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To cite this article: Uyigue Idahosa, Vladimir V. Golubev & Vladimir O. Balabanov (2008)
An Automated Optimal Design of a Fan Blade Using an Integrated CFD/MDO Computer
Environment, Engineering Applications of Computational Fluid Mechanics, 2:2, 141-154, DOI:
10.1080/19942060.2008.11015217
ABSTRACT: The work discusses the construction and application of an automated, distributed, industry-like multi-
disciplinary design optimization (MDO) environment employed to explore new conceptual designs of propulsion system
turbomachinery components optimized for high-efficiency performance. The integrated CFD/MDO system is developed
on the basis of commercially available optimization modules, and involves a user-friendly interface that provides an
easy link to user-supplied response analysis modules. Various issues in the automated optimization procedure are
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addressed with focus on turbomachinery design, including the proper geometry parameterization, algorithm selection,
and transparent interconnections between different elements of the optimization process. A test study considers the
problem of optimal blade design to maximize the aerodynamic performance of a low-speed fan. The approach employs
commercial CFD software, coupled with an unstructured mesh generator, as a response analysis tool. The ability of the
applied Response Surface Optimization algorithm to find a global optimum of the objective function is examined.
Keywords: MDO, design optimization, fan blade design, response surface optimization algorithm, CFD, fan
efficiency optimization
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
configurations, some using a multiobjective (iv) calculate analytical grid and geometry
optimization strategy and increasingly relying on sensitivities;
evolutionary algorithms. Various methods to (v) transfer data among disciplines consistently;
parameterize 3D geometries were analyzed, (vi) operate in an integrated system;
typically resulting in a large number of design (vii) parameterize discipline models consistently.
variables to adequately represent the optimized
In this work, we examine selected aspects of these
shapes in terms of Bezier surfaces or B-splines. In
features as they are implemented in our integrated
one such study (Idahosa, Golubev and Balabanov,
system and further in the test problem. We first
2006), a fuselage of a supersonic transport was
review the main elements of our automated
parameterized in terms of 37 Bezier polygons,
optimization system to illustrate its various
resulting in 131 design variables for an integrated
capabilities, particularly related to the requirement
wing-fuselage configuration. Various works also
to ensure a fully automated and efficient design
discussed automated grid generation procedures.
optimization process. Next, we discuss the
The design of highly efficient and quiet
benchmark test study that deals with the optimal
turbomachinery and general propulsion system
shape design of a fan blade. In this study, we
components represents a challenge to many
employ CFD software coupled with an automated
industrial applications ranging from aeropropulsion
unstructured mesh generator, with an objective to
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
maximize the total efficiency of an axial fan with the fan blade geometry (discussed in detail below).
uniform upstream flow using commercial CFD These parameters are then passed to the
software commonly employed in industrial optimization module that generates another set of
turbomachinery design. The focus is on examining parameters describing a new, prospective blade
various approaches to the efficient parameterization design. At the next stage, the new blade geometry is
of the blade geometry that would be most generated in BladeGen, followed by an automated
appropriate for the robust automated MDO process unstructured mesh generation, CFD analysis, and
when employed in conjunction with a commercial transfer of results to the optimization module. Fig. 3
CFD product. Contrary to the airfoil design studies, shows a general flowchart of the optimization
no guidelines have yet been established for the process. In summary, the optimization task can be
efficient parameterization of the three-dimensional roughly subdivided into four major segments:
blade geometry. The objective function for this (i) generation of blade geometry using BladeGen
study is the total efficiency (T) of the fan blade, software based on current input parameters;
defined as: (ii) CFD analysis performed on a new blade design
using BladeGenPlus; (iii) passing results of CFD
PT analysis to VisualDoc optimizer; (iv) generation of
LE TE (1)
abs
T
PT + PT mass a new set of design parameters based on an iterative
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abs rel
avg step of the selected optimization algorithm. In what
follows, we briefly describe some essential
3.1 Commercial CFD solver as a response elements of the MDO process and their functions,
analysis Tool with details provided in the work of Samareh
(1998).
As a response analysis tool, we have selected
BladeGenPlus software component from the CFX
TurboPlatinum Package developed by ANSYS, Inc.
(currently integrated in the ANSYS Workbench,
(Pulliam et al., 2003)). This RANS CFD blade-
passage solver is one of the most efficient
commercial CFD analysis tools used in industrial
turbomachinery design applications. BladeGenPlus
is an integrated blade design software (BladeGen)
coupled with the blade passage unstructured RANS
solver. The software is integrated with VisualDOC
in the automated optimization process governed by Fig. 2 Sample unstructured mesh profile for CFD
VisualScript. Fig. 2 gives a sample unstructured analysis.
mesh profile.
