction gearbox of 500KW co-rotating twin screw pulping extruder, the EMI of the gear drive reduces by 20.88% through the multi-objective optimization of gear parameters, and the moment of inertia of a bull gear reduces by 38.86% through structural topology optimization.

The Impact of Filter Function on Structural Topology Optimization

2014 ◽  
Vol 496-500 ◽  
pp. 1766-1769
Author(s):  
Zhen Shang ◽  
Yun Kang Sui
Keyword(s):  
Topology Optimization ◽  
Topological Optimization ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Filter Function ◽  
Integrated Method ◽  
Speed Up ◽  
Optimization Efficiency ◽  
The Impact ◽  
The Continuum

Based on ICM method, topological optimization model is established to minimize the weight with different constraints. The model is solved by constraint integrated method. The impact of different filter functions on continuum structural topology optimization efficiency is studied by numerical examples. The results show that: The application of nonlinear filter function can speed up the convergence, reduce the number of iterations, get a good stability in the continuum structural topology optimization.

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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