When a gas turbine combustor is manufactured, small geometrical differences between production runs are unavoidable. These geometrical differences potentially influence performances such as service life, lighting, lean blow off, pollutant emissions. To ensure performances, manufacturing tolerances are kept tight enough so as to neglect their impact. However, loosening some key manufacturing tolerances can result in lower manufacturing costs, while maintaining combustion performances at a satisfactory level. The present study aims at challenging some cost-driving manufacturing tolerances of Safran Helicopter Engines new turboshaft combustor, using state-of-the-art 3D numerical tools. The objective is to guarantee robust and long lasting combustor performances at a reasonable manufacturing cost. To this purpose, an optimized Latin Hypercube Sampling of 30 geometrical configurations around the nominal geometry has been simulated with a 3D LES solver. Simulation parameters had to be chosen to keep computation costs manageable and to have a high representability when comparing geometries. These aspects are checked using theoretical considerations and comparisons with both experimental data and previously validated simulations. The temperature field at the combustion chamber exhaust has been analyzed in detail using metamodeling. In particular, the Radial Temperature Distribution Factor (RTDF) at the combustor outlet appears to be robust. Such large designs of numerical experiments (DonE) are computationally expensive but they provide a reliable tool to assess the robustness of a combustor design, and define optimized manufacturing tolerances.
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