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
M -
differential meridional displacement
R -
differential radial displacement
Z -
differential axial displacement Span Layer: 0%
(Hub)
-
blade leading edge circumferential angle
(positive: x-towards-y)
Fig. 5 Meridional view (LHS) of fan with span layers
M - meridional coordinate (M) normalized by
visible.
the radial coordinate, R (thus, M = M/R)
At each span layer, the blade section (airfoil) is
created using the BladeGen coordinate system to
specify a set of points which represents the
Camber Line, P Q camberline (meanline) of the blade section at that
M-Z
span layer. The camberline coordinates are
specified using a -M distribution from the
x A
B z
leading edge (LE) to the trailing edge (TE). A
thickness distribution is then superimposed on the
camberline to create the complete profile of the
R blade section. A standard NACA 0012 thickness
distribution is used for all the models in this test
study in order to reduce the number of design
Axis of Rotation parameters. A separate study investigating the
effect of thickness distribution is anticipated in the
future.
The methodology for generating the blade profile is
y
illustrated in Fig. 6 and further below. In Fig. 6(a),
the camberline is shown in the -M coordinate
Fig. 4 Blade geometry coordinate system. system. Fig. 6(b) shows the camberline along with
the superimposed blade thickness distribution. In
In BladeGen, the blade model is defined by data Fig. 6(c), a 3rd order Bezier control polygon is
points distributed over a number of user-specified generated to control the shape of the blade section
constant-radius layers, spanning from 0% at the hub camberline. The Bezier control polygon is used to
to 100% at the shroud (as shown in Fig. 5). The ensure that the camberline is smooth and free of
geometrical properties, including blade angles and discontinuities, a necessary requirement for
thickness distributions, are then specified at each generating valid blade geometries.
spanwise layer, and interpolations between layers
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
(a)
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(b)
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
y BgBatch applies new operating parameters, such y BgSolve performs a CFD analysis of the blade
as the fan RPM and upstream flow conditions, to passage and stores results in a specified file;
the model;
y BgExtract extracts computational results from the
y BgGrid generates unstructured blade-passage BgSolve output file and stores them in a specified
mesh for the new BladeGen model; file.
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The need for completely automated optimization associated with invalid blade designs, unsuccessful
and response analysis procedures implies a mesh generation, or unsuccessful CFD analysis (in
considerable level of robustness to be built in the all cases, the optimization process automatically
MDO environment, allowing it to handle extreme recovers and continues).
design cases. To this end, MATLAB scripts are Fig. 10 shows the design variables and response
developed to handle the following issues identified parameters in the test study, as specified in the
as critical to the robustness of the MDO VisualDocs graphical user interface (GUI). The
methodology: responses include the target function (total
efficiency) along with other performance
y invalidity of extremely twisted, swept or
characteristics such as the fan head rise, blade
distorted blade designs is communicated to the
torque, and static efficiency (details are provided in
optimization module through the Geometry
Samareh, 1998).
Pass/Fail parameter;
The optimization module of the design process
y information on blade designs for which mesh detailed in Fig. 11 consists of the VisualDoc and
could not be successfully generated is passed to VisualScript components. VisualDoc controls
the optimization module through the Grid implementation of the selected optimization
Pass/Fail parameter; algorithm whose results are based on the CFD
y invalidity of CFD results stored in the response response analysis of the previous design iteration. A
analysis file is communicated to the optimization new set of design variables is generated by
module through the CFD Pass/Fail parameter. VisualDoc, and transferred for further analysis as
part of the MDO process governed by VisualScript.
The availability of the Pass/Fail parameter in The latter is thus responsible for all calls to various
VisualDOC, complemented with the softwares batch utilities performing critical analysis tasks,
ability to easily interface with MATLAB scripts, including the blade geometry modeling, grid
allows for a considerable robustness of the generation, CFD analysis, and transfer of the CFD
automated MDO process, as the latter is not results to the optimizer.
immediately terminated in the event of problems
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
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3.6 Optimization algorithm selection the employed subsets of design variables, and the
order in which the optimization subsets are
The response surface optimization (RSO) algorithm
performed. VisualDocs implementation of the RSO
has been selected for the test study. RSO has
algorithm requires that bounds are imposed on the
established itself as a more efficient method when
design variables and response parameters in order
the computational cost of performing a single
to define the design space within which the
analysis is rather high (Jones, Crossley and
response surface is generated. The bounds imposed
Lyrintzis, 2000), which is the case in the current
in the current study are shown in Table 2.
