A new methodology for thermostructural topology optimization: Analytical definition and validation

2020 ◽  
pp. 146442072097024
Author(s):  
R Caivano ◽  
A Tridello ◽  
M Codegone ◽  
G Chiandussi
Keyword(s):  
Topology Optimization ◽  
Heat Exchangers ◽  
Mechanical Performance ◽  
Turbine Blades ◽  
Mathematical Formulation ◽  
Service Condition ◽  
Manufacturing Processes ◽  
Structural Topology ◽  
Real Component ◽  
Rapid Diffusion

In the last few years, the rapid diffusion of components produced through additive manufacturing processes has boosted the research on design methodologies based on topology optimization algorithms. Structural topology optimization is largely employed since it permits to minimize the component weight and maximize its stiffness and, accordingly, optimize its resistance under structural loads. On the other hand, thermal topology optimization has been less investigated, even if in many applications, such as turbine blades, engines, heat exchangers, thermal loads have a crucial impact. Currently, structural and thermal optimizations are mainly considered separately, despite the fact that they are both present and coupled in components in service condition. In the present paper, a novel methodology capable of defining the optimized structure under simultaneous thermomechanical constraints is proposed. The mathematical formulation behind the optimization algorithm is reported. The proposed methodology is finally validated on literature benchmarks and on a real component, confirming that it permits to define the topology, which presents the maximized thermal and mechanical performance.

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.

Topology Optimization Design of Pre-Stressed Plane Entity Steel Structure with the Constrains of Stress and Displacement

2014 ◽  
Vol 945-949 ◽  
pp. 1216-1222 ◽  
Author(s):  
Li Yao ◽  
Yun Xia Gao ◽  
Hai Jun Yang
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Mechanical Performance ◽  
Steel Structure ◽  
Structural Topology ◽  
Unit Size ◽  
Structure Topology ◽  
Design Variables ◽  
Displacement Sensitivity ◽  
Low Sensitivity

For the prestressed plane entitiy steel structure topology optimization design which design variables include the cable pretension value, unit size and the structural topology, the optimized mathematical model which objective function is the minimum structural weight is established with consideration of the constrains of stress and displacement. As for the solving method, firstly we need to determine the pretension applying to the cable according to full stress design and choose the unit size; then we need to conduct displacement sensitivity analysis to delete the low sensitivity unit to realize the structural topology optimization design. The example result is in conformity with the corresponding system of mechanical performance, and it indicates that the method proposed in this paper is effective.

scholarly journals A novel lattice structure topology optimization method with extreme anisotropic lattice properties

2021 ◽  
Vol 8 (5) ◽  
pp. 1367-1390
Author(s):  
Chenghu Zhang ◽  
Jikai Liu ◽  
Zhiling Yuan ◽  
Shuzhi Xu ◽  
Bin Zou ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Design Space ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
Lattice Structure ◽  
Optimization Method ◽  
Structural Topology ◽  
Structure Topology ◽  
Elementary Lattice ◽  
Anisotropic Lattice

Abstract This research presents a lattice structure topology optimization (LSTO) method that significantly expands the design space by creating a novel candidate lattice that assesses an extremely large range of effective material properties. About the details, topology optimization is employed to design lattices with extreme directional tensile or shear properties subject to different volume fraction limits and the optimized lattices are categorized into groups according to their dominating properties. The novel candidate lattice is developed by combining the optimized elementary lattices, by picking up one from each group, and then parametrized with the elementary lattice relative densities. In this way, the LSTO design space is greatly expanded for the ever increased accessible material property range. Moreover, the effective material constitutive model of the candidate lattice subject to different elementary lattice combinations is pre-established so as to eliminate the tedious in-process repetitive homogenization. Finally, a few numerical examples and experiments are explored to validate the effectiveness of the proposed method. The superiority of the proposed method is proved through comparing with a few existing LSTO methods. The options of concurrent structural topology and lattice optimization are also explored for further enhancement of the mechanical performance.

Structural Topology Optimization Using Frame Elements Based on the Complementary Strain Energy Concept for Eigen-Frequency Maximization

2005 ◽  
Author(s):  
Akihiro Takezawa ◽  
Shinji Nishiwaki ◽  
Kazuhiro Izui ◽  
Masataka Yoshimura
Keyword(s):  
Topology Optimization ◽  
Cross Sections ◽  
Strain Energy ◽  
Optimization Procedure ◽  
Optimization Method ◽  
Structural Topology ◽  
Energy Concept ◽  
Conceptual Design Phase ◽  
Complementary Strain ◽  
Topology Optimization Method

This paper discuses a new topology optimization method using frame elements for the design of mechanical structures at the conceptual design phase. The optimal configurations are determined by maximizing multiple eigen-frequencies in order to obtain the most stable structures for dynamic problems. The optimization problem is formulated using frame elements having ellipsoidal cross-sections, as the simplest case. Construction of the optimization procedure is based on CONLIN and the complementary strain energy concept. Finally, several examples are presented to confirm that the proposed method is useful for the topology optimization method discussed here.

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