Design and Production of Innovative Turbomachinery Components via Topology Optimization and Additive Manufacturing

Abstract

The present paper proposes a methodology to design and manufacture optimized turbomachinery components by leveraging the potential of Topology Optimization (TO) and Additive Manufacturing (AM). The method envisages the use of TO to define the best configuration of the rotoric components in terms of both static and dynamic behavior with a resultant reduction of overall weight. Eventually, the topology-optimized component is manufactured by using appropriate materials that can guarantee valid mechanical performances. The proposed strategy has been applied to a 2D impeller used for centrifugal compressors to prove the effectiveness of a TO+AM-based approach. Although this approach has never been extensively used before to centrifugal compressors and expanders, its application on rotor and stator components might unlock several benefits: tuning the natural frequencies, a reduction in the stress level, and a lighter weight of the rotating part. These objectives can be reached alone or in combination, performing a single analysis or a multiple analyses optimization. Finally, the introduction of AM technologies as standard manufacturing resources could bring sensible benefits with respect to the time to production and availability of components. Such aspects are essential in the Oil and Gas context, when dealing with new projects but also for service operations.

A General Framework for Designing 3D Impellers Using Topology Optimization and Additive Manufacturing

“…High performance Inconel alloys meet all these standards when manufactured using subtractive technologies. In particular, the IN718 [16], a precipitation hardenable nickel-based alloy, is characterized by exceptionally high yield, tensile and creep-rupture properties at temperatures up to 700 • C, as depicted in Table 1 [11].…”

“…In [11] the researchers examined TO's potential for designing a 2D impeller mounted on a centrifugal compressor. The results obtained in [11] showed the efficacy of TO and AM approaches for designing innovative rotor components.…”

“…In [11] the researchers examined TO's potential for designing a 2D impeller mounted on a centrifugal compressor. The results obtained in [11] showed the efficacy of TO and AM approaches for designing innovative rotor components. The encouraging results obtained in such a prior work, prompted to investigate the possibility of applying an integrated method involving TO and AM for the design of 3D impellers i.e.…”

“…Such a preliminary work successfully applied some TO-based routines to design an effective 2D component, laying the foundation for a more systematic approach. However, in [11], no frameworks are provided to the designers to guide them towards the creation of optimized rotoric parts. Accordingly, the present article extends the previous study by proposing a systematic design procedure which, leveraging the potential of TO and AM, allows the optimal design of any rotoric component used in centrifugal compressors.…”

A preliminary design method for axisymmetric turbomachinery disks based on topology optimization

“…For example, two impellers were optimized and additive manufactured in Meli et al. 11 , 12 A low-pressure turbine guide vane was optimized in Seppälä et al. 13 Novel turbine blade designs were obtained by topology optimization in Magerramova et al., 14 Alkebsi et al., 15 and Amedei et al.…”