Innovative Structural Topology Optimization Approach for Rotordynamics Components Using Innovative Materials and New Manufacturing Techniques

2017 ◽  
Author(s):  
Enrico Boccini ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Simone Corbò ◽  
Giuseppe Iurisci
Keyword(s):  
Topology Optimization ◽  
Three Dimensional ◽  
Optimization Approach ◽  
Complex Structures ◽  
Concept Design ◽  
Structural Topology ◽  
Innovative Strategy ◽  
Innovative Materials ◽  
Manufacturing Techniques ◽  
Near Future

Topology optimization is an innovative strategy applied in the turbomachinery field with the aim of substantially improving the performances of turbomachinery components in terms of weights, stress levels and rotation speed, with a very remarkable economic impact. Being very flexible, topology optimization allows to manage the structures topology, significantly improving material distribution within a given design space for a given set of loads and boundary conditions. In this paper, the authors, in cooperation with General Electric Nuovo Pignone, develop a new concept design of a turbine disk and the optimized component is compared to the benchmark, in order to verify the achieved improvements. Special attention is paid to the use of innovative materials with lattice structures, characterized by complex three-dimensional geometries. Thanks to advanced technologies, as additive manufacturing, it is now possible to effectively exploit topology optimization to develop new components featured by complex structures. The developed prototypes will be manufactured and tested in the near future together with the industrial partners.

Structural Topology Optimization of Turbomachinery Components Using New Manufacturing Techniques and Innovative Materials

2017 ◽  
Author(s):  
Enrico Boccini ◽  
Enrico Meli ◽  
Andrea Rindi ◽  
Simone Corbò ◽  
Stefano Falomi ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Three Dimensional ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
Innovative Materials ◽  
Manufacturing Techniques ◽  
Increasing Demand ◽  
Traditional Manufacturing ◽  
Light Components ◽  
Mechanical Optimization

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.

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.

A Systematic Topology Optimization Approach for Optimal Stiffener Design

1998 ◽  
Author(s):  
Jian Hui Luo ◽  
Hae Chang Gea
Keyword(s):  
Topology Optimization ◽  
Location Problem ◽  
Eigenvalue Problems ◽  
Three Dimensional ◽  
Orthotropic Materials ◽  
Optimization Approach ◽  
Design Domain ◽  
Plate Structures ◽  
Shell Plate

Abstract A systematic topology optimization approach is developed to design the optimal stiffener of three dimensional shell/plate structures in static and eigenvalue problems. Optimal stiffener design involves the determination of the best location and orientation. In this paper, the stiffener location problem is solved by a microstructure-based design domain method and the orientation probelm is modeled as an optimal orientation problem of equivalent orthotropic materials, which is solved by a newly developed energy based method. Examples are presented to demonstrate the application of the proposed approach.

Three-Dimensional Electrical Impedance Tomography: A Topology Optimization Approach

2008 ◽  
Vol 55 (2) ◽  
pp. 531-540 ◽  
Author(s):  
LuÍs Augusto Motta Mello ◽  
CÍcero Ribeiro de Lima ◽  
Marcelo Britto Passos Amato ◽  
Raul Gonzalez Lima ◽  
EmÍlio Carlos Nelli Silva
Keyword(s):  
Topology Optimization ◽  
Electrical Impedance Tomography ◽  
Electrical Impedance ◽  
Three Dimensional ◽  
Optimization Approach ◽  
Impedance Tomography

Topology Optimization of Three-Dimensional Woven Materials Using a Ground Structure Design Variable Representation

2019 ◽  
Vol 141 (6) ◽  
Author(s):  
Seung-Hyun Ha ◽  
Hak Yong Lee ◽  
Kevin J. Hemker ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Design Variable ◽  
Three Dimensional ◽  
Structure Design ◽  
Optimization Approach ◽  
Ground Structure ◽  
Flow Equations ◽  
Combined Algorithm ◽  
Variable Representation ◽  
3D Weaving

Three-dimensional (3D) weaving has recently arisen as viable means for manufacturing metallic, architected microlattices. Herein, we describe a topology optimization approach for designing the architecture of such 3D woven lattices. A ground structure design variable representation is combined with linear manufacturing constraints and a projection mapping to realize lattices that satisfy the rather restrictive topological constraints associated with 3D weaving. The approach is demonstrated in the context of inverse homogenization to design lattices with maximized fluid permeability. Stokes flow equations with no-slip conditions governing unit cell flow fields are interpolated using the Darcy–Stokes finite element model, leveraging existing work in the topology optimization of fluids. The combined algorithm is demonstrated to design manufacturable lattices with maximized permeability whose properties have been experimentally measured in other published work.

