Novel Aero-Engine Multi-Disciplinary Preliminary Design Optimization Framework Accounting for Dynamic System Operation and Aircraft Mission Performance

Abstract

This paper presents a modular, flexible, extendable and fast-computational framework that implements a multidisciplinary, varying fidelity, multi-system approach for the conceptual and preliminary design of novel aero-engines. In its current status, the framework includes modules for multi-point steady-state engine design, aerodynamic design, engine geometry and weight, aircraft mission analysis, Nitrogen Oxide (NOx) emissions, control system design and integrated controller-engine transient-performance analysis. All the modules have been developed in the same software environment, ensuring consistent and transparent modeling while facilitating code maintainability, extendibility and integration at modeling and simulation levels. Any simulation workflow can be defined by appropriately combining the relevant modules. Different types of analysis can be specified such as sensitivity, design of experiment and optimization. Any combination of engine parameters can be selected as design variables, and multi-disciplinary requirements and constraints at different operating points in the flight envelope can be specified. The framework implementation is exemplified through the optimization of an ultra-high bypass ratio geared turbofan engine with a variable area fan nozzle, for which specific aircraft requirements and technology limits apply. Although the optimum design resulted in double-digit fuel-burn benefits compared to current technology engines, it did not meet engine-response requirements, highlighting the need to include transient-performance assessments as early as possible in the preliminary engine design phase.

A Review of Novel and Non-Conventional Propulsion Integrations for Next-Generation Aircraft

“…These secondary effects, therefore, could theoretically (partially or totally) undermine the benefit obtainable in terms of specific fuel consumption by increasing the BPR, affecting the overall performance of the whole aircraft (i.e., block fuel consumption). For this reason, in order to effectively foster the development and actual implementation of the UHBR turbofan, in addition to evaluating technological implementations in advanced materials and more efficient components [52], in nacelle design [53,54] and its shape optimization [55,56], it is also crucial to take into account the effects of the turbofan installation [57], together with the mission performance of the complete aircraft [58].…”

Robust lightweight design and digital twins considering manufacturing quality variation and sustainability requirements

“…The sustainability metrics and requirements can be treated as constraints in the optimization [6] and the product reliability [16] can be evaluated instead of using the traditional safety factors. The multi-objective and reliability-based optimization methods are used increasingly, as for example in [1] and in [11]. They enable better development of competitive products that fulfill the performance and sustainability requirements at controlled operational reliability.…”