June 18, 2014
Structural Optimization of
Turbine Engine Components
for a Competitive Advantage
Don Holcomb, Ph.D., MBB
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2014 Honeywell International Inc.
BP13-266-0
Honeywell.com
Outline
Honeywell - overview
The design problem
Optimize subject to ever changing constraints
Turbine engine design
The process
The opportunity
Example of component optimization
Bypass duct
Frame
Implication for improved system design
Conclusion:
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Optimization provides a
competitive advantage.
2014 Honeywell International Inc.
BP13-266-1
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Honeywell International Overview
$40.3-40.7B
in Sales*
54%
Sales Outside U.S.
1,300 sites, 70 countries
132,000 employees
22,000 engineers
Morristown, NJ
headquarters
Fortune 100
Aerospace
Performance
Materials and
Technologies
Automation and
Control Solutions
Transportation
Systems
*2014 guidance, April 2013
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Honeywells Businesses
Aerospace
Automation and
Control Solutions
Performance
Materials and
Technologies
Transportation
Systems
Phoenix, AZ
Headquarters
Minneapolis, MN
Headquarters
Morristown, NJ
Headquarters
Rolle, Switzerland
Headquarters
$12.1-12.3 billion
sales*
$16.4-16.6 billion
sales*
$6.9-7.0 billion
sales*
$3.6-3.7 billion
sales*
*2013 guidance, April 2013
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Design: Matches Requirements to Capability
Our product development
philosophy attempts to produce a
design that
matches production feasibility
with customer expectation.
CUSTOMER
REQUIREMENTS
DESIGN
PRODUCTION
CAPABILITY
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Design as an Optimization Problem
The design problem:
Max: Earning = value - cost
Subject To: Constraints
(customer, regulatory, internal)
Constraints change as the
design evolves.
Internal and external constraints
Customers perception of value changes
Identifying feasible designs of a complex system is
difficult.
Designs that may appear to be feasible, may be
infeasible upon closer review.
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Now, on to Aircraft Engines Design
HTF7000
Highly Successful 14-year Old Design, but a 2014
Engine Design Must Have Greater Power Density
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How Does a New Engine Design Evolve?
Gas turbine concept design can be viewed as a
hierarchical process
1) Thermodynamics
2) Flowpath generation
3) Airfoils
4) Disks
Rotating components,
internal and external
flowpaths
5) Shafts
6) Cases
7) Frames
Static features
8) Nacelles
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Current State of Component Design
Due to fewer constraints, structures often take the
unbounded left-over space
Tightly constrained design space.
Adding mass may hurt
Small changes to the optimal design
may result in an infeasible design.
Design established and set in early
design phases.
Usually adding more material solves
design issues.
Changes are common in late stages to
accommodate requirement changes
and issues with other components.
Historical design process has lead to
sub-optimized designs for weight.
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Honeywell / Altair Example: Outer Fan Ducts
Frame Flange
Aft Mount
Aft Outer Fan Duct
Flange
Complex Load
Cases
Forward Outer Bypass
Duct (FOBD)
Aft Outer Fan
Duct Ring
Aft Outer Bypass Duct (AOBD)
View From Above, Aft, Inboard
Initial: > 500 lb of Aluminum forgings
Final: ~53 lb Hogouts
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FOBD & AOBD Topology Optimization
Topology Results View 1
Original Design
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Topology Load Paths
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FOBD & AOBD Topology Optimization
Topology Results View 2
Topology Load Paths
Original Design
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FOBD & AOBD Topology Optimization
Topology Results and Interpretation
Topology Interpretation
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Topology Load Paths
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FOBD and AOBD Optimization Final Results
Optimization Weight Results
% Reduction
FOBD
27.0%
AOBD
29.5%
Total Weight
28.6%
Weight Reduction Results Very Significant
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HTF7000 Investment Cast Front Frame
Complexity Is Everywhere
Front Perspective
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Back Perspective
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Front Frame Structural Requirements
Primary engine to aircraft mount structure
Loads generated from:
Engine in flight maneuvers (complex matrix)
Fan blade-out dynamic event
Enormously complex event; major damage allowed
Large, medium, and small bird ingestion event
Very complex events, major damage allowed; 2 minute engine operation;
no damage
Fan blade ice shed scenarios
Post-blade-out windmilling fly home loads
Discrete source damage events e.g., fire, rotor burst, etc.
Provide proper placement and stiffness for rotor bearings
Plus many non-structural requirements:
Guides airflow and supports many external components
Provide oil carrying sumps and services
DFx: x assembly, reparability, cost, manufacture
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Honeywell Front Frame
OptiStruct Optimized Frame Geometry
Mid-ring Stiffeners Were
Scalloped to Lower
Mass and Help Reduce
Stresses in Outer Struts
Forward
Frame Part
% Weight
Savings
Outer Ring
0.3%
Mid Ring
11.5%
Inner Cone
31.0%
Struts
0.0%
Total
9.7%
Weight Reduction Results
Very Significant
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Optimized System from Optimized Components
Establish performance and feasible region boundaries
Predicted performance before production.
Each performance curve is a loci of optimal points.
Impeller Clearance vs Duct Stiffness
Duct Stiffness vs Weight
Stiffness
Stiffness
Component
Clearance
Clearance
Lose
Stiff
System
Tight
Soft
Light
Soft
Weight
Weight
Heavy
Stiff
Stiffness
Stiffness
Topological optimization of components
provides for a more optimal system design.
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Summary and Final Thoughts
Gas turbine industry is rapidly moving towards
sophisticated structural optimization
What is possible?
Emergence of tools, such as OptiStruct, and processes to use the
power of new tools will enable dramatically improved structures
design
What is the new business mind-set and expectation?
Growing awareness of the low hanging fruit of structure weight
reduction potential is driving the efforts and trend
How will we fully leverage non-conventional geometries?
New manufacturing processes take advantage of arbitrary
geometries (e.g., additive manufacturing)
Topological optimization creates greater product value
and may reduce cost
Enables more competitive product offering.
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