MDO study. On the other hand, the RSO algorithm
Additional restrictions are included in Table 3 with
is more effective when the number of design
the purpose of selecting a more accurate (quadratic)
variables is not too large (Fig. 1 illustrates a
response model without imposing excessively
nonlinear growth in the required number of data
stringent optimization convergence criteria.
points, i.e., calls for the response analysis, as the
number of variables increases).
4. RESULTS
In order to increase the efficiency of the RSO
algorithm in the current study, the 32 design In the MDO study, three base fan models
variables are grouped into subsets. The blade design (prototypes) are used to examine the ability of the
is thus sequentially optimized relative to the subsets MDO algorithm to converge to a globally optimal
of the design variables (i.e., the blade design is first fan design. The original base designs used in the
optimized relative to the first subset, with the best MDO study are shown in Table 4. We first discuss
obtained design then optimized relative to the optimization results obtained for two of the designs
second subset, etc.). The process is carried out (with the third producing similar results), and
iteratively until no appreciable increase in the further compare all three.
objective function can be obtained. Table 1 shows
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
Table 1 Subsets of design variables Table 2 Upper and lower bounds for design variables and response parameters
in the MDO study. in MDO study (unless otherwise specified, r = 1, 2, ..5).
+
Min/Max value (used if computed bound exceeds this value)
of TE Bezier Unless otherwise stated, 1 r 5 and 1 s 4
5 control points 5
( r|4)
Fan RPM and
6 number of 2
blades
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
4.1 MDO results: Model 1 Bezier geometry variables, the largest efficiency
Optimization results for Model 1 are summarized in gain is obtained from variations of the blade
Fig. 12, while Fig. 13 illustrates the history plot of coordinates. In order to re-examine the method of
the target function (efficiency) based on the sequential subset optimization employed in the
sequential design optimization conducted on the study, an additional round of design iterations is
subsets of design variables. Fig. 12 also shows the conducted by separately varying the sweep
efficiency gains obtained for each subset, and distribution of the blade LE line. The efficiency
compares the base and the optimized fan gain of 0.41% (compared to the original 1.84%)
geometries. The total efficiency gain for Model 1 is suggests that the method may indeed be successful,
approximately 11% after 323 design iterations. The provided that the proper subsets of design variables
largest gain in efficiency is obtained from the are identified. Finally, a wavy shape of the leading
simultaneous variation of the fan rotational speed edge line in the optimized blade design is noted.
(RPM) and the number of blades. In terms of the This feature is also observed in all other models,
and is further addressed below.
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0.80
0.79
0.75
0.74
0.73
0.72
0 50 100 150 200 250 300 350
[Ite ration]
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
0.86
Merid_R_3 Disp Fac
0.85
0.84 Beta_R_4 (T E CP)
0.83
RPM + #BLADES
0.82
Efficiency (%)
0.81
0.80 232, 0.7899
0.79
186, 0.7705
0.78 149, 0.7703
95, 0.7665
0.77
1, 0.7433 58, 0.7541
0.76
0.75
0.74
0.73
0.72
0 50 100 150 200 250 300
[Iteration]
4.2 MDO results: Model 2 points, the fan rotational speed and the number of
blades as the critical design variables with the most
The design optimization results for Model 2
significant influence on the target function (total fan
(illustrated in Figures 14 and 15) are similar to the
efficiency). An average efficiency gain of 12 % is
previous case. The efficiency gain plots also show
obtained for the three base models. The appearance
that the simultaneous variation of the RPM and the
of the wavy shape of the leading edge line in the
number of blades yields the largest efficiency gain
optimized models could be related to the specific
of 9%. The variation of the leading edge sweep (qr)
choice of the blade parameterization scheme
and the coordinates of the Bezier control points
(particularly, the spanwise discretization
(br|i) produces higher efficiency, compared to the
procedure), which will be further investigated in the
gains obtained from the meridional (Mr|s and dr)
future work.
Bezier CP coordinates.
To conclude on the ability of the RSO algorithm to
4.3 Comparison of results identify a globally optimal blade design, a
comparison of the optimized models is presented in
Fig. 16 and Table 5 compare the efficiency gains Table 5 to show a noticeable variation among the
for the three base models. In general, the results three resulting designs. Further studies will examine
identify the coordinates of the Bezier control if those are primarily related, e.g., to the initial
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
differences in the fan diameters and/or the hub-tip designs could be due to the absence of constraints
ratios of the original models. On the other hand, the on the total blade torque, forcing the optimizer to
resulting large numbers of blades in the final increase the solidity of the fan designs.
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Engineering Applications of Computational Fluid Mechanics Vol. 2, No. 2 (2008)
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