scholarly journals A local solution approach for level-set based structural topology optimization in isogeometric analysis

2020 ◽  
Vol 7 (4) ◽  
pp. 514-526
Author(s):  
Zijun Wu ◽  
Shuting Wang ◽  
Renbin Xiao ◽  
Lianqing Yu
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Isogeometric Analysis ◽  
Iteration Process ◽  
Solid Material ◽  
Optimization Approach ◽  
Structural Topology ◽  
Zero Level ◽  
Solution Approach ◽  
Level Set Function

Abstract This paper develops a new topology optimization approach for minimal compliance problems based on the parameterized level set method in isogeometric analysis. Here, we choose the basis functions as level set functions. The design variables are obtained with Greville abscissae based on the corresponding collocation points. The zero-level set boundaries are derived from the level set function values of the interpolation points in all knot spans. In the optimization iteration process, the whole design domain is discretized into two types of subdomains around the zero-level set boundaries, undesign area with void materials and redesign domain with solid materials. To decrease the size of equations and the computational consumptions, only the solid material area is recalculated and the void material area is discarded according to the high accuracy of isogeometric analysis. Numerical examples demonstrate the validity of the proposed optimization method.

scholarly journals Topology Optimization using the Discrete Element Method. Part 1: Methodology, Validation, and Geometric Nonlinearity

2021 ◽  
Author(s):  
Connor O'Shaughnessy ◽  
Enrico Masoero ◽  
Peter D. Gosling
Keyword(s):  
Topology Optimization ◽  
Discrete Element Method ◽  
Geometric Nonlinearity ◽  
Discrete Element ◽  
Optimization Method ◽  
Discrete Models ◽  
Structural Topology ◽  
Manufacturing Techniques ◽  
Strain Energy Minimization ◽  
Element Method

Structural Topology optimization is attracting increasing attention as a complement to additive manufacturing techniques. The optimization algorithms usually employ continuum-based Finite Element analyses, but some important materials and processes are better described by discrete models, for example granular materials, powder-based 3D printing, or structural collapse. To address these systems, we adapt the established framework of SIMP Topology optimization to address a system modelled with the Discrete Element Method. We consider a typical problem of strain energy minimization, for which we define objective function and related sensitivity for the Discrete Element framework. The method is validated for simply supported beams discretized as interacting particles, whose predicted optimum solutions match those from a classical continuum-based algorithm. A parametric study then highlights the effects of mesh dependence and filtering. An advantage of the Discrete Element Method is that geometric nonlinearity is captured without additional complexity; this is illustrated when changing the beam supports from rollers to hinges, which indeed generates different optimum structures. The proposed Discrete Element Topology Optimization method enables future incorporation of nonlinear interactions, as well discontinuous processes such as during fracture or collapse.

scholarly journals Topology Optimization considering Nonsmooth Structural Boundaries in the Intersection Areas of the Components

2020 ◽  
Vol 2020 ◽  
pp. 1-14
Author(s):  
Ruichao Lian ◽  
Shikai Jing ◽  
Zefang Shi ◽  
Zhijun He ◽  
Guohua Song
Keyword(s):  
Topology Optimization ◽  
Geometric Modeling ◽  
Compliant Mechanisms ◽  
Optimization Approach ◽  
Structural Topology ◽  
Topology Description Function ◽  
Structural Responses ◽  
Structure Boundary ◽  
Compliance Problem ◽  
The Impact

In the structural topology optimization approaches, the Moving Morphable Component (MMC) is a new method to obtain the optimized structural topologies by optimizing shapes, sizes, and locations of components. However, the optimized structure boundary usually generates local nonsmooth areas due to incomplete connection between components. In the present paper, a topology optimization approach considering nonsmooth structural boundaries in the intersection areas of the components based on the MMC is proposed. The variability of components’ shape can be obtained by constructing the topology description function (TDF) with multiple thickness and length variables. The shape of components can be modified according to the structural responses during the optimization process, and the relatively smooth structural boundaries are generated in the intersection areas of the components. To reduce the impact of the initial layout on the rate of convergence, this method is implemented in a hierarchical variable calling strategy. Compared with the original MMC method, the advantage of the proposed approach is that the smoothness of the structural boundaries can be effectively improved and the geometric modeling ability can be enhanced in a concise way. The effectiveness of the proposed method is demonstrated for topology optimization of the minimum compliance problem and compliant mechanisms.

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