Design of graded lattice structures in turbine blades using topology optimization

Alkebsi, Ebrahim Ahmed Ali; Ameddah, Hacene; Outtas, Toufik; Almutawakel, Abdallah

doi:10.1080/0951192x.2021.1872106

Cited by 43 publications

(19 citation statements)

References 44 publications

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“…They employed the additive manufacturing technique for manufacturing these samples and found that for three types of lattice structures, the 'strength/mass' ratio was 1.76 to 2.36 times greater than that for solid blades. Alkebsi, Ebrahim Ahmed Ali et al [32] designed a lattice-based gas turbine blade via lattice structure topological optimization (LSTO). They used three types of lattice structures, namely, primitive, diamond and gyroid, and achieved a weight reduction of up to 40%.…”

Section: Lattice Structuresmentioning

confidence: 99%

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Experimental and Numerical Vibration Analysis of Octet-Truss-Lattice-Based Gas Turbine Blades

Hussain

Ghopa

Singh

et al. 2022

Metals

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This paper aims to investigate the utilization of octet truss lattice structures in gas turbine blades to achieve weight reduction and improvement in vibration characteristics, which are desired for turbine blades to improve the efficiency and load capacity of turbines. A solid blade model using NACA 23012 airfoil was designed as reference. Three lattice-based blades were designed and manufactured via additive manufacturing by replacing the internal volume of solid blades with octet truss unit cells of variable strut thickness. Experimental and numerical vibration analyses were performed on the blades to establish their suitability for potential use in turbine blades. A maximum weight reduction of 24.91% was achieved. The natural frequencies of lattice blades were higher than those of solid blades. A stress reduction up to 38.6% and deformation reduction of up to 21.5% compared with solid blades were also observed. Both experimental and numerical results showed good agreement with a maximum difference of 3.94% in natural frequencies. Therefore, apart from being lightweight, octet-truss-lattice-based blades have excellent vibration characteristics and low stress levels, thereby making these blades ideal for enhancing the efficiency and durability of gas turbines.

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Section: Lattice Structuresmentioning

confidence: 99%

“…These blades achieved maximum stress reductions of 38.60%, 39.50% and 30.06% at 10,000, 15,000 and 20,000 rpm, respectively, compared with solid blades. Alkebsi et al [32] observed a reduction in stress and deformation levels for a gas turbine blade whose lattice configuration differs from that of a solid blade.…”

Section: Stress Analysismentioning

confidence: 99%

Experimental and Numerical Vibration Analysis of Octet-Truss-Lattice-Based Gas Turbine Blades

Hussain

Ghopa

Singh

et al. 2022

Metals

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“…More specifically, with truss‐based methods it is possible to fabricate items with high porosity and high surface area to volume ratio, suitable for biomechanical and mechanical application, such as synthetic bones, turbine blades, etc. [ 12,13 ]…”

Section: Introductionmentioning

confidence: 99%

“…More specifically, with truss-based methods it is possible to fabricate items with high porosity and high surface area to volume ratio, suitable for biomechanical and mechanical application, such as synthetic bones, turbine blades, etc. [12,13] Due to the aforementioned comprehensive advantages of the truss-based approach, extensive research has been performed on cellular materials and lattice structures. One of the first indepth researches on the topic has been performed by Gisbon and Ashby.…”

mentioning

confidence: 99%

Effective Mechanical Properties of Additive Manufactured Strut‐Lattice Structures: Experimental and Finite Element Study

et al. 2021

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Last decade, the scientific interest concerning the additive manufacturing (AM) technologies, as also known 3D printing, has been spiked leading to a rapid progress in this specific scientific field. Today, there are at least eight different AM techniques according to the ASTM F2792-12A standardization, [1] which are capable to fabricate products with a vast variety of materials, such as polymers, resins, metals, etc. Therefore, AM methods currently are employed in various applications, that is, in automotive, aeronautic, and biomechanical industries. [2][3][4] The rapid fabrication of prototypes (rapid prototyping, PR), the fast production of hard and soft tools (rapid tooling) and even the manufacture of fully functional components in a short-time period (direct manufacturing, DM) have been achieved through the utilization of these processes. [5,6] However, the major advantage of AM procedures is the ability to deliver complex structures without geometrical restrictions. This facilitated the development of TO processes and removed the structural constrains that occurred in traditional manufacturing techniques, such as machining, injection molding, etc. TO term stands for the procedure that achieves the optimum mass distribution to handle the applying loads in an already defined volume domain. [7] There are two distinct methods for TO. The first method is density-based approach, which also known as generative design and achieves optimal mass distribution employing sophisticated algorithms, such as SIMP and BESO. [8] Generative design is mainly employed to lightweight applications and to applications where the aesthetic of the product needs to be improved. [9,10] The other method of TO is named as truss-based approach and attain the optimal mass distribution replacing solid regions of a part with lattice structures with specific relative density. [11] A numerous of additional advantages may be acquired employing this approach besides the lightweight applications. More specifically, with truss-based methods it is possible to fabricate items with high porosity and high surface area to volume ratio, suitable for biomechanical and mechanical application, such as synthetic bones, turbine blades, etc. [12,13] Due to the aforementioned comprehensive advantages of the truss-based approach, extensive research has been performed on cellular materials and lattice structures. One of the first indepth researches on the topic has been performed by Gisbon and Ashby. [14] In their studies, they investigated 2D and 3D strut-lattice structures, such as honeycomb, octet, etc., in terms

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“…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. 16 Innovative lattice-infilled components were obtained in Boccini et al.…”

Section: Introductionmentioning

confidence: 99%

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

Wang

Tian

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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The topology optimization can be used to obtain preliminary turbomachinery disk designs which meet strength requirement. In order to eliminate enclosed holes which challenge manufacturing processes and to ensure distinct solid-void interface in the optimal result obtained by the topology optimization, a density distribution function is introduced for each element column in the design domain. Then, a parameter in each function is used to determine the disk’s thickness at corresponding radial position by controlling element densities. Once thicknesses at all radial positions are optimized, the shape of disk is thus determined. In this way, the optimization problem can be simplified by using these parameters as design variables. Illustrative examples are carried out to demonstrate the effectiveness of the proposed method in designing both compressor disks and turbine disks in comparison to the software T-Axis Disk and shape optimization method.

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Design of graded lattice structures in turbine blades using topology optimization

Cited by 43 publications

References 44 publications

Experimental and Numerical Vibration Analysis of Octet-Truss-Lattice-Based Gas Turbine Blades

Experimental and Numerical Vibration Analysis of Octet-Truss-Lattice-Based Gas Turbine Blades

Effective Mechanical Properties of Additive Manufactured Strut‐Lattice Structures: Experimental and Finite Element Study

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

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