Improving Aeromechanical Performance of Compressor Rotor Blisk with Topology Optimization

Alberto Bandini, Alessio Cascino, Enrico Meli, Lorenzo Pinelli and Michele Marconcini ()
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Alberto Bandini: Department of Industrial Engineering, University of Florence, Via S. Marta 3, 50139 Florence, Italy
Alessio Cascino: Department of Industrial Engineering, University of Florence, Via S. Marta 3, 50139 Florence, Italy
Enrico Meli: Department of Industrial Engineering, University of Florence, Via S. Marta 3, 50139 Florence, Italy
Lorenzo Pinelli: Department of Industrial Engineering, University of Florence, Via S. Marta 3, 50139 Florence, Italy
Michele Marconcini: Department of Industrial Engineering, University of Florence, Via S. Marta 3, 50139 Florence, Italy

Energies, 2024, vol. 17, issue 8, 1-20

Abstract: When it comes to modern design of turbomachinery, one of the most critical objectives is to achieve higher efficiency and performance by reducing weight, fuel consumption, and noise emissions. This implies the need for reducing the mass and number of the components, by designing thinner, lighter, and more loaded blades. These choices may lead to mechanical issues caused by the fluid–structure interaction, such as flutter and forced response. Due to the periodic aerodynamic loading in rotating components, preventing or predicting resonances is essential to avoid or limit the dangerous vibration of the blades; thus, simulation methods are crucial to study such conditions during the machine design. The purpose of this paper is to assess a numerical approach based on a topology optimization method for the innovative design of a compressor rotor. A fluid-structural optimization process has been applied to a rotor blisk which belongs to a one-and-a-half-stage aeronautical compressor including static and dynamic loads coming from blade rotation and fluid flow interaction. The fluid forcing is computed by some CFD TRAF code, and it is processed via time and space discrete Fourier transform to extract the pressure fluctuation components in a cyclic-symmetry environment. Finally, a topological optimization of the disk is performed, and the encouraging results are presented and discussed. The remarkable mass reduction in the component (≈32%), the mode-shape frequency shift from a fluid forcing frequency, and an overall relevant reduction in the dynamic response around Campbell’s crossing confirm the efficacy of the presented methodology.

Keywords: topology optimization; aeromechanics; unsteady CFD analysis; forced response; turbomachinery (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
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