Aerodynamic turbomachinery component design is a very complex task. Although modern CFD solvers allow for a detailed investigation of the flow, the interaction of design changes and the three dimensional flow field are highly complex and difficult to understand. Thus, very often a trial and error approach is applied and a design heavily relies on the experience of the designer and empirical correlations. Moreover, the simultaneous satisfaction of aerodynamic and mechanical requirements leads very often to tedious iterations between the different disciplines. Modern optimization algorithms can support the designer in finding high performing designs. However, many optimization methods require performance evaluations of a large number of different geometries. In the context of turbomachinery design, this often involves computationally expensive Computational Fluid Dynamics and Computational Structural Mechanics calculations. Thus, in order to reduce the total computational time, optimization algorithms are often coupled with approximation techniques often referred to as metamodels in the literature. Metamodels approximate the performance of a design at a very low computational cost and thus allow a time efficient automatic optimization. However, from the experiences gained in past optimizations it can be deduced that metamodel predictions are often not reliable and can even result in designs which are violating the imposed constraints. In the present work, the impact of the inaccuracy of a metamodel on the design optimization of a radial compressor impeller is investigated and it is shown if an optimization without the usage of a metamodel delivers better results. A multidisciplinary, multiobjective optimization system based on a Differential Evolution algorithm is applied which was developed at the von Karman Institute for Fluid Dynamics. The results show that the metamodel can be used efficiently to explore the design space at a low computational cost and to guide the search towards a global optimum. However, better performing designs can be found when excluding the metamodel from the optimization. Though, completely avoiding the metamodel results in a very high computational cost. Based on the obtained results in present work, a method is proposed which combines the advantages of both approaches, by first using the metamodel as a rapid exploration tool and then switching to the accurate optimization without metamodel for further exploitation of the design space.
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